A study to improve the TEF’s at Bar Mill of VISP, Bhadravati
- Samuel Prabhurajan, Dy.General Manager (Mills & RTS)
GRADES MANUFACTURED
• CARBON & ALLOY CONSTRUCTIONAL STEELS
• FREE-CUTTING STEELS
CASE HARDENING STEELS• CONSTRUCTIONAL STEELS• CASE HARDENING STEELS • SPRING STEELS
GRADES
• BALL BEARING STEELS• TOOL & DIE STEELS
• NITRIDING STEELS• SOFT MAGNETIC IRONTOOL & DIE STEELS SOFT MAGNETIC IRON
MAJOR CUSTOMERS
1. DEFENCE UNITS: ORDNANCE FACTORY, AMBAJHARI
ORDNANCE FACTORY KANPUR ORDNANCE FACTORY, KANPUR ORDNANCE FACTORY, KHAMARIA ORDNANCE FACTORY, TRICHY METAL & STEEL FACTORY, ISHAPORE RIFLE FACTORY, ISHAPORE SMALL ARMS FACTORY, KANPUR, HEAVY VEHICLES FACTORY, AVADI
2. RAILWAYS:2. RAILWAYS: INTEGRAL COACH FACTORY, PERAMBUR CENTRAL RAILWAY, MUMBAI RAIL SPRING KARKHANA GWALIOR RAIL SPRING KARKHANA, GWALIOR DIESEL LOCO WORKS, VARANASI SOUTHERN RAILWAY, PODANUR
RAIL WHEEL FACTORY BANGALORE RAIL WHEEL FACTORY, BANGALORE
3. POWER SECTOR: BHEL UNITS, HYDERABAD, TRICHY, HARDWAR
MAJOR CUSTOMERS
4. ENGINEERING INDUSTRY:
SHANTI GEARS, COIMBATORE KIRLOSKAR TOYODA TEXTILE MACHINERY, BANGALOREKIRLOSKAR TOYODA TEXTILE MACHINERY, BANGALORE DYNAMATIC TECH, BANGALORE FERROMATIC MILACRON, AHMEDABAD DEE TEE INDUSTRIES INDORE DEE TEE INDUSTRIES, INDORE BEML UNITS
5 AUTOMOBILE / FORGING INDUSTRY5. AUTOMOBILE / FORGING INDUSTRY: BHARAT FORGE LIMITED, PUNE AHMEDNAGAR FORGINGS LIMITED, PUNE KTTM, Bangalore MERCURY PRECISIONS, CHENNAI CVM PRECISIONS, Bangalore LGB, MYSORE AUTOMOTIVE AXLES LIMITED, MYSORE
MAJOR CUSTOMERS
TATA MOTORS, JAMSHEDPURSIFL THRISSUR SIFL, THRISSUR
MGM INDUSTRIES LIMITED, MYSORE SHARDLOW INDIA LIMITED, CHENNAI,
6. EARTH MOVERS: BEML UNITS BANGALORE MYSORE KOLAR GOLD FIELDS BEML UNITS, BANGALORE, MYSORE, KOLAR GOLD FIELDS L&T, BANGALORE
7. BEARING INDUSTRY: NEI, JAIPUR JINABAKUL FORGE PRIVATE LIMITED, BELGAUMJINABAKUL FORGE PRIVATE LIMITED, BELGAUM DUAL RINGS, HYDERABAD AUSTIN ENGINEERING, JUNAGADH
PROCESS & PRODUCT RANGE OF MILLS
PRIMARY MILL : Capacity – 78000 Tns/Year
Two Pusher type furnaces - 15 T/hr capacity (OFU)One Pusher type furnace 30 T/hr capacity (Wesman)
One CSP - 3 T/hr capacity
One Pusher type furnace - 30 T/hr capacity (Wesman)
One Blooming Mill - Single stand 3 Hi, 700 X 2000 mm
p y
Finishing Mill - 3 stand / 3 Hi / 600 X 1800 mm
g g ,
Shearing Machine, Hot Saws, Cooling Bed, Controlled Cooling Pits etc
Product range - 60 to 140 Rounds & Billets, Flats and Bl
Cooling Pits etc
Blooms
PROCESS & PRODUCT RANGE OF MILLS
BAR MILL : Capacity – 36000 Tns/Year
Two Walking Hearth furnaces – 7 T/hr capacity
p y
De-scaling unit
g p y
Roughing Mill - Single stand / 3-High – 520 x 1600mm
Intermediate Mill – 3-stand / 3-High – 440 x 1200 mm
Shearing Machine, Hot saws, cooling bed, controlled
Finishing Mill - 1 stand / 2-High – 420 x 800 mm
Product range (a) 20 to 60 Rounds (b) 36 to 75 Rcs and
Shearing Machine, Hot saws, cooling bed, controlled cooling Pits etc.
