Report On Internship

AN INTRENSHIP REPORT ON JSW STEEL LTD BELLARY
CHAPTER 1
INTRODUCTION
JSW Steel Ltd is an Indian steel company owned by the JSW Group based in Mumbai,
Maharashtra, India. JSW Steel is among India's largest steel producers, with a capacity of
14.3 MT. Sajjan Jindal led enterprise JSW Group is one of the largest business conglomerates
in India with a strong presence in the core economic sector. It had grown from a steel rolling mill
in 1982 and is presently a multi business conglomerate worth US$5 billion. As part of the US$10
billion O. P. Jindal Group, JSW Group has diversified interests in steel, energy, minerals and
mining, aluminium, infrastructure and logistics, cement and information technology.
Fig: 1 front view of jsw bellary
JSW Steel, the flagship company of the JSW Group, is the largest integrated private steel
manufacturer in India in terms of installed capacity. The Group set up its first steel plant in 1982
at Vasind near Mumbai. Soon after, it acquired Piramal Steel Ltd., The Jindals, who had wide
experience in the steel industry, renamed it as Jindal Iron and Steel Co. Ltd. (JISCO). In 1994, in
order to achieve the vision of moving up the value chain and building a strong, resilient
company, Jindal Vijayanagar Steel Ltd. (JVSL) was set up, with its plant located at Toranagallu
in the Bellary-Hospet area of Karnataka, the heart of the high-grade iron ore belt and spread over
POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 1

3,700 acres of land. It is just 340 km from Bangalore, and is well connected with both the Goa
and Chennai ports. In 2005, JISCO and JVSL merged to form JSW Steel Ltd.
1.1 JSW PROCESS FLOW
Fig 2: jsw process flow
Some noteworthy points about JSW are:
 A Greenfield integrated steel plant.
 US$ 2.5 Billion Company.
 Part of O.P.Jindal group.
 India’s only plant using COREX technology successfully for iron making.
 Single largest investment in Karnataka of over Rs 8200 crores.

CHAPTER 2
SAFETY
Safety: protecting ourselves from the hazards existent in the industry is called safety.
Hazard: is a dangerous occurrence that can happen in the industry.
A survey has shown that about 80% of these hazards happen due to “unsafe acts” 18% due to
“unsafe environment” and the rest 2% as a matter of “chance”. The above implies that 2% is
unavoidable but 98% is avoidable.
Few hazards in the Steel Plant are: Hot Metal Hazards, Gas based Hazards (CO), Fire
Hazards, Dust Hazards, Noise Hazards, and Electric Hazards.
However these can be avoided by simple steps.
1. Hot Metal Hazards: Hot metals falling on the skin can cause serious injury to the skin
and flesh. Hence jeans trousers and jeans Jackets must be worn at all times while working
in the plant. Gloves too are essential while working equipments.
2. Gas based Hazards (CO): The main gas that we should be aware of is carbon monoxide.
It’s a poisonous gas that replaces the oxygen in the haemoglobin oxygen complex that
carries the oxygen to the various parts of the body. Hence exposure to high levels of
carbon monoxide is not advised. A “CO Pointer/ Monitor” is always attached to the
person working in a CO concentrated area. A person can safely work in an area of 50ppm
CO concentration for about 8 hours. He needs to vacate the area after that. A 1200ppm
concentration will put a person to coma in 15mins. It can be fatal. Further to prevent the
effect of any other poisonous gases “Gas Masks” are used.
3. Noise Hazards: “Ear Plugs” or “Ear Muffs” are used to maintain the decibel level within
safe limits of 85Db. The former reduces the decibel by 20-30Db and the latter by 30-
40Db.
4. Dust Hazards: Dust exposure can cause various lung disorders including lung cancer.
Hence “Masks” are worn while working in a dusty area.

5. Fire Hazards: There are 5kinds of fire. These have been classified into 4 types with a
different kind of fire extinguisher for each kind.
Type of fire Substance (A) Extinguisher
a) Ordinary fire Paper (A) Water
b) Liquid fire Petrol, Diesel (B) Foam
c) Gas fire LPG (B) Foam
d) Metal Mg (C) Dry Chemical powder
e) Electric (D) Carbon di oxide
DCP can be used for any type of fire. But same is not the case not with the other kinds of
extinguishers.
6. Height Hazards: While working at heights safety harness has to be worn to prevent any
sort of fall resulting in injuries. Fall arrestors are also used.

