VNIT STUDENTS' CHAPTER

IEEE Tour Report

rd th
3 December to 8 December 2010
Comments By Faculty Incharges:

This IEEE tour to Vishakhapatnam consisting of thirty six students from 2nd and 3rd years
and two faculty incharges (Eswara Rao and Surender) is a memorable event organised by the
IEEE Committee VNIT Chapter.

The students committee have planned well in advance and organised properly with the
funds available. The students are also enthusiastic, eager to learn new things from the industrial
mentors and they too have participated actively by asking and discussing many questions during
their presentations.

The participants are cooperated and coordinated to each other and are well in the guide
lines given by the professor incharge.This tour is a big success without any problems and
misbehaviour. We too have enjoyed and learned many new things in accompanying our students.

This tour could have been much more useful and beneficial to the electronics and
electrical students with the inclusion of electronic related industries. I suggest the students to
visit electronic related industries and understand the designing, manufacturing, testing and other
related process involved in the fabrication of ICs.

P. Eswara Rao K.Surender

Professor In-charges:

P. Eswara Rao K. Surender

Assistant Professor Assistant Professor
Electronics and Computer Science Department Electronics and Computer Science Department
VNIT-Nagpur VNIT-Nagpur

Tour Coordinator:
Jay Kapasi
3rd year Student, Electrical and Electronics Engineering
VNIT-Nagpur
IEEE Committee Members, VNIT Student Chapter

Harshad Bokil Chair Person

Pranav Bhilpower Vice Chair Person
Nirav Aga Secretary
Aniket Salvi Technical Advisor
Anay Desai Treasurer
Jay Kapasi Tour Coordinator
Madhilik Chincholikar Girls Representative
Monish Mhatre Asst. Technical Advisor
Raunaq Lala Asst.Tour Coordinator
Sai Saket Membership Coordinator
Tour Participants:
Branch ECE:

3rd Years 2nd Years

Harshad Bokil Raunaq Lala
Pranav Bhilpower Tanmay Rabade
Anay Desai Rinita Datta
Madhulika Chincholikar Vaishali Lathi
Arun Yadav Neha Wanjani
Suhit Pathak Prachi Patel
Arun Kumar Banoth Pagya Agarwal
Aditya Pandey 3rd Year Mech
Kushagra Manik Nirav Aga
Mayuri Ghude 2nd Year CSE
Devajit Dutta Nandini Yelliwar

Branch EEE
3rd Years Aditya Agarwal
Jay Kapasi Rohit Musle
 GK Nagashruti Ajay Jamodkar
2nd Years Amol Kelkar
Sai Saket Divvela Kalik Vivek
Monish Mhatre Chitvan Killawala
Mohd Farazuddin Keshav Somani
Jayesh Gajre VVS Anusha
Amey Chandrayen S Ritika

Tour Schedule:
3rd December
Gather In front of the Auditorium 11:30am
Leave College 12:00 noon
Train to Vijayawada (Tamil Nadu Express) 3:30pm (Delayed by 1hour)
Reaching Vijaywada 1:30 am(4th December)
4th December
Boarding Train to Vishakhapatnam(Tirumala 4:20am (Delayed by 1hour)
Express)
Reaching Vishakhapatnam 12:00 Noon
Reaching Guest house 1:30pm
Lunch 2:00 pm to 3:00pm
Visit to Hindustan Sshipyard 4:00pm
5th December
Reaching Youth Hostel 7:30am
Visit to Vizag Steel Plant 9:00am to 1pm
Visit to Noval Dockyard 3pm to 6:00pm
6th December
Visit to HPCL 9am to 12:00 noon
Lunch Recess 1:00pm to 3:00pm
Visit to Kailashgiri 3:00pm to 6:00pm
7th December
Visit to NTPC 10:00am to 2pm
Free Time: Vizag visit has been cancelled because of the
bad whether condition

Dinner (Dinner sponcered by IEEE)

8th December
Boarding train(Samatha Express) 6:20am
Reaching Nagpur 12:10am
Reaching VNIT Campus 12:30am
 TECHNICAL DETAILS

Visakhapatnam :-

Visakhapatnam (Vizag) is second largest city in Andhra Pradesh with an area of 550km²
and eleventh largest city in India. It is primarily an industrial city, apart from being a port city. It
is also home to the Eastern Naval Command. Visakhapatnam has seen rapid development in the
past decade.

From a small fishing village in the 20th century, Visakhapatnam has grown into an mega-
industrial hub. Its saga began when the British needed a suitable port that could serve move the
rich mineral wealth from the countryside. Unlike the western coast of India, the east coast has
natural harbours. Vizag is the most protected natural harbour in Asia. They started building the
harbour in 1927; in 1933 it was opened to traffic.