g ( ) ( )(c) Flats
High Value Long Products
Majority of VISL Products are specific tailor-made t i l f S ifi iti Si Sh d materials of Specific composition, Size, Shapes and
lengths.
High Value Items Rolled for Defence Units:
GRADE: GOST B 9032-73 Grade III – OA Flats
M&SF I h78 X 14 20
g
M&SF, Ishapore90 X 17.20
M&SF, Ishapore78 X 14.20
OFAJ, Nagpur 230 X 21.20
M&SF, Ishapore 235 X 21.50
High Value Long Products
OFAJ, Nagpur140 Rcs - SAE 9260
OF K96 R 35M 6M 3
OFAJ, Nagpur140 Rcs - B 14
OFAJ, Nagpur105 R 48X3
OF, Kanpur96 Rcs - 35Mn6Mo3
, gpOF, Kanpur
105 Rcs - 48X3
OF, Kanpur 96 / 120 R SSB27
OFAJ, Nagpur 105 Rcs - 45X1
OFAJ Nagpur64 Rcs SSF44
, pOFAJ, Nagpur
96 / 120 Rcs - SSB27
OFAJ, Nagpur64 Rcs - SSF44
High Value Long Products
OFT36 SCS – 709 M40
RFI / OFT46 SCS - EN21
OFT53 RCS - 070 M55
RFISAF, KanpurOFT
32 Rds - EN 39B
RFISAF, Kanpur42 Rds - 655M13OFT
LENGTHY TIE-RODS
Fe410WA-40 dia 14.425 MtrsBhilai Engg Corpn, Bhilai
15Cr90MO55-50 dia 15.15 MtrsFe410WA 50 dia 14 625 Mtrs
Bhilai
15Cr90MO55-36 dia 14.50 Mtrs
Fe410WA 50 dia 14.625 Mtrs
Fe410WA-50 dia 17.20 Mtrs, BSP Bhilai
CI IV 36 dia 17.78 Mtrs
56 Dia 18.20 MtrsBSP, Bhilai
Fe410WA-50 dia 17.00 MtrsFe410WA 50 dia 17.00 MtrsFe410WA-50 dia 17.50 Mtrs
BSL, Bokaro
FFE Mineral India,
15Cr90MO55-36 dia 16.00 MtrsRSP, Rourkela
42CrMO4-32 dia 12.30 MtrsChennai ,M/s JVSL , Bellary
Other High Value Products
Borewell Drill Bits125 Rcs - EN 36C
Central RailwayRifle factory,Ishapore
20.64 Rds - 55Si750 X 38 mm flat-EN24
Crompton GreavesSoft Magnetic Iron
Rifle factory,Ishapore50 X 38 mm flat EN24
Bokaro Steel PlantCRM Rolls
Southern Railways20dia, 22dia, 25dia
Bokaro Steel PlantM/s JVSLRSP (Pipe Plant)
CRM RollsCC Rollers, HSM RollersD2 Rolls RSP (Pipe Plant)D2 Rolls
Other High Value Products
FLATS FOR INTER - PLANTS
BHILAI STEEL PLANTBHILAI STEEL PLANT
40 X 6, 50 X 8, 50 X 10, 50 X 14, 80 X 6, 90 X 20, 100 X 10, 100 X 12
TECHNO ECONOMIC PARAMETERS
Parameters 2017-18 2018‐19(Apr‐Dec)
Production ,MT 0.010 0.0053
A il bili % f l d h 1 33 42Availability, % of calender hour 75.71 33.42
Utilisation, % of available hour 72.09 69.08
Rolling rate / production rate, T/hr 7.41 7.93Yield ,% 96.26 96.57