CHAPTER 3
DIFFERENT SHOPS
3.1 RAW MATERIAL HANDLING SYSTEM
RMHS is the backbone of any industry which supply raw material of requisite quantity in
adequate quantity to respective departments. Plant performance in terms of productivity and
quality, is affected more by inconsistency in quality of raw material than the absolute value of
tonnage.
FUNCTIONS OF RMHS
1. Receive raw materials in adequate quantity.
2. Allocate space for raw material stacking.
3. Effective bedding and blending of incoming raw materials.
4. Timely supply raw material to respective department.
5. Maintain stock to continue the production at least for 30 days without interruption
when there is no supply of raw material.
RMHS IS DESIGNED TO HANDLE FOLLOWING RAW MATERIALS :
1. Iron ore
2. Pellets
3. Non coking coal
4. Coking coal
5. Coke
6. Limestone
7. Dolomite
8. Quartzite

MAJOR EQUIPMENTS
Raw materials are usually received through Rails. Various equipments are used to unload the
materials, store the materials, and convey the materials to various plants. Major equipments are,
1. Wagon Tripler
2. Track Hopper
3. Stacker cum Re-claimer
4. Conveyor Belts
5. Junction House
6. Twin Boom Stackers
7. Barrel Re-claimer
8. Transfer Car
POLLUTION CONTROL EQUIPMENT’S IN RMHS:
Dust is the main cause of Pollution in RMHS area. Fine dust is generated during discharge of
material from one Transfer point to the other of conveyor and also while reclaiming the material.
Dust is also generated due to the continuous movement of Trucks and tippers in the area.
Continuous efforts have been taken up to reduce the dust emission. Installation of Following dust
control measures speaks up the commitment in reducing the dust emission.
1. Industrial Vacuum Cleaning Machine
2. Plain water spray system
3. Pre-wetting system
4. Dry-Fog system
5. Yard sprinklers
6. De-dusting system

7. Conveyor hoods
8. Trapaulin covering
9. Wind screen
10. Air compressors
fig 3: conveyor belt system

3.2 BENIFICIATION PLANT
Hematite and magnetite are the most prominent of the iron ores. Of these, hematite is considered
to be the most important iron ore because of its high grade quality and lumpy nature, which is
consumed by a large number of pig and sponge iron industries. Magnetite deposits are not
exploited so for on account of their poor grade lumps (<40% Fe). However, it can be utilised
after beneficiation.
The behaviour of Blast furnace and Corex depends on chemical composition, structural forms,
physical form, size etc. of iron ore. The ore contains gangue materials like alumina, silica and
sulphur etc. as it is mined. These materials affect the behaviour of iron making process to great
extent. To have smooth process, removal of these gangue particles from the ore is highly
important.JSW has two beneficiation plant of each rated capacity 20 MTPA.
fig 4: benificiation plant

TYPES OF BENEFICIATION PROCESS
1. Dry processing
2. Dry cum wet processing
3. Wet processing
1. DRY PROCESSING: Most of the high-grade (>65% Fe) hematite iron ore are subjected to
dry process of beneficiation to meet the size requirement involving multistage crushing and
screening to obtain calibrated lumps i.e., -40+10 mm (for blast furnace): -18+6mm (for sponge
iron) and fines (-10/6mm) products. The fines are stacked at mine site as waste.
2. DRY CUM WET PROCESSING: Generally fine fraction, generated after dry processing, is
further processed in mechanical classifiers, hydro-cyclones, etc. to obtain finer size products that
constitute the feed for sintering. The classifier/hydro-cyclone overflow, constitutes the slime and
is dumped into tailing pond.
3. WET PROCESSING: Wet processing circuit is generally practiced for low/medium-grade

(60-62% Fe). The process consists of multistage crushing followed by different stages of
washing in the form of scrubbing and or wet screening, classification etc., but the advantage is
only partial removal of adhered alumina and free silica in the calibrated lumpy size fraction that
just meets the blast furnace grade. The classifier underflow is directly used for sinter making,
while classifier overflow is dumped in the tailing pond. The above washing practice marginally
improves the handling properties of mineral because of removal of adhered clayey matter.
However, the quality of sinter feed is impaired due to presence of lateritic material in the
classifier underflow.

