Mangement Intern Training in Visag Steel Plant

A Final Year Project Report Submitted in

Partial Fulfilment of the Requirements for the Degree of
Bachelors in Technology(PS-3)

Sri Harsha Sappa 15B00130

Under the Supervision of

S.Surya Shankar
DGM –Telecomminication (VSP)

Department of
Electronics and Communication Engineering
BML Munjal University
2015-19
 ACKNOWLEDGEMENT

It gives us immense pleasure to present our fortnight-3 report, which consists of the
amount of work that has been done in our internship titled PS-3 for Electronics and
communication department, School of engineering and technology, BML MUNJAL
UNIVERSITY. This report is based on methods given by the university.

We feel greatly privileged to express our deepest and most sincere gratitude to our
supervisor, Srinivas Rao sir for his invaluable suggestions and guidance from the start of
the internship, without which this work would not have been materialized. His critiques
helped us to be more precise in our learning, and his questions guided us to think more
carefully about our approaches. The comments and suggestions he gave us on this project
are invaluable.

We have been taking efforts and will continue throughout. However, it would have
not been possible without the kind support and help of many individuals and teachers.
We would like to extend our sincere thanks to all of them.

Last but not the least, we would like to present a special thanks to our families, for their
love, understanding, encouragement, and confidence in us.
 LITERATURE REVIEW
Visakhapatnam Steel Plant, popularly known as Vizag Steel, is an integrated steel
producer in Visakhapatnam, India built using German and Soviet technology.The
company has grown from a loss-making industry to 3-billion-dollar turnover company
registering a growth of 203.6% in just four years. Vizag Steel Plant was
conferred Navratna status on 17 November 2010. Founded in 1971, the company focuses
on producing value-added steel, with 214,000 tonnes produced in August 2010, out of
252,000 tonnes total of salable steel produced.

On 17 April 1970, the Prime Minister of India, the Indira Gandhi, announced the
government's decision to establish a steel plant at Visakhapatnam. With the offer of
assistance from the government of the erstwhile USSR, a revised project evolved some
years later. A detailed project report for a plant with a capacity of 3.4 Mtpa was prepared
in November 1980 and in February 1981, a contract was signed with the USSR for the
preparation of working drawings of coke ovens, blast furnace and sinter plant. The blast
furnace foundation was laid, with first mass concreting, in January 1982. The
construction of the local township was also started at the same time.[3]

In the 1970s, Kurupam Zamindars donated 6,000 acres of land for Vizag Steel Plant. A
new company Rashtriya Ispat Nigam Limited (RINL) was formed on 18 February 1982.
Visakhapatnam Steel Plant was separated from SAIL and RINL was made the corporate
entity of Visakhapatnam Steel Plant in April 1982.
 CONTENTS

Declaration i
Acknowledgement ii
Literature Review iii
Contents iv
Remote telemetry unit (Scada Contd v
Department of Communication )
xvi
Modems
Interposing relays xvii
Cables xix
 REMOTE TELEMETRY UNIT (RTU)

The micro processor based RTU s are installed at various plant Units. The
RTUs will be collecting the signals from the local Instrumentation & Electrical systems
and transmit to the MS when they are polled by the latter.

The RTUs are connected to the MS by under ground telephone cables with
ac MODEMS at MS end and dc MODEMS at RTU end.

OUTSTATION RTU HARDWARE:

The RTU H/W has the following contents:

(1) RTU cabinet

(2) Gland plates / field cables

(3) Terminations and interprosing relays

(4) Basic Tier

(5) I/O Tier

(6) Power Supply Arrangements

(7) Basic Modules

(8) I/O Modules

(9) RTU I/O configuration

RTU CABINET :

The RTUs are houses in standard fabricated steel cabinets of Rugged construction.

The RTU cabinet has an internal structure for:

# Routing the field cable to the terminations.

# Mounting the terminations and interprosing relays.

# Routing the I/O cables from the termination and

interposing relays to the electronic tires.

