SCADA SYSTEM IN VISAKHAPATNAM STEEL PLANT A Project report submitted in partial fulfillment of the requirements for the award of Bachelor of Technology In Electronics and communication Engineering Submitted by K.S.GAYATRI R.ARUNA SHEIK NAGOOR MEERAVALI Y.VENKATA RAMANA Y.ARUNA KUMAR Under the Guidance of B.KRUPANANDAM Manager(Telecom)
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SCADA SYSTEM IN VISAKHAPATNAM STEEL
PLANT
A Project report submitted in partial
fulfillment of the requirements for the
award of
Bachelor of Technology
In
Electronics and communication
Engineering
Submitted by
K.S.GAYATRI R.ARUNA
SHEIK NAGOOR MEERAVALI
Y.VENKATA RAMANA Y.ARUNA
KUMAR
Under the Guidance of
B.KRUPANANDAM
Manager(Telecom)
Visakhapatnam Steel Plant
Visakhapatnam
ST.THERESSA INSTITUTE OF ENGINEERING AND TECHNOLOGY
(Affiliated to JNTU)
GARIVIDI
CERTIFICATE
This is to certify that the Project work entitled “ SCADA system in
VSP” is a bonafide record of work done by Y.Venakta Ramana,
K.S.Gayatri, Shaik Nagoor Meera Vali, R.Aruna and Y.Aruna Kumar,
students of St.Theressa Institute of Engineering and Technology, Garividi
have been sincere, dedicated and the conduct throughout the study has been
excellent in partial fulfillment of the requirement for the award of degree in
BACHELOR OF TECHNOLOGY under the guidance and supervision in
VISAKHAPATNAM STEEL PLANT.
Visakhapatnam Signature of Guide
Date :
ACKNOWLEDGEMENT
We hereby take this opportunity to express our sincere gratitude to the
following eminent personalities whose aid and advice helped us to complete
this project work successfully without any difficulty.
We are thankful to Mr. B.Krupanandam, Manager (Telecom) who has
been with us all through the project to spend his valuable time and to share
his knowledge.
As a token of our feeling, we would like to acknowledge our sincere
regards to our internal guide Mr. B. Vijaya Bhaskar Rao and our HOD Mr.
B.Rajesh Kumar, for allowing us to take up a project in a working plant we
express our gratitude to Sri.V.V.Narayana Murthy (Principal) STIET and
Sri. M.Sreenivasa Rao (Correspondent), for their cooperation during the
project period. We are also thankful to faculty members for their kind
cooperation and assistance.
INDEX
Abstract
Major Department of Visakhapatnam Steel Plant
Different Communication Systems in Visakhapatnam Steel
Plant
Introduction
Supervisory control and data acquisition system -
Architecture
Remote telemetry unit (RTU) – Block Diagrams
Modems
Cables
Master Station
Power supply requirements and specifications
Software
Conclusion
ABSTRACT
In this modern world of Industrialization and automation, energy
plays a major role in the growth of any organization. The utilization of
energy plays an impacting and direct role in the growth of organizations like
Visakhapatnam Steel Plant.
In Vizag Steel Plant, there is a supervisory control and data
acquisition system (SCADA) present for monitoring of energy networks
which are present through out the plant. The objective of this proposed
SCADA system is to monitor the energy usage and demands of various
consumers of the plant and exercise effective control over their energy
consumption optimum utilization of in-house energy resources.
In this modern world of competition, the technology is changing very
rapidly. To compete with the changes and to sustain the development,
Visakhapatnam Steel Plant is going for upgradation of its existing SCADA
system with the latest state of art – technology with the features like using
high speed processors having cache – memory and using the powerful unix
based OS.
This project makes a brief study of existing “SCADA” system present
in Visakhapatnam Steel Plant and the changes that are going to come to in
the proposed SCADA system that is to be installed in the near future.
GROWTH AND IMPORTANCE OF STEEL
INDUSTRY IN INDIA
Steel comprises one of the most important inputs in all sectors of economy. Steel
industry is both a basic core industry. The economy if any depends on strong base of iron
and steel industry in that nation. History has shown base of iron and steel industry in that
nation.
