index

INAUGURATION

INDEX

ANURAG

Highlight

an Introductory Guide

to

Bhilai Steel Plant

Gateway

INDEX

(R. Ramaraju)(R. Ramaraju)

MESSAGE

I am pleased to note that HRD Center is bringing out the revised edition of "GATEWAY- An

introductory guide to Bhilai Steel Plant". This compilation of Bhilai Steel Plant's integrated working

processes and support departments is a very useful manual and guide not only for visitors, new

entrants and trainees but also for all those who wish to refresh their knowledge on the working of

departments other than their own.

The revision is timely and the CD-ROM version is in line with the latest learning methods. I am

happy that the edition will be placed on the net, thereby increasing its accessibility.

My compliments to the HRD collective, for keeping up an excellent tradition of knowledge and

information dissemination.

I am pleased to note that HRD Center is bringing out the revised edition of "GATEWAY- An

introductory guide to Bhilai Steel Plant". This compilation of Bhilai Steel Plant's integrated working

processes and support departments is a very useful manual and guide not only for visitors, new

entrants and trainees but also for all those who wish to refresh their knowledge on the working of

departments other than their own.

The revision is timely and the CD-ROM version is in line with the latest learning methods. I am

happy that the edition will be placed on the net, thereby increasing its accessibility.

My compliments to the HRD collective, for keeping up an excellent tradition of knowledge and

information dissemination.

jk- jkejktqçca/k funs'kd

R RAMARAJUManaging Director

INDEX

Bhilai Steel Plant, rightfully known as the flagship unit of SAIL is also one of the best

integrated steel plants in the country and world. The gigantic complex comprises several

departments and shops; all interwoven and interdependent in a way that the plant functions

uninterruptedly and creates new heights of performance and achievements regularly.

The pace of change is rapid and carefully planned and implemented projects result in

continuous improvements. The human side of this enterprise is second to none in the country and is

nurtured and groomed to respond to every situation and to welcome newer and tougher challenges.

Human Resources Development department's endeavour to align human potential and

motives with the organizational business goals is paying rich dividends. In its effort to ensure timely

and updated availability of information, HRD department is bringing out the latest edition of

'GATEWAY- An Introductory Guide to Bhilai Steel Plant' with the active support of all departments that

feature in this compilation.

I am happy to note that the edition will also be available on CD-ROMs as well as on the BSP

net.

My compliments and best wishes to the HRD collective.

Bhilai Steel Plant, rightfully known as the flagship unit of SAIL is also one of the best

integrated steel plants in the country and world. The gigantic complex comprises several

departments and shops; all interwoven and interdependent in a way that the plant functions

uninterruptedly and creates new heights of performance and achievements regularly.

The pace of change is rapid and carefully planned and implemented projects result in

continuous improvements. The human side of this enterprise is second to none in the country and is

nurtured and groomed to respond to every situation and to welcome newer and tougher challenges.

Human Resources Development department's endeavour to align human potential and

motives with the organizational business goals is paying rich dividends. In its effort to ensure timely

and updated availability of information, HRD department is bringing out the latest edition of

'GATEWAY- An Introductory Guide to Bhilai Steel Plant' with the active support of all departments that

feature in this compilation.

I am happy to note that the edition will also be available on CD-ROMs as well as on the BSP

net.

My compliments and best wishes to the HRD collective.

(Ashok Kumar)(Ashok Kumar)

MESSAGE

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ASHOK KUMARExecutive Director (Works)

INDEX

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P.K. AGGARWALExective Director (P & A)

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Foreword

I am happy to note that the HRD collective of Bhilai Steel Plant has come out with the revised

version of "GATEWAY - An introductory guide to Bhilai Steel Plant, wherein many new chapters have

been added and latest information about the working of the plant and its essential support functions

have been incorporated.

The revision of what was earlier known as "Works Visit Notes" is opportune, considering that

Bhilai Steel Plant is on the threshold of a massive expansion and modernisation phase. The guide is

dedicated to the Golden Jubilee Year of Bhilai and I am happy that the edition is being placed on the

net for the first time thereby increasing its accessibility manifold, which is indeed a praiseworthy

effort. The edition shall also be available as a hard copy and a CD-ROM version.

I am hopeful that this Manual will prove to be very useful not only to the fresh entrants and

visitors but also to all employees of Bhilai Steel Plant.

My congratulations to the entire team of Human Resources Development who have

contributed in bringing out this book.

I am happy to note that the HRD collective of Bhilai Steel Plant has come out with the revised

version of "GATEWAY - An introductory guide to Bhilai Steel Plant, wherein many new chapters have

been added and latest information about the working of the plant and its essential support functions

have been incorporated.

The revision of what was earlier known as "Works Visit Notes" is opportune, considering that

Bhilai Steel Plant is on the threshold of a massive expansion and modernisation phase. The guide is

dedicated to the Golden Jubilee Year of Bhilai and I am happy that the edition is being placed on the

net for the first time thereby increasing its accessibility manifold, which is indeed a praiseworthy

effort. The edition shall also be available as a hard copy and a CD-ROM version.

I am hopeful that this Manual will prove to be very useful not only to the fresh entrants and

visitors but also to all employees of Bhilai Steel Plant.

My congratulations to the entire team of Human Resources Development who have

contributed in bringing out this book.

(P.K.Aggarwal)

INDEX

Bhilai Steel Plant is synonymous with a sustainable culture of excellence where

the leadership and the enablers have a uniform focus on all aspects of a collective

enthusiasm for excellence in:

Quality of life

Quality of product

Customer care

Profitability and

Highest standards in individual, group and organizational

performance

The HRD department with its vision of being recognized as a valuable business

partner is engaged in continuous enhancement of employees' knowledge, skills and

attitudes not only for addressing the current needs but also for successfully meeting

the challenges of expansion and modernization that are on the anviL

Several plant wide interventions have been introduced and are ongoing and

some are forthcoming based on our constant vigil on the emerging and forecast

scenario. These initiatives result from the business and other contemporary

imperatives and are aimed at ensuring comprehensive excellence in everything that we

do. The Annual Business Plan is the guiding beacon and there are immense

opportunities for us to play a proactive role in the achievement of these goals at both

the macro as well as the micro levels.

Wide reaching awareness and dissemination of information is the key to

collective ownership of change. With this in view the HRD Department has compiled

information on all the functioning departments of Bhilai Steel Plant and has made it

available as:

A book called "Gateway - An introductory guide to Bhilai Steel Plant"

A CD-ROM version

A soft copy on HRDD's web site

The latest edition, dedicated to the Golden Jubilee Year, is based primarily on the basis

of similar compilations made earlier but features many new departments which had not

been previously included. There is always a scope for improvement and we welcome

any feedback, suggestion or evaluation of our efforts so that we improve and stay

aligned with Bhilai's spirit of Excellence.

�

�

�

�

�

�

�

�

Bhilai Steel Plant is synonymous with a sustainable culture of excellence where

the leadership and the enablers have a uniform focus on all aspects of a collective

enthusiasm for excellence in:

Quality of life

Quality of product

Customer care

Profitability and

Highest standards in individual, group and organizational

performance

The HRD department with its vision of being recognized as a valuable business

partner is engaged in continuous enhancement of employees' knowledge, skills and

attitudes not only for addressing the current needs but also for successfully meeting

the challenges of expansion and modernization that are on the anviL

Several plant wide interventions have been introduced and are ongoing and

some are forthcoming based on our constant vigil on the emerging and forecast

scenario. These initiatives result from the business and other contemporary

imperatives and are aimed at ensuring comprehensive excellence in everything that we

do. The Annual Business Plan is the guiding beacon and there are immense

opportunities for us to play a proactive role in the achievement of these goals at both

the macro as well as the micro levels.

Wide reaching awareness and dissemination of information is the key to

collective ownership of change. With this in view the HRD Department has compiled

information on all the functioning departments of Bhilai Steel Plant and has made it

available as:

A book called "Gateway - An introductory guide to Bhilai Steel Plant"

A CD-ROM version

A soft copy on HRDD's web site

The latest edition, dedicated to the Golden Jubilee Year, is based primarily on the basis

of similar compilations made earlier but features many new departments which had not

been previously included. There is always a scope for improvement and we welcome

any feedback, suggestion or evaluation of our efforts so that we improve and stay

aligned with Bhilai's spirit of Excellence.

�

�

�

�

�

Foreword

(SN Singh)

General Manager (HRD)

(SN Singh)

General Manager (HRD)

INDEX

INDEX

1. A Brief Introduction to Bhilai Steel Plant .........................................i-iv

2. Gateway Team ............................................................................. v

3. Bhilai Steel Plant - Major Landmarks ............................................... vi

4. Awards & Accolades ............................................................... vii-xv

5. Flow Chart of Bhilai Steel Plant ...................................................... vi

MINES & QUARRIES

6. Mines & Quarries ....................................................................... 1-6

IRON ZONE

7. Ore Handling Plant .................................................................... 7-15

8. Sintering Plant-I ..................................................................... 16-19

9. Sintering Plant-II ..................................................................... 20-28

10. Sintering Plant-III .................................................................... 29-37

11. Coke Ovens and Coal Chemicals Department ............................. 38-57

12. Blast Furnaces ....................................................................... 58-84

13. Slag Granulation Plants ........................................................... 85-92

STEEL ZONE

14. Steel Melting Shop-I ............................................................. 93-107

15. Steel Melting Shop-II ........................................................... 108-125

16. Refractory Materials Plant-I .................................................. 126-134

17. Refractory Materials Plant-II ................................................. 135-145

18. Refractory Engineering Department ....................................... 146-148

19. Material Recovery Department ............................................. 149-152

Sl.No. Chapter’s Name Page No.

MILLS ZAONE

20. Blooming & Billet Mill .......................................................... 153-158

21. Plate Mill ........................................................................... 159-169

22. Rail and Structural Mill ........................................................ 170-178

23. Merchant Mill..................................................................... 179-184

24. Wire Rod Mill ..................................................................... 185-189

25. Roll Turning & Repair Shop and Roll Pass Design Bureau ......... 190-196

QUALITY ZONE

26. Research & Control Laboratory ............................................. 197-202

27. Total Quality Management Department (TQM) ....................... 203-210

SERVICES ZONE

28. Production Planning & Control .............................................. 211-221

29. Cost Control Department ..................................................... 222-226

30. Traffic Department ............................................................. 227-236

31. Safety Engineering Department ............................................ 237-241

32. Fire Service Department ...................................................... 242-250

MAINTENANCE, UTILITY, POWER & AUTOMATION ZONE

33. CHM, GMG, CRM (Mech/Strl) & RVC .................................... 251-253

34. Crane Engineering Department .................................................... 254

35. Design & Drawing Department ............................................. 255-256

36. Central Hydraulics .............................................................. 257-258

37. Lubrication Department .............................................................. 259

38. Bearing Engg. Deptt. Mechanical Services of 4 MT (Mech.) Area ..... 260

39. Tools and Tackles ..................................................................... 261


40. Central Planning Department ................................................ 262-264

41. MARS-I ............................................................................. 265-269

42. MARS-II ................................................................................... 270

43. MARS-III ........................................................................... 271-272

44. Forge Shop ........................................................................ 273-274

45. Foundry & Pattern Shop ...................................................... 275-278

46. Steel Structural Shop .......................................................... 279-280

47. Reclamation Shop .............................................................. 281-282

48. Garages & Vehicle Pools ..................................................... 283-286

49. Shop Inspection (Engg. Shops) ............................................. 287-288

50. Oxygen Plant -I .................................................................. 289-291

51. Oxygen Plant -II ................................................................. 292-309

52. Acetylene & Propane Plants ................................................ 310-318

53. Air Conditioning And Works Environment .............................. 319-321

54. Compressed Air Stations & Chilled Water Plants ..................... 322-329

55. Water Management Department ........................................... 330-338

56. Heavy Maintenance (Electrical) ............................................. 339-340

57. Capital Repair and Modification (Elect.) ................................. 341-342

58. Power Systems Department................................................. 343-358

59. Electro-Technical Laboratory ................................................ 359-363

60. Electrical Repair Shop ......................................................... 364-370

61. Telecommunication Department ........................................... 371-374

62. Power and Blowing Station .................................................. 375-391

63. Environment Management Department .................................. 392-408


64. Computerised Maintenance Management System ................... 409-415

65. Condition Based Maintenance Systems (CBMS) ...................... 416-418

66. Instrumentation & Weighment Department ............................ 419-435

67. INCOS .............................................................................. 436-452

68. Civil Engineering Department ............................................... 453-454

69. Building Structural Inspection and Survey Group..................... 455-456

70. Energy Management Department .......................................... 457-462

NON-WORKS DEPARTMENTS

71. Personnel Department ......................................................... 463-465

72. Human Resources Development Department .......................... 466-470

73. Organisation & Methods Department .................................... 471-474

74. Statistical Quality Control & Operations Research ................... 475-482

75. Printing Services Department ............................................... 483-486

76. Town Services Department .................................................. 487-492

77. Industrial Engineering Department......................................... 493-496

78. Medical & Health Services ................................................... 497-507

79. Marketing & Strategic Planning Department ........................... 508-513

80. Finance & Accounts Department .......................................... 514-520

81. Projects Department ........................................................... 521-530

82. Bhilai Engineering & Design Bureau (BEDB) ............................ 531-537

83. Material Management Department ........................................ 538-540

84. C & IT Division (Formerly EDP) ............................................. 541-544

85. Corporate Social Responsibility ............................................ 545-552


Bhilai Steel Plant

A Brief Introduction to Bhilai Steel Plant

- i -

A Brief Introduction To Bhilai Steel Plant

Bhilai Steel Plant - a symbol of Indo-Soviet techno-economic collaboration,

is one of the first three integrated steel plants set up by Government of India to

build up a sound base for the industrial growth of the country, The agreement

for setting up the plant with a capacity of 1 MT of Ingot steel was signed

between the Government of erstwhile U.S.S.R. and India on 2nd February,

1955, and only after a short period of 4 years, India entered the main stream of

the steel producers with the commissioning of its first Blast Furnace on 4th

February, 1959 by the then President of India, Dr Rajendra Prasad.

Commissioning of all the units of 1 MT stage was completed in 1961. A dream

came true-the massive rocks from the virgin terrains of Rajhara were converted

into valuable iron & steel.

In the initial phase the plant had to face many teething problems, mostly

unknown to the workforce at the time, But by meticulous efforts and team-

sprit, these problems were surmounted and the rated capacity production was

achieved only within a year of integrated operation of the plant.

Thereafter, the plant was expanded to 2.5 MT capacity per year, and then

to 4 MT of crude steel per year, with Soviet assistance.

All the units of the plant have been laid out in sequential formation

according to technological inter-relationship so as to ensure uninterrupted flow

of in-process materials like Coke, Sinter, Molten Iron, Hot Ingots, as well as

disposal of metallurgical wastages and slag etc., minimizing the length of

various inter-plant communications, utilities and services.

BSP is the sole manufacturer of rails and producer of the widest and

heaviest plates in India. Bhilai specializes in the high strength UTS 90 rails, high

tensile and boiler quality plates, TMT bars, and electrode quality wire rods. It is

a major exporter of steel products with over 70% of total exports from the

Steel Authority of India Limited being from Bhilai. The distinction of being the

first integrated steel plant with all major production units and marketable

products covered under ISO 9002 Quality Certification belongs to BSP. This

INDEX

Bhilai Steel Plant


- ii -

includes manufacture of blast furnace coke and coal chemicals, production of

hot metal and pig iron, steel making through twin hearth and basic oxygen

processes, manufacture of steel slabs and blooms by continuous casting, and

production of hot rolled steel blooms, billets and rails, structural, plates, steel

sections and wire rods. The plant's Quality Assurance System has subsequently

been awarded ISO 9001:2000.

Not content with the Quality Assurance system for production processes,

Bhilai has one in for ISO 14001 certification for its Environment Management

System and its Dalli Mines. Besides environment-friendly technology like Coal

Dust Injection System in the Blast Furnaces, de-dusting units and electrostatic

precipitators in other units, BSP has continued a vigorous afforestation drive,

planting trees each year averaging an impressive 1000 trees per day in the steel

township and mines.

A leader in terms of profitability, productivity and energy conservation, BSP

has maintained growth despite recent difficult market conditions. Bhilai is the

only steel plant to have been awarded the Prime Minister's Trophy for the best

integrated steel plant in the country seven times.

Bhilai Steel Plant, today, is a panorama of sky-scraping chimneys and

blazing furnaces as a modern integrated steel plant, working round the clock, to

produce steel for the nation. Bhilai has its own captive mines spread over

10929.80 acres. We get our iron ore from Rajhara group of mines, 85 kms

south-west of Bhilai. Limestone requirements are met by Nandini mines, 20 kms

north of Bhilai and dolomite comes from Hirri in Bilaspur district, 135 kms east

of the plant. To meet the future requirement of iron ore, another mining site

Rowghat , situated about 100 km south of Rajhara, is being developed; as the

ore reserves at Rajhara are depleting.

Bhilai expanded its production capacity in two phases - first to 2.5 MT

which was completed on Sept. 1, 1967 and then on to 4 MT which was

completed in the year 1988. The plant now consists of ten coke oven batteries.

Six of them are 4.4 metres tall. The 7 metre tall fully automated Batteries No 9

& 10 are among the most modern in India. Of Bhilai's seven blast furnaces,

three are of 1033 cu. metre capacity each, three of 1719 cu. metre and one is

2000 cu. metre capacity. Most of them have been modernised incorporating

state-of-the-art technology.

INDEX

Bhilai Steel Plant


- iii -

Steel is made through twin hearth furnaces in Steel Melting Shop I as well

as through LD Convertor -continuous Casting route in SMS II. Steel grades

conforming to various national and international specifications are produced in

both the melting shops. Production of cleaner steel is ensured by flame

enrichment and oxygen blowing in SMS I while secondary refining in Vaccum

Arc Degassing ensures homogenous steel chemistry in SMS II. Also in SMS II is

a 130 T capacity RH (Ruhshati Heraus) Degassing Unit, installed mainly to

remove hydrogen from rail steel and Ladle Furnace to meet present and future

requirements of quality steel. Bhilai is capable of providing the cleanest and

finest grades of steel.

The rolling mill complex consists of the Blooming & Billet Mill, Rail &

Structural Mill, Merchant Mill, Wire Rod Mill and also a most modern Plate Mill.

While input to the BBM and subsequently to Merchant Mill and Wire Rod Mill

comes from the Twin Hearth Furnaces, the Rail & Structural Mill and Plate mill

roll long and flat products respectively from continuously cast blooms and slabs

only. The total length of rails rolled at Bhilai so far would circumvent the globe

more than 4.5 times.

To back this up, we have the Ore Handling Plant, three Sintering Plants - of

which one is most modern, two captive Power Plants with a generating capacity

of 110 MW, two Oxygen Plants, Engineering Shops, Machine Shops and a host

of other supporting agencies giving Bhilai a lot of self-sufficiency in fulfilling the

rigorous demands of an integrated steel plant. Power Plant No.2 of 74 MW

capacity has been divested to a 50:50 SAIL/NTPC joint venture company.

The plant has undertaken massive modernization and expansion plan to

produce 7.5 MT of hot metal by the year 2010.

HUMAN PROFILE

More than the machinery and processes, it is the men i.e. the engineers,

technicians, skilled and unskilled workers behind them that constitute the flesh

and blood of this steel plant.

Bhilai at present has around 34000 persons to run this pulsating giant. The

culture which has today become the hallmark of Bhilai is a result oriented

approach to work. It is their effective and co-operative working relationship

INDEX

Bhilai Steel Plant


- iv -

nurtured in a spirit of dedication and enthusiasm that has shaped Bhilai's image

today.

Adjoining the plant, a modern township - Bhilai Nagar, having the

spaciousness of a village and the cleanliness of a modern town is spread - over

in 17 self sufficient sectors with schools, markets, parks and other facilities.

Free Medical aid is given to all the employees and their dependents through

a network of health centers, dispensaries and hospitals. Medical facilities are

extended to retired employees & their spouses also.

The Education Department runs a number of higher secondary, middle,

primary, and pre-primary schools in Bhilai and also in the mines townships at

Rajhara, Nandini and Hirri.

INDEX

Bhilai Steel Plant

Bhilai Steel Plant - Major Landmarks

- vi -

Bhilai Steel Plant - Major Landmarks

Signing of Agreement for setting up of the plant Feb. 02, 1955

Commencement of work at site May 06, 1956

Commissioning of Coke Oven Battery # 1 Jan. 31, 1959

Commissioning of Blast Furnace # 1 Feb. 04, 1959

Commissioning of Power & Blowing Station Jun. 04, 1959

Commissioning of Steel Melting Shop O.H. Fce # 1 Oct. 11, 1959

Commissioning of Blooming Mill 1150 stand Nov. 12, 1959

Commissioning of Billet Mill Dec. 24, 1959

Commissioning of Rail & Structural Mill Oct. 27, 1960

Commissioning of Sintering Plant # 1 Jul. 03, 1961

Commissioning of Merchant Mill Feb. 02, 1961

Commissioning of Wire Rod Mill Sep. 01, 1967

Commissioning of Sintering Plant #2 Aug. 01, 1979

Commissioning of Plate Mill Mar. 31, 1983

Commissioning of Converter #1 Jul. 29, 1984

Commissioning of Continuous Casting Shop M/C #1 Mar. 15, 1986

Commissioning of First Twin Hearth (at SMS-1) Sep. 12, 1986

Commissioning of Blast Furnace #7 Aug. 30, 1987

Commissioning of Coke Oven Battery a Mar. 31, 1988

Commissioning of Second Twin Hearth Jan. 01, 1990

Commissioning of VAD unit at SMS-2 Jan. 17, 1991

Commissioning of Third Twin Hearth Jun 29, 1992

Commissioning of Fourth Twin Hearth Jan 21, 1998

Commissioning of Ladle Furnace at SMS-2 Dec 23, 1999

Commissioning of RH Degasser Unit at SMS-2 Mar. 30, 2000

Commissioning of Sintering Plant # 3 Dec. 12, 2001

Only Steel Plant in India to cross 5 MT Mar 31, 2006Curde Steel Production in the financial year.

Bhilai's expansion & modernisation to 7.5 MT Feb. 09, 2008capacity inaugurated

Bhilai repeats 5 MT + performance Mar. 31, 2008

INDEX

Bhilai Steel Plant

Awards & Accolades To Bhilai Steel Plant

- vii -

Awards & Accolades To Bhilai Steel PlantJANUARY 28, 2008Golden Peacock Award for Corporate Social Responsibility - 2007

Bhilai Steel Plant has been adjudged winner of the "Golden Peacock Award forCorporate Social Responsibility for the year 2007" by the Golden Peacock AwardJury, under the Chairmanship of Justice PN Bhagwati, former Chief Justice of Indiaand member UN Human of Rights Commission and Co-Chairmanship of Justice MNVenkatchaliah, former Chief Justice of India. The award received by Shri Sunil Jain,Deputy General Manager (Corporate Social Responsibility) at Vilamoura, Portugal on15th February 2008, was formally handed over to MD BSP Shri Ramaraju by ShriP.K.Agrawal, ED(P&A) in the presence of Shri TK Gupta, ED (F&A) and Shri NKMayson, ED (Mines).

The award was presented to Bhilai by Dr.Ola Ullsten, former Prime Minister ofSweden in presence of H.E.Ms Nilima Mitra, Indian Ambassador at Portugal, otherdistinguished business and public leaders and CSR experts during the 3rd GlobalConference of Social Responsibility.

JANUARY 4, 2008BHILAI STEEL PLANT QUALITY CIRCLE TEAMS EXEL AT NATIONAL CONVENTION

Quality Circle teams representing Bhilai Steel Plant participated in the NationalConvention of Quality Cicles (NCQC) - 2007 at Jadhavpur University, Kolkata fromDecember 27-30, 2007 and won 8 par excellence awards, 13 excellent awards and3 distinguished awards. 24 QC teams had been sponsored by Bhilai Steel Plant. Thus33 % of BSP teams received "Par Excellence Award" against the national average of11.6 % (77 out of the total 661 participating teams).

The par excellence award was bagged by Aastha QC (T&SM), Anupam(Instrumentation & SP-3), Bhaskar (RMP-1), Khoj (SMS-1), Life Line (M&HSOrganisation), NIshkarsh (SP-3), Sarthi (RMP-1) and Shraddha (MRD).

Excellent Award was won by total 13 teams including Aakarshan QC (SP-3),Ajay (SP-3), Akanksha (OHP), Anant (Merchant Mill), Kundan (CO&CCD), Pragati(F&P Shop), Prayas (OHP), Sangam (Fire Services), Shakti (ETL), Vatayan (SMS-2),Vasundhara (CO&CCD), Vikas (TKO) and VGishwas (ERS).

Distinguished award was won by Kiran (CO&CCD), Shubham (CO&CCD) andSpandan (HME).

Managing Director Shri RAMARAJU receives twin Environment awards

Bhilai Steel Plant added another feather to its cap by receiving the 'Corporate

INDEX

Bhilai Steel Plant


- viii -

Green Responsibility Award' for making Bhilai green and 'Prakriti Ratna award' toShri Ramaraju for implementation of exemplary waste management and naturalresource development practices in Bhilai. The award was given by Exnora International,a trust which conducts awareness programmes, promotes literature, publishes booksand journals.

Bhilai Steel Plant is the proud recipient of many awards for its best practices inEnvironment like the Greentech Environment Excellence Gold Award 2007 forenvironment conservation and CII - ITC Sustainability Award.

Managing Director, Bhilai Steel Plant, Shri R Ramaraju received the 'Corporate GreenResponsbility Award' by Exnora International from Shri M K Stalin, Minister for Ruraldevelopment and local administration, Tamil Nadu at a function at Chennai on January21, 2008. Tamil Nadu's Chief Secretary Shri L K Tripathy handed over the 'PrakritiRatna award' to Shri Ramaraju for implementation of exemplary waste managementand natural resource development practices in Bhilai at the same function.