3.3 PELLET PLANT
Pelletisation is process in which iron ore fines are agglomerated to form tiny balls of suitable
sizes by rolling. Apart from the iron ore fines, an excellent binder, fluxes or additive and more
importantly critical amount of water are mixed together in order to make good quality pellets.
Generally, the modern iron making process (COREX) works at high pressure (3-4 bar), at such a
high pressure, charging sinter will result in generation of high amount of fines. Fines generation
is not desirable since it reduces the permeability as well as actively participates in choking of gas
valves. Hence palletisation (pellets having higher mechanical strength than sinters) came in to
picture. Though pellets have definite shape, they are used in restricted amounts in blast furnaces
as compared to sinters owing to their less porosity.
In JSW the rated capacity of pellet plant 1 is 4.2 MTPA and pellet size ranges from 8 to 16mm in
diameter. The major units are Dryers, Ball Mills, pelletisers of 7.5 mm dia, Induction furnace,
Electrostatic precipitator, and Water recirculation systems.
RAW MATERIALS REQUIRED IN PELLET PLANT
1. Iron core
2. Limestone
3. Dolomite
4. Coal/cdp dust
5. Bentonite as binder
6. Corex/bof sludge
7. Water

fig 5: Pelletization
FINAL PRODUCTS OBTAINED
1. Pellets
2. Gas
3. Slag
PROCESS OF PELLETISATION
1. Feed preparation - Drying, Grinding and Mixing.
2. Formation of Green pellets and sizing.
3. Green ball induration - Drying, Pre heating, Firing and Cooling.

3.4 COKE OVEN PLANT
Coke is the residual product obtained up on carbonization of coking coal. It is fair to call
coke as ‘Cooked coal’. Coke is metallurgical coal that has been baked into a charcoal-like
substance. This substance burns more evenly than coal and also has more structural strength.
When many bituminous coals are heated, they soften and form a plastic mass that swells and
solidifies into a porous solid. Coals that exhibit such behavior are called caking coals.
Strongly caking coals, which yield a solid product (coke) with properties suitable for use in a
blast furnace, are called coking coals.
There are two types of coke ovens non-recovery and by product recovery coke ovens. In
non-recovery type the by products from hot gas are not separated and hot gas produced is
used in power production. In recovery type by products are recovered and used for different
purposes.
JSW has both recovery and non-recovery type coke making facilities. The non-recovery type
coke making facility with capacity of 1.25 MTPA has two units with unit 1 having 139
ovens, and unit 2 with 140 ovens. The recovery type coke oven making with 1.5MTPA has
four batteries each of 56 ovens. The salient features of non-recovery coke making is the
waste heat recovery for power generation.
COKE IS PREFERRED OVER COAL IN BLAST FURNACE BECAUSE:
1. Coke has higher burden sustainability,
2. Coke has higher permiability to gases produced in Blast furnace,
3. Coke has a higher reducing capacity,
4. The residual ash mixes with slag and gets piped out,
5. Impurities are less in coke

Fig 6: coke oven

3.5 BLAST FURNACE
A blast furnace is a type of metallurgical furnace used for smelting industrial metals
generally iron. It is the oldest, most proven and widely used technology in hot metal making.
In a blast furnace fuel, ore, sinter, pellets and flux (limestone) are charged from the top into
the vertical shaft, while a hot blast (air with oxygen enrichment) is blown through the tyres
located at the bottom, so that the chemical reaction take place throughout the furnace as
metal moves downwards. The oxygen from the hot blast reacts with the carbon (coke), which
results in carbon mono-oxide. As this gas ascends, it reacts with the charge materials, thereby
reducing iron ore to iron which is tapped as hot metal along with the slag.
There are four blast furnaces in JSW BF-1 of rated capacity 0.9 MTPA, Bf-2 is 1.3 MTPA,
BF-3 is 3 MTPA and BF-4 is of 4 MTPA capacity.
RAW MATERIALS REQUIRED IN BLAST FURNACE
1. Iron ore
2. Limestone
3. Sinter
4. Dolomite
5. Coke
6. Quartz
7. Water
FINAL PRODUCTS OBTAINED
1. Hot Metal (Pig Iron)
2. Blast furnace Gas
3. Slag