# Mounting the electronics comprising PCCs fitted in tires.

# Mounting the Power supply unit for providing the logic supplies

to all cards.

The genrnal layout of the RTU cabinet is attached.

A signal cabinet can accommodate a basic tier and an I/O tier. If further
expansion requires two I/O tiers can be added.

GLAND PLATES / FIELD CABLES :

All external connections to the RTU enter the cabinet through Gland plates. The
external connections are communications connection, Power connection and mainly the field
cable connecting to the plant Instrumentation.
Termination & interposing relays :

The field cables entering the RTU are terminated on screwed Terminals mounted
on vertical rails. The interposing relays are plug in type and are accommodated in power
supply
cabinet installed adjacent to RTU cabinet.

The interposing relays are provided where the output control Logic power is not
sufficient to operate a high voltage and current Points.

The connections are made by standard multicore twisted paid Cables and gold
ribbon connectors.

Dia : Testing of in coming signals to RTU from field.

BASIC TIER :

The basic tier is fitted at the top of the cabinet . It houses

1. The basic cards comprising microprocessor card (MP 3) the Analog/Digital

converter (ADC 4) and the master control / test Cards (MCT 2).

2. Upto 8 input / output cards.

3. Power supply Adapter card to distribute the supplies to PCBs.

INPUT / OUTPUT TIER :

The input / output tier is fitted below the basic tier and can Accommodate upto
19 input / output cards.

POWER SUPPLY ARRANGEMENTS :

All RTUs are provided with 230 KV AC operation. The RTU Power supply unit
operates on 24 V DC input and generates all logic Supplies +5V, +12V and -12V required
for the oprations of the RTU. The input 24 V DC is derived from local mains power
supply with a Battery back –up provisiopn with maintenance free sealed lead acid batteries
for 8 hours.

BASIC MODULES :

a) Micro Processor Module (MP 3) :-

The MP 3 is a signal printed circuit board designed for general Use in telecontrol
systems to provide intelligence at the out station, Master station front end to the main
computers telecontrol test Equipment and standby system operation.

# The units is based on 8 bit Motarola M6800 micropocessor.

# The module incorporates a maximum of 8K bytes of PROM

and 4 K bytes RAM.

# The data acquisition, data processing, communication and

housekeeping information of the RTU are performed using
this module with memory.

# This card provides I /O bus catering to the I /O modules end

serial communication interface to modem for communication.
The logic requires the following supplies for a fully fitted card +5
 at 2A, +12V at 0.3A and -12V at 0.15A.

# Facility has been provided for memory extension.

b) Master control test card ( MCT 2 ) :

# This module provides the number of RTU house keeping and

security checking functions.

# This card is degigned to fit a standard I / O card position.

# Main functions :

# Supply of powre to state control relays with local isolation

racllities.

# Generation of check logic pattern on a spection monitor

adderss.

# Generation of ADC calibration check reference voltage .

LEDs are provided to indicate controls.

Internal power required +12V at 28mA

+12V (HU) at 1mA

+15V (ISOL) at 1mA

External power required 24 V or 48 V.

c) Analog to digital conversion card ( ADC 4 ) :

 This card provides successive approximation A / D converter which

Converts 1- 5 volts full scale into 11 bits plus sign digital value.

# This card is used to convert analog input signals into digital

binary data (2’s complement or unipolar or offset binary )

# Opto Isolater s -> to form a barrier between the floating

analog conversion side and an 8 bit moniter high way.

# Analog input are superimposed on common mode. Voltages

to be digitized. Maximum voltage is 50 V dc & value is –80 bd.

# A start conversion signal starts the ADS digitizing cycle and

resets the clock control at the end of conversion.

# When the cycle is complete, the digital data is transferred to

shift register and clocked out across the isolation barrier to a
second shift register. Then data transfer complete signal resets
the clock control and also generates an ADC interrupt / Resets
to indicate data is ready to transfer.