One important milestone is the setting up of the Scindia Steam Navigation Co., later
known as Hindustan Shipyard Ltd in 1940. With the construction of the K.K. line connecting the
iron ore mines of Bailadila in M.P. (present day Chattisgarh), its importance grew. In the 1950s
and 1960s the government and the private sector set up large scale basic industries like Bharat
Heavy Plates and Vessels (B.H.P.V.), Hindustan Zinc Ltd., Caltex oil refinery (later acquired by
government as H.P.C.L.), Coromandel fertilizers, and Andhra Polymers (now LG Polymers). The
1980s saw a major development with the development of the Visakhapatnam Steel Plant and
other major industries. Economic liberalization in the 1990s brought a modest growth to the city
but not as much as it did to Hyderabad. However, some industries sprang up like Rain Calcining
Ltd., expansion of HPCL, setting up of Vizag Export Processing Zone, and the Simhadri
Thermal Power plant of N.T.P.C. Visakhapatnam was declared one of ten fastest growing
cities of the world in a recent study conducted by the United Nations.
 DAY 1 4/12/2010

HINDUSTAN SHIPYARD LIMITED

At 3:00pm we went to Hindustan Shipyard Limited.

Hindustan Shipyard Ltd is located in the picturesque port city of Visakhapatnam on the
East coast of India. The shipyard is easily accessible by direct air, sea, rail and road connections
from India and Abroad. The foundation stone of the shipyard was laid on June 22, 1941 by Dr.
Rajendra Prasad who later became the first President of India. Today, HSL is a fully owned
Government of India Undertaking under the Administrative control of the Ministry of Defence.

We were given brief introduction about their setup by their HR deputy Head.

DESIGN CAPABILITY :-
HSL has well equipped design facility with latest TRIBON 3M and AUTOCAD 2008
shipbuilding software. HSL has also done a number of in-house designs and built ships on
these designs for various clients. The design department has nearly 50 full time engineers
working in support of various shipbuilding and ship repair activities of the yard.
 Covered Building 240x53x11.25 mtrs 80,000 dwt 300 tons
Dock

Slipway No.1 140x22.7 mtrs 15,000 dwt 100 and 60 tons

Slipway No.2 195x28 mtrs 30,000 dwt 2x45 & one 35 tons

Slipway No.3 195x28 mtrs 30,000 dwt 2x45 & one 35 tons

Out fitting Jetty 550 meters All ships 1x120 tons, 1x50 tons,
1x25 tons

We moved to HULL shop whose function is to cut the raw material and mould it into
desired shape. The main machine used here were hugh smith and messer griestriem.

Then we moved to assembly section where independent elements from HULL shop are
assembled, pre-fabrication and block preparation is done. We were shown bulk carrier assembly
of 53,000 tonne ships.

The visit was very educative and very informative.

Ship Repairs Division :-

HSL has a full fledged and independent ship repair department with a Graving Dock, Wet
Basin, Outfit Jetty and other facilities. HSL has also specialised in submarine repairs
INFRASTRUCTURE

ˆ Dock side working platform

ˆ High pressure water jet cleaning
ˆ Grit Blasting facility
ˆ Use of hydraulic elevators and scissor lifts for works
ˆ Dynamic balancing facilities
ˆ Repairs of all types of vessels, Drill rigs, Naval Vessels
ˆ Dedicated design department
ˆ Large scale steel renewals
ˆ Dedicated and qualified personnel

Ship in Repair Dock

Dry Dock 244x38x12 mtrs 70,000 dwt 2x40 tons 2x10 tons

Wet Basin 226x75x10 mtrs 70,000 dwt 1x45 tons

1x20 tons
1x10 tons

Repair Delphin 150 mtrs 20,000 dwt 1x20 tons

 DAY 2 5/12/2010

VIZAG STEEL PLANT:

Vizag Steel Plant has been conferred Navratna status on November 17, 2010. Founded in 1971,
the company focuses on producing value-added steel, with 214,000 tonnes produced in the month of
August 2010, out of 252,000 tonnes total of saleable steel produced. It is the only integrated steel plant in
the country to be certified for ISO 9001:2000, ISO 14001:2004 and OSHAS 18001:1999.

We proceeded for Vizag Steel Plant and reached there at 10am. We were briefed about
plant in production area. First we visited coke production plant.