Shri Stalin lauded Bhilai for maintaining large acres of land with green cover andalso talked about the presence of Eco clubs in different schools of Bhilai and largenumber of gardens in the plant premises.

A conscious corporate citizen, Bhilai Steel Plant has gone in for ISO-14001certification for its Environment Management System in the Plant, township and theDalli Mechanised Mines.

The plant has introduced environment friendly coal dust injection system in theBlast Furnaces, de-dusting system and electrostatic precipitators in other units andhas over the years planted over 52 lakhs trees in a concerted afforestation drive thathas seen Bhilai transform into one of the cleanest industrial townships in the country.

AUGUST 14, 2007

Dr. Gopichand Narayan Das Chandwani awarded the Shri Gajanan MadhavMuktibodh Smriti award

Dr. Gopichand Narayan Das Chandwani, Sr. Lecturer at BSP's Sr. Secondaryschool, Sector-10 was awarded the Shri Gajanan Madhav Muktibodh Smriti awardfor his technical papers on Binomial theorem and trignometrical equation, Symposiumon Roll theorem, academic achievements and excellent work rendered by him.Chhatisgarh's Governor Shri E S L Narasimhan gave away the 'Rastriya ShikshakSamman Puraskar 2006' instituted by Rastriya Shikshak Kalyan Pratishthan,Chhattisgarh unit and 50,000 Rs. to Dr. Chandwani on August 13, 2007 at Rajbhavan, Raipur. Shri Ajay Chandrakar, Education Minister, Chhattisgarh was presenton the occasion.

INDEX

Bhilai Steel Plant


- ix -

Dr. Chandwani is a renowned teacher in Bhilai. He is the recepient of numerousawards for his exemplary work - the President's award, Bhartiya Vidyaratna Puraskar,Lifetime Education award by Health and Education Development Association, Delhi,Bhartiya Ratna award, 8 gold medals, Jewel of India Gold award etc..

On 14th Aug '07, when the Home Ministry announced the President's GallantryAwards, Bhilai added another feather to its cap with Asst Chief Fire Officer, ServerGhulam Mohd bagging the President's Fire Service Medal for Gallantry. This the firsttime that Bhilai Steel Plant has won this award.

6. On 16th August '07, the Ministry of Labour announced the RashtriyaVishwakarma Awards for year 2006. Out of the 28 groups, as many as 7 groups arefrom Bhilai Steel Plant. There are five employees in each group. With ten employeesin two groups from the Coke Ovens & Coal Chemicals Deptt., ten employees in twogroups from the Instrumentation Deptt., five employees from Material Recovery Deptt.,five from the Wire Rod Mill and five from Merchant Mill, the total number of BSPemployees who will receive the award is 35. They join the 262 Bhilaians who havewon this prestigious award earlier.

7. Then came the announcement of five National Safety Awards for Bhilai SteelPlant by the Ministry of Labour. While the Shram Awards, Vishwakarma Awards andthe Gallantry Awards announced earlier in the month are based on individual or groupperformance, the National Safety Awards are given to individual shops or departments.The five shops that are going to receive the award are Refractory Material Plant II,Machine Shop II, Machine Shop III, Roll Turning Repair Shop (RTRS) and OxygenPlant II.

APRIL 10, 2007Prime Minister's Shram Awards 2004 given on April 27, 2007 at New Delhi

The Prime Minister's Shram Awards 2004 were given to the awardees on April27, 2007 at Vigyan Bhavan, New Delhi at 9.30 am. They were also felicitated at theSAIL Corporate office.

Shri Satyawan Nayak, C'man cum Sr. Technician from Plate Mill has beenconferred the Shram Vir while A K Kerketta, Jr. Manafer/ C'man cum Master Technicianand Trilochan Maharana, Sr. technician from Coke Oven & Coal Chemical deptt. havealso been conferred the Shram Vir award.

2 groups (of 5 nominees each) have been granted the Shram Vir category ofAwards under the PM's Shram Awards - 2005. A total of 10 nominations with 33nominees were submitted in the year 2005. There are a total of 17 awards for Govt./Public Sector (out of which BSP has won 2) and 16 awards for the Private Sectorunder the PM's Shram Awards scheme. No one has been granted the highest award,the Shram Ratna this year.

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1. Three employees - Dani Prasad Sharma, Satyavan Nayak and Vijay Kumar Vermaget Shramik Sahitya Puraskar of State Govt. on 11 May '07.

2. Archana Pandey from Bhilai Steel Plant's Medical & Health Services Deptt. Got theExcellence trophy in All India Steel Medical Officer's Conference in June '07

SEVEN GROUPS FROM BHILAI STEEL PLANT BAG THE VISHWAKARMARASHTRIYA PURASKAR 2006

There is no stopping members of Team Bhilai when it comes to bagging nationallevel awards established for the Industry. Close on the heels of the award of theprestigious Prime Minister's Shram Vir Awards to two groups from SAIL's premierunit - Bhilai Steel Plant, has come the announcement of the award of the VishwakarmaRashtriya Puraskar to as many as seven groups in different categories.

S/Shri Shekhar Bhattacharya, Junior Manager (Safety), SK Patankar, Sr Technician,GP Verma, Technician, AK Dwivedi, Technician and Sumant Adhikary, Sr Technician ofthe Instrumentation Department of Bhilai Steel Plant have been awarded the VishwakarmaRashtriya Puraskar-2006 in category A for their role in the revival of defunct mass flowcontrollers of RH degasser unit of SMS-II thereby effecting a recurring saving of Rs.2.073 crores. The team will receive a cash award of Rs. 50,000/-.

Another team from the Instrumentation comprising of S/Shri SP Ambade, Chargeman,SK Patil, Sr Technician, Bheemsen Sinha, Sr Technician, K Shrinivas Rao, Sr. Technician,Vijay Shankar Ram, Technician also received the 'A' category Vishwakarma RashtriyaPurashar for their efforts in the development and implementation of experience basedfurnace pressure control system in the Reheating Furnaces of Rail & Structural Mill. Thisteam too will receive a cash award of Rs. 50,000/-

S/Shri B Ishwar Rao, Chargeman, AK Baghel, Operator, Anthony, Technician, YRajurkar, Chargeman and Abdul Khuddus, Technician from the Materials RecoveryDepartment will be receiving the category "B" Vishwakarma Rashtriya Puraskar with acash award of Rs. 25,000/-. The team has been selected for the award for theirmodification work in lime coating system. This job ensures a recurring saving of Rs. 1.1crores.

For their job in introducing one conveyor belt in existing coal conveyor network,the team from Coke Ovens & Coal Chemicals Department comprising of S/Shri SLPatel, Chargeman, Rajesh Singh, Technician, KP Sinha, Sr Technician, Bipul KumarViswas and Rajeev Kumar Pandey, Operator have been selected to receive theVishwakarma Rashtriya Pursakar in category "C". They have ensured a saving of Rs.83.5 lakhs and will receive a cash award of Rs. 10,000/-.

For cost control measures in Coke Ovens Battery # 9 & 10 that involved eliminatingcoal jamming in skips the team from Coke Ovens & Coal Chemicals Department: S/Shri Sabbir Alam, Master Operative, KM Krishna Kumar, Master Operative, NarayanYadav, Sr Technician, SK Shrivastava, Sr Technician, Devanand, Operative received

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the Vishwakarma Rashtriya Puraskar Award 2006 in category 'C'. Their endeavouraccrued a net saving of Rs. 1.03 crores for the Plant.

The team from Wire Rod Mill consisting of S/Shri Praveen Sharma, Sr Technician,Harish Chandra Sinha, Chargeman, Jasbir Singh, Sr Technician, Madan Kumar Soni, SrTechnician, Ramarshray, Sr Technician effected stabilization of 105 x 105 Sq.mm BilletRolling in Roughing group of Wire Rod Mill. A recurring saving of Rs. 1.28 crores wasensured. For the Category "c" award, the group will get Rs. 10,000/-.

S/Shri K Nikhale, Chargeman, Shiv Kumar, Chargeman, AS Ekka, Sr Technician,Ashok Larendra, Technician and BP Verma, Technician from Merchant Mill receivedthe Vishwakarma Rashtriya Puraskar in category “C” for modifying the finishing stand12 delivery roll table and effecting a recurring saving of Rs. 10.5 crores.

3. Four employees Inderjit Kaur, Jitendra Kathrani, Anil Mishra and Vijay Vermawin Shramik Sahitya Puraskar of State Govt. Raghunandan Prasad VermaSarvshrestha Seva Bhavi Shramik Award of State Govt. in Sept '07

4. ITS SAIL ATHLETICS ACADEMY CADETS IN BHILAI SAYING CHAK DE! NOWWhat do Hammer Thrower Vinay Singh, Triathlete Mukesh Kumar Mahato, Middledistance runner Manish Sahu, Sprinters Harsh Kumar, Naresh Markam (100 m)and Mrityunjay (400 m) have in common?

They are all cadets of the SAIL Athletics Academy at Bhilai. Upcoming athleteswho hail from different parts of the country. Not just the national cricket orhockey teams, but the boys of the Academy too have been imbued with theChak De Spirit!! In a shot span of three years since these and other promisingathletes, who had been inducted raw into the academy, have now begun toshowcase their athletic achievements in zonal and national competitions withstars in their eyes and fire in their bellies.

Vinay singh who hails from Allahabad, bagged gold, throwing the hammer to adistance of 64.66 metres while participating in the U-18 age group of the 19thwest Zone Junior athletics championship at Vadodara earlier this month. Onlylast year Vinay had bagged silver in the Youth Nationals at Vijayvada beatingthe earlier meet record with a throw of 67.85 metres. For his exemplaryperformance in recent years Vinay Singh has been awarded the Saheed KaushalYadav Puruskar with a cash award of Rs. 1 lakh by the Government ofChhattisgarh.

In the same meet at Vadodara, Triathelete Mukesh Kumar Mahato bagged goldin the U -14 category of the event. Earlier, Mukesh had bagged Silver in theSchool Nationals. A Bhilai Boy, Mukesh's father runs a small cycle repair shopwhich happens to be quite near his son's Academy.

Other athletes from the academy also shone in the meet at Vadodara. Runningin the 400 meters run, Harsh Kumar, who has come from the tribal area of

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Dantewada, bagged silver in the U-20 category. In the U-16 category, MritunjayYadav also grabbed silver in the 400 metres race.

The Medley relay team comprising of Naresh Markam, Mangiya Ram, JaishuKowachi and Mritunjay Yadav bagged silver in medley relay race. The 4x100 mrealy team comprising of Manglu Koram, AK Mishra, Sanjay Bhowmik and RupeshKoma also bagged silver in the U-18 category. The 4x400 relay team consistingof Manish Saho, Vinod Oraon, Mehendra Oraon, Manglu Pottai won the bronzein the U-18 category.

Other athletes to perform creditably are Vinod Oraon(4th in 1500m), Manglu Korram(6th in 200m), Sanjay Bhowmik (4th in 400m), Dhannu Ram Jhurri(7th in 400m),Ranjeet Sharma(4th in Javelin), AK Mishra( 6th in 100 m hurdles and 4th in 400mhurdles), Mahendra Oraon(4th in 500 m), Rupesh Koma (5th in long jump -U-18),Tanmay Maan (5th in long jump U-16) and Ramesh Oraon (5th in 5000m).

5. BSP wins Greentech Environment Excellence Gold Award 2007 for environmentconservation. Award given on 29th Aug in Goa.

6. BSP wins CII - ITC Sustainability Award for the second successive year. MDreceived the award on 12th Dec '07.

7. Three QC teams from BSP - Anurakshan from RSM, Adarsh from SP 3 andInstrumentation Deptt. and Akash from SMS I won Gold medal at the InternationalConvention of Quality Circle in which 202 teams from 13 countries participated.

8. BSP pavilion adjudged Best in Rajyotsav 2007 Exhibition at Raipur for secondconsecutive year.

9. Sanjay Mishra and Sangeeta Rajgopalan win Gold (men's singles) and Bronze(women's singles), respectively at Senior World Badminton Championship (above35 years age group) in Taipei from 24-29th April 07.

10. Sandhya Chandrakar, a ward of BSP employee won Gold in karate-kata event in33rd National Sports Championship at Guawahti from 9to 18th Feb '07.

11. Golden Peacock National Quality Award 2006 at the 17th World Congress onTotal Quality & IOD Convention-2007 on 14th Jan '07 at Kolkata.

12. Golden Peacock National Training Award 2006 at the 17th World Congress onTotal Quality & IOD Convention-2007 on 13th Jan '07 at Kolkata.

13. Shilpa Janbandhu, a ward of BSP employee receives wins National BraveryAward 2006 from then President of India, Dr Abdul Kalam in Jan '07.

14. K S Giridharan, DGM (MM) has been appointed Coach of Indian Umpires by BCCI.

15. Vigilance Deptt certified with ISO 9001 : 2000 certification. Awarded on 1stJune 2007 by TUV, Germany.

16. Mr. A.K.Saha DGM (SED) lauded the efforts of Mill collective in bringing downthe number of accidents and told that BBM should become the role model forother departments in the plant being the only major shop in Bhilai Steel Plant to

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have been awarded the RCGS Diamond certification by Steel Safety Organisation,Ranchi . Jan 08

JANUARY 2006

Bhilai Steel Plant was awarded the IOD Golden Peacock Award for InnovativeProduct/Service 2005. Bhilai Steel Plant was adjudged winner of the award in thiscategory for its innovation in developing, rolling and supplying special quality steelplates in DMR 249 A grade to meet the Indian Navy's requirement for this grade. Theplates are being used by the Navy to build the hull of India first indigenouslymanufactured aircraft carrier ship.

Nikita Daharwal, daughter of Shri Anand Daharwal, AGM (T&D) won the ThirdPrize in the International Drawing & Painting Competition, organized by theToyota Motor Corporation, Japan for the year 2005. Her painting 'Dream CarAll-rounder' succeeded among the creations of 16000 participants from allover the world.

Bhilai Steel Plant bagged the 2nd prize for best performance for suggestionscheme in category-4 at the 16th National Convention of INSSAN (Indian NationalSuggestion Association) held at Mumbai.

AWARDS & ACCOLADES TO BHILAI STEEL PLANT DURING 2006

APRIL 2006

Bhilai Steel Plant was awarded the Greentech Safety Silver Award-2006 bythe New Delhi based Greentech Foundation for the Mining & Metallurgical Sectorfor its special achievements on the safety front and its successful efforts inbringing down accidents during the past financial year. Shri SK Jain, ED (Works)received the award on behalf of Bhilai Steel Plant from Shri G Vinod, theHon'ble Minister for Labour and Employment, Government of Andhra Pradeshin Hyderabad.

MAY 2006

Bhilai's superlative performance in all fronts and particularly in the area of industrialrelations, technological upgradation and human resource management front inboth 2003-04 and 2004-05 has fetched it the coveted and prestigious PrimeMinister's Trophy for the Best Integrated Steel Plant in the country for these twoconsecutive years. The Hon'ble Prime Minister, Dr Manmohan Singh handed overthe twin trophies to SAIL Chairman, Shri V S Jain and the MD, Bhilai Steel Plant,Shri RP Singh at a function in Visakhapatnam on 20th May 2006.

JUNE 2006

Bhilai Steel Plant received the 'Golden Peacock Eco-Innovation Award instituted

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by World Environment Foundation for the in-house project of 'RetrofitIntroduction of BF Gas Firing System in Boiler-6 in Power & Blowing Station.'ED(Works) Shri S.K.Jain received the award from Shri Virabhadra Singh , ChiefMinister of Himachal Pradesh on June 9, 2006 during the 8th World Conferenceon Environment Management organized by World Environment Foundation atPalampur from June 9-11, 2006.

JULY 2006

Bhilai Steel Plant has received the ISO-14001 Certification for EnvironmentManagement System of Bhilai Township. This makes it one of the few townshipsin the country to have acquired the certification and the only one of its size tohave done so. The Certificate was handed over at a function held in IspatBhavan on July 26, 2006. Shri R Ramaraju, Actg. Managing Director, BhilaiSteel Plant received the certificate from Shri Anil Mittal, Chief Marketing, LloydsRegister of Quality Assurance (LRQA), India Operations

OHSAS 18000 certificate for safety and health and SA-8000 for socialaccountability were handed over by Chairman SAIL, Shri VS Jain to the concerneddepartments at BTI Assembly Hall on 25th July '06.

Bhilai has become the only public sector organisation to have been awarded allthe four cetifications of ISO 90001 for quality, ISO 14001 environmentalcertifications for plant and mines, OHSAS 18000 for safety and health and SA8000 for social accountability.

AUGUST 2006

Rajesh Patel, Junior Manager (Sports) and well known Basketball coach receivedthe 'SAIL Coach of the year 2005-06' award for coaching national-level playersfrom Bhilai in different competitions for the year 2005-06. Shri Rajesh Patel isthe only coach in BSP and SAIL, who has got this award for the fourth time.Earlier, he has received this award in 1998, 2000 and 2002.

Bhilai Steel Plant's Environment Management department has been awardedthe Greentech Environment Excellence Gold Award in Metal and Mining Sectorby the Greentech Foundation, Delhi. GM (Power & Environment) Shri R K Agrawalreceived this award from Shri S C Jamir, Governor of Goa in the 7th AnnualGreentech Environment Excellence Award ceremony held in Goa on August 31,2006. This is the third consecutive time Bhilai Steel Plant is the recipient of thisaward. Bhilai Steel Plant has also been accorded ISO:14001 for EnvironmentManagement System.

SEPTEMBER 2006

Vishwakarma Award, Shramik Yashshashvi, Uttam Shramik, Shram Sahatiya.........

The Vishwakarma awards for noteworthy and innovative practices in public

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and private sector industries constituted under the Ministry of Labour,Government of India's Directorate General Factory Advice Service & LabourInstitutes, Mumbai, have been announced. Out of the total 28 awards, one-fourth of them have been won by employees of Bhilai Steel Plant (BSP) for theyear 2005.

Five employees of BSP have won the Category 'A' awards with a cash prize of50, 000 rupees, 10 have got the Category 'B' award of 25, 000 rupees and 20have got the Category 'C' awards of 10, 000 rupees each.

OCTOBER 2006

The Indian Institution of Industrial Engineering (IIIE) bestowed its highest nationalaward, The Lillian Gilbreth Award 2005-06 on Shri K Patel, GM I/c (P&A) for hisoutstanding services to the profession of Industrial Engineering, his efforts forthe propagation of the values of Industrial Engineering and his distinguishedaccomplishments in the field of engineering and technology and to society. Theaward was given away at the inaugural function of the two day 48th NationalConvention of IIIE held at the Nimhans Convention Centre in Bangalore onSeptember 29, 2006.

NOVEMBER 2006

The Human Resources Development Department received the CSI-Nihilent e-Governance Award 2005-06 for Best e-Governance Project for its 'e-Abhiyaan'Programme. The award was given away at the awards distribution ceremonyheld during CSI Annual Convention at Science City, Kolkata on November 24,2006. The HRD department got the award for preparing the organisation'speople for E-Governance through Massive Computer Competency .

Bhilai Steel Plant, SAIL has bagged the coveted Rajiv Gandhi National QualityAward - 2006 in the "Best of all" Category. This is the highest award among allcategories of awards given away by the Bureau of Indian Standards. The awardwas instituted in 1991.

Shri Bharal Lal, GM I/c (Mills & Quality) was awarded the coveted O P JindalGold Medal for the year 2006 by the Indian Institute of Metals for his outstandingcontribution to development of ferrous metals and alloys.

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MINES & QUARRIES

Bhilai Steel Plant is an ore based plant. The location of the plant at Bhilai wasbased on the fact that three basic and important raw materials required for steelmaking i.e. Iron Ore, Limestone and Dolomite are available in close proximity toBhilai. The total iron ore requirement of BSP is met from a group of mines at DalliRajhara known as Iron Ore Complex. Except for some quantity of high grade limestonebeing procured from Rajasthan, the total limestone requirement of BSP is met fromcaptive mines at Nandini. A major portion of dolomite requirement is procured fromcaptive mine at Hirri. The limestone mine at Nandini and dolomite mine at Hirri togetherare known as Flux Group of Mines. where as Iron ore mines at Dalli Rajhara is namedas "Iron Ore Complex Mines".

IRON ORE GROUP OF MINES

Dalli Rajhara is situated approximately 90 Kms south-west of Bhilai. There arefive working mines, viz. :

(i) Rajhara Mechanised Mine (ii) Dalli Mechanised Mine(iii) Jharandalli Mechanised Mine (iv) Dalli Manual Mine and(v) Mahamaya Manual Mine.

Aridongri deposit has beeen surrendered & handed over to stategovernment.

Ore deposit at Kokan has been exhausted while Dulki Mine is yet to be started.The initial reserve, and reserve position as on 01.04.2007 for iron ore, is as follows:-

Initial Reserve :

Sl.No Name of Mine Reserve (M.T.) 1. Rajhara Mech. 102 2. Kokan 20 3. Rajhara-West 06 4. Dalli Mech. 108 5. Jharandalli 31 6. Dalli Manual 29 7. Mahamaya 21 8. Dulki 10

Total 327.00

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Reserve as on 01.04.2007

Sl.No Name of Mine Reserve(M.T.) Fe% SiO2% Al2O3% 01 Rajhara Mech. 32.97 67.31 1.76 0.84 02 Dalli Mech. 36.53 64.09 4.38 03 Jharandalli 11.08 63.44 4.36 1.90 04 Dalli Manual 4.50 62.33 4.70 2.61 05 Mahamaya 4.80 62.00 5.00 2.90 06 Dulki 8.52 63.67 3.60 2.76 Total 98.40 64.88 3.48 1.83

The iron ore occurring in the above deposits is mainly Hematite ( Fe2O

3). Principal

ore types include Massive ore, Laminated Ore, and high grade powdery ore alsoknown as Blue Dust or HGF. Wastes occurring in these deposits include Laterite,Shale, & Phyllites. The host rock for the iron ore hematite is known as Banded HematiteQuartzite (BHQ).

All the mines are worked by opencast method with a combination of fullymechanized, or partly mechanized and partly manual means. Crawler mounted drillingrigs are used to drill rows of holes of 6/12 mtrs deep for manual/mechanized mine.These holes are then charged with cartridged slurry explosives, and blasted. Thisblasted mass known as ROM is then loaded into 50 ton dumpers/ 10 ton tippers, fortransportation to processing plants.

Two processing plants have been set up for processing of iron ore, the firstbeing dry circuit plant installed at Rajhara and the second being wet circuit installedat Dalli. Iron ore from Rajhara Mechanised Mine is rich in Fe content, and thus, a drycircuit plant of 3.7 MTPA capacity has been installed at Rajhara. Iron ore from Dalli ,having lower Fe and higher percentage of Alumina, has a wet circuit plant of 5.55MTPA capacity.

RAJHARA MECHANISED MINE

This mine was commissioned way back in 1960 as a fully mechanized mine witha capacity of 2.8 MT per year. The hanging wall side of mine consists of shales andphyllites, and the foot wall side consists of banded haematite quartzite (BHQ) whichis the host rock of iron ore.

Working is done by Open-Cast method deploying Electric Power Shovels (4.6cubic mtr bucket capacity) and Hydraulic Shovel (5.5 cu. m. capacity) in combinationwith 50 T dumpers. Drilling is carried out by 150 mm dia drills, and subsequently, thedrilled block is blasted by cartridged slurry explosives.

The high grade ore from this mine is used to improve quality of ore from Jharandalliand Mahamaya Mines, by blending. The ore feed is crushed in three stages and

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screened, to produce (i)BF lumps (10-40 mm) and (ii) Sinter Fines (-10 mm) gradeore, which are loaded by shovels into wagons for dispatch from mine sidings to BhilaiSteel Plant. in 2007-08,plan of processing of 3.7 MT has been made.

DALLI MECHANISED MINE

This mine consists of Konde-A and Konde-B blocks. Working is similar to RajharaMechanised Mine with 150 mm dia drills, 4.6/5.5 cu.m. shovel and 50 T dumpers.Ore at Dalli has lower Fe content and high alumina, and thus requires beneficiation bywet processing by two stage crushing, wet screening, scrubbing and classification toproduce lump (10-40 mm) and fines (-10 mm). This mine is a ISO 14001 certifiedmine. It is planed to prouduce 5.95 MT in 2007-08 through this planed.

JHARANDALLI MECHANISED MINE

This is a mine working with 1.2/1.5 cu.m. hydraulic shovel and 10 T tippers. Orefrom Jharandalli is fed to Rajhara Bunker and upgraded by high quality ore fromRajhara. This mines to targeted to produced 2.05 MT is 2007-08.

DALLI MANUAL MINE

This is a manual mine worked by DPR workers who excavate ore from 6 meterbenches and separately stack the 8 to 250mm size ore, generated fines, waste, etc.Loading and Transportation of ore/waste is done by contractual mechanized means.The sorted ore is fed exclusively to Dalli Plant. Target production is 1.2 MT for2007-08.

MAHAMAYA MINE

This mine, situated 20 Km south of Rajhara, is worked with DPR workers in asimilar manner as that of Dalli manual mine and the ore is transported to RajharaCrushing Plant. Target production 0.55MT for Mahamaya &0.1 MT for Dulki ; in2007-08

Dulki/Kalwar deposit near Mahamaya is yet to be opened pending clearance byMinistry of Environment & Forests.

Kokan Mine, worked manually till 2001, has been amalgamated with RajharaMechanised Mine as the deposit is nearly exhausted and found unsuitable to beworked separately.