Specific fuel/ heat consumption, Gcal /T 0.9398 0.6455Specific power consumption, kwh / T 140.96 121.02Specific water consumption, M3 /T 96.62 43.66
Specific roll consumption, Kg/T 0.01 0.01p p gSpecific lubricant consumption, L/T 0.01 0.01
Specific rolling oil consumption, L/T 98.60 79.33Specific rolling oil consumption, L/T 98.60 79.33Quality diversion,% Nil Nil
R lli f 40 di G d MSIS 2062Rolling of 40 mm dia, Grade MSIS 2062, M/S. BHEL
Period : 03/11/2018 to 20/11/2018
ROLLING ROLLING
PRODUCTIONOIL
CONSUMPTIONPOWER
YIELD RATE
INPUT OUTPUT Ltr/tnCONSUMPTION % Tns/hr
INPUT OUTPUT Ltr/tnKwh/tn
97 38 8 822407 2344 59.81 101 97.38 8.82
COST BENEFIT ANALYSIS
Particulars Norm Three shift operation
TEF Rate V.Cost TEF Rate V.Cost
Rs/Unit Rs/Tn Rs/Unit Rs/TnMill Utilisation 18 HrsProduction 150 TnsProduction 150 TnsPower(KWh/tn) 130 7.64 993 101.4 7.64 775Fuel(Ltrs/tn) 70 32.00 2240 59.81 32.00 1914General Stores 92 78General Stores 92 78Pur.Refractories 139 139Own Refractories etc 75 75Services 362 362Services 362 362Shop & Fdry charges 27 27
T t l 3928 3370Total 3928 3370Savings (Rs/Tn) 558
R lli Yi ld 98% 97 38%Rolling Yield 98% 97.38%
Savings considering Yield Impact 556
2407 X 556 - 13,38,292
Rolling of 90X17.2 mm Flats for M/s MSFPeriod of study: 21/01/2019 to 29/01/2019
OILROLLING
YIELDRATE OFROLLING
PRODUCTIONOIL
CONSUMPTIONPOWER
YIELD ROLLING
INPUT OUTPUT Ltr/tnCONSUMPTION
/ K h/
% Tn/hr
/ Kwh/tn
1200 1160 57.51 100.53 96.66% 10.44
COST BENEFIT ANALYSIS
Particulars Norm Three shift operationParticulars Norm Three shift operationTEF Rate V.Cost TEF Rate V.Cost
Rs/Unit Rs/Tn Rs/Unit Rs/TnMill Utilisation 20 HrsProduction 150 TnsPower(KWh/tn) 130 7.64 993 100.53 7.64 768( )Fuel(Ltrs/tn) 70 32.00 2240 57.51 32.00 1840General Stores 92 78Pur Refractories 139 139Pur.Refractories 139 139Own Refractories etc 75 75Services 362 362
h d hShop & Fdry charges 27 27
Total 3928 3290Savings (Rs/Tn) 638
Rolling Yield 98 00% 96 66%Rolling Yield 98.00% 96.66%
Savings considering Yield I t 629Impact 629
1200 Tns X 629 - 7,54,800
BENEFITS DERIVED DUE TO THE STUDY
Case:1 Rolling of 40 mm dia, Grade MSIS 2062, M/S. BHEL
R 13 38 292Rs. 13,38,292
Case : 2 Rolling of 90 X 17 2 mm Flats for M/S MSFCase : 2 Rolling of 90 X 17.2 mm Flats for M/S MSF
Rs. 7,54,800Rs. 7,54,800