History has shown that countries having a string potentiality for iron and steel
production have played a prominent role in the advancement of civilization in the world.
Steel is such a versatile commodity that every object we see in our day to day life has
used steel either directly or indirectly.
However its use is innumerable to mention a few, it is used for such small items as
nails, pins, needles, etc., through surgical instruments, agricultural implements, ships,
boilers, frigates, railway materials, automobile parts etc., the great investment that has
gone in to the fundamental research in iron and steel technology has helped both directly
and indirectly many modern fields of today's civilization without steel. Steel is versatile
and indispensable item. The versatility of steel can be traced to mainly three reasons:
It is the only material item, which can be conveniently produced in tonnage
quantities.
It has got very good strength coupled with ductility and malleability.
Its property can be changed over a wide range.
It alloys easily with many of the common elements.
The properties can be manipulated to any extent by proper heat treatment
techniques.
Taking these factors in to consideration, it can be said without committing a
serious error, that the types of steel available are innumerable.
"Visakhapatnam steel plant is an integrated steel plant."
CHARACTERISTICS OF INTEGRATED STEEL PLANT:
This integrated steel plant has large capacities, highly capital intensive, labour
intensive and they would have all facilities including raw material resources, water
supply, power supply, testing and inspection facilities, township facilities, medical,
educational recreational etc., all under one administrative control. This would reduce
the extent of dependency on outside agencies, which would help the smooth running of
the plant.
TECHNOLOGY IN STEEL PLANT:
Visakhapatnam steel plant is the most sophisticated and modern integrated steel plant
in the country. Modern technology has been adapted in the many areas of production,
some of them for the first time in the country, among these are :
Selective crushing of coal.
Evenching of coke
Conveyor charging and bell less top for blast furnace.
100% continous casting of liquid steel.
Gas expansion turbine for power generation utilizing blast furnace top gas pressure.
Hot metal desulphurization.
Etensive treatment facilities for effluents for ensuring proper environment protection.
Computerization for process control.
Sophisticated, high speech and high production rolling mills.
HALL OF FAME:
Visakhapatnam steel plant has the distinction to be first integrated steel plant in
India to become a fully ISO9002 certified company. The certificate covers the quality
systems of all operational, maintenance, service units. Besides purchase systems,
training and marketing functions spreading over regional marketing offices,20 branch
offices and 22 stock yards located all over the country.
Visakhapatnam steel plant by successfully installing and operating efficiency
Rs.480 crores worth of pollution control and environment equipments and converting
barrel landscape by planting more than three million plants has made the steel plant
township and surroundings in to heaven of greenery.
Visakhapatnam steel plant exports quality pig iron and steel products to Srilanka,
Myanmar,Nepal, Middle East ,USA and South East areas.RINL- Visakhapatnam steel
plant was awarded "STAR TRADING HOUSE" status during 1997-2000. Having
establishing a fairly dependable export market.
Having a total man power of 17250 Visakhapatnam steel plant has envisaged a
labour productivity not less than 230 tonnes of liquid steel per man, which is the best in
the country and is comparable with the international levels.
MAJOR DEPARTMENTS OF
VISAKHAPATNAM STEEL PLANT
RAW MATERIAL HANDLING PLANT(RMHP):
The RMHP receives the basic materials required for the steel making process from
various sources through wagons which are stacked and reclaimed by stackerd and
reclaimed by stackers-cum reclaimers and distributed to various departments of
Visakhapatnam steel plant through conveyor systems.
COKE OVENS (CO):
Coke is a hard, porous mass obtained by fractional distillation of coal in the absence
of air at a temperature above 200deg.centigrade for period of 16 hrs to 18 hrs. It is used
as a fuel and reducing agent of iron ore in blast furnace. Three coke oven batteries for
production of 2.26 MT dry coke, each with 7 meters tall 67 ovens. Each battery is
provided with facilities for dry cooling of coke using nitrogen as quenching media for dry
cooling of coke as well as for recovering sensible heat of coke. As a by-product a CO
gas is produced in this processes and this gas is having a very high calorific value for
about 2400-2700KCAl and is produced throughout the plant as a fuel.