EXPANSION AND MODERNISATION

Presently total requirement of iron ore of BSP is met from Dalli Rajhara, Iron OreComplex. In view of fast depleting reserves at Iron Ore Complex, Rajhara and to meetfuture requirement, BSP has decided to open up an iron ore mine at Rowghat whichis located about 80 Kms from Rajhara in Narayanpur District of Chhattisgarh.Accordingly, BSP will develop the mine in Block-A of Deposit-F of Rowghat with aproduction capacity of 14.0 MT per year wef 2011-12. Due to environmental reasons,

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the beneficiation plant shall be of dry circuit type. However, grant of forest clearanceunder Forest (Conservation) Act, 1980 is still awaited. work of layings Railway linefor Rajhara to Rawghat has already been selected into by SECR.

DALLI RAJHARA TOWNSHIP

Iron Ore Complex, Dalli Rajhara has a well planned township over an area of 260acres and having 244 houses for executives and 2523 houses for non-executives.Besides this, there are substantial numbers of private dwellings around this townshipconsisting of 250 shops, banks, schools, etc. Medical facilities are provided by BSPby means of a modern, 45 bed hospital. There are various entertainment facilities atRajhara like a Cinema Hall, five Football grounds, 4 volley ball ground, one cricketground, one basket ball and a 30,000 capacity stadium.

FLUX GROUP OF MINES

The Flux group comprises two mines, namely Nandini Lime Stone Mine, and HirriDolomite Mine. The ore reserve as on 01.04.2007 is as under.

Sl.No Name of Mine Reserve(M.T.) Cao % Mgo% SiO2 % 01 Nandini (Lime Stone) 105.87 41.84 6.22 6.72 02 Hirri (Dolomite) 21.74 30.93 20.67 3.93

NANDINI

Nandini Mine is situated at a distance of 25 Km NNE of Bhilai. The mine isproducing limestone which is used to remove silica and alumina contents as slagduring iron and steel making. The annual production of this mine is about 1.0 MT.Nandini Mine is a mechanized open cast mine being operated by Shovel and Dumpersand Shovel-Tipper combination. To make the blocks ready for blasting and excavation,primary drilling of 150 mm dia is done. The blasting is carried out mainly by large diaslurry explosives. Secondary drilling and blasting is resorted to, to reduce the oversizeboulders. The blasted mass is excavated and transported to Crushing and ScreeningPlant for further sizing and screening . The final product of limestone is transportedto Bhilai by wagons having a capacity of 62 T each. The mines is to produce 0.75 MTin 2007-08.

HIRRI

This mine is situated at the North-East extremity of Chatona Dhaurabhata Dolomitebelt in Bilaspur district of Chhattisgarh at a distance of 140 Km from Bhilai. Mining isdone using 1.5 Cu. M excavators, 10 ton tippers and 105mm dia drills. The excavatedore is processed through a contractual agency to produce (i) SP grade (0-60mm) and(ii) SMS grade ( 10-25mm) and dispatched by BOXN wagons loaded at Dadhaparasiding situated 7 kms from the mine. The mines is to produce 1 MT in 2007-08.

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ORE HANDLING PLANT

The Central Raw Material Blending and Storage Yard (CRMBSY) renamed as OreHandling Plant (OHP) has come up Under 4 MT expansion programme of BSP in 1983.With this, Bhilai got bedding / blending facilities for raw materials for the first time,alongwith facilities for unloading of raw materials at the periphery of the steel plant.

SALIENT FEATURES OF OHP

Under 4MT Expansion of Bhilai Steel Plant ,the principal scheme and materialflow in OHP comprises the following :

1. Receipt / unloading of raw materials.

2. Bedding / Blending and reclaiming facilities, in a big stock yard.

3. Supply of raw materials to the consumer shops : SP-2, SP-3 RMP-2, CONVERTORSHOP, & B.F -7, 6, 5, 4, 1.

Above scheme facilitates handling of following raw materials in OHP :

a. Blended Ore Fines for SP-2 & SP-3.

b. Dolomite & Lime stone for SP-2 & SP-3.

c. Screened Iron Ore to Blast Furnaces. ( Iron Ore screen installed in 1996.)

d. Low Silica Lime Stone and Iron Ore for SMS 2.

e. High Silica Mn ore to B.F.-7 & High line bunkers of 1,5.

f. Coke breeze (added from 2001-2002).

RECEIPT / UNLOADING OF RAW MATERIALS :Mainly two categories of Raw Materials are received in OHP

1. From captive mines.

2. From other than captive mines.

Raw materials from our captive mines are generally received in BOBS type ofwagons which railways have specially designed for BSP. These wagons are unloadedin the track hoppers in the peripheral yard of OHP There are two rows, of 20 hopperseach, in track hopper building.

Lime stone (SP -grd.) fom Nandini for both Sinter Plants (SP-2 &SP-3). Iron Orefines / Lumps Iron Ore from Dalli Rajhara are received in BOBS type of wagons andunloaded in two row of hoppers called Track hoppers. Dolomite from Hirri Captivemines & raw material from other than captive mines like Low Silica lime stone dolomiteMn Ore etc. are receieved in BOX type of wagons & unloaded at wagon tippler of OHP.

STORAGE / BEDDING -BLENDING OF RAW MATERIALS :

The raw materials unloaded in peripheral yard are transported to open Storage

yard of OHP by conveyor belts . The facilities for stacking bedding - blending areprovided to handle different types of raw materials in the stock yard.

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The storing in OHP stock yard provides sufficient reserve of raw materials to

guarantee continuous operation of consumer shops. The blending methodology is aprocess of mechanised stacking and reclaiming functions.

The bedding-blending process consists of spreading out different grades of raw

materials in many layers over full length of bed by using stackers and reclaimation ofthe same by blender reclaimer in successive cross -sections of the bed. The blending

efficiency of a bed is defined as the ratio of the standard deviation of the input &output of the bed.

A transfer car has been provided in the storage yard to transfer the Stackers &

Reclaimers and Excavators from one bed to another.

SUPPLY OF RAW MATERIALS TO CONSUMER SHOPS

Reclaiming is the process of transportation of the raw materials from the storageyard beds to the consumer shops with the help of excavators, reclaimers & belt

conveyors to fulfil needs of different cosumer shops.

At present, raw materials being supplied to the consumer shops are :

1) Blended Ore Fines to SP-2 & SP-3.

2) High Silica Lime Stone and Dolomite to SP-2 & SP-3

3) Low Silica Lime Stone to RMP-2.

4) Hirri dolomite to RMP-2.

5) Iron Ore, High Silica Dolomite & Low Silica Lime Stone to SMS-2.

6) Iron Ore to BF-7 and High line bunkers of B.Fs 6 & 5, 4

7) Quartzite & High Silica Mn Ore to BF-7.

OBJECTIVES OF OHP :

1. a) To reduce interference of internal Railway traf-fic movement and to Unload Raw Materials

at the periphery of the plant, by avoiding de-tention of railway wagons.

2. b) Blending by making homogeneous pile of rawmaterials received from our captive mines andother sources / purchased raw materials, soas to achieve consistent quality.

a. Keeping buffer stock of raw materials andtheir uninterrupted supply to different Consumer shops.

INDEX

Bhilai Steel Plant

- 9 -

MAIN SECTIONSBroadly OHP can be divided in three sections :

(a) Stacking Route -Unloading of raw materials at Wagon Tippler &Track Hoppers and then convey

to yard.(b) YARD -

Stacking of raw materials in beds and reclaiming the same from bed / pile for theconsumer shop.(c) Reclaiming Route -

Despatch of raw material up to the consumer shop bunkers.Unloading of wagons is controlled from J 4 -junction control room (No. CR-1A) &

all despatches are controlled from Junction -10 control room

MEANS OF UNLOADING AND EQUIPMENTS AVAILABLE :(i) Track Hoppers (a) -20 + 20 No. 1 to 20 - Ore fines (on J1C1)

(J1C1 Side) (J1C2 Side) No.1 to 12-Flux }No. 13 - Empty }(to avoid mixing) }No. 14 to 20 - Iron Ore} (on J1C2)(b) - Capacity of each bunker = 110 t.

(ii) Wagon Tippler -16 to 17 Wagons/Hr with help of Pushercar (1 No.)

RAW MATERIALS HANDLED, SOURCES & CONSUMERS

Raw Material Sources Consumers Iron ore fines Dalli Rajhara SP-2 & SP-3 Low Si Lime Stone Jaiselmer, Katni,

Kuteshwar RMP-2, SMS-2

High Si Lime Stone Nandini SP-2 & SP-3 High Si Dolomite Hirri SP-2, SP-3, SMS-2 Iron Ore Dalli, Rajhara B.Furnace-7/ Highline Bunkers High Si Mn Ore Ramteke Tirodi Moil Blast Furnace No.1 & 7

INDEX

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GATEWAY

INDEX

Bhilai Steel Plant

- 11 -

Note :-Any other wagons having length over coupling up to 16500 mm andin between 23003200 mm. & height between 2250-3750 mm.canbe handled, provided gross load doesn't exceed 110 t.

EQUIPMENTS

(1) Paddle Feeder 4 Nos.

(2) Wagon Tippler 1 No.

(3) Pusher Car 1 No.

(4) stacker 4 Nos.

(5) Blender barrel reclaimer 3 Nos.

(Wheel on boom reclaimer) 1 No.

(6) Excavator 3 Nos.

(7) Travelling Feed Bins 3 Nos.

(8) Transfer car 1 No.

(9) Tripper car 4 Nos.

(10) Crane ( EOT) 4 Nos.

(11) Dozer 1 No.

(12) 3D Excavator 1 No.

(13) Hydromac 2 No.

1) PADDLE FEEDER - 4 NOS.

Rotating blade paddle feeder is used to take out material from the track Hopper.

Capacity 260m3/Hr. and 600 T. Hr.

Travel speed 3 M/Min

No. of blades six

Rotor drive 30 KW dynodrive 120 to 1200 r. p.m.

Rotor r.p.m. 0 - 10

Rotor diameter 3050 mm

Types of wagons Capacity L x W x H Materials (a) BOBS 65 T. O/F,I/ Ore, N.L.S.,I/Ore

Lumps (b) BOX 56-58 T. 1480 x 3136 x 3138 L.si L/S,Dolo Mn Ore

(Purchased raw Mat) (auto coupling)

(c) BOX N 56-58 T. 10715 x 3136 x 3735 mm ---------do----------

INDEX

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GATEWAY

2) WAGON TIPPLER - 1 No.

Utilised for tilting BOX & BOXN wagons for unloading. Type Rotary GravityClamping.

Tippling time Forward 30 sec.

Pause 10 sec.

Backward 20 sec.

Degree of rotation 175°

Dimensions Length 19.80 m.

Breadth 9.6. m

Height 8.505 m

Drive 2 Slipring induction motors 63 KW each.

3) PUSHER CAR - 1 No.

Used for pushing and placing the BOX / BOXN one by one over the tippler tablefor unloading.

Pushing Force - 23000 Kg.

Pushing Speed - 0.25 to 0.5 M / Sec.

No. ofs Wagon - 30 Loaded Wagons.

4) TWIN BOOM STACKER - 4 Nos.(1 No. ADDED UNDER SP-3 EXPANSION OF OHP)

Blending in bed no. 1, 2, 3, 4, 8 & 9 is done through twin boom stackers . Anyof the two booms can be utilised to stack the raw materials after receiving fromstacking conveyor.

Capacity - 520 M3 / Hr.

Stacker speed - 15 M/Min. forward / reverse for all stackers.

20 m/min & 30 m/min for stacker. 4.3.2 M/Sec.

For all stackers.

Forward/Reverse

Boom Conv. Speed

Hoisting/Lowering Range - 12 to 28°

5) BLENDER BARREL RECLAIMER - 3 Nos.(1 No. ADDED UNDER SP-3 EXPANSION OF OHP)

Reclaimers are used in bed no 1, 2, 3, 4, 8 & 9.

INDEX

Bhilai Steel Plant

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6) EXCAVATOR - 3 Nos.

Excavators are used in assorted piles namely no 5, 6, 7, 7A.

7) TRAVELLING FEED BINS - 3 Nos.

Travelling through-out the length of the bed raw materials are discharged fromthe excavator bucket to T.F. Bins hopper, get finally discharged on the main reclaimingconveyor

8) TRANSFER CAR - 1 No.

As the no of major equipments are limited, the equipments are required to beshifted from one bed to the other bed, so as to unload each raw material in the rightbed. For shifting of the equipments, transfer car is used.

Tr Car Speed 5&10 M /Min.

Maximum wheel load 30 T.

No of Wheels } No. of drive wheels - 12

} No. of a non drive wheels - 28

Total - 40

9) WHEEL ON BOOM RECLAIMER - 1 No.

Capacity 800 T. /Hr.

Bucket No of 8 Nos.

Speed 6.3 R.P.M.

POLLUTION CONTROL

During material handling huge amount of dust is generated at different transferpoints & in the yard etc. For last few years number of pollution control equipmentshave been installed and commissioned for reducing the pollution level within thenorms.

Following steps have been taken for dust control -

A) Commissioning of water sprinklers in yard.

B) Dust suppression at track hoppers and wagon tippler.

C) Water spray system at major transfer points at stacking and reclaiming routes.

D) Inculcating awareness among employees regarding pollution control system byorganising workshops, and training.

E) Modernization

- Replacement of PLC with state of art PLCs. (in both control rooms.)

- Wheel on Boom Reclaimer 1 No. commissioned under OHP's expansionscheme of SP-3 (PKG-IV).

INDEX

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GATEWAY

- Fourth stacker & third reclaimer have been commissioned under OHPexpansion. scheme of SP-3. (pkg II)

- Polymer liners in track hopper, ss liners in chutu of stackers to enhanceflowability for fast unloading of wagons of Ore Fines Tree plantation atyard welfare building surrouding area.

HIGHLIGHTS :

Wagon pushing capacity BOX /BOX'N WAGONS of pusher car has been increasedfrom 2 0 to 3 0 wagons for improving unloading of wagons and minimisewagon detentions.

Installation of radio control system in stacker No1 is first of its kind in a stackerof SAIL.This modification has replaced the use of the conventional cable reelingdrum. This has resulted in savings of 2.5 lakhs / year.

Unserviceable mobile crane of TPL work shop has been revitalized with internalresources in (2001-2002). Due to this, buying of new mobile crane costing 16lakhs has been averted.

In (1997-1998) feed hopper has been installed in stc-5 unloader to removedead stock of 1 Lakhs T ore fines from bed No - 8 to bed No -1. Savings of Rs30/- Lakhs by avoiding the job on contract.

A single deck screen has been installed at J-11 for on-line screening of -10 mmsize fraction from Iron ore for B. Furnaces. This has resulted in improvingproductivity by reducing undersize by 50 % of iron ore being sent to BlastFurnaces .

Winner of MD's Q.C. Cup jointly with RMP-2 In category "B" In 2001-2002.

Trophy won at Bokaro at chapter level convention by Q.C." NIDAN " in 2004.

Trophy won at Bokaro at chapter level convention by Q.C." PRAYAS " in 2001.

Trophy won at chapter convention & National convention at Durgapur & Bombayin 2004 by Q.C. " PRAYAS ".

Trophy won at chapter convention at Vizag and National convention at Ernakullamby Q.C. "PRAYAS" in 2005.

Trophy won at chapter at Kolkata and National level at Ernakullam by Q.C."AKANKSHA" in 2005.

Trophy won at chapter level at Nagpur & National level at Kanpur by Q.C. ."AKANKSHA" in 2006.

INDEX

Bhilai Steel Plant

- 15 -

YEAR

UNLOADING

(T)

DESPATCH

(T)

TOTAL HANDLING

(T) GROWTH %

2002-03 7013215 7131199 14144414 11.90

2003-04 7563892 7878167 15442059 9.17

2004-05 7193859 7240349 14434208 -6.53 2005-06 7629243 7631983 15261226 5.73 2006-07 7359262 7552867 14912129 -2.29

ORE HANDLING PLANT YEARLY PERFORMANCE OF O.H.P

INDEX

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GATEWAY

SINTERING PLANT-ISintering Plant-I has the capacity of 2.04 MT/yr based on the production from

4m/cs. It works on the principle of Dwight-Lloyd process - down draft system.

Sintering Plant No.1 comprises :-

a. Raw material receiving section.

b. Raw material screening & flux crushing section.

c. Fuel crushing & flux screening section.

d. Storage & Proportioning section and

e. Machine building.

FUNCTION:

To produce fluxed or super fluxed sinter. We are now manufacturing sinter ofbasicity 1.8 to 2.0 with the following proportions of the material.

Ore fines : 53.53%Lime Stone : 23.4%Coke breeze : 5.18%

B.F. Sinter return is 16.63 and moisture in the charge is 6 to 8% Iron contentof the sinter is 51 to 53%

The proportions shown above are not constant and the composition changes asper the requirement of blast furnace.

RAW MATERIALS RECEIVING SECTION:

Ore fines, lime stone and dolomite are transported from the yard/ trench by OBCto sintering plant receiving bunkers (20 nos.) coke breeze comes from coke oven bybelt conveyor to four coke receiving bunkers. The same also comes from B.F. bywagons and by trucks from different yards. Volume of each bunker is 90 cu.m. Orefines can also be unloaded from BOBS wagons received from mines.

RAW MATERIALS SCREENING AND FLUX CRUSHING SECTION:

Functions of this section are :a. Preparation of the ore mixture. The ore fines, after being mixed up with

mill-scale & lime dust is subjected to screening whereby 12mm goes to thestorages section section and ore mixture and + 12mm is treated as waste.Flue dust is directly transported to storage bins.

b. Crushing & flux screening section - Fuel curshing is carried out in four-rollcrushers, each with the average capacity of 16 to 20 tonnes/hr. for propersintering more than 90% of the crushed material should be of 3mm size. Thefuel after being crushed is sent to the storage section.

INDEX

Bhilai Steel Plant

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FUEL CRUSHING & FLUX SCREENING SECTION:

Fuel crushing is carried out in four-roll crushers, each with the average capacityof 16 to 20 tonnes/hr. For proper sintering more than 90% of the crushed materialshould be of 3mm size. The fuel after being crushed is sent to the storage section.

Crushed flux received from the hammer mills is screened and 3mm size istransported to the storage section +3mm size is again sent to hammer crusher forclosed circuit grinding.

RAW MATERIALS STORAGE & PROPORTIONING SECTION:

Screened ore mixture, crushed flux and fuel and sinter returns are stored in thissection in twenty bunkers arranged in two rows. Flux and fuel bunkers are providedwith batch meters while other are having disc feeders. A proportioned sinter chargeis made out of these ingredients and supplied to machine building through beltconveyors.

MACHINE BUILDING:

The building is equipped with four downdraft dwinght Lloyd sintering m/cg. Eachhaving the following dimensions :

Length : 25 metersWidth : 02 metersArea : 50 sq. meters

Sinter charge from the proportioning section is stored in 4 bunkers, one for eachmachine. The sinter charge from the bunkers goes to pugmill. The function of pugmill is mixing and moistening the charge. The charge after proper mixing is fed on topendulum feeder which distributes the material uniformly on to the pallets of sinteringmachine. Each sintering machine is provided with an ignition hood where a mixtureof 12% coke oven gas and 88% blast furnace gas is burnt. The temperature of thehearth zone is 1250 to 1300°C.

Top layer of sinter charge is ignited under the ignition hood. Suction of air throughthe charge propagates the ignition. By the time the charge moves to the end of thesintering machine, the entire charge is converted to sinter. Combustion of coke breezewithin the charge takes place resulting in the following chemical equations :

C + O2 = CO

2 + 94,220 cal

2C + O2 = 2CO + 53,140 Cal

The heat liberated from the reactions stated above, raises the temperature ofthe charge a creates a condition necessary for the following reactions to occur :

CO + 3Fe2O

3 = 2Fe

3O

4 + CO

2 + 8870 Cal

CO + Fe3O

4 = 3FeO + CO

2 - 4990 Cal

FeO so formed combines with SiO2 and fluxes resulting in the formation offluxed sinter.

INDEX

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GATEWAY

INDEX

Bhilai Steel Plant

- 19 -

Sinter cakes are crushed in a sinter cutter, which cuts the sinter discharged fromthe moving pallets to -80mm size and the broken pieces are afterwards screened ona self-balancing screen in hot condition. Sinter having size between 10-80mm isdischarged on to the pancoolers (one each m/c). -10mm size is utilize as return sinter.Sinter is cooled in the pancooler by induced 100-1500C. Cooled sinter is screenedagain on vibrating screen to separate out fines (-10mm) to arise during coolingoperation, before being stored in loading bins. Sinter loading bins comprise twocompartments of capacity 100 cu.m.each.

Control

All production units except the sintering section are controlled from a centralizedcontrol panel in the central room. Sintering section is controlled from a special controlpanel installed at to head of the m/cs next to the sintering process control panel.

Specific consumption of raw material Service per tonne of sinter

Iron ore fines Kg 760 Heat of gas 85x103

Lime Stone (HS) 325 Electricity 39 Kwh

Coke breeze 81 Compressed air 21 cum

BF Sinter returns 219 Rail transport 0.2min

Water 7.5 cum

Operational Characteristics

Screen analysis 54 (+10mm)

46 (-10mm)

DTI 70%

STI 70%

INDEX

- 20 -

GATEWAY

SINTERING PLANT-II

Sintering Plant-II (SP-II) was set up during 6th BF stage; started on 1st August1979 with one inter machine of 75 M2 sintering area with rated capacity of o. 75 MT/YR Subsequently, three more machines were added to it, making the total capacityof SP-II as 3.137 MT/YR.

Initially, the acceptability of sinter was very poor at blast furnaces, and thesinter process was basically for utilization of metallurgical waste of mines and plant,viz. iron ore fines, lime stone chips, flue dust, mill scale etc.

Later on the importance of Sinter gained momentum and it was accepted as amajor raw material in BF burden due to its good metallurgical properties. Therequirement of sinter went up necessitating the setting up of second Sintering Plant.(Subsequently Sintering Plant-III has also been set up).

GENERAL:

Sinter now is the major component in BF burden. Sintering process originallystarted as a process of agglomeration of iron ore fines. Later on, it was advanced toutilise not only fine ore, but also other in-plant metallurgical waste materials such asflue dust, mill scale, converter slag etc. It has also become a source for introducingall the required flux into the BF. The following are the major advantages of sinteringprocess of agglomeration :

1. Simplicity of unit.

2. High specific productivity of unit.

3. Less conversion cost.

4. Better metallurgical properties of sinter.

RAW MATERIALS :

The various raw material used at SP-II for producing sinter are as follows:

1. Iron ore fines 0 - 8 mm

2. Lime stone 10 - 50 mm

3. Raw Dolomite 0 - 50 mm

4. Coke Breeze 0 - 16 mm

5. Lime Dust 0 - 5 mm

6. Mill Scale 0 - 3 mm

7. Sinter Return 0 - 5 mm

8. Settling Tank Dust 0 - 3 mm

9. LD slag 0 - 10 mm

INDEX

Bhilai Steel Plant

- 21 -

The SP-II is located South-East of Coke Ovens. It comprises following mainsections :

A. Raw Material Section.

B. Mixing and proportioning section.

C. Sintering Building.

D. Priority Route.A. RAW MATERIAL SECTION :

The Raw Material section has following sub sections :

a) Raw Material Receiving Bins.b) Raw Material Preparation Section.c) Flux crushing section.d) Fuel Receiving Bins.e) Fuel & Flux Preparation Section.

a) RAW MATERIAL RECEIVING BINS :

There are 24 Nos. bins of 85 cum volume each, in two rows, 12 in each row;where various raw materials are being received from different sources. On one sideof bins, flux materials are being received, and on the other side iron bearing materialsare received.

The flux side bins, bins/bunker nos. 1 to 10 and 21 & 22 are located overconveyor RB-2; and the iron bearing side bins, bins/bunker nos. 11 to 20 and 23 & 24are located over conveyor RB-1. All the bins, except bins no. 11, 21 & 22 are havingdisc feeder discharge system of 2400 mm diameter and the bins no. 11, 21 & 22 areequipped with variable speed belt feeder discharge system.

Installation of Raw Material Screen

In the existing layout, Iron ore mix, contains Iron ore fines, Sinter Return fromBFs, lime, mill scale etc. Removal of +8 mm fraction of ore mix by 1.5 to 2 % leadsto better homogenization of ore mix and reduced sinter return generation.

INDEX

- 22 -

GATEWAY

INDEX

Bhilai Steel Plant

- 23 -

Use of LD Slag

Now a days, LD Slag is being used in SP-II as partial replacement of Lime Stone.

In the existing layout there were 2 screw feeders for feeding lime dust to Ironore fine route (RB-1). Because of lumps in lime dust, screw feeder used to trip frequentlyresulting in out age of screw feeder often. RMRB 21,22 screw feeder were convertedin to belt feeder & belt feeders are feeding L.D. slag to RB-1 conveyor along with IronBearing Material.

LD Slag used in SP-II is of 0-10 mm size. Now we are using LD Slag @ 25 Kg /T of Sinter. 1 Kg of LD Slag replaces approximately 1 Kg of Lime stone.

By using LD Slag lime stone consumption is also reduced .

b) RAW MATERIAL PREPARATION SECTION :

Initial stage proportioning is being done at RMRG from RMRB 11 to 24. Iron orefines, sinter return, mill scale, L.D. Slag and lime dust are discharged over RB-1conveyors in a proportioned ratio and sent to mixing bins for intermediate storage.The track used is as given below:

RB-1->RB-4 ->RS-1 ->RM Screen ->M-1 ->M-2 ->M-3/M-4->Mixing Bins.