Coke Ovens & Coal Chemical Plant :-

Coal is converted into coke by heating the prepared coal blend charge in the coke ovens
in the absence of air at a temperature of 1000oC-1050oC for a period of 16/18 hours. The
volatile matter of coal liberated during carbonization is collected in gas collecting mains in the
form of raw coke oven gas passing through stand pipes and direct contact cooling with ammonia
liquor spray. The gas cooled from 800oC to 80oC is drawn to Coal Chemical Plant by Exhauster.
The residual coke is pushed out of the oven by pusher car through a guide into coke bucket. The
red-hot coke is taken to coke dry cooling plant for cooling.
Facilities
There are 4 batteries, each having 67 ovens.
The volumetric capacity of each oven is 41.6 m3.
Dry Coal charge /Oven is 32 t.
Salient Features
• Largest and technologically unique Coke Oven Batteries in the country at the time of
commissioning.
• 7 metre tall coke ovens batteries.
• Selective crushing of coal to improve the coke quality.
• 100% Dry Quenching of coke using Nitrogen gas.
• Power generation, from the waste heat recovered, at BPTS (Back Pressure Turbine
Station).

Capacity
Production capacity – 2.635 Mt of Gross coke per annum (2.261 Mt of BF Coke per annum).

Then we moved to Blast furnace where pig iron is formed from iron ore.

Blast Furnace

Iron is made in the Blast Furnaces by smelting iron bearing materials with the help of
coke and air. The solid charge materials like sinter, sized iron ore, etc. are charged in the vertical
shaft of the Blast Furnace at top and hot air blast is blown through the tuyeres located at the
bottom. The oxygen from the hot air combines with the carbon of the coke and generates heat
and carbon monoxide. The gases while ascending upwards react with the charge. Eventually the
charge melts and hot metal and slag are produced and tapped out. The cooled gas is also used as
fuel in the plant. The Paul-wurth, bell loss top system is installed for furnace charging.

There are four hot blast stoves for each furnace with a total heating surface of 224,000
2
m . High temperature zone is lined with silica and mullite corundum refractories, medium
temperature zone, with kaoline refractories and low temperature zone with fire clay refractories.
Its novel circular cast house with four tap holes ensures continuous tapping of hot metal.

Facilities
Two Blast furnaces of 3200 cum. useful volume each.

Salient Features

• Conveyorised charging of Blast Furnaces

• Paul-Wurth “Bell-less” top charging system for Blast Furnace.
• On-line correction of coke moisture and batch weights.
• Circular cast house with four tap holes and no slag notch.
 • Cast house slag granulation plant.
• Tuyere leakage detection system
• Gas Expansion turbines for power generation by utilizing the blast furnace gas top
pressure
• Automation with Programmable Logic Controllers (PLC).
• A circular cast house with four tapholes and no slag notch.
Capacity : Production Capacity – 3.4 MT of Hot Metal per annum.

Steel Melt Shop & Continuous Casting:

Steel is made in steel melting shop in the refractory lined vessels called LD Converters by
blowing oxygen through the hot metal bath. While iron making is a reduction process, steel making is an
oxidation process. The oxygen reacts with the carbon in the hot metal and this reaction releases large
quantities of gas rich in carbon monoxide along with huge amount of dust. The gases released from the
converter are collected, cooled, cleaned and recovered for use as fuel in the steel plant. The entire molten
steel at VSP is continuously cast at the radial type continuous casting machines resulting in significant
energy conservation and better quality steel. 100% Continuous casting on such a large scale has been
conceived for the first time in India.

Facilities

• Three LD converters of 133 cum. volume each

• 6 nos. of 4-Strand Continuous Bloom Casting machines.

Salient Features

• 100% Continuous casting of steel

• Converters gas cooling, cleaning and recovery systems
• Use of Sublance and computerisation of the converter process
Capacity

Production Capacity – 3.0 MT of Liquid Steel per annum

2.820 MT of CC Blooms per annum
NAVAL DOCKYRAD VIZAG

After visiting Vizag Steel Plant, we visited Naval Dockyard.

We had a glimpse of one of the oldest submarine which
was to be decommissioned on this month -end.
Luckily we got chance to get into INS Jalashwa and INS Ranvijay ships

INS JALASHWA:-

We visited INS Jalashwa.

INS Jalashwa (L41) is an amphibious transport dock currently in service with the Indian Navy.
Formerly the USS Trenton, it was procured by India for USD 48 million. It entered service in 2007,
becoming the second largest ship of the Indian Navy (after the Aircraft Carrier INS Viraat). INS Jalashwa
joined the Eastern Fleet (under the Eastern Naval Command) of the Indian Navy upon its arrival at
Visakhapatnam naval base on 12 September 2007.