SINTER PLANT:
Sintering is one of the most widely used and economic agglomeration techniques.
Sinter is a hard and porous lump obtained by agglomeration of fines of iron ore, coke,
limestone , and metallurgical waste. Sinter increases the productivity of blast furnace,
improves the quality of pig iron and decreases the consumption of coke rate. Two 312
square meter sinter machines with 420 square meter straight stand type coolers for annual
production of 5.26 MT sinter.
BLAST FURNACE(BF):
Pig iron or hot metal is produced in the Blast Furnace. The furnace is named as
BF as it is run with blast at high temperature and pressure of 1500 deg. C. Raw materials
required for pig iron and iron are iron making ore, sinter, coke, and lime stone. There are
two 3200 cubic meter blast furnace to meet 3.0 MT annual metal requirement. Each
furnace is designed for 205 at mg top pressure, and will be belt charged and equipped
with bell-less Paul-wurth top. Each furnace is provided with a set of four hot blast
furnace stoves designed for supplying air blast up to 1300 deg.C. Three turbo
blowers ,one for each furnace and one stand by common to both furnaces are provided
with 12 MW top pressure recovery turbo generating power. BF gas is produced from
each furnace is being cleaned in gas cleaning plant comprising dust catcher, high pressure
scrubber and is distributed through out the plant as a fuel.
STEEL MELT SHOP(SMS):
Steel is an alloy iron and carbon ,where carbon should be less than 2%.Hot metal
produced in B.F contains impurities like carbon, sulphur, phosphorous, silicon etc., these
impurities will be removed in steel making by oxidation process. These are the three L.D
convertors to convert hot metal in to steel. The steel melt shop complex comprising two
1300-ton hot metal mixers, three 130-ton LD converters (two operating) and six 4-stand
bloom casters. Each converter is being provided with gas cleaning plant for cleaning and
recovery of LD gas, which will be used as fuel in plant.
ROLLING MILLS(RM):
Blooms cannot be used as they are in daily like. These blooms have to be reduced
in size and properly shaped to fit for various jobs. Rolling is one of the mechanical
processes to reduce large size sections in to smaller ones. The cast blooms from CCM
are heated and rolled in to long products of different specifications like high capacity,
sophisticated high-speed rolling mills. The rolling mill complex comprises :
Light and medium merchant mill (LMMM)
Wire rod mill (WRM)
Medium merchant and structured mill (MMSM).
Each mill is well equipped with required number of walking beam furnaces for
heating of walking beam furnaces for heating of blooms or billets and except for wire rod
mills, each furnace is provided with evaporative cooling system for generation of steel for
plant consumption.
THERMAL POWER PLANT(TPP):
The estimated power requirement for V.S.P in 280 at 3.0 MT stages, the peak
load being 292 MW essential loads being 49 MW. The generating capacities 286.5
MW. A captive power having 3*60 MW turbo-generator sets and 5*330 ton/hr steam
generators. In this plant, 6000 Nm^3/min turbo blowers are being provided for supplying
cold air blast furnaces.
TYPES OF COMMUNICATION EQUIPMENT AVAILABLE
In this modern age of industrialization telecommunications plays a very important
role in coordinating the activities of various departments / sections and in achieving the
set targets and also in improving the performance of any organization. In Visakhapatnam
Steel Plant, different types of communication systems are being used to meet the internal
and external communication needs. These are broadly classified as follow:
a. General purpose communication systems.
b. Process communication systems.
c. Monitoring & Signaling Systems.
GENERAL PURPOSE COMMUNICATION SYSTEMS :
The following facilities are provided under category of general purpose communication
systems:
3000 lines Electronic Exchange in Plant.
2000 lines Electronic Exchange in Township.
100 lines Electronic Exchange in Visakha Steel General Hospital.
44 lines Electronic exchange in Hill Top Guest House.
2500 Lines Electronic Exchange of Bharat Sanchar Nigam ltd (BSNL) in Project
Office is catering to the needs of Plant area and Sectors-I to VII in township.