From RMRB 1 to 10 lime stone, lime stone chips, raw dolomite and are dischargedover RB-2 conveyors and sent to hammer crusher via RB-2, RB-3, FC-1, FC-3 &FC-3B where the feed material is crushed through hammer crushers.

c) FLUX CRUSHING SECTION :

There are four reversible hammer crushers of capacity 250T/Hr each. Each hammercrusher is fed from a bunker of live capacity of 50 Cu. M. The limestone and rawdolomite mix from FC-3 and FC-3B is fed to bunkers; and from bunkers it is fed to thehammer crushers by means of a conveyors discharge arrangement.

d) FUEL RECEIVING BINS :

There are 4 nos. under-ground bins of 85 Cu. M capacity for receiving coke from

CSP-II -> By rail transport, i.e. by dump-cars.CSP-III -> By ConveyorStock Yard -> By road

Fuel Receiving Bins are having mechanical gate discharge system which dischargeson FB-1 Conveyors. FB-1 Conveyors feed to the coke screen, and -10 mm size fractionis sent to 4 roll crushers. After primary crushing coke is also sent to 5 nos. four-roll-crushers.

Coke breeze is crushed to -3 mm size(90%) for sinter making. Coke crushers areused for crushing coke.

INDEX

- 24 -

GATEWAY

e) FUEL AND FLUX PREPARATION :

There are 7 nos. vibrating flux screens of size 1.6 X 3.6 M and 100-150 T/Hrcapacity for screening the flux mix.

There are 5 nos. coke crushers of capacity 16 T/Hr each. Each 4 roll crusher isfed with coke breeze from a bin having a live capacity of 70 Cu.M, which feeds cokebreeze from the primary fuel crushing Plant by the Conveyors FF-2 & FF-3. FF-3conveyor is having a provision of traveling trippers with a 3 way discharge chute.The coke breeze from the bin is fed to the four roll crusher via multi speed conveyorbelt. The coke breeze is crushed to -3 mm size 92% and transported to Mixing binsvia Conveyors FF-8, M-9, M-10, M-11 & M-12 for intermediate storage.

Automation of this section is completed. Section is totally controlled by PLC andPC system.

Sinter charge mix proportioning is always done in sequence, taking care that allthe raw mix discharge in such a way that no layer of any mix is missing throughoutthe transit. The sequence is as given below:

I. Iron ore Mix.II. Sinter Return.III. Flux MixIV. Coke BreezeV. Process Sinter Return.

Sinter charge mix proportioning is always done in sequence, taking care that allthe raw mix discharge in such a way that no layer of any mix is missing throughoutthe transit. The sequence is as given below:

I. Iron ore Mix.II. Sinter Return.III. Flux MixIV. Coke BreezeV. Process Sinter Return.

INDEX

Bhilai Steel Plant

- 25 -

ELECTROSTATIC PRECIPITATOR (SINTERING PLANT-II)

Elevation SideView

LEGEND

01. Inlet Cone.

02. Collective Electrode.

03. Emitting Electrode.

04. Gas Distribution Screen.

05. Insulator.

06. Insulator Housing.

07. Transformer Rectifier Set.

08. Hopper Inspection Door.

09. Hopper.

10. Outlet Gas Distribution

Screen.

11. Outlet Cone.

12. Cooling Inspection Door.

13. Monorail

14. Monorail Hoist

15. Stair Case.

16. Rolling Air Lock Feeder

with Drive

INDEX

- 26 -

GATEWAY

In each row 4 bunkers are earmarked for iron ore mix, 2 bunkers for coke breeze,3 bunkers for flux, 1 bunker for sinter return/mill scale/flue dust and 2 bunkers forprocess sinter return (internal).

Two tracks M-18 and M-19 have been provided below these bunkers whichcarry discharge material of these bunkers and feed to Primary Mixing Drum throughPM-1&PM-2 conveyors.

Primary Mixing Drum :

There are two mixing drums of capacity 850 T/Hr. The drum is of 3.2 M diameterand 8.0 M length. There is a provision for moisture addition in the primary mixer. Themixed sinter charge mix from the primary mixer is transported to the bunker, on thetop of Sintering Building, having a capacity of 80 Cu.M., through conveyors PM-3,PM-4, PM-6, SB-1, SB-2, SB-12 & SB-13.

C. SINTERING BUILDING:

Sinter is produced by agglomeration of raw material fines into a hard and porousmass by igniting top layer and downward suction.

The aim is to obtain sinter of homogeneous chemical composition of adequatestrength with uniform porosity.

The sinter mix from the bunker of SB-1 level is processed for balling in SecondaryMixing Drum where optimum moisture is added to get the desired permeability in thesinter charge mix. The secondary mixing drum is of 2.8 M diameter and 6.5 M lengthwith provision of three speeds to handle up-to 250 T/Hr.

There are four Sintering Machines in this building. The charge is loaded on thepallet through charging mechanism, which consists of 800X300 mm shuttle chargeDistributor, intermediate bunker, Drum feeder, inclined chute. Ignition is done bymeans of low C.V. mixed gas of calorific value 1700 K/Cal/Cu.M. The gas is burntthrough 4 nos. of side mounted short flame inclined burners. The hearth temperatureis maintained 1150+/-25 degree centigrade. To meet the combustion, air requirementis met by three blowers of type SC/ NW/P of capacity 12000 Cu.M/Hr each, keepingone as standby.

The roof of hearth is vault type suspended roof, with BRO-62 refractory bricks.The side walls are LCC casted walls.

The sintering machine is driven by a 14 KW DC Motor. The sintering process isregulated by 15 Nos. dampers placed at even distance over a length of 30 m. Sinteringprocess has down draft system, the draft is maintained by centrifugal exhauster ofcapacity 6500 Cu. M/Min. The exhauster is driven by a synchronous motor of 2000KW.

The process of sintering is controlled by means of control and measuringinstruments and visual observation. There are 2 local instrument panels for eachsintering machine.

When sintering is completed the sinter cake is crushed in 1300 X 2700 mmsingle roll sinter crusher, to 80 mm size. Then screened in hot condition by 200 X5000 mm self Balancing Vibrating screen. The screened hot sinter is subsequently

INDEX

Bhilai Steel Plant

- 27 -

cooled in straight line sinter cooler which has a working area of 128 Sq.M andcapacity of 125 T/Hr. The cooler is driven by a 26 KW D.C. motor. 8 nos. fans/airblowers of capacity of 60000-80000 Cu.M/Min each, maintaining a pressure of 220mmwc in the blowing chambers, bring down the temperature of the sinter to 100+/- 25 degree centigrade. The cold sinter is transported by SS-1 and SS-2 conveyors tosinter screen. Sinter of size less than 8 mm screened by the self balancing screen iscooled in sinter Return Drum cooler. The drum is of 18 M diameter and 4.95 Mlength. The cooled sinter return is transported by SB-8 & SB-9 Conveyors from thesinter building.

The seepage material from sintering machine and the bigger particles arrestedfrom the stream of gases, sucked by exhauster, inside the windmain are transportedto SB-8 and SB-9 conveyors via SB-4, SB-5, SB-10 & SB-20 conveyors.

The gas from the windmain is cleaned in a battery cyclone and is blown by theexhauster through the chimney (of height 100M).

SINTER MACHINE'S DETAIL :

PARTICULARS M/C 1, 2 & 3 M/C-4 No of stands 3 1 Sintering area(Sq. M) 75 80 Width of pallet (MM) 2500 2500 Depth of pallet/Bed Height 450 500 Length of pallet (mm) 1000 1000 Length of machine (Meter) 30 32 Length of Hearth (mm) 8450 8450 Height of hearth (mm) 3866 3866 Width of hearth (mm) 3074 3074 No. of burners 4 4 Ignition temp(deg Cent) 1150 (+/- 25oC) 1150 (+/- 25oC) No of wind boxes 15 16 Exhauster capacity(Cu.M/Min) 6500 7500 Windmain suction (mmwc) 1000 1250 Exhauster inlet suction (mmwc) 1200 1400 SBS capacity (T/Hr) 120 NO SBS Cooler capacity (T/Hr) 125 128

INDEX

- 28 -

GATEWAY

Coke oven and blast furnace gases are mixed in gas mixing station, LCV andHCV mixed gas pipe lines are taken to an elevation of 35 M in the Sintering Buildingand tapping are brought for ignition hood.

SINTER SCREENING BUILDING :

The cold sinter undergoes a two stage screening in a 3100 X 7500 mm doubledeck screen of capacity 600 T/Hr. The cold sinter of size +6 mm is transported bySS-9 and SS-10 conveyor, which feed to a system of conveyor belts, carrying thesinter to sinter loadings bins and sinter storage bunker of JH-44. The -6 mm sizesinter return from this building is carried by SS-5 and SS-6 conveyor belt which feedsthis return to conveyor belts SB-8 and SB-9. The Sinter return is finally transported tothe four bunkers in mixing bins by conveyors M-13, M-14, M-15 and M-16. Thesludge from the disc feeder of the settling tank is fed by conveyor ST-1 to conveyorsSB-8 and SB-9.

D. PRIORITY ROUTE :

Priority route is the section which transports the finished sinter, coke and ironore etc.to BFs.

Sinter from Conveyors SS-9 and SS-10 is unloaded on Conveyors J17C4, J17C5in junction houses-15, there after via JH-20 the sinter is sent JH-27. From JH-27sinter is either filled in loading bins or it is conveyed to Jh-44 for BF-7.

In loading bins there are four bunkers of 200 Cu.M each. Each bunker is fitted atthe bottom with the pneumatically operated tilting chutes. The bins are filled one byone and the sinter is discharged into a transfer car by means of pneumatic gate ineach bin. There are two gates and both of them can be opened simultaneously forloading the transfer car.

When it is to be despatched to BF-7, the sinter is conveyed to JH-44 byconveyor belt from JH-27. In JH-44 sinter is stored in four bins; from there it ischarged to BF-7.

At JH-20 to JH 27 a new conveyor belt is commissioned, by which SP-III sinteris transported to BFs.

INDEX

Bhilai Steel Plant

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SINTERING PLANT-IIISintering Plant-3 with capacity of 3.2 MTPA has been installed with the state of

the art technology viz.

Energy efficient ignition furnace.

Integrated control system for quality product.

Pollution control system to keep environment healthy.

Mixing cum nodulising drum.

Compact Dip Rail Deep Bed circular cooler.

State of the art of fire detection system.

It was commissioned on 12th Dec. 2001,although production trials were startedin Oct. 2001.

SP-3 facilitates production of super flux sinter (basicity 1.6 to 2.2) consisting ofapprox. 70% iron bearing input in Blast Furnace charge burden.

SINTER : Sinter is a porous, lumpy agglomerate of ore fines, waste solid, cokefuels, sized flux and other metallurgical wastes.

BASIC TECHNOLOGY

Sintering is a technology for agglomeration of iron ore fines into useful BlastFurnace burden material. This technology was developed for the treatment of thewaste fines in the early 20th century. Now sinter has become the widely acceptedand preferred Blast Furnace burden material. Presently more than 70% of hot metalin the world is produced through sinter by Dwight-Llyod sinter machines. Same hasbeen adapted at BSP also. Presently in Bhilai Steel Plant 65% average sinter burdenis being used in Blast Furnace.

The major advantage of using Sinter in Blast Furnaces are :

- Utilisation of iron ore fines, coke breeze, metallurgical waste, lime, dolomite forhot metal production

- Better reducibility and other high temperature properties.

- Increased B.F. productivity.

- Improved quality of hot metal.

- Reduction in coke rate in Blast Furnaces.

- Use of super fluxed sinter eliminates raw flux at BFces.

INDEX

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GATEWAY

MAJOR AREAS OF SINTER PLANT -IIIRAW MATERIAL AREA:

- Coke storage, crushing and screening.

- Flux storage, crushing and screening.

- Track hopper : for receipt of raw materials.

- B-1 and B-2 dedusting (B-1 for flux route and B-2 for coke route) systems:

The function of raw material area is to receive various raw materials from OHPand other metarugical waste like lime stone chips from RMP-2, LD slag from convertorshop, mill scale from various mills, sinter return from Blast Furnaces etc. The materialsafter receipt are processed and prepared as per requirement and supplied to rawmaterial area for Sinter making.

SINTER MACHINE AREA:

- Storage and proportioning building.

- Mixing cum nodulising drum.

- Sinter making and sinter cooling building.

- Main exhauster and E.S.P.

- Room dedusting and E.S.P.

- Compressed air station.

- Gas mixing and boosting station.

- Granulation unit

- Emergency sinter storage unit

- Pump house

- Heat recovery unit

- Area repair shop

The main function of sinter machine area is production of sinter, screening and to transport sinter to Blast Furnaces via JH 32 and. JH 27 (SP- 2).Transportation ofreturn sinter (fines) form Blast Furnace to SP-3 through conveyors.

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INDEX

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GATEWAY

SINTER MAKING PROCESS

At Storage & Proportioning Unit, raw material, Iron Ore fines, Flux, Coke breeze,return fines are stored. Raw material from each hopper is discharged by Belt WeighFeeders at predetermined rate on the belt conveyors and fed to Mixing cum NodulizingDrum (MND). After MND, raw material is charged to Sinter Pallet through Raw Mate-rial Hopper. Hearth layer sinter is laid on the grate bars to avoid leakage of materialfrom pallet. After feeding raw material to the pallet, pallet moves to the IgnitionFurnace and coke on the surface is ignited. Flame front moves from bed surface tothe bottom of the bed by the suction of air through wind boxes. After sintering,sinter cake is discharged to Primary Sinter Crusher. Then after crushing, sinter is fedto Sinter Cooler for cooling. Cooled sinter from cooler is screened at the cold screensand is classified as Sinter Product, Hearth Layer and Return Fines. Sinter Product issent to Blast Furnace While Hearth Layer and Return Fines are transferred to hearthlayer and return fine hopper respectively and will be used for sintering again. Exhaustgas through wind boxes passes to Main Electrostatic Precipitator for removal of dustand then exhausted to air through main blower and stack..

ADVANCED FEATURES OF SINTER PLANT-3

- Electronic proportioning.

- Use of Lime Fines.

- Combined mixing and nodulising.

- Pre-heating of Raw Sinter Mix.

- Modern Machine Charging System and segregated Sinter Mix Feeding.

- Latest Energy Efficient Ignition Furnace.

- Elimination of Hot Sinter Screening.

- Circular Cooler of latest desgin.

- Waste heat recovery system.

- Deep bed Sinter Machine & higher under-grate suction.

- Plant & process de-dusting and pollution control measures.

- Fully automated process control system for optimum plant utilisation.

- Latest communication facilities including CCTV monitoring and maintenance.

- Emergency sinter storage.

- Totally enclosed pneumatic conveying of dust.

- Granulation plant for utilisation of Micro-Dust.

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INDEX

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GATEWAY

MAJOR EQUIPMENT DETAILS- One Sinter M/C with 320 m2 sintering area and 1 m/c with enhanced sintering

area in near.

- Bunkers in storage and proportioning building to store about 5500 T iron orefines, 2800 T limestone, 550 T coke, 1000 T Mill scale and flue dust, 1900 TSinter return and about 300 T burnt lime - 24 nos.

- Mixing cum nodulising drum to feed about 800 T/hr mix charge - 1 nos.

- Hot sinter crusher to crush sinter to 150 mm size - 1 nos.

- Dip rail deep bed circular cooler with two cooler fans blowing air 2 X 7,80,000m3/hr to cool sinter from 800 deg.C to below 100 deg. C (capacity:800 TPH)- 1 nos.

- Fuel storage yard to stock about 6,500 T coke - 1 nos.

- Hammer crusher primary and secondary to produce about 6,000 T flux per day- 6 nos.

Self balancing flux screens to screen out 6,000 T, size-3mm flux for sintermaking - 6 nos.

- Two roll crusher for coke to produce about 1,200 T, size -10mm coke fines -1 nos.

- Rod mill for coke to produce 700 T, size-3 mm coke fines - 2 nos.

- Cold screens to screen out sinter - 6mm as fines to sinter return, +15 to -25mm as hearth layer and +25 mm Sinter at the rate of 404 T/hr

goes to B.F. by single conveyor belt - 3 nos.

- Emergency sinter storage hopper to store about 10,000 T sinter per day- 6 nos.

- Centrifugal compressor with flow rate 4250 Nm3/hr - 2 nos.

- Main exhauster connected with electrostatic precipitator of capacity

5,000 KW, blowing air 8,64,000 m3/hr - 2 nos.

- Roof mounted KSC slit burner type ignition furnace of ignition intensity7470 K cal/m2/min. with advanced starting panel BMS (Burner managementsystem) - 1 nos.

- For monitoring the functioning of sinter process and important equipment 11number of color cameras (for CCTV system) and 4 numbers of color monitorsare provided.

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Pollution Control Measures In order achieve work zone air quality & stack dust emission as norms, centralized dust Extraction System & Insertable Bag Filters are installed. The Centralized Dust Extraction System consists of 2 ESPs, 2 Dedusting Fans & a common stack. Room ESP Type - Dry Horizontal Capacity - 9150m3/minx2

At 70oC Specification Area - 100m2/m3/sec Dust Content Inlet - 10g/Nm3 Outlet - 75mg/Nm3 Room Dedusting Fan Type - Outdoor

Centrifugal,Directly coupled with Motor

Capacity - 18,300m3/minx2 At 70oC

Motor - 2100KW, 750rpm Pressure Suction - -400mmWC Delivery - +50mmWC Room ESP Stack Type - Steel Plate Height - 60mtr Main ESP Type - Dry Horizontal No. of Fields - 8*2 Capacity - 14,400m3/minx2

at 160oC Specification Area - 100m2/m3/sec Dust Content Inlet - 3g/Nm3 Outlet - 100mg/Nm3 Main ESP Stack Type - RCC Height - 120 mtr Top Diameter - 6.4 mtr Hearth Diameter - 8.0 mtr Apart from the above ESPs, • Dust Extraction System 2 no.s are installed in

Raw Material Area for Flux & Coke Routes. • Bag Filter 5 No.s are installed in Sinter Dispatch

Route. • Tree Plantation undertaken on large scale for

cleaner air.

Automation in SP-111 Sinter Plant 111 is the most modern and automated Sinter Plant in the whole of Asia. The complete plant is run from two controls centers, one each in Sinter Machine Area & Raw Material Area. The data from all over the plant come in HMIS (Human Machine Interface) in these controls the whole plant from a single location only. Sinter Machine Area

• Integrated control System (ICS) • Siemens S5 155H PLCs • No. of PLCs- 6*2

• (in Hot Standby configuration) • No. of Remote I/O racks 46 • Rack situated in 10 different locations • 5000 Digital Inputs • 1000 Analog Inputs • 1000 Digital Outputs • 175 Analog Outputs • No. of HMIs – 5 • Software used – Step 5, APT, PCS • Levels-2 Automation having

Supervisory Control & Operator Guidance System(OGS)

Raw Materials Area

• Allen Bradley 5/60 PLCs • No.s of PLCs 2*2 (in Hot Stand

configuration) • No. of Remote I/O Racks – 45 • Racks situated in 5 different locations • 2000 Digital Inputs • 100 analog Inputs • 700 Digital Outputs • 50 Analog Outputs • No. of HMIs-3 • Softwares used- RS Logix, RS View32

INDEX

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GATEWAY

UTILITIES

The following utility services are operational in Sintering Plant - 3 for the processof sinter making.

- Power

- Gas

- Water

- Steam

- Compressed air

- Rail & Road Transport

POWER

In Sintering Plant - 3 high tension (HT) power 11 kV & 6.6 kV AC supply isdrawn through MSDS-IV via Sub-station- 41 and low-tension (LT) 415/240/220 VAC from SS 41A, SS 41, SS 41C and SS 41D in the sinter machine area. Totalconnected load of SP-3 being of the order of 40 MWs with a specific powerconsumption of 69KWH per ton of sinter as per DPR. Projected Power requirement is17MW to produce about 10000 Tons sinter per day.

GAS

Mixed gas of Blast Furnace and Coke Oven is used as a fuel for heating themachine hearth during Sintering Process. The Calorific Value is 3000 K. Cal.

Coke Oven and Blast Furnace gases are mixed in gas mixing station and gas pipelines are taken up-to Sinter Machine level, from where tapping is taken to ignitionhood.

WATER

The need of water in sintering plant is mainly for the following purpose :

- Processing & smooth operation of equipment.

- Cooling purpose.

- Ventilation purpose.

- Fire fighting and drinking purpose.

- Cleaning purpose.

The industrial and drinking water is supplied from Water Supply Department.

RAIL & ROAD TRANSPORT

Normal work of any integrated steel plant is possible only when its transportsystem is working well. In Sintering Plant-3 coke breeze used as fuel is transportedfrom BF and Coke Oven in dump cars and is controlled by BF station and Raw Materialstation. PVP department has provided the haulpak for the transportation of BF returnsinter.

To maintain the house keeping and cleanliness in the area, metal scrap and other

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waste material is shifted from site, by the trucks & tippers provided by MRD, Garageand CED.

STEAM

In SP-3, steam is used for the purpose of purging the gas pipe lines at the timeof blanking and de-blanking job during furnace ignition and extinguish. The supply isfrom the main network of steam.

COMPRESSED AIR

Mainly used in Lime unloading , Pneumatic dust transportation , Air cannons, allPneumatic shut off valves, Pneumatic gates operation in Loading Section, High lift inRod Mill etc. The compressed air is produced in-house in compressor station.

ACHIEVEMENTS

First Sinter Plant in SAIL units to achieve specific productivity of 1.492 T/m2/hr

Best judged shop lubrication in Group-II (2006)

Certification for Quality Management System ISO:9001:2000 since 2005.

Certification for Environment Management System ISO:14001:2004 since 2005.

Certification for OHSAS:1800 & SA-8000

Completion of Multiskilling training.

First production shop in Bhilai Steel Plant to implement e-DPR.

Successful implementation of e-Logbook.

Coveted Vishwakarma Award.2005- 06, to six employees.

Representation of NISKARSH Quality Circle team at Seoul and technical paperpresentation in ASIA-2006, Japan.

FUTURE PROJECTS IN SP-III

Second Sinter Machine with enhanced capacity and base blending facility forboth the Sinter Machines.

Dedicated lime plant for SP-III.

INDEX

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GATEWAY

COKE OVENS AND COAL CHEMICALS DEPARTMENT

The main function of Coke Ovens is to convert coal into coke which is used as afuel and reducing agent in the Blast Furnace. Its secondary function is to recoverVolatile Matter and CO gas from coal and extract chemicals known as Coal Chemicals.CO gas produced is used for heating purposes in the plant.

The Coke Ovens and Coal Chemical Department has three main sections viz.

I. Coke Ovens

II. Coal Chemicals

III. Maintenance and Repairs

The description of each of these sections is given below :

COKE OVENS :

Various sub-sections of Coke Ovens and their functions are as follows :

1. Coal Handling Plant (CHP-I) and : To prepare coal blend suitable for

Coal Preparation Plant (CPP-II) carbonisation in Coke Ovens Batteries to

produce BF coke.

2. Partial Briquetting : To prepare briquettes of coal to charge

along with coal into the oven.

3. Coke Oven Batteries : To convert coal into coke by

carbonising coal in absence of air and

thereby distilling the volatile matter out

of coal. The resultant coke oven gas is

treated in CCD for recovery of chemicals.

4. Coke Sorting Plant : To crush and screen coke to 25-80mm

size required by blast furnaces. The

0-10 mm fraction is used in sintermaking and 10-25 mm fraction (nut

coke) is added along with sintersupplied to Blast Furnace.

COAL HANDLING PLANT

There are two Coal Handling Plants : Coal Handling Plant -I (CHP -I ) and CoalPreparation Plant-II (CPP-II).

Indigenous Coal comes from Bhojudih, Sudamdih, Nandan, Rajarappa, Swangand imported coking coal is recieved from Australia & New Zealand. Imported coking

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coal is prime coking coal, having less than 10% ash. Blend is approximate PCC 10%,MCC 15% and imported 75% for Batteries.

Range of analysis of Indian Coals :

Types of coal Ash V.M.1) Prime Coking Coal (PCC) 20-23% 22-24%2) Medium Coking Coal (MCC) 20-23% 25-30%3) Imported Coal 8-10% 20-23%

The wagons bearing the source, type and weight of the coal are unloaded bywagon tipplers in CPP-II. Iron pieces contained in the coal are removed by suspendedmagnet in CHP-I & CPP-II. In CHP-I the coal is then conveyed to stockyard or silothrough gallery conveyors. In CPP-II, the coal is conveyed to stock yard, silos orgallery conveyors of CHP-I.

In stockyard, Stacking, Averaging and Recalaiming are done by Gantry Crane inCHP-I and stacker cum-reclaimer in CPP-II.

Mixing Bins/Silos are provided for sorting coal of different varieties. A propotionateblend is made with the help of Automatic Proportioning Devices (APD) mountedunder the mixing bins.

Reversible Hammer crusher are provided to crush the coal blend to a fineness of80% below 3.2mm size. A water spray is provided after the Mixing Bins and at fixedpoints along the conveyors to ensure correct amount of moisture in coal.

Coal towers of Batteries 1 to 8 are supplied coal blend from CHP-I and Battery 9& 10 is supplied by CPP-II. In case of emergency, coal tower-4 can be fed by CPP-IIand Coal Tower5 can be fed by CHP-I.

CHP-I and CPP-II together supply 11,000 Tonnes of coal blend every day forcoke making.

INDEX

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GATEWAY

FLOW DIAGRAM

INDEX

Bhilai Steel Plant

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PARTIAL BRIQUETTING OF COAL CHARGE :

With an increasing thrust towards improving productivity and coke quality,especially with respect to strength (M 10 index), a partial briquetting for coal chargehas been installed in coke ovens.

PBCC is capable of producing 2000 T per day of briquette. It is based on theNSC technology and was commissioned on 28th August, 1990. It caters to the needof four coal towers 1 to 4.

The basic process involves briquetting a part of coal charge (28% by weight)with coal tar (soft pitch) and charging the briquettes and fine coal in a pre-determinedratio (25 : 75).

The rationale for using briquettes in charge is to increase the bulk density of coalcharged into the oven and to improve the micum index and crushing strength ofcoke.

The PBCC plant has a completely computerised system of conveyor belt and theweighing systems are thyristor controlled.