INS RANVIJAY:-

INS Ranvijay (D55) is a Rajput class destroyer in active service with the Indian Navy. Ranvijay
was commissioned on 15 January 1988.Ranvijay participated in the multinational Malabar Naval
Exercise between Australia, India, Singapore, Japan and United States in the Bay of Bengal.

We saw missile compartments, anti-aircraft machine guns and ships control room.

That was life-time experience for all of us!

 DAY 3 6/12/2010

HINDUSTAN PETROLEUM CORPORATION LIMITED

We reached HPCL at 9:30 am where we were briefed

information about HPCL refinery. Visakhapatnam (Visakh) Refinery is
one of the two oil refineries of HPCL in India, the other being
Mumbai Refinery. A brief history of Visakh Refinery is below.

In 1957, Visakh Refinery went on stream under the ownership

of M/s Caltex India Ltd. In May, 1978, M/s Caltex Oil Refinery
(India) was amalgamated with Hindustan Petroleum Corporation Ltd.
The installed capacity of 1.5 MMTPA was increased to 4.5 MMTPA in
1985 and 7.5 MMTPA in 1999, through an expansion programme.

VRCFP (Visakh Refinery Clean Fuels Project):

This project is being implemented by the Projects Department at Visakh Refinery. This
project is essentially to produce fuels for environment improvement at an estimated cost of Rs
1635.18 Crores with an FE component of Rs 252.49 Crores.

The project was approved by the Board on 30 April 2003. M/s EIL is the consultant for the
project. Process licensors include M/s UOP, M/s Axens and M/s Belco. A dedicated team of
professionals from HPCL is executing the project.

We were briefed about cracking of crude oil and how exactly fractional distillation takes place.
 DAY 4: 7/12/2010

NATIONAL THERMAL POWER CORPORATION, SIMHADRI

We reached NTPC Simhadri at 9:30 am where we were briefed information about

NTPC Simhadri.

NTPC Limited is the largest state-owned power generating company in India. Forbes
Global 2000 for 2009 ranked it 317th in the world. It is an Indian public sector company listed on
the Bombay Stock Exchange although at present the Government of India holds 84.5%(after
divestment the stake by Indian government on 19october2009) of its equity. With a current
generating capacity of 31134 MW, NTPC has embarked on plans to become a 75,000 MW
company by 2017. It was founded on November 7, 1975. NTPC's core business is engineering,
construction and operation of power generating plants and providing consultancy to power
utilities in India and abroad.

The total installed capacity of the company is 31134 MW (including JVs) with 15 coal
based and 7 gas based stations, located across the country. In addition under JVs, 3 stations are
coal based & another station uses naphtha/LNG as fuel. By 2017, the power generation portfolio
is expected to have a diversified fuel mix with coal based capacity of around 53000 MW, 10000
MW through gas, 9000 MW through Hydro generation, about 2000 MW from nuclear sources
and around 1000 MW from Renewable Energy Sources (RES). NTPC has adopted a multi-
pronged growth strategy which includes capacity addition through green field projects,
expansion of existing stations, joint ventures, subsidiaries and takeover of stations.

Some statistics about NTPC Simhadri---

Approved Capacity/Installed Capacity 1000 MW

Plant Configuration 2X500 MW
Land Availability 3384.24 acres (entire land)
Coal Source Kalinga Block of Talcher Coal
Water Source Yeluru canal for sweet water
Beneficiary States Andhra Pradesh (100%) .
Approved Investment Rs.3650.79 Cr.(I Qtr.97).

After long chatting with engineer of NTPC, we went for plant visit. We visited control room,
cooling towers followed by turbines and generators.

Hence with high spirits and added knowledge we came to the end of the tour. With all the
participants very much satisfied, as they got to see and know much more than they expected, the
tour was a success.
So we take this opportunity to thank everyone who helped us make this trip a memorable one.

IEEE TOUR FINANCIAL REPORT

PARTICULARS AMOUNT (Rs)

Train Tickets 16500.00
Hostel Charges 12160.00
Local Transport 31500.00
Kailashgiri Entrance 200.00
Hindustan Shipyard 1000.00
Local Transport (Nagpur 2700.00
Meals(NTPC+Steel Plant) 1800.00
Miscellaneous 2540.00
Grand Total 68400.00

Sixty Eight Thousand and four hundred rupees only/-

“We are grateful to our Director Sir for encouraging us, Ghare mam for standing by us in all
our ventures and specially Eswara Rao sir and Surinder sir for accompanying us. We thank
everyone who helped us make this tour a success.”

The committee (2010-11)

IEEE Students Chapter
VNIT,Nagpur
Gallery