# The basic conversion time is 300ms.

# An ADC output enable signal enables the two- byte transfer

of digitized data on to the moniter highway .

First byte  consists of 8 MSB bits includes sign bit ( if bipolar )

Second byte  contains the 4 LSB bits.

I / O MODULES :
 I/O module unit comprises of the following five I/O cards.

1. ANALOG INPUT MODULE (AMFS 3) :

The AMFS cardscales and filter 8 high level analog current or Voltage input
which are multipexed by relays on to a common output circuit .

# It accepts voltage or current input presented by the instrumentaion.

# The card multiplxexes 8 input to the ADC

# The card accepts either 4—20 m Amps or 1—5 Volts Signals .

# The card function address ( lower ) is set by switches or liens on

the card

# For an 8 bit A/D conversion  1 function adderss is required .

For more than 8 bit conversion  2 function adderss is required .

# In cases of Ms. 8 bits of each of 4 digitized values are allocated

byte position 0,2,4 and 6. The remainder of each value is placed

in the adjacent add byte.

# The card operates from a + 12 V source at 1mA .

( for CMOS Logic )

(2). STATE MONITER BARRIER ( SMB 11 ) :

The SMB 11 card provides an electrically isolated interface between 32 signal bit
plant status inputs and an 8 bit monitor high way . Plant input is typically a dry contract
switching 24 volts ( negative ) to a filter , limiter and opto isolators which gives 1500 volts
plant to logic isolaction . The filter time constant is nominally set to 10 mA . The current for
each input is 5 mA and the 32 inputs have a common positive return.

The card is addressred from a function highway and the 4 x 8 bit bytes are
selected by a slot highway . Function and addresses are set by switches or links on the
cards . When the card in addressed and strobed a card present signal is generated .

The CMOS logic operates from a + 12 volt supply at 10 mA .

(3). STATE CONTROL BARRIER ( SCB 8 ) :

The SCB 8 provides 8 signal bite stae control output an 8 bit control Highway .
Electrical isolation is provided by the use of opto-isolators- ( 1500 volt isolated ) which
provide an output of 100 mA at 24 V DC . An ‘on’ output sinks into a common negative
rail .

The card is addressed from an 8 bit function highway , the control portion
responding to four consecutive addresses each of which allows control data to be latched
in one or four 8 bit latches . Each 8 bit batch is associated with a timer which will reset
the controls after a pre--set time each opto—coupler input is monitored using a
signal monitor address along with the appropriate slot address by a three ploe switch.

In each case the switches may be replaced by appropriate wire links . Circuitry is
provided to ensure that control security is maintained During switch ON/OFF etc .
These circuits are also associated with External control allow and inhibit signals .
 The CMOS logic operates from a 12 volt supply and requires 4 mA plus a nominal
30 mA for each control energized .

(4). TOTALISER CARD ( TL 3 ) :

The TL 3 card count 4 independent pulse stream , in to 8 digit BCD counters . Each
total , 32 bits , can be read by the appropriate function address on to the moniter highway
in 4 byte each of 8 bits .

The card is addressed from an 8 bit function highway . which with A strobe and
slot address selects the appropriate total . each card Requires 2 or 4 function addresses .
Switches are links on the card set

The lowest address when the correct funtion address is received a card present signal is
generated . Varlants of the card input pulses up to 50 V , and TTL or variable level
inputs . Each pulse stream has a maximum has a maximum pulses of less than a
duration set by the card variant .

Local reset is affected by 4 card mounted push buttons . Remote

Reset is provided is by the two LSB s on the control highway in conjunction with
current function address .

A fast count test facility , witch can be isolated by switches on the card , is provided
for each store .

The CMOS logic operates from 12 V supply at 8 mA , which may be Supplied from
external battery back up to hold the count when the Main supplies fail .

(5). ANALOG CONTROL ( AC 5 ) :

The AC 5 card stores and converts 8 bit digital word from a control Highway in to
current or voltage isolated outputs . Each card has four independent D/A converters
which provide the analog outputs when enabled by the appropriate funtion address. The
card has four consecutive control address , which are selected as a block by the 6 most
significant switches or the card .