Typical Blend Composition and Coal Charge Analysis :

Blend Composition Coal Blend AnalysisPCC 10% Moisture 7.0% - 8.0%MCC 15% Ash 12.0% - 13.0%IMPORTED 75% VM 24.0% - 25.0%

Fixed Carbon 58.0% - 60.0%

Critical Equipments Installed in CHP-I, CHP-II and PBCC

S.NO. EQUIPMENT UNIT CHP-I CHP-II1. A) Wagon Tipplers Nos. - 3

B) Unloading capacity of each T/hr - 600

2. A) Primary Toothed Roller Crusher Nos. - 2B) Capacity of each T/hr - 300

3. A) Gantry Cranes Nos. 2 -B) Stacker cum Reclaimer Nos. - 2C) Receiving capacities of each T/hr 600 600D) Reclaming capacities of each T/hr 300 400

4. A) Stock yard capacity T 180000 120000

5. A) Moisture content of Coal % 7 7

6. A) Hammer crusher Nos. 6 4B) Capacity of each T/hr 250 275

INDEX

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GATEWAY

7. A) Mixing Bins/Silos Nos. 15 14B) Capacity of each T 750X2 850X2

900X13 1000X12

8. A) Coal Towers Serviced Nos. 4 2

PBCC9. Mixing Kneaders - 2 Nos.

10. Briquette Press - 2 Nos.

COKE OVEN BATTERIES :

There are eight coke oven batteries 4.3 M tall having 65 ovens in each battery(in 2.5 MT stream) and two batteries 7 M tall having 67 ovens in each (4.0 MTstream). Battery 10 commissioned on 5.11.1996 is most modern Battery.

Out of 8 batteries of 2.5 MT stream, 4 are operating and two i.e. battery No. 5& 6 are put down after getting their full life. 4 batteries are capable of producing1.33 MT of BF Coke per annum at an average coking period of 17 to 18 hours. Theseare twin flue regenerative, compound PVR (Pair Vertical recirculation) and side firedtype.

Battery 9 & 10 can produce 1.23 MT of BF coke per annum at average cokingperiod of 17 to 18 hours. These twin flue, regenerative, compound PVR and under jetfired type.

The waste gas is recirculated in the heating system. The heat consumption perKg. of dry coal is around 650 K.Cal. Battery-9&10 uses mixed gas heating. Gasmixing station is provided in both these batteries to mix blast furnace gas with COGas.

The temperature of control verticals flues on pusher side is 1175°C to 1225°Cand 1200°C to 1250°C on coke side. These however can be increased or decreaseddepending upon the coking time.

The ovens are maintained under positive pressure by maintaining high hydraulicmain pressure of 7 MM water column in Batteries 1 to 8 and 14 MM water column inBattery 9 &10.

Coke ovens are mainly constructed of silica, fireclay, high alumina and ordinaryinsulating bricks. The coke oven chimney is made of concrete lined with fireclaybricks. Normal life of a coke oven battery under Indian condition is considered to be25 years. Battery No. 1, 2, 3 & 4 have been rebuilt. Battery No.4 has been rebuiltwith underjet system of heating and single hydraulic main.

The heating of ovens is done from both the sides in side fired batteries withreversal of heating.

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Bhilai Steel Plant

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The coal is taken in charging car from the coal tower and is charged into theempty oven. Each oven has three charging holes and each charging car has threebunkers for charging of coal into the ovens.

Coke is made by heating coal in the absence of air (carbonization / destructivedistillation of coal) in a series of ovens called batteries.

The coal to be coked is charged through the charging holes by charging cars(which in turn receives coal from coal tower above it). After this the coal is carbonizedfor 17-18 hrs, during which period the volatile matter of coal distills out as "CokeOven" gas and is sent to CCD for recovery of chemicals. When the Central temp. ofthe oven is 950-1000 Deg.C., coking is said to be complete. At this point, the ovenis isolated from hydraulic mains and after proper venting of residual gases, the doorsare opened for coke pushing. The coke mass at the end of coking period has avolume shrinkage which leads to detachment of mass from the walls ensuring easypushing.

The expansion property as shown above is desirable, as this results from meltingof coal mass (vitrain) leading to formation of concrete like composite structure (Fusainmass distributed in this matrix) giving coke its desired strength.

The coke after being pushed into quenching car, is quenched in quenching towerwhere phenolic water is pumped @50 Cu.M./hr (quench time = 2.5 Min.). Thequenched mass is unloaded in wharf, from where it is conveyed to coke sortingplant, before being conveyed to Blast furnace.

Battery has a six layered structure as below :

Oven Roof Heating wall & Oven chambers, Inclined Flue Zone, Regeneration Zone,Bus Flue Zone & Nozzle Deck

The elaborate regenerator system (of refractory bricks) ensures good preheatingof mixed gas as well as heat recovery from flue gases. The heating arrangementconsists of 24 port holes in battery 1 to 8 and 32 port holes in battery 9 & 10 alongthe length in the heating wall. Heating control & sequence is quite critical for batteryperformance, and life of battery itself. A whopping 1848 no. of burners (7th and 22nd burner temp. is usually taken as representative of that of heating wall) in battery1 to 8 and 2176 no. of burners (6th & 23rd burner temp. is usually taken asrepresentative of that of heating wall) in battery 9 & 10 have to be properly controlledto ensure uniform quality of coking & least mechanical (refractory) damage to thestructure due to thermal stresses. A CPMS (Coke process management system) inbattery no.10 helps in this heating control. An Integrated Coking Process ManagementSystem is being installed in battery - 3 for better control of heating and reducingspecific heat consumption.

INDEX

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GATEWAY

BATTERY DATA :

BATT. NO. OF OVEN COAL HOLDING USEFUL SP.HEATNO. OVENS HEIGHT(M) CAPACITY PER VOLUME CONSPN.

OVEN (T) PER OVEN KCAL/KGCU.M.

1-8 65 4.3 16.8 21.6 625-6759&10 67 7.0 32.0 41.6 625-675

The productivity of battery is improved by increasing bulk density of coal charge- this is done by means of oil - water emulsion addition to coal charge, partial briquettingof coal etc. The best case of productivity improvement was achieved by stampcharging else where in the country - not possible in our plants due to differentinfrastructural requirements.

Importance of Pressure in Ovens :

The control of oven pressure is quite important because pressure on lower sideleads to air entry into system (dangerous) while on higher side leads to excessivegassing, leakage of doors, stand pipe etc. The oven pressure is maintained at anoptimum balance between ovens, in the beginning, end of coking cycle, as they areall connected to a common exhauster via hydraulic main.

Importance of Levelling :

After charging coal from charging car bunkers, battery is levelled to allow enough"Free board" space above (= 300 mm) so that gas exit is free and no chokingoccurs. Levelling also helps in good spreading and packing of coal within oven toensure optimum utilization of wall heat transfer area.

INDEX

Bhilai Steel Plant

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INDEX

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GATEWAY

Laser Guided Alignment :

This is a new development in batt. 9&10 where innovative methods using Toylasers to position the pusher car and door extractor in a straight line to oven properhas been installed and found to be successful. This ensures good & accurate aligmentso that doors are not damaged while opening, closing and that oven walls are alsonot damaged during pushing. The system is now going is to be installed in otherbatteries also.

HPLA :

This is a system used in batteries 10 and 4 to create suction during coal chargingafter the batteries are isolated from hydraulic mains. HPLA stands for high pressureliquor aspiration where ammonical liquor at high pressure (28 Atm.) is sprayed throughan orifice in the gooseneck leading to hydraulic main and the gas in the oven issucked into hydraulic main thro' standpipe due to suction created by liquor pressure.As a result of this suction arrangement, coal dust emission during charging andconsequent gassing is greatly minimised.

IMPORTANT QUALITY PARAMETERS OF COKE :-

(1) Size distribution

(2) CSR & CRI

(3) Moisture & VM

(4) M-10, M-40. (Strength)

Analysis of B.F. Coke (on dry basis) obtained from coal blend charge is givenbelow :

Description Battery (1-8) Battery (9&10)

Moisture 3.5% - 4.5% 4.5% - 6.0%

Ash 15.5% - 17.0% 15.5% -17.0%

V.M. <1.00% <1.00%

Sulphur 0.65% max. 0.65% max.

Fixed Carbon 79.0% - 81.0% 79.0% - 81.0%

Strength

a) M 40 >80% >80%

b) M 10 7.5% - 8.5% 7.5% - 8.5%

INDEX

Bhilai Steel Plant

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Other important data of Batteries :Description Battery (1-8) Battery (9&10)

Total length of oven 14,080 mm 16,000 mm

Total height of oven 4300 mm 7000 mm

Useful height 4000 mm 6700 mm

No. of ovens 65 67

Width on Pusher side 382 mm 385 mm

Width on Coke side 432 mm 485 mm

Average Width 407 mm 410 mm

Useful volume 21.6 Q.M. 41.6 Q.M.

Heating level (Distance 800 mm 1100 mmfrom the top of cross overwindow to the roof of oven)

Vertical flue per heating wall 28 32

Heating system PVR side fired PVR underjet

Fuel for heating Either CO Gas or Mixed gas

B.F. Gas (CO gas & BF gas)

Numbers of control vertical 7 & 22 6 & 23

Coal Charge per oven 16.4 Tonne 30.0 Tonne(on dry basis)

Chimney height 100 M 120 M

COKE SORTING PLANT :

Hot wet coke from quenching car is dumped on the wharf. After cooling, it isdischarged on conveyor belt. Then coke is sieved at 80 mm, grizzly and over sizecrushed in toothed roll crushed of capacity of 70 T/hr. The coke is then sieved on 25mm, grizzly screen. The size 25-80 mm is conveyed to blast furnace bunkers throughbelt conveyors and the under size which still contains 3-4% metallurgical coke issieved over a 25 mm vibrating screen. Over size is mixed with metallurgical coke and0-25 mm coke is sent to 13 mm vibrating screen, where it is sorted in to 0-13 mmsize called breeze is sent to sintering plant for using in sinter production and 13-25mm size called nut coke is sent to sintering plant through conveyor belt and dump carfor adding it to sinter being conveyed to blast furnace from sintering plants.

INDEX

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GATEWAY

There are three such coke sorting plants known as CSP-I, CSP-II & CSP-III havingtwo wharves each. Coke is supplied from coke sorting plant to blast furnaces byconveyor belt or BOBC wagons. CSP-I supplies normally to blast furnace No. 1,2 & 3.It can also supply to blast furnace - 4. CSP-II supplies coke to blast furnace 4,5,6 andCSP-III to blast furnace - 7.

COAL CHEMICALS SECTIONS :

The coke oven gas coming out from batteries contains valuable chemicals liketar, ammonia and benzol. These chemicals are recovered and gas is cleaned in theby-products plant.

This plant comprises of the following sections :-

1. Gas Condensation section 1 & II

2. Ammonium Sulphate Plant I & II

3. Benzol Recovery section I & II

4. Benzol Rectification Plant

5. Tar Distillation Plant

6. DCDA Sulphuric Acid Plant

The gas after coolers is sucked by ten exhauster, 4 of which are steam turbinesdriven & 6 electric. A suction of 150-300 mm is created at the battery side and apressure of 2000-2200 mm. w.c. at the delivery side of the exhauster.

Capacities and types of Exhausters.

Exhauster Type Capacity(Thousand N.Cum/hr.)

1 Electric 55

5 Electric 72

6 Electric 55

8, 9 & 10 Electric 76

2, 3, 7 Steam 55

4 Steam 72

The gas after exhauster goes to elctro-static precipitators working on 70,000Volts. These precipitators are installed to remove the last traces of tar present in thegas. The tar free gas goes to Ammonium Sulphate Plant. There are 9 nos. of electro-static precipatators provided, of capacity - 40,000 Cu.M./hr each.

One Tonne of dry coal yields 300 - 310 Cu.M. of gas, 330 Kg. Tar and 0.28%Ammonia or 1.0%-1.04% (NH4)2SO4

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Bhilai Steel Plant

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Gas free from tar, containing 5-8 gm ammonia per cu.m. is preheated to 60°Cand is then bubbled through dilute (4-5%) solution of sulphuric acid in saturators.Temperature of reaction is 65°C. Ammonia is absorbed by the acid and ammouiumsulphate is formed as per the following reactions :

2NH3 + H2SO4 = (NH4)2SO4

The slurry containing crystals of ammonium sulphate is withdrawn from theconical bottom of the saturator by means of pumps and pumped to crystalliser tankwhere crystals settle down and the mother liquor through an overflow, goes back tosaturator. The crystals along with small quantity of mother liquor go to centrifugeswhere crystals are separated from the liquor. The crystals of ammonium slulphateare dried in fluidized bed drier and then packed in bags for sale.

Quality of Sulphate :

Nitrogen content 20.6%Free Acidity 0.05 %Moisture < 1%

Gas load to each saturator is 45,000 cu.m./hr. and capacity of each saturator is16,000 kg. salt per shift.

Consumption of sulphuric acid for the above process is about 0.80 tons per tonof ammonium sulphate. This is produced in the acid plant that works on doublecontact double absorption (DCDA) process with imported sulphur as raw material.

Ammonium sulphate plant-I & II together can produce 140 tonnes of ammoniumsulphate per day.

Recovery of Benzol :

Gas from the saturators goes to the 3 final coolers and then to benzol scrubbers.Here regenerated solar oil or wash oil with a distillation range between 230 - 300°Cabsorbs crude benzol upto a concentration of 2.5% Bz.

Crude benzol content in the gas before the scubber is 25-27 gm/cu.m. and afterthe scrubber 5 gm/cu.m.

Benzol scrubbed crude oil goes to the benzol recovery plant where benzol isremoved and the wash oil after treatment is sent to the scrubbers.

Crude benzol thus recovered goes to benzol rectification plant where fractionlike benzene, toluene, xylene and solvent naphtha are recovered by the process offractional distillation.

INDEX

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GATEWAY

INDEX

Bhilai Steel Plant

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Clean gas is sent to various sections of the steel plant. There is a hydraulic sealgas bleeder in the line, to bleed off the surplus gas above the desired pressure of 650- 700 mm w.c.

BENZOL RECTIFICATION PLANT :

The light crude benzol contains, (i) low boiling sulphur compounds mainly CS2(ii) benzene b.p. 80°C (iii) thiophene b.p. 88°C (iv) toluene b.p. 110°C (v) Xyleneb.p. 137°C - 144°C (vi) solvents, a mixture of fractions upto 155°C (vii) still bottomresidue.

Benzol is first washed with 98% H2SO4 to remove thiophene and other sulphercompounds, then neutralised with a caustic soda solution. The washed benzene,toluene, xylene (B.T.X.) mixture sent to benzol column to make nitration grade benzene.The bottom of the benzol column is further sent to toluene column to produce nitrationgrade toluene and the remaining is treated in a batch distillation unit to producesolvents and the residue called still bottom oil.

The present capacity of Benzol Rectification Plant is to process 96 kl/day of lightcrude benzol.

Tar Distillation :

The tar containing around 5% moisture is first dehydrated before distillation.This is accomplished by heating the tar to 110-120°C in a gas fired furnace calledfirst stage pipe still and then flashed in first stage evaporator. The dehydrated tar isheated to 375-400°C in the 2nd stage pipe still furnace and then taken to the secondstage evaportator where super heated open steam (420°C) is used to drive out theflashed vapour from 2nd stage evaportor, and the residue from 2nd stage evaporatoris taken out as pitch. The quality of the pitch is controlled by the temperature of feedtar and the quantity of super heated steam. The pitch may be sold either in moltencondition in road tankers, or filled in drums or in granulated form.

The oil vapours coming off the second stage evaporator is fed to an anthracenecolumn where top temp. is maintained as 150-240°C to get the anthracene oil andheavy oil is fed as reflux. Anthracene oil is cooled in submerged cooler before storing.

The vapour coming out of anthracene column is taken to the fractionating column.By feeding light oil as reflux, the top temp. of the fractionating column is maintainedaround 82-130°C in order to get the various tar oil fraction viz. Light oil, phenolfraction, naphthalene fraction & Heavy oil fraction . The vapour from fractiontingcolumn is condensed & after separating water, light oil is used as reflux & execsslight oil is stored for despach.

The remaining fraction are cooled in submerge cooler & stored.

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GATEWAY

The naphthalene fraction (70% Naph. content) is fed in crystallisers & other 48hrs. of crystallisation it is centrifuged to separate naphthalene. The naphthalenecrystal are further hydraulically pressed to form hot pressed naphthalene.

Heavy oil, Anthracene oil & pitch are blended in suitable ratios to prepare PCM,Road tar etc.

The phenol fraction is treated with caustic soda to produce sodium phenolateand dephenolised oil both of which are sold.

The processing capacity of each unit of TDP = 170 TPD.

Analysis of Coke Oven Gas :Methane - 26.0%Hydrogen - 56.5 %Hydrocarbons - 2.3%Carbon - monoxide - 8.5%Carbon dioxide - 3.0%Oxygen - 0.4%Nitrogen - 3.3%Density - 0.4848 kg/cu.m.Calorific value - 4300 Kcal/cu.m.

DCDA SULPHURIC ACID PLANT :

The purpose of the sulphuric acid plant is to produce sulphuric acid to meet theneed of the ammonium sulphate plant, benzol rectification plant and water treatmentplant PP-II.

The production of sulphuric acid is based on the DCDA process. The raw materialfor this process is pure sulphur which is imported.

The Process Scheme is as follows :-

Solid sulphur is method in sulphur melters by indirect steam heating at atemperature of 135-140°C. The molten sulphur after settling is pumped through killyfilter into the furnace through sulphur sprayer for burning . The air required for burningsulphur is supplied by air blowers through drying tower where 93% cone. H2SO4 issprayed from absorbing moisture from air to make it dry.

Reaction in furnace - S + O2 = SO2.

The hot SO2 gas at 970-990°C temp. is cooled to 570-590°C by passing throughwaste heat boiler-1 & subsequently to 430-440°C by passing through super heater.The SO2 gas at 430-440°C is passed through hot gas filter to make it free from dirt,dust, ash etc. The SO2 gas at 430-440°C then enter the 4 stage converter packedwith about 26000 lits of Vanadium Pentoxide catalyst. In presence of V2O5 catalystSO2(g) converts into SO3(g)

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INDEX

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GATEWAY

Reaction in converter : 2SO2 + O

2 = 2SO

3

The optimum temperature for the above reaction is 440°C and the reaction isexothermic. So to maintain the optimum temperature at the inlet of each layer, gasafter each layer is cooled.

The gas after 1st layer comes out at 580-590°C & and is cooled to 440°C bypassing through waste heat Boiler-2. The gas after 2nd stage conversion comes outat 510-520°C & is cooled to 440°C by passing through Hot heat Exchanger.

The gas after 3rd stage of conversion come out at 465-480°C and is cooled to170-180°C by exchanging heat with cold boiler feed water in economiser. The SO

3

gas & some unconverted SO2 gas at 170-180°C temp. enters the bottom of

Intermediate Absorption Tower (IAT) where SO3 gas is absorbed by spraying 98%

H2SO

4 from the top. The cold unconverted SO

2 gas gains heat by passing through

cold heat exhauster No.1,2 & hot heat exchanger. At 420-440°C SO2 gas enters the

4th stage of convertor and after 4th stage the gas comes out at 460-470°C. Thisgas is cooled by passing through cold heat exchanger 1 & 2 and then enters to FinalAbsorption Tower (FAT) at 170-180°C. From the top of the FAT 98% H

22SO

4 is

sprayed to absorb SO3 gas.

After FAT the gas passes through the candle plate for arresting the entrainedacid particles & escape to atmosphere through 40 M chimney.

Stack Analysis - SO2 content - 1 Kg/ton of acid prodn.

SO3 content - 50 Mg/Cu.M.

DCDA Sulphuric Acid Plant rated capacity - 140TPD : installed in April 1993.

Important equipment in CCD :

Equipment CCD-1 CCD-2 Total

Tar decanters 06 05 11

Primary coolers 16 13 29

Exhausters 05 05 10

Tar precipitators 04 04 09

Ammonia saturators 04 03 07

Final coolers 03 02 05

Benzol scrubbers 08 03 11

To look after the assets of CO&CCD an elaborate and comprehensive maintenanceorganisation has been provided.

The assets can be summarised as under :-

1) Mechanical & Electrical equipment of coke ovens, PBCC, CHP, CSP & CCD.

INDEX

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2) Total structures installed in CO & CCD.

3) Refractory brick work of the ovens and other furnaces.

4) Pipe lines laid within the shop.

5) Electrical cables.

6) High voltage power trolley lines.

The maintenance of the above assets, except refractory, was being carried out onthe lines of other shops of the plant. But in the year 1971, necessity was felt tore-organise the shop organisation in which the maintenance activity was given acomprehensive character and this section "maintenance and repairs" was established.The whole section is divided into the following wings.

a) Mechanical Maintenance (Regular)

This section looks after the routine maintenance, shift maintenance, breakdownjobs and plans out the preventive maintenace programme of the entire cokeoven and by-product plant.

b) Electrical maintenance (Regular & Capital)

The section is responsible for the maintenace of the electrical equipment ofCO&CCD. It looks after the routine maintenance, shift maintenance & breakdownjobs, plans out the preventive maintenance for the smooth working of all machines(electrical part) and also undertakes the capital repairs of the electrical equipment.

c) Capital Repair (Mechanical & Refractory)

This group is formed to take care of the mechanical and refractory repairs of thebattery and the mechanical repairs of the entire CO&CCD. The sole responsibilityof the complex repairs of ovens and other capital repairs of the whole of CokeOvens & CCD including refractories, lies with the capital repair group.

d) Repair Shop-I&II :

There are two repair shops in the department equipped with basic machine toolsand other facilities. Small jobs pertaining to the repairs for the department aredone in this repair shop. However major jobs are sent to the central mechanicalshops.

IMPORTANT SAFETY RULES FOR WORKING IN CO&CCD

1) Do not travel on belt conveyors.

2) If some Coal/Coke piece enters the eye, do not rub. Wash it with water and goto medical post.

3) Beware of free moving wagons.

4) Do not stand on any machine tracks.

INDEX

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GATEWAY

5) Quenching car and pusher car, power trolley lines which are within the reach ofhands should not be touched.

6) Do not go under quenching tower. Do not put your hands in hot quenchingwater.

7) Taking open flame or smoking in some protected areas is prohibited. Theseareas are - Coal Bunkers. Battery gas tunnel, Exhausters, Benzol RectificationPlant and Tar Distillation. If any welding is to be done in these areas, it whouldbe done with specific permission of the Manager of the shop in the presence ofgas safety and fire brigade personnel with protocol.

8) Do not stand over a charging hole lid.

9) Double security check is exercised for entry to benzol rectification plant. Personswith matches or nailed shoes are not permitted to enter the area.

10) In case of acid burn, wash in running water and rush to hospital.

11) Wear cotton clothes only.

12) All PPE (Personal Protective Equipments) provided by the management must beutilized without fail.

AWARDS

AWARD YEAR EXECUTIVES NON EXECUTIVESVISHWAKARMA 1995 2 5RASHTRIYA PURASKAR 1996 2 2

1998 1 52000 11 17

SHRAM RATNA 1997 - 4SHRAM SHRI 2002 - 1SOME HIGHLIGHTS OF CO & CCD

- Accidents have reduced due to number of initiatives taken by the shop. Somestatistics are shown below :

Calendar Year No. of Accidents2000 2492001 1402002 75

- Fire calls have also been reduced considerably

Calendar Year No. of Fire Calls2000 2262001 97

2002 59

INDEX

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- Pollution control in coke oven has been a major and uphill task for CO & CCD,but the challenge was accepted by the collective and great improvements havebeen made. It can be appreciated by the visitors themselves after visiting CokeOvens.

Some of the innovative measures taken for achieving the above are as follows:

- Awareness regarding safe working, effects of fire, and consequences of pollutionhas been brought about in the Coke Oven collective (Executives and NonExecutives) by in house training programmes, presentations and interactions,technology awareness programmes, safety talks and counselling etc.

- Technological improvements like straight charging of ovens, sealing of hatchcovers after charging the ovens, ceramic welding and dusting of ovens etc.have helped in achieving the above status.

- Modification of oven doors and leveller windows have helped in greatly reducinggassing from batteries.

- Introduction of HPLA system (High Pressure Liquor Aspiration) has helped inreducing emissions during charging.

- Cost control has also been achieved by creating cost awareness in Executivesand Non Executives in all activities carried out by them. Regular trainingprogrammes and display of posters have helped in achieving this.

INDEX

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GATEWAY

BLAST FURNACES

INTRODUCTION – Iron Production Basics:

The first step in theproduction of steel is toproduce iron, and ironproduction involves separatingiron from iron ore. There aremainly three basic methods ofproducing iron: DirectReduction, Iron Smelting andthe Blast Furnace method.Direct Reduction methodincludes both gas and coalbased processes. The productcoming out of these processes (Sponge Iron or Direct Reduced Iron) is in the solidstate. Electric Arc Furnace follows DRI process for the production of crude steel.

In Iron smelting process coal and iron ore fines are used as charge materials andliquid product will come out of the furnace, example Corex process. EAF or BOFroute is followed for steel making.

For achieving high production rates with great degree of heat utilization BlastFurnace (BF) route is the most economical way till date. So Bhilai Steel Plant, whichis an ore based Integrated Steel Plant had chosen Coke ovens – Blast Furnace – BOF/ THF route for the production of crude steel.

What is a Blast Furnace? BF is a counter current heat and mass exchanger, inwhich solid raw materials are charged from the top of the furnace and hot blast issent through the bottom via tuyeres. The heat is transferred from the gas to theburden and oxygen from the burden to the gas. Gas ascends up the furnace whileburden and coke descend down through the furnace. The counter current nature ofthe reactions makes the overall process an extremely efficient one.