3.6 STEEL MELTING SHOP
The hot metal (pig iron) produced in Blast furnace or Corex contains elements like Carbon,
Manganese, Sulphur, Phosphor, and Silicon more than desired amount. These elements are
reduced to costumer requirement in steel melting shop.Mainly Basic oxygen furnace is used for
this process. Presently, 60% of total steel produced in world is produced using BOF.
In JSW the rated capacity of BOF shop is 7 MTPA liquid steel and this has five converters in
two separate shops SMS-1 and SMS-2. SMS-1 has a heat size of 130 tonnes (3 converters) and
SMS-2 has 175 tonnes (2 converters) and tap to tap time is 45 min. The major units are Hot
metal de-sulphuring station, Hot Metal mixer, Basic Oxygen Furnaces, Scrap Yard, Ladle
preparation and handling bay, Ladle refining furnace, gas cooling and cleaning plant, and a water
Re-circulation system. The salient technical features are Pre-treatment of hot metal, bottom
stirring in BOF, adjustment of chemistry and temperature in ladle furnace, automated container
laboratory for quick analysis of bath samples, utilisation of converter gas as fuel and slag
splashing system to enhance converter lining life.
HOT METAL DE-SULPHURISATION (HMDC)
Sulphur cannot be removed by oxidation so before BOF, the hot metal undergoes de-
sulphurisation. The hot metal produced in Blast furnace or Corex is brought to SMS in a torpedo
rail car of capacity 350t, it is rotated about 150° so that the hot metal in ladle falls in to the de-
sulphuring furnace. Sulphur is reduced by injecting reducing agents like CaC 2, CaO and
magnesium. Magnesium has high efficiency because it has high affinity to sulphur (highly
reactive with sulphur).
There are two types of injection of reducing agents
1. Mono Injection: Once only one reducing agent is used for de-sulphurisation, i.e. either
lime or carbide is used.
2. Co Injection: Once more than one reducing agent is used for de-sulphurisation, i.e.
Either lime+Mg or carbide+Mg is used.

Fig 7: Steel melting shop

3.7 HOT STRIP MILL
Rolling is the process of plastically deforming metal by passing between rolls. Rolling is the
most widely used forming process, which provides high production and close control of final
product. Rolling process can be mainly classified as, Hot rolling and cold rolling. Hot
rolling causes wrought structure finer grains and enhanced ductility, breaking up brittle grain
boundaries, remove porosity.
Hot rolling consists of physical deformation of metal above the recrystallization

temperature. The primary function of the hot strip mill is to reheat semi-finished steel slabs
of steel nearly to their melting point then roll them thinner and longer through successive
rolling mill stands and finally coiling up the lengthened steel sheets for transport to the next
process.
In JSW there are two HSM plants HSM-1 is of rated capacity 3.2 MTPA and that of HSM-2
is 3.5 MTPA.
MAJOR UNITS IN HSM
1. Slab Yard
2. Re-Heating Furnace (RHF)
3. De-Scaling unit
4. Roughing Mill
5. Edging
6. Finishing Mill
7. Cooling
8. Coil Handling

Fig 8: hot strip mill

3.8 COLD ROLL MILL
Cold rolling is plastic deformation of metal below the recrystallization temperature. The cold
rolling of metals has played a major role in industry by providing sheet, strip, foil with good
surface finishes and increased mechanical strength with close control of product dimensions.
The steel from HSM contains hard and sticking layer of oxide and residual stresses, so it is
subjected to cold rolling.JSW has one CRM complex with 1MTPA rated capacity which was
commissioned in 2007. It produces products with Bright and Matte finishing and accuracy
of 1.6+/-0.005mm. The CRM complex is focused on the value added products geared towards
automobile and white goods industry.
Fig 9: Cold roll mill

MAJOR UNITS IN CRM
1. Continuous Pickling Line (CPL)
2. Compact Cold Mill (CCM)
3. Electrolytic Cleaning Line (ECL)
4. Batch Annealing Furnace (BAF)
5. Skin Pass Mill (SPM)
6. Re-Coiling Line (RCL)
7. Auto Packaging Line (APL)
Hot Rolled Coils produced in Hot Strip Mill (HSM) are sent to the Cold Rolling Mill to remove
the scales, oxide layer and other impurities on the rolls. And then according to the requirement of
customer the rolls undergo Continuous Annealing or Galvanizing. JSW’s Cold Rolled Closed
Annealed (CRCA) Coils and Sheets are produced through the cutting-edge Cold Rolling Mills
(CRM) at Vijayanagar. The 3.3 Mtpa CRM’s modern facilities, advanced operational
technologies, strict inspection processes and integrated quality control, ensures an excellent
product.JSW’s CRCA is manufactured in Deep Drawing, Extra Deep Drawing, Interstitial Free
Steels and High Strength grades, which are conformed to JIS, EN, ASTM and IS standards.
Dimensional accuracy is guaranteed by an automatic thickness control system using advanced
numerical models. Easy formability, High-quality Surface Finish, consistent surface texture with
the optimum balance between texture (for paint keying) and smoothness (for image distinction)
makes JSW’s CRCA the product of choice for automobiles, appliances, furniture and many other
applications.
NEED OF COLD ROLLING

1. Appearance of the product is of major importance.
2. In order to increase the corrosion resistance of the surface.
3. To get required sections as they cannot be achieved in HSM.