Another 2000 Lines Electronic Exchange of Bharat Sanchar Nigam ltd (BSNL) in
Township is catering to the needs of Sectors-VIII to XI in Township.
The 3000 Lines electronic exchange in plant and 2000 lines exchange in township
are having the following facilities:
Extension (subscriber) to extension call, Auto call back, Hot lines, Music on hold,
Reminder Alarm, Automatic line testing facility, Faults man ring back, Call consult
facility, Malicious call tracing facility, 3 party conference Facility and Howler Tone alert
etc.
All exchanges working in the steel plant are interconnected by means of junction
lines and have closed numbering scheme. For communicating with any subscriber of any
exchange no extra digits have to be dialed and only the desired number is to be dialed. –
connection pattern given at fig 1.
The 2000 lines exchange in township is interconnected to the BSNL network. Due
to this interconnection all the subscribers of this exchange can receive incoming calls
from any part of the world. A few subscribers are provided with facility to contact
subscribers connected to the BSNL network and cellular and mobile phones in and
around Visakhapatnam.
PROCESS COMMUNICATION SYSTEMS :
To facilitate coordination, operation & management activities of production,
maintenance & service departments, the following process communication systems are
provided:
a) Despatcher communication system
b) Loudspeaker intercom systems
c) Loudspeaker broadcasting systems
d) Loudspeaker conference communication system
e) Industrial public address system
f) Hotline communication systems
g) VHF communication systems
A) DESPATCHER COMMUNICATION SYSTEMS:
Initially cordless switch board type manual exchanges of electromechanical
version were provided. Since manufacture of such systems and their spares is
discontinued in the country, these despatcher systems are being replaced by Electronic
exchanges progressively. Except the ones in CCCP other systems have been replaced.
These would also be replaced very soon.
Production coordination at plant level being conducted by ED (Works) with all
HODs in the morning every day is facilitated with the help of the digital EXCOM system
provided in the plant control room.
B) LOUDSPEAKER INTERCOM SYSTEMS:
Loudspeaker intercom systems are working LMMM & WRM. These systems are
used for communication between various sections of the same production shop.
Communication is made possible using microphones and loudspeakers provided in the
subscriber stations. This system is very useful in noisy environment where conventional
telephones are ineffective. This system helps to establish communication between any
two stations having interconnectivity on selection basis. By using group call facility it is
possible to communicate to all the subscribers in the group at a time.
c) LOUDSPEAKER BROADCASTING SYSTEMS:
Loudspeaker broad casting systems are provided in C&CCD, BF, SP and SMS
departments. This system is useful to make general announcements to the entire area of
working and so can be used to locate operation / maintenance personnel working on the
shop-floor so as to pass-on important instructions from the control room.
D) LOUDSPEAKER CONFERENCE COMMUNICATION SYSTEMS:
Loudspeaker conference communication systems is working in CCCP. These
systems are provided with both paging and private channel communication facilities. In
case of paging a general announcement can be made which is heard on all the stations. In
the private mode communication is possible between two selected stations only. Here
also communication is carried out by means of microphones and loudspeakers provided
in the subscriber stations.
E) INDUSTRIAL PUBLIC ADDRESS SYSTEM:
Industrial Public Address System is working in TPP. It is a combination of
loudspeaker broadcasting system and conference communication system. From the main
control room it is possible to make announcements which are heard on the shop-floor.
From certain locations the communication can also be established through handsets in
private mode with the main control room.
F) HOTLINE COMMUNICATION SYSTEMS:
To ensure direct telephone communication between closely related critical
locations hot lines are provided. By using the hot lines specified locations are connected
permanently. Communication is possible only between these two locations. When one
subscriber lifts his telephone the other will immediately get a ring and communication
can be had without any loss of time. This is useful to pass-on urgent messages. These hot
lines are initially provided with direct line communication systems which are electro
mechanical systems. Due to obsolescence electronic systems are now being used for most
of the locations. Hot lines are working in CCCP, BF,SMS, LMMM, WRM, MMSM,
TPP, PPM, DNW and WMD departments.