In the blast furnace process iron ore and reducing agents (coke, coal) aretransformed to hot metal, and slag is formed from the gangue of the ore burden andthe ash of coke and coal. Hot metal and liquid slag do not mix and remain separatefrom each other with the slag floating on top of the denser iron. The iron can then beseparated from the slag in the cast house. The other product from the Blast Furnaceis dust laden blast furnace gas, which is further cleaned in the gas cleaning plant andis used as a fuel all over the plant.

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Blast Furnace constructional features:

A blast furnace has a typical conical shape. The sections from top down are:

Throat, where the burden surface is.

The shaft or stack, where the ores are heated and reduction starts.

The bosh parallel or belly and

The bosh, where the reduction is completed and the ores are melted down.

The hearth, where the molten material is collected and is cast via the taphole.

Fig. 1 Schematic cross section of the Blast Furnace

INDEX

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GATEWAY

Blast Furnace process:

The basic raw materials and their functions:Iron Ore: Iron bearing materials; provides iron to the Hot Metal

Sinter: Iron bearing material. Fines that are generated in the plant are effectivelyutilized by converting them to sinter. Provides the extra lime required for theiron ore that is charged in the blast furnace.

Coke: Acts as a reductant and fuel, supports the burden and helps in maintainingpermeable bed.

Limestone: Acts as Flux. Helps in reducing the melting point of gangue presentin the iron bearing material

Manganese Ore: Acts as additive for the supply of Mn in the Hot Metal

Quartzite: Acts as an additive

Coal Dust: Acts as an auxiliary fuel, reduces coke consumption in the BF

Coal Tar: Acts as an auxiliary fuel, reduces coke consumption in the BF

Pellets: Iron bearing materials. Although not in use right now, there is a proposalto utilize the fines below the sinter grade for pellet manufacturing and thepellets formed are going to be charged in the BF.

The specifications of the above materials is given in Table 1.

Table 1. SPECIFICATIONS OF RAW MATERIALS

Material Chemical Analysis Specification Size Other Properties

Iron Ore Fe 64.0 % min. 10-40 mm (Lumps) SiO2 2.5 ± 0.5 %

P 0.10 % max. Softening Melting range:

Al2O3 / SiO2 0.88 % max. 1175 - 1540 ?C Sinter Fe 50% 5-40 mm

FeO 10% SiO2 6% RDI: 23 - 25 Al2O3 3%

CaO 14-15 % Softening Melting range:

MgO 4-5% 1330 – 1600 oC

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Bhilai Steel Plant

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The raw materials from various places are transported to the bunkers placednear the furnaces and properly screened and weighed. These batched proportions ofthe raw materials are conveyed to the top of the blast furnace via skip car or conveyorsand are charged in the blast furnace. The distribution is maintained in such a fashionthat alternate layers of coke and iron-containing burden (sinter and iron ore) areformed inside the BF. The blast, which is heated in the stoves, is called Hot Blast andthis is blown into the BF via tuyeres. The hot blast gasifies the reductant componentsin the furnace, those being coke as well as auxiliary materials injected via the tuyeres.In this process, the oxygen in the blast is transformed into gaseous carbon monoxide.The resulting gas has a high flame temperature of between 2,100 and 2,300°C.Coke in front of the tuyeres is consumed thus creating voidage.

Coke Ash 15-16 % 52 -55 mm CRI: 22 -24 max. VM 0.3-0.4 % CSR: 60 min.

M 5 ± 0.5 % M40: 80 – 82 % S 0.5-0.6 % M10: 7.8 – 8.4% C 75-80 %

Limestone CaO 38% Min. 6-50 mm SiO2 6.5 ± 0.25 % MgO 8.5 ± 0.5 %

LD Slag CaO 40.8 ± 1 % 10-40 mm MgO 10.5 ± 0.5 %

SiO2 15.50%

Mn Ore Mn 30 % min. 25-80 mm

SiO2 30 % max.

Al2O3 5 % max. P 0.30 % max.

CDI Coal Ash 9 – 11 % 90 microns VM 28% Moisture 1.80% FC 56%

Quartzite SiO2 96 % min. 25 -50 mm Al2O3 1.5 % max.

INDEX

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GATEWAY

The very hot gas ascends through the furnace, carrying out a number of vitalfunctions.

Heats up the coke in the bosh/belly area.

Melting the iron ore in the burden, creating voidage.

Heats up the material in the shaft zone of the furnace.

Removes oxygen of the ore burden by chemical reactions.

Upon melting, the iron ore produces hot metal and slag, which drips downthrough the coke.

zone to the hearth, from which it is removed by casting through the taphole. Inthe dripping zone the hot metal and slag consume coke, creating voidage. Additionalcoke is consumed for final reduction of iron oxide and carbon dissolves in the hotmetal, which is called carburisation.

Thus the liquid products Hot Metal and Slag settle in the Hearth. These twoproducts are removed periodically from the blast furnace. The process is called tappingthe blast furnace. The other gaseous product, which is going to the top of the furnace,contains dust in it. It is cleaned in the Primary (dust catcher); Secondary (ventury andscrubber) and Tertiary (electro static precipitator) gas cleaning system and the cleanedgas is used as a fuel all over the plant.

It will take minimum 6-8 hours for the solid raw materials that are charged fromthe top to reach the bottom, whereas gaseous products that are sent through thetuyeres will go out in 2-8 seconds.

The efficiency of the process is judged by two parameters:

Productivity: The amount of Hot Metal produced per cubic meter of the furnacevolume in a day.

Unit: tonnes/m3/day (either on Working Volume or Useful volume basis)

Fuel Rate: The amount of fuel required to produce one tonne of hot metal.

Unit: kg/thm. (Includes coke rate + aux. Fuel rate + nut coke rate (added insinter)). (Carbon rate is the right measure as carbon content of the fuel variesfrom time to time)

Continuous monitoring of the top gas analysis will give an indication about thefurnace efficiency.

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Bhilai Steel Plant

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1.3.0. Reactions in the Blast Furnace:

UPPER STACK ZONE

Reduction of Oxides

3 Fe 2O3 + CO = 2 Fe3O4 + CO2

Fe3O4 + CO = 3FeO + CO2

FeO + CO = Fe + CO2

Decomposition of Hydrates

Water - Gas Shift Reaction CO + H2O = CO2 + H2

Carbon Deposition

Decomposition of Carbonates

MIDDLE STACK ZONE

Direct / Indirect Reduction

FeO + CO = Fe + CO2

CO2 + C = 2CO

FeO + C = Fe + CO

Gas utilization

LOWER STACK ZONE

Calcination of Limestone

Reduction of Various elements

Reduction of unreduced Iron

Reduction of Silicon

Reduction of Mn, P, Zn etc.

Formation / melting of slag, final reduction of FeO and melting of Fe.

COMBUSTION ZONE

Burning and combustion of Coke

C+O2 = CO2 + 94450 cal (direct reduction)

CO2+C = 2CO - 41000 cal (solution loss reaction)

Complete reduction of Iron Oxide

RACEWAY

Coke and Hydrocarbons are oxidized

Large evolution of heat

Fig. 2 Isothermal Zones in BF

< 600°C

600-900°C

900-1100°C

> 1100°C

INDEX

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GATEWAY

HEARTH

Saturation of Carbon with Iron

Final Reduction of P, Mn, Si and Sulphur

Reaction impurities reach their final con-centrations

Falling/drop of Metal and Slag bring heatdown into the Hearth.

2.0.0. THE FACILITIES AT BSP:

The Blast Furnace Department of Bhilai SteelPlant is operating 7 Blast Furnaces. All thesefurnaces are commissioned in various phases ofmodernization. In the first phase when plant isat 1 MT stage BF No. 1, 2, and 3 arecommissioned. During the second phase ofexpansion i.e. in 2.5 MT stage BF No. 4, 5, and 6 are commissioned. In 4.0 MTexpansion phase BF No.7 is commissioned. Further capacity enhancement took placerecently (February, 2007) by modernizing BF No 7. The furnace capacities and theircommissioning dates, with major modifications are given in Table 2. At present theannual rated capacity of Hot Metal is 4.7 MT.

Table 2. BF COMMISSIONING AND RECOMMISSIONING DETAILS

* Different isothermal zones can be seen inFig. 2.

< 6 0 0 °C

6 0 0 -9 0 0 ° C

9 0 0 -11 0 0 °C

> 11 0 0 ° C

Phase Commissioning date

Recommissioned after modernization

Major modifications during modernization

1 MT 04-02-1959 15-08-1988

Complete conveyorisation of charging with full automation, eliminating conventional scale car system.

1 MT 28-12-1959

Complete conveyorisation of charging with full automation, eliminating conventional scale car system.

1 MT 28-12-1960 15-07-1998 RCU, Stock house Conveyorisation

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Bhilai Steel Plant

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2.1.0. Some more modifications during modernizations:

Introduced Coal Dust Injection in BF#6 to achieve low coke rate, extended toBF#7, 1 and 5.

Tar Injection facility for BF # 2 and 3.

Phase Commissioning date

Recommissioned after modernization

Major modifications during modernization

2.5 MT 8-12-1964 8-12-1989

Stock house conveyorisation with elimination of scale car Paul Wurth Bell less top. A separate charging operators control room. Twin tap hole arrangement. Cast house slag granulation INBA type.

2.5 MT 27-11-1966 27-09-1992

Stock house conveyorisation with elimination of scale car; Paul Wurth Bell less top. A separate charging operators control room. Twin tap hole arrangement. Cast house slag granulation INBA type A supervisory control system was adopted Hydraulic mud guns and drilling machines replacing the electo-mechanical counterparts. Castable runners

2.5 MT 31-07-1971 7-12-1990

Stock house conveyorisation with elimination of scale car; Paul Wurth Bell less top. Twin tap hole arrangement. 4 Nos. of old Russian stoves were replaced by 3 nos of hoogovens stoves.

4.0 MT 30-8-1987 22-2-2007

Capacity enhanced to 1.55 MT/annum Cu staves cooling provided Flat Cast House

INDEX

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GATEWAY

Castable Runners in all furnaces except in Fce # 1,2, &3.

In all furnaces, stoves are operated in auto mode.

Sinter Screening facilities in every furnace.

Usage of Tar bonded clay for closing the tap hole.

Hydraulic mud guns and drilling machines.

The main dimensions of all the furnaces are given in table 3.

Table 3. MAIN DIMENSIONS OF BLAST FURNACES

BF--> 1,2,3 4,5,6 7 DIMENSIONS Useful Volume (top of the Hearth to stock level) 1033 m3 1719 m3 2355 m3

Working Volume (Tuyere to stock level) 886 m3 1491 m3 2105 m3

Full Height , mm 28750 31250 32350 Useful Height, mm 26000 28500 29700 Top Height, mm 2300 1900 2300 Top Dia., mm 5800 6000 7800 Large Bell Dia., mm 4200 No bells No bells Stack Height, mm 15000 17800 17700 Stack Angle 85° 25’ 34’’ 84° 42’ 18’’ 84° 36’ Bosh Height, mm 3000 3000 3300 Belly Height, mm 2000 2000 2225 Bosh Dia, mm 8200 10200 12135 Bosh Angle 80° 32’ 15” 79° 36’ 48” 72° 50’ Hearth Height, mm 3200 3200 3400 Hearth Dia., mm 7200 9100 9750 No of Tuyeres 14 18 24 No of Tap holes 1 2 2 Monkey 1 0 0

INDEX

Bhilai Steel Plant

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The equipment and other details of BF's are shown in table 4.

Table 4. EQUIPMENT AND OTHER DETAILS OF BLAST FURNACES AT BSP

BF # 1 BF # 2 BF # 3 BF # 4 BF # 5 BF # 6 BF # 7

COOLING

Stack Cooling

Cantilever coolers

Cantilever coolers

Cantilever coolers

Plate Coolers

Plate coolers

Plate coolers

Cu staves

TOP

Type

Double Bell

Double Bell

Double Bell with RCU

BLT with single bin

BLT with single bin

BLT with single bin

BLT with double bin

Charging System

Skip car Skip car Skip car Skip car

Skip car

Skip car

Skip car

? ? ?? ? ? ? ?

INDEX

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GATEWAY

BF # 1 BF # 2 BF # 3 BF # 4 BF # 5 BF # 6 BF # 7 Top Pressure

1.0 1.0 1.0 1.1 1.1 1.1 1.8

Cast House

Single Single Single Single Single Single Double

Tap Holes

1 1 1 2 With 40O

apart

2 with 40O

apart

2 with 40O

apart

2 with 180 O

Apart

Monkey

1 1 1 0 0 0 0

Slag Granulation

Nil, slag collected in ladles



INBA SGP

INBA SGP

CAST HOUSE SGP 2LINES

CAST HOUSE SGP 2 X 2 LINES

INDEX

Bhilai Steel Plant

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MAIN SECTIONS:

Blast Furnace department is headed by GM (BF) who will report to GM (IRON),under GM (BF) sectional heads will be there of DGM rank. Under them area heads willbe there.

The organization chart of the BF department is shown below:

Mud gun Electric Electric Hydraulic Electric Hydraulic Hydraulic Hydraulic

Drill Machine

Electric Electric Hydraulic

Electric Twin Taphole

Hydraulic Hydraulic Hydraulic

STOVES

NO 3 3 3 4 4 3 4

Design Russian Russian Russian Russian Russian Hoogovens

Russian

Combus tion Chamber

Internal, Horizon tal fired

Internal, Horizon tal fired

Internal, Horizontal fired



Internal, Vertical fired


AUXILI ARY FUEL INJEC TION

CDI CTI CTI NIL CDI CDI CDI

INDEX

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GATEWAY

Broadly speaking the persons who are inducted into the department will join anyone of the teams shown below.

1. Furnace Operation

2. Furnace Equipment

- Furnace Equipment 1-5

- Furnace Equipment 6-7

1. Bunker

Stock house 1-6

Stock house 7

2. Top charging

3. High Line

4. Cooling

5. Hydraulics

6. Lubrication

7. PCM

8. LRS

9. SGP -7 & GSTS

10. CDI

11. CDPP

12. THMS

13. Planning including Repair Shop

14. Shift (BRIGADE -I, II, III)

15. Tar pumping

16. Stoves

For academic convenience we can divide the department into three main sections.

1. Raw Material Section (Charging)

2. Furnace Section and

3. Auxiliary Section

3.1.0. RAW MATERAL SECTION (Charging):

The main responsibility of this section is to receive the raw materials requiredfor the production of Hot Metal from various sources, storing and transportingthem to the top of the furnace in time, for the smooth running of the furnace.The functions of this section are:1. Receiving the Iron Ore from ' Dalli, Rajahara Mines and purchased ore from

outside' and storing it in the ore trench / OHP ' transporting to bunkers via OBC,and OTC ' transporting to the top of the furnace via skip car.

INDEX

Bhilai Steel Plant

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2. Lime Stone from' Nandini mines ' and storing it in the ore trench' transportingto bunkers via OBC, and OTC' transporting to the top of the furnace via skipcar.

3. Manganese Ore from ' Balaghat Mines and storing it in the ore trench' andtranporting it to bunkers via OBC, and OTC ' transporting to the top of thefurnace via skip car.

4. Sinter from ' Sintering Plants (SP-1, SP-2, and SP-3) ' through conveyors 'andtransporting it to bunkers through Ore Transfer Car (OTC) and conveyors 'transporting to the top of the furnace via skip car.

5. Coke from 'Coke Ovens (coke sorting plants -I,II &III) through conveyors and storingit in bunkers' transporting to the top of the furnace via skip car.

6. Converter Slag from' SMS - II through haul packs'yard ' to bunkers ' transportingto the top of the furnace via skip car.

3.1.1. Ore Yard:

Raw materials arriving to the Blast Furnace department from various sources areunloaded in the Ore Trench of Ore Yard. After the Ore Trench, Ore Yard is locatedtowards the Blast Furnace. The Ore yard is meant for stocking and averaging ofmaterials. The materials from Ore Trench are transported to Ore Yard with the help ofOre Bridge Cranes (OBCs) having a span of 76.2 meters. Approximately, the followingamount of materials can be stored in Ore Yard at a particular time.

1. Fine Ore : 85,000 tonnes

2. Iron Ore (Lumps) : 1,80,000 tonnes

3. Limestone : 40,000 tonnes

4. Mn. Ore : 11,000 tonnes

5. Quartzite : 3,000 tonnes

Raw materials from the Ore yard are charged by means of OBCs into 6 5 Tonelectrically Operated Transfer Cars. They carry the materials into the respectivebunkers. There are 7 electrically Operated Transfer Cars. Two transfer cars are fittedwith electric loco.

Furnace wise bunker status is given in Table 5. The intention of keeping somany bunkers is to ensure continuous supply of raw materials to the BF. The bunkersonce filled are able to supply 16hours continuously. Because of modifications duringmodernization, the number of bunkers below high line has been reduced.

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GATEWAY

BFNo. Coke Iron ore Sinter Mn. Ore Lime Stone Quartzite

1 2 x 400 m3 8 x 90 m3 12 x 90 m3 1 x 90 m3 2 x 90 m3 1 x 90 m3

2 2 x 400 m3 6 x 90 m3 10 x 90 m3 2 x 90 m3 2 x 90 m3 2 x 90 m3

3 2 x 400 m3 8 x 90 m3 11 x 90 m3 2 x 90 m3 1 x 90 m3 1 x 90 m3

4 2 x 400 m3 6 x 90 m3 12 x 90 m3 2 x 90 m3 1 x 90 m3 1 x 90 m3

5 2 x 400 m3 9 x 90 m3 15 x 90 m3 2 x 90 m3 2 x 90 m3 2 x 90 m3

6 2 x 400 m3 10 x 90 m3 19 x 90 m3 2 x 90 m3 3 x 90 m3 2 x 90 m3

7 2 x 550 m3 8 x 110 m3 4 x 290 m3 2 x 110m3 1 x 110 m3 1 x 110m3

Earlier sinter from SP - I bunker located on the extension tracks of high line wascollected in transfer cars moving on rail tracks. This was the old route. After arrivalof SP-3, sinter from SP-3, comes upto Jn-32 by means of Conveyor belt and is storedin a receiving hopper of capacity 300T (200M3). Sinter is screened, and the fines arereturned to SP-3 through conveyor belts RSC and SFC 3, 4. BF size sinter is stored intwo hoppers of capacity 60 Tons each. From this it is loaded into ore transfer car andis unloaded into sinter bunkers of BF#1 to 6 situated below the high lines.

Screened sinter from SP-2 comes to junction house Jn-27 through conveyorsand is stored into two different hoppers (capacity 120T each) situated above trackno.18 and 19. From these sinter is loaded into ore transfer cars for furnaces 4 to 6.

For feeding sinter to BF # 7:- Sinter from Jn.-27 is transferred to J-44 andthen through reversible shuttle conveyor it is transported to the bunkers.

For feeding Iron ore and Mn ore:- Ore from ore yard to BF # 7 there are 3 statichoppers (2 for Iron ore and 1 for Mn Ore ), which can be fed by means of OBCs.

Coke (25 -80mm) from Coke sorting plant 1 and 2 is supplied to the cokebunkers of the blast furnace with the help of conveyor belts. BF#7 is getting cokefrom CSP-3. There are two stockyards of coke, one near BF#1 and the other behindBF#7, which are used in case of emergency. Fig.3 gives an idea about raw materialflow to the Blast Furnace.

3.1.2. STOCK HOUSE

In the past system all raw materials from the bunkers, except coke, were drawnby scale car, which transports the materials and loads into the skips. The scale caroperator was required to maintain a sequence of drawing materials from the differentbunkers, which helped in averaging the chemical composition. Now this system hasbeen totally replaced by conveyorisation in the Stock House.

Table 5. NUMBER OF BUNKERS AND THEIR VOLUME

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Under modernization program, the bunker gates have been modified and thestock house has been completely conveyorised. Below the bunkers there is a vibro-feeder, which feeds the material to the conveyor belt, which charges the material onscreen. The BF size material is fed to a weighing hopper through ore dischargeconveyor. The weighing hopper discharges the material into the skip. There areconveyors to remove the fines from the system. BF # 1,2,3 and 4 do not have anyore screen. So the path of Iron ore is from -

Bunkers-Vibro feeder-Conveyor Belts-Weighing hopper-Skip Car.

3.1.3. COKE CHARGING SYSTEM

Coke from coke bunkers falls on a vibratory screen. BF size coke from the screencollects in a weighing hopper. The fines below 25 mm size collect in a bottom bunkerfrom where it is hoisted to top bunker by means of coke breeze skip (Volume 0.5 m3to 0.75 m3 ). Top bunker is emptied in every 4th hour into dump cars that carry cokebreeze to sintering plants. However for BF#7 instead of bottom bunkers and topbunkers arrangement, coke fines are conveyed by fines conveyor into a coke finesbunker from where it is sent to SP- II by means of haul packs.

3.1.4. HOIST HOUSE

For taking charged materials to the Furnace top, two-way skip hoist with 2 skipsof useful volume 6.5 m3 for BF# 1,2,3; 10 m3 for BF #4,5,6 and 13 m3 for BF # 7are provided. The hoist house operates the skip that is driven by two motors. Bellhoist, equalizing valves, test rods etc. are also operated from hoist house.

3.1.5. CHARGING OPERATORS CONTROL ROOM (COCR):

All the charging activities are monitored from the COCR round the clock. Thusraw materials are transported to the top of the furnace.

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GATEWAY

Fig. 3 Raw Materials flow to the BF and the Products to various sources

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Fig.4 BF complex in a nutshell

3.2.0. FURNACE SECTION

Blast Furnace is a vertical shaft furnace, enclosed in a welded shell, lined withfire-clay bricks of high alumina content. The hearth bottom, hearth, bosh, belly andthe shaft are cooled by means of coolers of various designs. Steel refractory linedplates protect the walls of the furnace top. In BF # 7 copper staves had been installedin recent modernization for cooling the shaft.

The bigger furnaces are lined with carbon blocks in the hearth and in the peripheryof the hearth bottom. Fig.4 gives an idea about the BF complex in a nutshell.

3.2.1. Top Charging Equipment:

The burden material which reaches to the top of the furnace by skip car is tobe distributed into the furnace. For this in BF 1 & 2 double bell charging system isthere (Fig.5). In BF-3 along with bells Rotating Charging Unit (RCU) is provided (Fig.6). BFs. # 4,5,6 and 7 are equipped with Paul-Wurth Bell Less Top (BLT) chargingsystem, which replaces bells with charging bins, upper material gate, upper sealingvalve, lower material gate and lower sealing valve (Fig. 5). This system also has agearbox to operate a rotating chute. The latter distributes the material inside thefurnace peripherally in different rings. This facilitates better burden distribution insidethe furnace.

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GATEWAY

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Fig. 5 Double Bell and BLT systems

Fig.6 Rotary Charging Unit (RCU) in BF# 3

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GATEWAY

3.2.2. Charging Sequence

To facilitate smooth working of furnaces, the coke and the non-coke material isto be distributed in a particular fashion in the whole circumference of the blast furnace.For those different charging sequences is followed. A typical charging sequence isgiven below:

Sequence 1: COC / COOCC / CCOOC

Sequence 2: CCOO

Each charging cycle consists of 5 sequences of either 1 or 2 exclusively or incombination depending on the periphery conditions. Generally in Bell-less Top furnacesthe 2nd sequence is followed i.e. CCOO. C=COKE; O=NON-COKE ie ore, sinter, Mnore, lime stone or quartzite. The material is distributed in the BF in different sectorsas shown in Fig.7.

Fig. 7 BLT and Burden distribution inside the Blast furnace

3.2.3. Hot Blast Stoves

Air preheated to temperatures between 1,000 and 1,250°C is produced in thehot blast stoves and is delivered to the furnace via a hot blast main, bustle pipe andfinally through the tuyeres. The hot blast reacts with coke and injectants, formingthe so-called raceway in front of the tuyeres.

There are 3 or 4 stoves for each furnace. Each stove consists of a combustionchamber and refractory checker brickwork. Except BF#6 all furnaces are equipped

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with Russian designed stoves. In BF#6 Hoogoven designed stoves are in operation.The main difference in these two designs is the burner position. In Russian design theburner is kept in the horizontal position and in the Hoogoven design a ceramic burneris used which is kept in the vertical position. The maximum temperature attainedfrom the Hoogoven design is 200 OC more than the Russian designed stoves,accordingly different type of refractories are used in the Hoogoven design.

There are two cycles in the stove operation.1. ON GAS: Stove in the heating mode

2. ON BLAST: Stove in the blast mode

In the first cycle the stoves are getting heated by using BF gas and Coke Ovengas for 2 hrs. The flue gases will be carried out through the chimney. This is called'ON GAS'. When the dome temperature reaches to the desired level the gas is removedand cold blast that is coming from the Power and Blowing station is sent thoroughthe cold blast valve. In this cycle called ' ON BLAST' the sensitive heat that is storedthe checker brickwork is carried away by the cold blast and is getting heated. Thushot blast is produced and this blast is sent into the blast furnace via hot blast main,bustle pipe, compensator, tuyeres stock and tuyeres. 'ON BLAST' will continue forone hour and will be followed by "ON GAS' cycle. Thus at any point of time twostoves or ON GAS and one or two stoves are ON BLAST and the cycle is repeatedcontinuously.

Fig. 8 Hot Blast Stove and its Valve Arrangement

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GATEWAY

For controlling cold and hot blast there are several valves given on the stove.They are: Cold blast valve (1), Hot blast valve (1), Chimney valves (2), By-passchimney valves (3), Gas butter fly valve (1), Gas burner (1), Air fan (1).

A snort valve on the cold blast main regulates the volume of blast. The steam isinjected for the humidification of the blast before pre-heating in the stove. Oxygenenrichment is also done whenever necessary through the blast itself. A mixer valveregulates hot blast temperature.

3.2.4. Auxiliary Fuel Injection

In the present competitive environment, there is a lot of pressure on BF operatorsto lower the operating costs and maximize productivity. One way to achieve this isby injecting auxiliary fuel into the blast furnace. The fuels used for this purpose arepulverized coal, and coal tar.