4. Required mechanical properties and dimension tolerances are achieved in CRM

Fig 10:final product of CRM

3.9 BAR ROD MILL
Billets from SMS are stored in the billet yard. Billets are fed to furnace through roller
table. Capacity of the furnace is 80 billets. Corex gas is used as fuel in furnace. Billets are
heated to 1050-1200°. Water at 230 bar pressure is used in a de-scaler to remove the scales
(oxidized surface of billet) which is formed on surface of billet while heating.
The billet is passed through roughing mill (6 stands), intermediate mill (6 stands) and
finishing mill (4 stands), twist mill (6 stands), stands are in alternating horizontal and
vertical (H-V) arrangement. After finishing mill thee rod is split into two which doubles the
productivity. Two rods are further processed in line A and line B. No twist mills (NTM) have
carbide rings with slitter facility for two line rolling with HYQST (High yield Quenched and
Self Temper) water boxes. Enables controlled temperature rolling to produce superior grain
structure and more uniform scale.
HYQST PROCESSING
1. High Yield Strength is produced by a combination of fine grain size and self–tempered
martensitic surface zone.
2. Cooling soon after the last rolling stand to lock in grain structure.
3. Quenching reduces the rod surface temperature below that is required form low carbon
Marten site which is tempered, as the remaining heat in the core dissipates.
4. Rods (72m long) are then cooled in cooling bed, aligned and passed to cold shear. At
interval of 12m, rods are sheared and packaged, and stored in stock yard.
TESTING FACILITIES IN BRM
1. Pneumatic sample conveying system

2. Universal testing Machine
3. Optical emission spectrometer
4. X-ray Fluorescence Spectrometer
5. Oxygen, Nitrogen, Hydrogen Analyzer

Fig 11: bars and rods mill

Fig 12: final output of BRM

CHAPTER 4
UTILITY
In economics, utility is a measure of preferences over some set of goods and services. The is an
important underpinning of rational choice theory in economics and game theory, because it
represents satisfaction experienced by the consumer of agood.A good is a something that
satisfies human wants. Since one cannot directly measure benefit, satisfaction or happiness from
a good or service,economics instead have devised ways of representing and measuring utility in
terms of economic choices that can be measured.
JSW UTILITY MAINLY CONTAINS TWO SECTIONS

1. WATER SECTION
2. POWER SECTION
1. WATER SECTION
There are mainly two sources for water
1. TB dam: The tungabghadra dam is constructed across the thungabhadra river ,a tributary of
Krishna river.the dam is near the hospet in Karnataka. This dam is 40 KMs from jsw. From
TB dam 32.5 MGD(millions of gallons per day) of water can be taken. One pumping station
and one boosting stations are there.
2. Almatti: The Krishna (Almatti) Pennar link canal is proposed to off-take from the right flank
of the Almatti dam in Karnataka State. This dam is 170 KMs from jsw. From TB dam 40
MGD(millions of gallons per day) of water can be taken. . One pumping station and two
boosting stations are there.
Fig13:TB dam

2. POWER SECTION
As the JSW is an integrated plant they will generate power by them self. The total generation
capacity of JSW is 1800 MW.
POWER GENERATION PLANTS IN JSW
1. CAPTIVE POWER PLANTS
2. STRATEGIC BUSINESS UNITS
3. TOP RECOVERY TURBINE GENERATOR
4. COKE DRY QUENCHING
The detailed explanation of powe generation is done in the next chapter.

CHAPTER 5
JSW ENERGY LIMITED
Fig 14: jsw energy department

5.1 GENERATION OF ELECTRICAL ENERGY

The conversion of energy available in different forms in nature into electrical energy is known as
generation of electrical energy.
Energy is available in various forms from different natural sources such as pressure head of
water,chemical energy of fuels,nuclear energy of radioactive substances etc.All these forms of
energy can be converted into electrical energy by the use of suitable arrangements.The
arrangement essentially employs an alternator coupled to a prime mover.The prime mover is
driven by the energy obtained from various sources such as burning of fuel,pressure of
water,force of wind etc. can be used to produce steam at high temperature and pressure.The
steam is fed to a prime mover which may be a steam engine or a steam turbine.The turbine
converts heat energy of steam into mechanical energy which is further converted into electrical
energy by the alternator.
The total complex generation in jsw is 1800 MW.
Total complex load in jsw is 960 MW.
POWER GENERATION PLANTS IN JSW
1. CAPTIVE POWER PLANTS
2. STRATEGIC BUSINESS UNITS
1. CAPTIVE POWER PLANT

Captive Power Plant (CPP) is a plant which produces electricity for its owner’s own uses or for
a group for their own use.
In jsw there are 4 captive palnts are present
 CPP1-104 MW(GAS&LDO)
 CPP2-125 MW(GAS&LDO)
 CPP3-315 MW(COAL)
 CPP4-315 MW(COAL)