The card is addressed from a 8 bit function highway , which in Conjunction

with a strobe , allows the digital word on a control highway To be read in and stored .

The stored outputs operate opto – electric devices which from an Isolating barrier
between the digital logic and the D / A converters . This

Allows the analog outputs to be operated from independent power Supplies . The
status of each store can be monitored via the Monitor Highway on receipt of the
appropriate function / slot address .

The latches can be powered from an independent 12 V hold up Supply and

during switch ON—OFF this supply the latches are set to give zero analog output . This
circuit is also associated with an external analog control inhibit signal . A card present
signal is indicated when the correct function is present .

The external load should be the range 250 — 500 ohms . The analog output are
isolated from the control logic and each other . The output circuits required external
isolated power supplies each of 24 V at 26 mA .The CMOS logic, together with the op--to
isolators ,operates from a 12 V at 1.2 mA when other supplies are present and 2.2 mA when
other supplies fail .

PRINCIPLES OF SYSTEM OPERATION :

The basic principle of this system of data transmission between the Master Station (
MS ) and any particular RTU in either direction is time – division multiplexing .
 Where the MS has to communicate with a number of RTU’s multidropped
on a common communication circuit . this system normally uses time — division
multiplexing between RTU’s .This is achieved by use of the uniqe outstation address
encoded in the hardware of each RTU.

The basic of data transmission is the word . In interrogation mode the word comprises
two message , the interrogation message directed from MS to RTU s .

Each message comprises up to 32 bytes . The first byte contains RTU addressing
information . The second byte indicates message length. There then follows a number of
information and or status bytes and finally

A Bose - Chaudhury - Hoocquenhem ( BCH ) check character generated Over the

message using the generator polynomial .
X^8+X^7+X^5+X+1

Each byte comprises a start bit ( logic zero ) eight data bits and byte comprises A
start bit (logic zero) , eight data bits and a stop bit (logic one ).

The Eight data bits are numberded 0 , least significant ( LS ) to 7 , most Significant ( MS
) . Bit 0 is terminated to a serial communication channel first , bit 7 last .

INTERROGATION MODE WORD STRUCTURE:

Address byte: out station address.This is the unique address of the RTU being interrogated.

Byte count Byte: this is the number of information bytes in the message.

Information bytes: function address and data bytes.These bytes may be used to transmit
information to the RTU, or to define which information to the RTU is to transmit back to the MS.
Check byte: BCH code check.

Reply Message(13 bytes):

Address byte: outstation address. This is the repeat of the first byte of the interrogation message.

Byte count byte: this is the number of information/status bytes in the massage.

Information bytes: function address and data where information has been transmitted to the RTU ;
these bytes are used as acknowledgement, which may include information received by the RTU.
When information is requested information is transmitted in these bytes.

Status bytes: RTU status. This is a monitor of important RTU status conditions.

Check byte: BCH code check.

MODEMS

The multi-tech computers multi 748 A is a microprocessor controlled CCIT V.27 bits/tier
compatable leased line modem. It can be operated at 2400 or 4800 baud, in either two or four wire
synchronous modes. Two-wire operation is only half duplex. The multi modem 748 A incorporates
fall back to 2400 baud when operating the V.27 internal DIP switches, jumpers and modem
commands control the mode of operation.

The multi modem 748 A uses 8 level DPSK modulation. The carrier frequencies are 1800 Hz at
4800 baud. The transmit level is adjustable from 0 DBm with the help of a potentiometer given on
the PCB. In asynchronous operation the character length is 10 bit. The receiver sensitivity of the
multi modem 748 A is 43 DBm.

Operation:

On power up or reset of the multi modem 748 A, the microprocessor reads the operating
parameters from either the DIP switch settings and ROM or if the user has told options from RAM.

The speed switch on the front panel controls the speed of the data rate. The rate of high and
low speeds is determined by the mode of operation.