Economic and operational benefits achieved by using Pulverized Coal Injection(PCI) (as shown in Fig. 9) include:

lower consumption of expensive coking coals. Replacing coke with cheapersoft coking or thermal coals reduces reductant costs;

extended coke oven life since less coke is required to be produced. This isimportant as many coke ovens are reaching the end of their useful life andsignificant investment is required to replace or maintain them;

higher BF productivity, that is, the amount of hot metal produced per day (inconjunction with other operational changes);

greater flexibility in BF operation. For instance, PCI allows the flame temperatureto be adjusted, and the thermal condition in the furnace can be changed muchfaster than would be possible by adjusting the burden charge at the top of thefurnace;

improved consistency in the quality of the hot metal and its silicon content;

reduced overall emissions, in particular, lower emissions from coke making dueto decreased coke requirements.

Taking the above advantages into the consideration BF department had alsotaken a decision to inject auxiliary fuel into its blast furnaces. Accordingly PCI unit iscommissioned in BF-6 in September'98, later it is extended to BF-7 in December'04.A second unit is commissioned in BF-1 in October '05 and is extended to BF-5 inNovember'05

Soft coal / PCI coal is used for this purpose. In BF#6. Maximum CDI rate achievedis 103 Kg/THM, correspondingly coke rate has been reduced to 450 - 460 Kg/THMwith a replacement ratio of 1.1-1.2.

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Coal Tar Injection started in BF#3 in 2004 later it is extended to BF#2 in 2005.

The challenge now is to achieve these high PCI rates with cheaper, lower qualityraw materials, without losing hot metal quality, productivity or BF availability.

Fig. 9 Cross section of Tuyere with Pulverized Coal Injection

3.2.5. The Cast house:

The liquid iron and slag collect in the hearth of the furnace, from where they aretapped via the taphole into the cast house and to transport ladles.

The equipments available at the cast house are:

1. Drill Machine' used for opening the tapping

2. Mud gun' used for closing the tapping

3. Cast House Crane' for material handling during cast house preparation

4. Rocking Runner' to divert the metal into a different metal ladle

5. Pusher Car' used for local placement of the metal ladle

In BF 1,2 and 3 in which only single tap hole exists, there is a provision to flushthe slag through the slag notch (called monkey) situated at a height of 1400 mm -1600 mm from the axis of the taphole. The monkey is equipped with pneumaticcinder stopper. Increasing the number of tappings can reduce Flushing operation.

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GATEWAY

The Hot Metal is tapped out at an interval of 2-3 hrs depending upon the furnacecondition. The tapping time will be around 90 - 120 minutes. Generally 8 -9 tappingswill be done in a day. The usual way of opening the taphole is to drill the taphole untilthe skull is reached. Some times oxygen lancing is carried out to melt the skull.

Generally the tap hole is located in such a way that after tapping minimumamount of metal should remain in the hearth. So it is almost at the bottom most partof the hearth. After opening the tapping Hot Metal will comes out first. After sometime the liquid level in the hearth decreases and the slag that will be floating on themetal comes out of the tap hole. The skimmer plate separates the slag from themetal and diverts the slag into the slag ladles/SGP through slag runners. The hotmetal continues to flow down the bend runner from which it is diverted into individualmetal ladles. The control of this operation is accomplished by cutters located in therunners or with the help of rocking runner and pusher car. At the end of the tappingthe taphole is closed with the mudgun , which is electrically or hydraulically operated.BF # 4, 5, 6, and 7 are having twin tapholes. So the tapping is carried out alternately.

The hot metal is collected in a refractory lined vessel called hot metal ladle,which is having 100 T capacity, and for safety reasons it is filled upto 85-90%.Using these ladles hot metal is transported from Blast Furnace to mixers in SMS,PCM and Foundry. A fleet of 78 hot metal ladles is available, out of which normally52-55 are in circulation in case all seven furnaces are in operation.

Similarly in BF 1,2 and 3 slag is collected in slag ladles and is dumped in thedump post. BF 4,5,6,and 7 are having Slag Granulation Plants (SGPs) in which slag isgranulated, and this granulated slag is sold to cement manufacturers. SGP details aregiven in a separate section.

The other product BF gas contains lot of dust in it and it is cleaned in dustcatcher, ventury washer, and scrubber and finally in electro static precipitator. Thisactivity is done under the supervision of energy management department. The cleanedBF gas is sent to the gas network and is used as a fuel all over the plant.

The analysis of hot metal, slag and top gas is given in table 6.

3.2.6 Furnace Foreman Control Room:

All the activities burden distribution, stoves, cast house, auxiliary fuel injectionetc. are controlled from FFCR located in the furnace. LEVEL-0 and LEVEL-1 automationfacilities are there in all BF's. All the details regarding the furnace are monitored usingDDCs and mimic panels kept in the FFCR.

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HOT METAL SLAG BF GAS

Si 0.5-0.8 % SiO2 32-33

% CO 25-26 %

Mn 0.8-1.0 % Al2O2 19-20

% CO2 15 -16 %

S 0.04 % max. CaO 31-33 % N2 55-57 %

P 0.20% MgO 9-10 % H2 2-3 % C 4-5% MnO <1%

Basicity: CaO/SiO2

0.98

3.3.0. AUXILIARY SECTION

The auxiliary section of Blast Furnace consists of following sections :

1. Ladle Repair Shop

2. Pig Casting Machine

3. Cold Pig Yard

4. Taphole Mass Shop

5. Slag Dump Post

6. Slag Ladle Depot

3.3.1 Ladle Repair Shop: There are 3 ladle repair shops provided for relining,repairing and leaning of the iron ladles. Each shop contains an E.O.T. crane(75T) for speeding up the job.

3.3.2 Pig Casting Machine: There are 4 double strand Pig Casting Machines,each having a capacity of 1600 T/day. Each machine contains 308 moulds inone belt with lime coating arrangement underneath the machine. Moulds arefilled with the hot metal from the ladle at the spout, cooled by water sprays onthe bed while on movement and the pigs are separated from mould chain byknockout arrangement. Each pig weights about 45 kg.

Table 6. ANALYSIS OF HOT METAL, SLAG AND TOP GAS

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GATEWAY

3.3.3 Cold Pig Yard : Cold Pigs from PCM come here. These are stackedaccording to their quality, and loaded in box wagons for dispatch to stackyards of customers.

3.3.4 Tap Hole Mass Shop: Here, Refractory Mass required for Blast Furnacedepartment is made e.g. Mudgun clay, Tap hole frame mass and Runner Massetc.

3.3.5.Slag Dump Post: The slag ladles from BF 1,2 &3 and slag coming fromBF 4,5 &6 in case of SGP failure is sent to the dump post for emptying theladles. Provision exists at the dump post for tilting and hammering out theslag with the help of cranes.

4.0.0. THE FUTURE

As per the decision of SAIL management, BSP's hot metal production is going toreach 7.5 MT per annum.

To achieve this the following measures have been envisaged in the Blast Furnacearea.

1 Modernization of the BF - 6

2 Installation of a new furnace (BF-8) of capacity 8,030 t/d hot metal production(about 4060 m3 useful volume) at a separate location along with a new stockhouse and new material handling facilities.

3 Modification of the existing material handling system

4 Introduction of torpedo ladles

5 Improvement of logistics in Blast Furnace area etc.

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SLAG GRANULATION PLANTS

As on date BSP has six Slag Granulation Units. Out of these six units, CHSGP-BF7 is under control of BFs department. Rest 5 units, namely SGP-1, SGP-2, INBA-4,INBA-5 and CHSGP-6 are looked after by SGP department. The BF slag of BSP isbasic in nature and meets the requirements for use in cement production. The importantproperty which decides the suitability of slag for making cement is hydraulicindex.

Slag Granulation Units (under SGP Deptt.) :

UNIT

Date of Commissioning

Capacity

1. SGP-1 3.11.1964 9.5 Lakhs T/Yr. (Closed down in 1998. Assets sold off.) 4.75 Lakhs T/Year.

2. SGP-2 17.04.1982 5.00 Lakhs T/Year.

3. CHSGP-BF6 25.12.1990 5.00 Lakhs T/Year

4. INBA –CHSGP-BF4 29.03.1994 5.00 Lakhs T/Year 5. INBA –CHSGP-BF5 27.01.1994

SGP- I :

Total capacity of the plant was 0.95 million tons with the installation of balancingfacility Conveyer System. This unit has been stopped since 1998 and equipment soldoff.

SGP- II :

After a few years' stoppage, this unit has been re-commissioned in April'2002to meet the increased market demand of Granulated Slag. Molten slag from BF isdelivered to SGP-II in self-tilting type slag ladles of 16 M3 each. The crust of thehardened slag formed is broken by means of slag piercing device (a metallic conicalhammer of 1.5T) attached to an EOT Crane. To avoid the entry of metal and solidifiedslag lumps/crust into the hydrochute, ladles are not completely poured-out. Residualslag in ladle normally amounts 10% to 15% of ladle volume. This residual slag isremoved out at slag dump yard. The minimum temperature at the time of granulationshould be 1250 °C.

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GATEWAY

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Sections of SGP - II :

1. Pouring Platform # Receiving Baths 6 Nos.

# Hydrochutes 6 Nos.

# 1.5/3 T Piercing Crane 1 No.

2. Pump House # 600 M3/Hr. Centrifugal pumps 3 Nos.

# 300 mm Motorized Gate Valve 3 Nos.

# Re-circulation Water Tank 3 Nos.

3. Tunnel Valves Room # 250mm Motorized Gate Valves 6 Nos.

4. Storage Bay # 12.5T E.O.T. Grab Cranes 2 Nos.

# 80 T Bunkers 2 Nos.

5. Shipping 30T Electronic Road Weighbridge 1 No.with computerized central Invoicing

facility.

The granulation of molten blast furnace slag performed by the hydro-chutetechnique in SGP-II ensures high efficiency, adequate economy, and reliability inoperation and good quality of the product.

This plant comprises 1 granulation unit. Arranged along the discharge section ofthe slag transfer track, slag trains of max. 6-7 ladles each are tilted in this unit.

When the ladle is tilted, the molten slag flowing from the receiving bath towardsthe chute comes in contact with water coming out of nozzle mounted at the headend of hydro chute at a pressure of 8 ATM. It cools the molten slag and breaks it intofine granules. Under the action of water, granulated slag falls 15-20 meters awayfrom the end of the chute.

Water consumption per tonne of granulated slag is approx. 1 cu.m.

The duration of ladle discharge is approximately 7 minutes based on a rate of3.16 tonnes/min. Processing of one slag train lasts for 35 min. approx.

The maximum slag residue in the ladle is up to 15%. After slag granulation theslag ladle train proceeds for cleaning in the dump yard for removal of skull andresidual molten slag.

After granulation the moisture content of granulated slag is 8 to 10%. Conveyingof granulated slag from the granulation units and piling it up in the store house, aswell as loading it into the bunker for discharging into trucks, are done by a 12.50tonne travelling grab bucket crane with a 4 cu.m. Bucket. From here the granulatedslag is lifted by consumers by trucks, after weighment.

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The average chemical analysis of granulated slag is as follows:

SiO2

- 32-33 %

Al2O

3- 18-21 %

CaO - 31-34 %

MgO - 7.9 to 11 %

MnO - 1.2 to 1.5 %

S - 0.9 to 1.0 %

H2O - 8 to 10 %

FeO - 0.5 %

Bulk density - 1.02 to 1.05 kg./Liter.Use :

The granulated slag is used mainly in the manufacture of PBFS cement. Mainbuyers are A.C.C, Century Cement, Grasim Cement & L&T Cement Co. Drawbacksof SGP-I & SGP-II units :

a) GP-I & GP-II is 2.5 Km. away from BFs. Due to this distance & time taken fortravelling, crust forms on the surface of ladle (slag).

b) 100% slag granulation is not possible by this process because of tech. difficulties.The new systems of granulation were adopted; first in BF-6 called "Cast HouseSlag Granulation System" (CHSGP)" and then in BF 4 & 5 called, "INBA" system;to overcome these problems.

The Modern method of Cast House-Granulation of BF Slag has been appreciateddue to following reasons :

1. Higher efficiency of Blast Fcs Production.

2. Control on time delay due to want of empty slag ladles (as no slag ladles arerequired in the method).

3. The space requirement (for cast house slag granulation plant) is less.

4. Percentage of utilization of slag for granulation is more.

5. Granulated slag production is more economical as compared to old method.

CHSGP - BF-6 :

In CHSGP-BF-6, designed by USSR, fresh liquid slag is granulated near BF-6 andcollected in Granulation Chamber.

The installation helps the Plant in avoiding (or decreasing) the transportation ofthe liquid slag; granulating it completely in the cast house of Blast Furnace. Thisgranulated slag is a high quality raw material for cement industries.

In this method the granulation unit is located in the cast house at the dischargeend of the hot slag runner. High-pressure water jets from nozzles are made to impinge

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on the stream of hot liquid slag falling from the slag runner. The slag streamdisintegrates and solidifies in to small granules, and these granules are carried by theexcess water to de-watering unit.

The slag/water mixture is received in the receiving or settling bin, which is filledwith water up to a fixed level. The steam and other gases are exhausted into theatmosphere through a stack. In the receiving bin, natural thickening of slurry takesplace due to settling of granulated slag at the bottom.

The thickened slurry is taken out from the bin bottom by Airlift. The slurry (gr.slag& water) is lifted by Airlift and goes to Thickening Funnel and finally to Dehydratorfor water removal. Granulated Slag from Dehydrator falls on conveyor belts & goesto Bunkers or stockyard for truck loading. The loaded trucks go to Weigh Bridge forfinal despatch. Granulated Slag is also despatched through railway wagon.

Following are the important component of CHSGP BF-6 :

GRANULATOR :

It provides high pressure water jets at desired angle for effective granulation ofliquid slag.

RECEIVING BIN :

It encompasses protective screen and metallic grill. Protective screen absorbsthe impact of high pressure water jets whereas metalic grill screens the bolders andprevent any foreign material bigger than permissible limit going into the air lift chambers.A water level of 1.25 M above metallic grill is maintained in the receiving bin.

AIR LIFT CHAMBER & AIR LIFT :

It is a deep vessel going upto -17 M. from ground level & contents suctionchamber from which water is fed or sucked by a main pump for granulation. In Air liftchamber a water level, of 2.7 M above ground level, is maintained. Airlift goes throughthe entire airlift chamber up-to the bottom from where slurry is lifted with the help ofcompressed air. Airlift can move up and down 5 M, with the help of rack and pinionarrangements. The top end of airlift is connected to separator through telescopicpipe arrangement.

SEPARATOR :

It is a cylindrical vessel with top cover known as separator cover. It has twooutlets, one at the upper end for the steam and bottom one for slag & water. Steamoutlet is connected to the stack.

HARMETIC RUNNER :

It is an airtight runner with top covers removable for cleaning, connects separatorand thickening vessel.

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GATEWAY

THICKENING VESSEL :

It is again a cylindrical vessel with bi-conic bottom. It acts as a buffer vessel andfeed the slurry to the dehydrator in a controlled way. At top end of the vessel aoverflow pipe is given which is connected to stack.

DEHYDRATOR :

There are four dehydrators connected to thickening vessel, each dehydrator hastwo discharge pipes : top and bottom one.

PUMP HOUSE :

It consists of two main granulation pumps M-31 and M-32, and two drainage pumps.

FLOAT TANK :

It is provided to take care of excess water in Airlift chamber. It has three outlets,incoming fresh water supply, overflow pipe and filling pipe. Once the required levelreached the excess water overflow through overflow pipe of float tank.

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CONTROL ROOM :

In control room , mimics for both granulation process and granulated slagtransportation system are provided. The various operations of the system are manualwith safety interlocking. Flow meter and pressure meter are also provided in thecontrol room for compressed air.

GRANULATED SLAG TRASPORTATION SYSTEM :

It consists of 6 conveyor belts K-1, K-2, K-3, K-4, K-5, K-6. Paralleled belts areinstalled in pairs like K-1 & K-2, K-3 & K-4, K-5 & K-6. After K-1 & K-2 flap gateselector is provided so that material can be discharged on either K-3 or K-4. Conveyorbelts K-3 or K-4 are used to fill the intermidiate bunker. Another selector is providedin bunker to discharge the material either on K-5 or K-6 depending on the availabilityof section-1 or section-2 of Blast furnace-7, whichever is in operation.

INBA-4 & 5 :

In CHSGP BF-4 & BF-5, the modern method of slag granulation called INBASystem, developed in Europe has been installed. In these plants, granulation systemis attached to cast house & slag from BF through slag runner directly falls in front ofnozzle box fixed at the beginning of cold runner which gives high pressure water jetsfor granulation. The slag after granulation in cold runner, goes to Receiving Hopper.In Receiving Hopper waste gases & water vapour go out of chimney.

The granulated slag mixed with water, goes to Distributor and Dewatering Drumin which water of the slag is isolated. The Granulated slag is discharged to INBA belt& further goes to Slag Disposal System which is around 2.5 Km long and consists of9 conveyor belts transporting Gr. Slag to the stock yard.

STANDARD VALUES :

PRODUCT :

The slag granules produced at the slag granulation plants should have the followingcharacteristics :

a) Glassy phase in granulated slag: Min. 90 glasses.

b) Moisture content of granulated slag : less than 10% in CH SGP-6 & less than13% in INBA.

c) Porous free compact slag and at (on average) grain size less than 3mm.

d) Bulk density of granulated slag : maximum 0.98 T/M3.

TECHNICAL DATA (INBA CHSGP) :

a) Air purging pressure - min. 6.0 Kg/cm2.

b) Water purging pressure -

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GATEWAY

c) Pressure in - 3 to 3.5 Kg/cm2.

Granulation Pump No. 1 -

Granulation Pump No. 2 -

d) Optimum liquid slag flow per min. - upto 5,00,000 T./yr. (1400T/day)

e) Quantity of liquid slag to be - Ave-80-100 & Max.upto 120T.

processed by plant.

f) Qty. of slag/tapping. - Ave - 2-3T/Min & Max. 10T/Min.

g) Rate of slag entry -

h) Quality of slag after processing Not less than 90-95%.

- Contents of glassy phase. - upto 3mm.

- Size of granulated slag. - Not more than 10%.

- Moisture in Granulated slag. - 0.7 M3/T. of slag.

i) Specific consumption of water - 70NM3/min.

j) Compressed air average consumption. - 6.5 KWH/T. of slag.

k) Power consumption -

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STEEL MELTING SHOP-I

Steel Melting Sop - 1 (SMS-1) follows the conventional route of steel making inwhich steel is produced through Twin Hearth furnaces and cast into ingot moulds.The ingots are stripped off from the ingot moulds and are sent to BBM for furtherheating and rolling into blooms.

Initially SMS-I was set up to produce 1 MT steel annually, from 6 Open-Hearthfurnaces of 250 T capacity each. First tapping was done on 12th October 1959.Sixth Open-hearth furnace was commissioned on 22nd February 1961. Later on itwas decided by the corporate management to increase the capacity of the shop to2.5 MT, by installing 4 more open hearth furnaces of 500 T capacity and convertingOH no. 6 from 250 T to 500 T capacity, which was completed on 14th April 1967.

Steel production through Open-hearth furnaces had the following drawbacks :

1. Low productivity.

2. Cumbersome operation of the furnaces.

3. Higher fuel & refractory consumption.

To overcome the above drawbacks it was decided by the management to replaceopen hearth furnaces by Twin Hearth furnaces (Both hearths having capacity of 250T each). The following table shows the commissioning of different twin-hearth furnaces(by replacing different open-hearth furnaces) :

Sl.No. TH Furnace Replaced OH. Furnace Date of Commissioning

1 1 10 12/09/86

2 2 1, 2, 3 01/01/90

3 3 4, 5, 6 29/06/92

4 4 8 21/01/98

Remaining two open-hearth furnaces, i.e. No. 7 & 9 have been scrapped, andpresently SMS-I has four twin hearth furnaces only. The production capacity of theShop is 2.5 MT by running 3 Twin-hearth furnaces at a time.

SMS-I comprises of various sections for melting, casting & stripping of 2.5 MTingots annually. The main sections are :

1. Mixer

2. Stock Yard

3. Furnace

4. Pit side

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5. Mould Yard

6. Stripper Yard

MIXER

Mixers in any Steel Melting shop serve the following purpose :

i) They act as a reservoir, for storing liquid pig iron hot metal received from Blast

Furnaces and supplying it to the SMS furnaces when required.

ii) For homogenization of chemical composition and temperature of hot metalreceived from different blast furnaces.

For maintaining temperature of the hot metal.

Two mixers have been installed in SMS-I, one at each end of the main building.Both the mixers are drum-type, inactive mixers, lined with magnesite bricks, havinga capacity of 1300T each. An average temperature of 1300°C is maintained withburners using coke oven gas as fuel. The hot metal in mixer contains following(averagely) :

C - 3.5% to 4.0%,

Mn - 0.6%,

S - 0.045%,

P - 0.18% to 0.22%

Si - 0.6% to 1.2%

Each mixer building is provided with a crane of 125T/30T capacity. The hotmetal received from the blast furnace is poured into the mixer, through the pouring-in spout, with the help of these cranes. Hot metal upto 500T in the mixer is calledzero level. The mixer balance, as a practice, is always maintained above -200T level.

Each mixer is provided with one electric loco of 800 HP capacity. This loco pullsthree ladle chassies, coupled with each other, with ladles place over it. Whenever hotmetal is required by the furnaces, Mixer Loco pushes the chassis and positions oneladle under the pouring spout of mixer. Mixer is then tilted towards the ladle and hotmetal is poured into the ladle. The poured out metal is weighed on the weighingbridge provided in the mixer section itself. After filling one ladle mixer is tilted backand next empty ladle is positioned under the spout by the loco. Mixer is again tiltedto fill the ladle and in this fashion, all the three ladles are filled with required tonnageof hot metal, which varies from 200T to 230T per order. Capacity of each ladle is100 T and therefore requirement or one furnace is easily fulfilled by 3 ladles.

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There are two hatches provided near both the ends of the main building (nearTHF-I & THF-II) from where the hot metal ladles arriving from the blast furnace canbe lifted directly by Hot Metal Cranes of main building and poured into the furnaces.The hatches are used whenever the mixer cranes are under maintenance or underbreakdown and also when the mixer is under repair.

STOCK YARD

The stockyard is located parallel to the main building and comprises the Magneticyard and Bulk charge yard (B.C.Yard). In Magnetic yard steel scrap, rejected ingots;rejected castings from Foundry etc. are stored. Handling of these materials is doneby 5 cranes provided with electromagnets of 15T capacity each. Bulk charge materialsare stored in BC Yard in bins. They are iron ore; limestone, bauxite, magnesite andraw dolomite. These materials are handled with the help of two cranes, each havinga grab bucket of 10M3 capacity. Burnt dolomite and lime are continuously drawnfrom RMP-I through conveyors and are kept in hoppers. Weigh bridges are installedat both ends of the stockyard. All outgoing materials from the yard are weighed. Atthe far end of BC Yard, we have Ferro alloy yard. In this yard Ferro-manganese andSilico-manganese are stored, and weighed quantity of these Ferro-alloys is suppliedto the furnaces in tilting boxes, as per the requirement. Materials here are handled bytwo finger grab cranes of 10T capacity each.

There are 5 Bins in Magnetic yard :

78 X 14 X 2.6 m3 - 1 Bin 24 X 14 X 1 m3 - 4 Bins

These bins are used for storing bloom butts, broken ingot moulds & bottomstools, rejected castings, rejected ingots, heavy & light scrap. These materials aresent from MRD; excepting rejected ingots & ingot butts, which are supplied from theshop itself.

In bulk charge yard 9 bins of different capacities are provided for storing differentmaterials as written below :

Iron ore 8000 Ton - 1 Bin

6000 Ton - 1 Bin

Lime stone 6000 Ton - 1 Bin

5000 Ton - 1 Bin

Raw Dolomite 2000 Ton - 2 Bins

Bauxite 2000 Ton - 1 Bin

Magnesite 2000 Ton - 1 Bin

Manganese Ore 1000 Ton - 1 Bin

Scrap & bulk charge are loaded into charging boxes in magnetic and bulk chargeyards respectively. Normally two sets of scrap & one set of bulk charge are loaded.

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One set consists of 3 charging bogies. Each bogie can accommodate four chargingboxes. On an average 45-60 Ton of scrap, which consists of 80% steel scrap & 20%iron scrap, is loaded on two sets. This is done on line no. 98 with the help ofelectromagnetic cranes. Similarly, 9-12 T of limestone and 10 T of iron ore are loadedin another one set. This is done on line no. 100 with the help of grab cranes. Thus,one complete set of charge consists of two sets of charging bogies loaded with scrap& one set loaded with limestone and iron ore. Each set is weighed separately, onweigh bridges located on line no. 93 and 94, at both ends of the main building, andsupplied to the furnaces from both ends of the main building. On an average, 30complete sets of charge are loaded every day, and supplied to the furnaces afterweighment. Diesel locos are used for placement of charges and removal of emptybogies.

FURNACE

The furnaces are housed in the main building of the shop. There are at present 4Twin hearth furnaces of 2 x 250 T capacity. Of these, only 3 furnaces are kept inoperation and one is kept as cold reserve. The section is equipped with 6 chargingmachines (10 T capacity) and 5 over-head hot metal cranes (capacity 125/30 T). Thefurnaces are fixed type with basic lining (magnesite) and basic roof (magnesite-chrome).Twin hearth furnace consists of two hearths separated by a bridge wall with a commonroof. Twin hearth furnace works on synchronization between the two hearths; therebyboth the hearths are engaged in different operations. While one heath is in solid periodthe other is in liquid period. The technological regime of a Twin Hearth Furnace is basedon equal duration for both "Solid" and "Liquid" periods of a heat in both hearths.