A top-pressure recovery turbine plant is installed in the downstream of gas-cleaning equipment

for a blast furnace. There are two types of gas-cleaning equipment: a wet type that uses water
and a dry type that does not use water. After dust is collected by either of them, blast furnace gas
is led to the turbine and drives it while expanding from around the furnace top pressure to
atmospheric pressure. The power generated by the turbine is transferred to the generator and
converted to electric power. In conventional practice, the energy of blast furnace gas was wasted
by pressure reduction at a septum valve. It is now recovered as electric power, realizing
significant energy saving.
In jsw there are two TRTs are present
 BF3 TRT-12 MW(GAS)

 BF4 TRT-12 MW(GAS)
3. STRATEGIC BUSINESS UNIT
Strategic Business Units or SBUs have been defined as autonomous divisions or organizational
units, small enough to be flexible and large enough to exercise control over most of the factors
affecting their long-term performance. They focus on product offering and market segment—
having clear marketing plan, campaign and analysis. They have autonomous mission and
objective. They inspire the owning empire to respond quickly to changing economic situations.
The author has tried to explore the concept of business structure and management from the SBU
perspective, while looking at different categories of SBUs, in this article. He has also discussed
the management mechanism of the SBUs in details. Read on to understand this crucial
perspective.
In jsw there are four SBUs are present
 SBU1-130*2 MW(GAS/COAL)
 SBU2-315*2 MW(GAS/COAL)
CDQ is a system to recover the sensible heat of red hot coke by means of inert gas. Then by the
use of the recovered heat, produce high-temperature and high-pressure steam in a boiler. The
steam produced without additional energy is used for the generation of electric power,
production of steel, etc. Because of its dry quenching system without using water, as well as
effective utilization of energy, CDQ has the following excellent features.
In jsw there is only one CDQ is present
 CDQ1-75 MW(GAS&HEAT RECOVERY)

5.2 POWER PLANT DETAILS
Fig15:power plant details

CHAPTER 6
POWER DISTRIBUTION (MSDS)
6.1 INTRODUCTION
 MSDS- Main Step Down Station
 Largest Industrial power distribution system in India.
 Receives power from JSW energy, JSWPL, Captive Power Plants & KPTCL Grid.
 Distribute power to all the steel plant units, Ancillaries and Oxygen plants.
 Co-ordinate with customers for un-interrupted and reliable supply of electrical energy.
 Reports generation for analysis
 Receives power at 400KV & 220KV level from JSWEL, Captive Power Plants, JSWPL
and KPTCL Grid.
 Step down voltage from 400KV/220KV to 33KV&11KV levels through power

transformers.
 16Nos of power transformers capacity ranging from 50MVA to 315MVA, 220KV &
400KV Class.
 We handle around 900MW of power at MSDS.
 Plant consumes 7885 Million units of electrical energy per annum
6.2 MSDS SWITCH BOARD DETAILS

 33 KV Switch board’s at MSDS. There are 25 sections of 33 KV circuit breakers with
bus coupler & tie feeding to various shops from each section.
 33 KV Switch board’s at CPP-1.There are 2 sections of 33 KV circuit breakers feeding

nearby loads.
 33 KV Switch board’s at CPP-2.There are 2 sections of 33 KV circuit breakers feeding

nearby loads.
 33 KV Switch board’s at CDQ.There are 2 sections of 33 KV circuit breakers feeding

nearby loads.

 11 KV Switch board’s at MSDS.There are 06 sections of 11 KV circuit breakers with bus

coupler & tie feeding to shops.
fig16: 220&400 kv switch yard SLD
6.3 ROLES & RESPONSIBILITIES

 Co-ordination with all steel plant shops & oxygen plants.Co-ordination with JSWEL
power plants & Captive power plants to achieve effective & un-interrupted power supply
to JSW complex.
 Forecasts the power consumption plan (power projection) to achieve best power export
schedule.
 Carries out the maintenance activities at MSDS & shop level.
 Power availability during grid disturbances by the way of Composite Intelligent Load
management systems & SCADA System.
 Prepares daily power report for Specific Power monitoring & power optimization of all
the shops.
 PF control through Capacitor Banks at shop level.