There are two blocks of DIP switches on the multi modem 748A circuit board used for
configuring various options. 8 positions and 4 positions DIP switch, are both accessed from the
bottom of the chassis.

INTERPOSING RELAYS

MODEMS :
PRESENT SYSTEM :

Presently the power supply (230 Volts AC) arrangement to the PSU and AC modems (18
nos.), which are at MS, is taken from one breaker (5 Amps), which is in side by system department
room. This power supply is directly terminating in terminal strip in loop as a loop out fashion. The
PSU of AC modem is directly connected to another side of the terminal strip. There is no ON /
OFF control on PSU in order to do maintenance or attend problem of PSU of AC modem. Working
of AC modems are intiable the functioning of CSCS. So in order attend complaint at power supply
 unit of AC modem the main breaker has to switch off, which in turn causing total shut down of
CSCS.

PRESENT DIFFICULTIES:

The PSU arrangement to PSU of AC modems is in such a way that to attend the complaint in
one PSU of AC modem requires total shut down of CSCS does not permit coordination and meeting
the demands of the various in plant consumers and to exercise effective control over their
consumption for optimum utilization of energy resources.

More over permission for total shut down of CSCS is very lengthy process. The main
breaker, which is in systems department room, is not in convenient for maintenance position.

PROPOSED SYSTEM :

In proposed system of power supply 230 AC arrangement to PSU of AC modems has to take
AC power supply from U.P.S and install one double pole, double breaker is fed to 18 nos. of single
pole breakers and output of breakers is connected to terminal strip. At another side terminal strip it
is connected to PSU neutral has to directly take from double pole switch and it should connect to
terminal strip directly in loop out put fashion. All breakers should keep in one enclosed box and it
should install nearby AC modem rack. So while doing maintenance or attending problem in any
PSU of any modem it is easy maintenance people. Another important advantage is that avoids the
total shutdown of CSCS.

REQUIREMENTS :

To carry out the modification of the power supply arrangements to PSU and AC modem of
CSCS needs.

o One Double pole double switch

o Eighteen pole single switch.
o Eighteen, 50 mts multi strand
o Enclosures for installation of all these switches
o Locking arrangements

BENEFITS :

The modification in power supply arrangements to PSU of AC modems of CSCS is mainly

intended to increase the availability of system in generation.

This modification,
 Eliminates the down time to total CSCS
 Increases the optimum utilization of resources like fuel utilities and electric power.
 Helps in reducing specific energy consumption of steel.
 Improvement in safety, quality of service
 Ease in maintenance.

CABLES

Objective :
In both interrogation and broadcasting mode there is a continuous Transfer of
information between the RTU and the MS so there is a Necessity of a physical
medium to facilitate the flow of information

( Electrical Signal ) . Cables perform the job of interconnected the field RTU’s and MS
.

The inter connectig cables required for connecting various terminals Can be clssified
in to 3 categories and the technical specification of various cables are also given below .

CATEGORY – I :

Telephone cables required for inter connection of RTU’s and the MS.
 # 5Pair Petroleum jelly filled.
# Armored.
# Over all polythene packeted.
# Solid annealed high conductivity copper.
# Diameter 0.633mm.
# Resistance 57 ohm /KM.

CATEGORY-- II :

Twited pair cables rwquired for the inter connection of remote video terminal to the
master stations .

# 5Pair.

# Diameter 7/ 0.2 MM.

# Individually and over all shielded.

# Armored cables.

CATEGORY – III :

Control cables required for the inter connection of signals from plant units and
junction boxes to the RTU’s .

# Size 1.5 mm.

# Solid annealed copper conductor.
# Multi core control cable.
# Armored and unarmored.
# Thickness 0.8 mm.
 # Resistance 12.1 ohm / KM.
# PVC Insulated.

The cables will be laid partly on cable trays in cable tunnels and balance the
directly buried under ground .

Progress till 26th Feb 2019…….!!!