G) VHF COMMUNICATION SYSTEMS:
VHF communication systems are used in our plant to establish two way
communication between two or more when either or one of them is moving. There are
three models working in our plant. They are hand-held units (walkie-talkie), vehicle
mounted – mobile units and base station units. Walkie-talkies are used by operation and
service personnel in almost all of the production shops. Vehicle mounted units are being
used by DNW, CISF (Fire) and CISF (security). Base station units are used by CISF
(fire), CISF (Security), Administration, DNW and largely by CCCP departments. In
CCCP these can be seen in pusher cars, charging cars, door extractors, electric locos,
lifters and CDCP area.
MONITORING AND SIGNALING SYSTEMS :
To facilitate monitoring production, maintenance & service activities, the following
monitoring and signaling systems are provided:
a) Closed Circuit Television Systems (CCTV):
b) Central fire alarm signaling system
c) SCADA system
d) Shift change Announcement Siren System
A) CLOSED CIRCUIT TELEVISION SYSTEMS (CCTV):
For monitoring critical operations in different production units continuously from the
concerned control rooms / pulpits CCTV systems are used in SP, BF, SMS, LMMM,
WRM and MMSM departments. CCTV system comprises of CCTV camera with a lens
and a CCTV monitor. In some cases a video switcher, a central control console, pan and
tilt head and zoom lens are also used. These are interconnected by means of control
cables and / or coaxial cables Necessary protection is provided for the CCTV equipment
depending on the locations where they are used
B) CENTRAL FIRE ALARM SIGNALING SYSTEM:
The central fire alarm system is provided for communicating the exact location of
outbreak of fire in any part of the steel plant complex to the central fire station and
simultaneous actuation of sirens to alert personnel of the affected plant zone. The system
employs manual call points located all over the plant.
c) SCADA SYSTEM :
To monitor the consumption of energy by various users in the plant SCADA system is
provided. This is placed at Energy and Telecom centre. The system comprises of a master
station equipment with supervisory consoles and mimic panels located in the Energy &
Telecom Building, 23 Nos Remote Telemetry Units (RTUs) installed in different plant
units and 3 local RTUs for driving the mimic panel in the Energy centre. The RTUs will
be collecting the signals from the local instrumentation & electrical systems and
transmitting to the master station by means of RTUs. The RTUs are connected to the
master station by under ground telephone cables.
D) SHIFT CHANGE ANNOUNCEMENT SIREN SYSTEM:
The shift change announcement siren system is provided for ensuring uniform and
accurate shift timings throughout the plant. This system consists of two(2) nos quartz
crystal controlled master clocks in the Energy & Telecom Centre. The shift timings are
programmed in the Master Clock. At the specified time, the signal will be transmitted for
energizing the sirens located at strategic points in plant area simultaneously at the preset
timings.
Apart from the above facilities Telecom department maintains the following cable
networks also
a) DATACOM cable network in plant
b) Telephone cable network in plant and township
INTRODUCTION
Acronym for supervisory control and data acquisition, a computer system for
gathering and analyzing real time data. SCADA systems are used to monitor and control
a plant or equipment in industries such as telecommunications, water and waste control,
energy, oil and gas refining and transportation. A SCADA system gathers information,
such as where a leak on a pipeline has occurred, transfers the information back to a
central site, alerting the home station that the leak has occurred, carrying out necessary
analysis and control, such as determining if the leak is critical, and displaying the
information in a logical and organized fashion. SCADA systems can be relatively simple,
such as one that monitors environmental conditions of a small office building, or
incredibly complex, such as a system that monitors all the activity in a nuclear power
plant or the activity of a municipal water system.
SCADA systems were first used in the 1960s.
CENTRAL SUPERVISORY CONTROL AND DATA ACQUISITION
SYSTEMS :
The system comprises of Micro VAX ll based Master station equipment with
supervisory controls and mimic panels located in the energy and telecom building
and 23 RTUs installed in different plant units and 3 local RTUs for driving the mimic
panel in the energy centre . The RTUs will be connecting in the signals from the
instrumentation and electrical systems and transmitting to the Master station when
polled by the latter. The RTUs are connected to the master station by under ground tele
phone cables . Supervisory controls are also provided in MRS & EMD departments in