 Energy saving project -VVF Drives for motors, Solar Plants water heater for Township
 Responsible for non conventional energy source utilization ex: Installed Wind mill of
12KVA & Solar Plant 70KW.
 Maintains Approx 2580 No's of switchgears and 850No’s of transformers at

33/11/6.6/3.3KV levels in JSW complex.
 Emergency power supply to all the units by maintaining around 28 No’s of Diesel
Generator sets.
 Electrics of 03 townships namely Vidyanagar, VV Nagar & SG Hill town and also JSMS
Hospital
6.4 SHOP WISE AVG POWER CONSUMPTION DATA
Fig17: Shop wise AVG power consumption data

6.5 POWER TRANSFORMER

Total 16 power transformers are present in the jsw which are maintained by the MSDS
department and details of these transformers is given in the below table
Fig18: power transformer’s details

6.6 NEUTRAL EARTHING TRANSFORMER

 Neutral transformer is a device used to create neutral point in a three phase three wires
system.
 The advantages of earthing transformers are -
• Eliminate increase in line to neutral voltages during earth faults.
• Early isolation of faulty electrical equipments.
• Provides an earthing path for ground fault current during earth faults.
• It can be used additionally as station transformer for Low voltage power.
• No change in line to line voltages during single line to earth faults.
 23 Nos of Neutral Earthing transformers are installed to protect the transformers, cables
etc.
fig19:msds net’s details

CHAPTER 7
TESTING AND MAINTANANCE
The following things could interrupt the power supply they are
 GENERATION – loss of cooling, electrical shutdown, etc.

 TRANSMISSION – Lightning, protective device malfunction, overload?
 DISTRIBUTION – animal contact, car pole accident, storms, lightning, overload!
 UTILIZATION – lack of maintenance, inadvertent operation, ground fault, human error
fig20: maintanance

So in order to have continues power, supply there should be testing and maintenance of electrical
equipments take place. In jsw this work will be done by MSDS department. MSDS will undergo
the testing and maintenance of the following equipments,
1. CIRCUIT BREAKER TESTING
2. RELAY TESTING
3. MEGGAR
4. TRANSFORMER OIL TESTING
5. TRANSDUCER
1. CIRCUIT BREAKER TESTING
PROCEDURE
 autotransformer is supplied from single phase source.

 autotransformer is connected to rectifier with converter(AC to DC).
 This DC is connected to timer kit where continues positive DC is given(110 V).
 RYB and R’Y’B’ from timer kit is connected to CBs.
 By using the timer kit we can check the close time, open time, close open time.
 When close time is selected the timer kit gives command to the closing coil in CB,the
closing time of the CB is shown in the time kit.
 Similarly commands are are given to the tripping coil and spring coil and other timings
are noted down.
 Usually close time, open time and close open time varies in terms of 30-45 ms.
The procedure is shown in the figure below

Fig21: Testing of circuit breaker
2. RELAY TESTING
PROCEDURE
 Usually relay is connected to CT, but while relay testing the CT is disconnected from
relay and two contacts which are taken from timer kit is connected to relay. the current is
injected to relay by using the knob on the relay timer kit and relay tripping time is noted
down.
 Similarly for NDR(neutral displacement) test the PT is usually connected. Now remove
the PT and connect the terminals of autotransformer to relay and supply is given, the
relay trip is noted down and this gives earth fault trip time.
 When current is exceeded, the relay will sense that current and master relay will trip and
the breaker will open

Fig22:relay testing
3. MEGGAR
PROCUDER
 It is the procedure used to measure the insulation strength of an electrical equipments.
 For a circuit breaker (say vacuum circuit breaker) it measures insulating strength of
vacuum between two phases.
 Connect the terminals of meggar meter to R&R’ and keep the mode button to 5 kv .
 Then tune yellow color knob up to its maximum value, then note down the resistance (it
may in terms og mega ohm, giga ohm or terra ohm)
 Similar procedure is followed for phase to earth test.

Fig23:meggar
7.1 STATIC VAR COMPANSATOR AT SMS-3

 Only SMS-3 is having SVC in entire jsw plant, because SMS-3 is having ladle
heating furnace and electric arc furnace
 In LHF preheating will takes place where as in EAF directly the pellets gets into
molten metal, So the power factor is very less and it requires lot of reactive
power. In order to compensate this a yard which contains SVC is employed. This
SVC generates reactive power which will supplied to the EAF&LHF.
 If there is excess of reactive power is generated which is more enough for
EAF&LHF then this excess reactive power is absorbed by reactors(shown in
figure below).total 180 MVAr each having 60 MVAr.
 Thyristor controlled reactor is used in SVC. When the gate signal is given to
thyristor,it will operate and allows reactive power to flow into the reactors.

 If gate signal is not given, then the reactive power supplied to LHF&EAF
 Mainly the reactive power is generated by the capacitors. Along with capacitors
inductors are also connected in series and resistors, which will also acts as a
passive filter in order to remove filters of different harmonics as shown in fig
below.
Fig24:SVC yard

CHAPTER 8
CONCLUSION
In these days of our internship we were able to understand the working of a steel plant right from
the Raw material handling till the finished products (such as HR coils, CR coils, Billets, TMT
bars, wire rods, Cement etc.) are out for dispatch. With the help of the kind guidelines from our
mentors I was able to learn the overview of the JSWEL&MSDS.
The jsw group set up its first steel plant in 1982 at Vasind near Mumbai. Soon after, it acquired
Piramal Steel Ltd., The Jindals, who had wide experience in the steel industry, renamed it as
Jindal Iron and Steel Co. Ltd. (JISCO). In 1994, in order to achieve the vision of moving up the
value chain and building a strong, resilient company, Jindal Vijayanagar Steel Ltd. (JVSL) was
set up, with its plant located at Toranagallu in the Bellary-Hospet area of Karnataka, the heart of
the high-grade iron ore belt and spread over 3,700 acres of land. It is just 340 km from
Bangalore, and is well connected with both the Goa and Chennai ports. In 2005, JISCO and
JVSL merged to form JSW Steel Ltd.
JSW Steel offers the entire gamut of steel products – Hot Rolled, Cold Rolled, Galvanized,
Galvalume, Pre-painted Galvanized, Pre-painted Galvalume, TMT bars, Wire Rods & Special
Steel Bars, Rounds & Blooms. JSW Steel has manufacturing facilities at Toranagallu in
Karnataka,
Finally we would like to thank the JSW Steel Plant and all our mentors without whom it would
not have been impossible for us to complete my internship.

References
1. Benifitiation.pellet,corex planta jindal steel works bellary.
2. Blasr furnace,corexsteel melting shop hot streep mill jindal steel works.
3. Energy management system jsw bellary
4. Main step down station jsw bellary.
5. Distribution system jsw bellary.

Report On Internship

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AN INTRENSHIP REPORT ON JSW STEEL LTD BELLARY

Fig: 1 front view of jsw bellary

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 1

1.1 JSW PROCESS FLOW

Fig 2: jsw process flow

Some noteworthy points about JSW are:

 A Greenfield integrated steel plant.

 US$ 2.5 Billion Company.

 Part of O.P.Jindal group.

 Single largest investment in Karnataka of over Rs 8200 crores.

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 2

Hazard: is a dangerous occurrence that can happen in the industry.

However these can be avoided by simple steps.

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 3

Type of fire Substance (A) Extinguisher

a) Ordinary fire Paper (A) Water

b) Liquid fire Petrol, Diesel (B) Foam

c) Gas fire LPG (B) Foam

d) Metal Mg (C) Dry Chemical powder

e) Electric (D) Carbon di oxide

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 4

1. Receive raw materials in adequate quantity.

2. Allocate space for raw material stacking.

3. Effective bedding and blending of incoming raw materials.

4. Timely supply raw material to respective department.

RMHS IS DESIGNED TO HANDLE FOLLOWING RAW MATERIALS :

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 5

3. Stacker cum Re-claimer

6. Twin Boom Stackers

POLLUTION CONTROL EQUIPMENT’S IN RMHS:

1. Industrial Vacuum Cleaning Machine

2. Plain water spray system

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 6

10. Air compressors

fig 3: conveyor belt system

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 7

3.2 BENIFICIATION PLANT

fig 4: benificiation plant

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 8

TYPES OF BENEFICIATION PROCESS

2. Dry cum wet processing

3. WET PROCESSING: Wet processing circuit is generally practiced for low/medium-grade

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 9

3.3 PELLET PLANT

RAW MATERIALS REQUIRED IN PELLET PLANT

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 10

FINAL PRODUCTS OBTAINED

1. Feed preparation - Drying, Grinding and Mixing.

2. Formation of Green pellets and sizing.

3. Green ball induration - Drying, Pre heating, Firing and Cooling.

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 11

3.4 COKE OVEN PLANT

COKE IS PREFERRED OVER COAL IN BLAST FURNACE BECAUSE:

1. Coke has higher burden sustainability,

2. Coke has higher permiability to gases produced in Blast furnace,

3. Coke has a higher reducing capacity,

5. Impurities are less in coke

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 12

Fig 6: coke oven

POWER SYSTEM ENGINEERING,UBDT, DAVANAGERE Page 13

3.5 BLAST FURNACE

RAW MATERIALS REQUIRED IN BLAST FURNACE

FINAL PRODUCTS OBTAINED