The major operations during Solid period are :1. Tapping and fettling

2. Charging

3. Heating and sill making

4. Hot metal pouring.

The major operations during Liquid period are :1. Melting

2. Refining

3. Holding.

For reference a schedule of 4hrs. (i.e. 240 minutes) tap to tap time, has beengiven below. Any distortion or delay in the pattern of activities in the two hearths asgiven below is said to be improper synchronization of the furnace.

In Solid Period, the first operation after tapping is fettling. It is done with the helpof a fettling machine, which is placed in front of the furnace using a hot metal crane.The fettling material used is either sintered dolomite or magnesite. Fettling is done tomaintain the furnace bath profile and rebuild those areas which have been erodedduring heat working.

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SCHEMATIC DIAGRAM OF A TWIN HEARTH FURNACE

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Next operation is charging. Weighed quantities of scrap and bulk charge aremade available from the stockyard in charging boxes placed on bogies. 30 - 60 T ofscrap and 9 -11T of limestone is charged. Charging is done with the help of a chargingmachine and is done evenly through the three doors. Limestone is sandwiched betweenthe scraps. After charging, sills are made in each door. Raw Dolomite chips aredischarged on sill plate of each door upto the height of approx. 800 mm., from abunker, by a hot metal crane. After this, a chute is fixed onto one of the side doors,for hot metal pouring. Hot metal is received from the mixers in 3 ladles and the metalis poured into the furnace through the chute with the help of hot metal cranes.

After completion of hot metal pouring, liquid period starts. Oxygen is blown intothe hearth, through 3 lances fitted at the roof, at a rate of 6500 NM3/hr. and apressure of 10.0 Kg/ cm2. During melting, the generated slag is removed through thecentral door by lowering the sill, with the help of the peel of a charging machine,from time to time. The slag is collected into two thimbles placed on a trolley, belowthe central hatch hole. After completion of flushing, a metal sample is sent andtemperature is recorded and refining is done as per the bath analysis. When theaimed bath chemistry and temperature are achieved, O2 lancing is stopped and holdingis done. Then tap hole is opened and tapping operation starts. Tapping is done into aladle, and as per required specifications, weighed quantity of Petroleum Coke breeze;Fe-Si and Fe-Mn/ SiMn are added in-to the ladle with the help of a teeming crane.

In front of each furnace is a control room, from where different elements offurnace like doors, lances, burners, reversal system etc. can be operated. All movingparts like lances, burners, doors are water-cooled while stationery elements like door-frames, skew beams and screens are having Evaporative Cooling System (ECS). Thecontrol room is also provided with various alarms to indicate any problem in coolingsystem, SRS and high-pressure pumps. The flue gases pass through down-take,cooled with the help of atomizers, and are sent to gas cleaning plant for removal ofdust particles. Clean gas is discharged into atmosphere.

SALIENT FEATURES OF TWIN HEARTH FURNACE

1. Uncooled cross - beam : 4 nos.

2. Cooled cross beam : 9 nos.

3. Total angle pairs : 19 pairs

4. Total rings : 212 rings

5. Total length of furnace : 32720 mm

6. Hearth area at sill plate level : 69.4 M2

7. Length of hearth at sill plate level : 11200 mm.

8. Width of hearth at sill plate level : 6200 mm.

9. Depth of hearth from sill plate level : 1800 mm.

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10. Thickness of front-wall : 900 mm.

11. Thickness of back - wall : 1450 mm.

12. Height of roof from sill plate level : THF-I - 4100 mm.

: THF-II - 4000 mm.

: THF-III - 4150 mm.

: THF-IV - 4150 mm.

13. Volume of two slag pockets : 250 M3

14. Volume of liquid metal : 32.0 M3

15. Volume of slag : 10.0 M3

16. Height of roof from diamond wall : 3200 mm.

17. Roof height from end bank : 2800 mm.

18. Angle of inclination of front wall / back wall : 69°/ 70°

19. Thickness of twin hearth roof : 460 mm.

20. Distance between the lances : 2400 mm.

21. Effective length of lance : 5000 mm.

22. Length of Burner : 4111 mm.

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PIT SIDE

The area under 'A' row & 'B' row (621 X 25 M2) is called 'pit side'. It is animportant area of multifarious activities. It is equipped with 7 Teeming Cranes of350T/75T/15T capacity & 4 Cantilever Cranes (3 of 5 Ton capacity and one of 10 Tcapacity). Hydraulic systems to operate slide gate mechanism of Teeming Ladles arealso installed on teeming platforms in the Pit side area. Two locos are also attachedwith the section for thimble movement. Pit side operation consist of various activitiesthat are carried out side by side with the ultimate aim of feeding the furnace withladle, launder, thimble etc., so that tap out at scheduled tapping time and teeming ofliquid steel into quality ingots is possible.

Facilities and equipments available on pit side :

Teeming Platforms - 4 Nos.

Teeming Cranes - 7 Nos.(350T/75T/15T Capacity) 4 Nos. (5Tx3, 10Tx1)

Cantilever Cranes - 4 Nos.(5T x 3, 10T x 1)

Teeming ladles - 26 Nos.

Ladle cooling stands - 7 Nos.

Ladle heating stands - 9 Nos.

Relining Pits - 4 Nos.

After the tapping is over, the ladle is lifted by the main hoist of a teeming craneand launder is removed, with help of a tackle, by another teeming crane. The ladle isthen taken to the teeming platform, where the mould train has been placed. Now, thehydraulic cylinder is attached to the slide gate mechanism of the ladle and teeming isstarted by opening the gate of the mechanism. Meanwhile, the other teeming craneprovides the furnace with new launder and thimbles. After the teeming is over, theremaining slag in the ladle is dumped into a dumping thimble, and the ladle is preparedfor next tapping. Used thimbles are sent to the slag yard in slag cars, and emptythimbles are sent back to the pit side for reuse.

All the pit side activities can be divided into two groups i.e. major activities andsupportive activities.

Major Activities

1. Launder making and timely supply to furnace.

2. Providing thimbles for flushing & tapping.

3. Providing ladles for tapping.

4. Teeming of steel into ingots as per steel grade.

Supportive Activities

1. Dismantling of ladles.

2. Relining of ladles.

3. Heating of ladles.

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4. Mech. repair of Ladles, Launders, thimbles etc.

5. House keeping & cleaning

- Cleaning at ground level Furnace area & surroundings.

- House keeping of Teeming platforms.

- Cleaning of Teeming Tracks.

- Cleaning of Teeming crane walk way.

- Scrap and skull disposal.

6. Disaster Management.

MOULD YARD

There are two mould yards attached to SMS-I. Function-wise they are similar.The main activities of mould yards are.

i) Preparing & supplying mould train to pit side.

ii) Receiving moulds on cooling plates after stripping.

iii) Receiving bottom stool trains after charging of ingots in the soaking pits.

Mould trains are sent to stripper yard after teeming is over at pit side. Ingots arestripped off and ingot moulds are placed on cooling plates. These ingot moulds alongwith cooling plates are sent to mould yard. The cooling plate trains are parked outsidethe mould yard for minimum two hours for natural cooling to avoid moulds crackingduring water-cooling.

After natural cooling, the cooling plate trains are sent to hydraulic cooling stationand moulds are cooled with the help of high-pressure water jets. After proper cooling,the trains are sent to mould yards.

In the mould yard, moulds are coated with mould coating powder, which has thefollowing two advantages :

i) It avoids adherence of liquid steel with mould surface.

ii) Facilitate easy stripping of moulds.

Coating is done with specially designed mould coating gun. Coating powderconsists of min 20% graphitic carbon; rest being silica flour & other oxides. Itsrefractoriness is 1600°C.

Ingots along with bottom plates are sent to soaking pits where the ingots arecharged into soaking pits and the bottom plate sets are sent back to mould yards. Inmould yards bottom plates are cleaned and liquid lime is sprayed over them. Insertplates are placed over bottom plates at proper position. Fire clay paste is placedaround the insert plates and ingot moulds are put over it. It is done to avoid mouldleakage during teeming. Top cleaning of ingot mould is also done with the help ofspecial tackles. Mould Yard - I & II each are equipped with 3 over head cranes of 20T/5T capacity.

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STRIPPER YARD

Mould trains, after teeming at pit side, are brought to stripper yard. Here ingotsare stripped off and are sent to soaking pits. The main function of stripper yard is asfollows:

i) Sending hot ingots to soaking pits.

ii) Storing return ingots, or ingots made during BBM repair day, in Ingot Storage Yard.

iii) Shifting of ingots from ingot storage yard to other places in case of accumulationof ingots in this yard.

iv) Proper identification of cold ingots and supplying the same to soaking pits asand when required.

v) Release of mould striker and butts.

Stripper yard is equipped with three cranes of capacity 250T / 50T / 25T.Sometimes ingots do not separate freely from the moulds. In these situations, thepusher from the top of the ingot can apply a force of 250T to separate them. Ingotstorage yard is equipped with two overhead cranes of 50T capacity each.

With 180 no. of mould bogies, the entire activities of mould yard, and stripperyard are managed. Rolling stock is handled by 6 diesel locos, 3 for mould yards & 3for stripper yard. Total requirements of mould & bottom stool are met by our captivefoundry shop.

SMS-1 MILE STONES :

- 1ST TAPPING OF STEEL 12-10-59

- 1.0 MILLION TON SHOP 22-02-61

- 2.5 MILLION TON SHOP 14-04-67

- ACHIEVED 25 MT STEEL PRODUCTION FEB' 76

- LADLE SLIDE GATE INTRODUCTION IN TEEMING FEB' 86

- THF-I COMMISSIONING 12-09-86

- ACHIEVED 50 MT STEEL PRODUCTION JULY' 88

- THF-II COMMISSIONING 01-01-90

- THF-III COMMISSIONING 29-06-92

- ISO-9002 CERTIFICATION JAN' 97

- THF-IV COMMISSIONING 24-01-98

- ACHIEVED 75 MT STEEL PRODUCTION 11-08-99

RECORDS MADE IN SMS-I

- EVERBEST DAY PRODUCTION 44 LADLES 17-12-91

- 17 LADLE FROM ONE THF (4250 T) 05-12-98

- 32 LADLE FROM TWO THF ( 8150 T) 21-05-98

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- 36 LADLE FROM THREE THF ( 9100 T) 22-01-99

- EVER BEST MONTH PRODUCTION (2, 40, 100 T) JAN' 99

- EVER BEST YEAR PRODUCTION (25, 24, 200 T) 1998-99

- MAXIMUM ROOF LIFE ACHIEVED (THF-III) 892 HEATS

- LOWEST HEAT DURATION (2HRS IN THF-IV) 28-11-98

- MINIMUM COLD REPAIR DURATION (77HRS,THF-II) 77Hrs.

- BEST LADLE LINING LIFE (LADLE NO. 30, 41 HEATS) 16-01-99

- HIGHEST NO OF HEATS STRIPPED IN A DAY (38 HEATS) 16-03-99

- TWO TWIN HEARTH FURNACE WORKING 187000 TONS

HIGHEST PRODUCTION AUGUST '99

NEW PROJECTS

1. Bottom pouring practice started on 26/03/2002

2. Introduction of slag arrester to produce clean steel.

For more details of every sections of the shop, readers can refer to the "OPERATIONAND MAINTENANCE MANUAL OF TWIN HEARTH FURNACE". The Manual has been preparedby SMS-1, and it is available in the libraries.

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STEEL MELTING SHOP-II

Steel Melting Shop-II (SMS-II) is designed to produce 1.5 MT of Cast Steel in theform of Slabs and Blooms. The shop was commissioned on 29th of July'1984. Withevery passing day, the shop has improved its systems and processes. Many in-housemodifications along with acquisition of most modern steel making equipments havehelped in fulfilment of ever increasing customer demands in terms of quality andquantity. The revised production capacity is estimated to be about 1.8 MT.

SMS-II is equipped with secondary steel making units like VAD, Ladle Furnaceand RH Degasser to produce low hydrogen, low sulphur and micro-alloy steels.

SMS-II COMPRISES CONVERTER SHOP & CONTINUOUS CASTING SHOP.

CONVERTER SHOP

The Convertor Shop has 3 convertorsof 130 T capacity each. The working liningof the Convertor is of 690 mm MagnesiaCarbon bricks. The lining life has increasedfrom 100 Heats with TBDB in the beginningto a level of 6252 Heats in SEP'2006.withMagnesia carbon bricks.

Tap to tap time of the Convertors isaround 60 minutes, with an average heatweight of nearly 120 Tons.

There are two hot metal charging cranesof 180 + 50 T capacity and a semiportal crane of 40 + 40 T capacity. Lancehandling cranes of 30 / 5 T capacity have also been provided for fixing and changingof oxygen lances, convertor relining and other related maintenance activities. Theoperation cycle of the convertor is as follows :

a) Charging - 5 Min

b) Oxygen blowing - 20 min

c) Sampling & temperature measurement - 8 min

d) Corrections before tapping - 5 min

e) Tapping - 5 min

f) Nitrogen splashing, coating & deslagging - 7 min

TOTAL - 50 min

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GATEWAY

Before charging, the converter is inspected for lining condition, after which scrapand hot metal are charged. For getting the prediction of O2 and bulk material,hotmetal weight analyises, temp. and scrap weight is fed to the computer before startof blow.As per perdction O2 is blown and the bulk materials are charged through acomputerised addition system during the oxygen blowing process. Oxygen blowingis done for about 18 min according to computer model prediction. The oxygen isblown through a 5-hole nozzle, water cooled lance, at a pressure of 16 Kg/Cm2 anda flow rate of 400 - 450 NM3 /min. After the blow, convertor is tilteded for sample &temp. Reconditioning of bath is done with O2 and lime addition if bath analysisdevate from desired analysis. Reblowing is done for temp. correction.

The analysis of the steel sample is checked in the site laboratory. Tapping ofsteel is done after necessary adjustment in temperature and chemistry.

The steel is tapped into a 130 T steel ladle, placed on steel transfer car movingbelow the convertor. Ferro-Alloy additions are made in the ladle as per the requirementof the grade of steel.

The steel tapped from here has various possible routes :

i) Through Argon Rinsing Unit to the Con-Cast machines (in case of normal slabgrade heats).

ii) Through VAD unit (in case of special steel heats like API, Boiler Quality and RailSteels).

iii) Through Ladle Furnace & RH Degasser route (in case of Rail Steels).

The Convertor Shop has many sections as described below :

MIXER SECTION

The main function of Mixer is to supply Hot Metal (Pig Iron) to the convertors ata fairly uniform temperature and composition, in required quantity whenever demanded.The mixer acts as a buffer between the Blast Furnaces and the Convertors.

There are two mixers of 1300 T capacity each. At a time only one mixer is keptin operation.

The pig iron reaches mixer in ladles of 100 T capacity. The metal from these ladlesis poured into the mixer with the help of two 125 + 30 T cranes. Burners are providedin the mixer to maintain the temperature of hot metal. Metal from the mixer is suppliedto the converters by hot metal ladles, kept on self- propelled hot metal transfer cars.Weigh bridges are provided to weigh the quantity of hot metal supplied.

SCRAP YARD

Scrap yard receives the scraps generated from all over the plant in wagons andtrucks. Two 30 T magnet cranes do the unloading / loading of scrap. Scrap is suppliedto the converters in 11 M3 scrap boxes kept on two scrap transfer cars. Two weighscales below the scrap transfer car track check quantity of scrap supplied.

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LADLE PREPARATION SECTION

As the name suggests, the steel casting ladles, required for tapping of steel fromconverters are prepared here. There are 28 ladles of 130 T capacity each. All theladles have provision for bottom purging through porous plugs and fitted with slidegate FLOCON 6300 system for pouring of steel for casting.

Two 75 + 15 T cranes and 5 T cantilever cranes are provided here.

The ladles are lined with magnesia carbon bricks to withstand the heat anderosion during treatment in the VAD, LF and RH units.

Repair of ladle lining, pre-heating, fixing of slide gate system, purging system isthe major activity of this section.

SLAG POT HANDLING SECTION

The slag produced during steel making is poured out of the convertor into 16 M3

slag pots (also called thimbles). The slag cups are loaded on to the tilting type slagcars with the help of two 100/20 T slag pot cranes. The tilting slag cars are taken bylocomotives to the slag yard where the slag cups are tilted and emptied. They arethen coated with lime and received back in slag pot handling section to be usedagain.There are 26 Thimbles and 20 Slag tilting cars to handle Convertor shop slag.

BULK MATERIAL HANDLING SECTION

The following Bulk Materials are handled in this section :

1) Lime.

2) Calcined Dolomite.

3) Lime stone.

4) Coke.

5) Raw Dolomite.

6) Iron Ore

Lime and calcined dolomite are used as fluxes; Iron Ore & Limestone are used ascoolants. Coke is used for pre-heating the convertor and coating. Lime and calcineddolomite are received from RMP-II & RMP-I. Limestone, Iron ore and dolomite comefrom OHP. Coke is received from Coke Ovens Department.

All these materials come in the bunkers at a location called junction-34, fromwhere it is supplied by conveyors to the Convertor Shop via junction-35, and distributedto their respective bunkers by means of reversible shuttle conveyor.

Each converter has 9 bunkers, 3 for lime, 2 for calcined dolomite, 1 for rawdolomite, 1 for Iron ore, 1 for limestone and 1 for coke. Required quantities of thesematerials are charged into the converter by means of weigh scales of 5 T and 1 Tcapacity. The 5 T weigh scale is for Lime and 1 T scale for other materials.

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Very sophisticated microprocessor based system, of weighing and then charg-ing of bulk materials into converter, is installed in the main control pulpit.

GAS CLEANING PLANT

This is a modern and sophisticated plant, which cools, cleans, and collects thegases emerging from the mouth of the converter during oxygen blowing. The systemis based on suppressed combustion principle (air factor 0.1) i.e. the gases rich in COare not allowed to come in contact with the atmospheric oxygen and are stored foruse as a fuel.

The gases at converter mouth are at a temperature of 1850 °C - 1900 °C andcontain above 230 gms of dust per NM3. They pass through water cooled hood andstack. The gas cools to 1019 °C at the end of the stack. The gas then enters thequencher, where water is sprayed on by nozzles, cooling the gas to 72 °C, andremoving the dust which goes out in the form of slurry.

The cooled and partially cleaned gas enters the kinpactor venturi where it iscleaned further. The kinpactor venturi has a variable throat, opening of which isadjusted to maintain a pressure of ± 1 mm w.c at converter mouth by regulating theflow of gas to avoid any infiltration of air into the system or any possibility of gasesescaping to atmosphere.

The gases then pass through a mist eliminator to remove any water droplets.After this gases go to ID Fan, and then to the change over valve which directs thegases to the recovery side if the carbon monoxide content is more than 45 %,otherwise, the gases are burnt and let off into the atmosphere through a flare stack.

The gases to be recovered pass through a booster fan and a hydraulic non-returnvalve before going to the gasholder of 40,000 M3 capacity where they are collectedover water.

Before gasholder, the dust content of the gases is 100 Mg/NM3. The gases passthrough an electrostatic precipitator after the gasholder to reduce the dust content to10 mg/ NM3. This gas is called LD Gas and is used as a fuel. The calorific value of theconverter gas is 2000 k.cal/Cu.m and the average composition is :

CO = 65 - 70 % N2 = 15 - 20 %

CO2 = 15 - 20 % O2 = 0.10 %

About 85 M3 gas is recovered per ton of steel.

CONTINUOUS CASTING SHOP

Continuous Casting Shop comprises the following sections :

1) Argon Rinsing Bay

2) Tundish preparation Bay

3) Casting Bay

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4) VAD (Vacuum Arc Degassing Unit)

5) Ladle Furnace

6) RH Degasser

7) Discharge Bay

8) Slab & Bloom Storage Yard (SBS)

9) Mould Repair Shop

10) Casting Powder Plant (SFMPP)

This shop has three single strand radial slab casters, one 4-strand radial bloomcaster and a combi caster - which can be converted to a slab caster or a 3-strandbloom caster as per requirement. All sections of the Continuous Casting Shop exceptthe Mould Repair Shop & Casting Powder Plant are parallel to Converter Shop bays.Converter Shop has 3 LD Converters of capacity 130 Tons each. Liquid steel is takenin 130 T steel casting ladle transfer car. There are 3 such cars, each running onseparate rail track - stretching from below each converter to casting bay via on-lineArgon Rinsing Station. An additional ladle car is provided for returning the emptyladles.

ARGON RINSING BAY

At Argon Rinsing Bay, the ladle tapped (with liquid steel) is received on the steelcar. Argon / Nitrogen gas is bubbled into the liquid metal from top through a refractorylined lance called the argon rinsing lance. The rinsing operation does homogenisationof temperature & composition of liquid metal, as well as deoxidation is carried out byAl addition. Temperature is measured after rinsing and steel sample is sent to the labfor analysis. Trimming additions are done as per requirement, for achieving targetedchemistry of Carbon, Manganese and Aluminium content in steel. If the temperatureof the liquid metal is high, it is brought down by further rinsing, after which heats aresent to CCS machines at required temperature or sent to secondary steel makingunits like VAD, LF or RHD.

SECONDARY REFINING UNITS

LD process is most fitting for tonnage steel production but it has its limitationson the quality front due to dissolved gases such as H2 and N2. So for the productionof high quality steel, secondary refining units are used all over the world.

SMS-II secondary refining units comprise three units :

1) Vacuum Arc Degassing Unit (VAD)

2) Ladle Furnace (LF)

3) RH Degasser (RHD)

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INDEX

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GATEWAY

VAD UNIT

The VAD unit was commissioned on 17th January'1991. The unit consists of avacuum chamber where ladle tapped with liquid steel from converter is placed fortreatment. There is a provision of inert gas (Argon) purging from the bottom. Thevacuum chamber is made air tight with a metallic cover with the help of special typeof rubber sealing. and is connected to vacuum pumps comprising a series of ejectorsystem and condensers. High pressure super-heated steam is used for creating vacuumas low as 1 millibar or less.

The unit is also provided with heating facility and ferro alloy addition system fortemperature and chemistry adjustments. Heating is done by submerged arcing withthe help of three columns of graphite electrodes using electrical energy. A dedicatedtransformer is provided for the purpose. Partial vacuum is maintained in the vacuumchamber to suck out any fume or dust generated during arc heating. Continuouspurging of bath from the bottom helps in temperature and composition homogenisation.A separate pump house along with cooling towers and settling tanks is provided tocater to the water requirement of VAD unit. Continuous chemical dozing of watercurrent is ensured to avoid any deposition and also to ensure auto corrosive coatinginside the narrow pipe lines.

A CaO / Alumina rich slag is formed by addition of lime and prefused syntheticslag for facilitating desulphurisation if required.

A 50 T / 15 T EOT crane, 3 T telpher and 1 T jib crane are provided for handlingand maintenance purposes.

The VAD unit thus serves following functions :

1) Temperature adjustment

2) Chemistry adjustment

3) Desulphurisation

4) Removal of dissolved gasses ( H2, N2, O2 )

5) De-oxidation as per requirement.

TECHNICAL DATA OF VADHeat size nominal : 110 - 115 T

Free Board necessary : 600 - 800 mm

Transformer rating : 24 MVA

Roof lifting : Hydraulic, 2 cylinder

Electrode lifting : Hydraulic

Type of electrode : Graphite low density

No of electrodes in a column : 4

Diameter of electrode : 457 mm

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Electrical power HT : 11 KV

Electrical power LT : 415 V

Heating rate : 3 - 4 °C / minute of arcing

Industrial Water :Pressure : 3.5 Kg / Cm2 minimum

Inlet temperature : 32 °C Max

Outlet temperature : 41 °C approx.

Maximum flow rate : 650 M3 / Hr

Flow rate during heating : 50 M3 / Hr

Soft Water :Pressure : 5.0 Kg / Cm2

Inlet temperature : 32 °C

Flow Rate : 80+20 M3/Hr (for heat shield) primary

100 M3 / Hr Secondary

Compressed Air :Pressure : 3 Kg / Cm2

Consumption / treatment : 2 - 3 NM3

Argon :Pressure at manifold : 4 - 10 Kg / Cm2

Flow rate for stirring : 70 Nl / min Avg & 200 Nl / min Max

Nitrogen pressure :For releasing electrode clamps : 25 Kg / Cm2

Type of Vacuum Pump : 6 stage steam jet vacuum pump with 1

starting ejector and 1 heating ejector.

Steam :Pressure at manifold : 13 Kg / Cm2

Temperature at take over point: 350 - 375 °C

Soft water for de-superheating : 1.6 M 3 / Hr Approx.

Temperature at manifold : 220 °C

Flow rate during degassing : 10.5 T / Hr

(ejector 1 to 6)

Flow rate during heating : 0.800 T / Hr

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GATEWAY

LADLE FURNACE

Ladle Furnace and RH Degasser units are recent additions to SMS-II. Theequipment and technology of 130 T Ladle Furnace was given by M/s GA Danieli. Theunit was started on 23rd December'1999.

Ladle Furnace is a heating unit where liquid steel tapped in ladle from convertercan be heated using the similar principle that of VAD unit. Continuous inert gas(Argon) bottom purging is done for temperature and chemistry homogenisation.

The lid of Ladle Furnace is water cooled and is provided with three holes forthree columns of electrodes, one hole for ferro alloy addition and one for aluminium/ Calcium silicide wire injection.

A 2 T jib crane is provided for electrode column preparation and replacement ofsame in Ladle Furnace.

A dedicated fume extraction system with bag filters for dust separation is providedto suck out the fumes and dust generated during arcing.

Ladle Furnace performs all the functions of VAD excepting removal of dissolvedgasses.

TECHNICAL DATA OF LADLE FURNACE

Heat size nominal : 130 T

Transformer rating (continuous) : 28 MVA

Roof lifting : Hydraulic Cylinder

Electrode lifting : Hydraulic Cylinder

Electrode de-clamping : Hydraulic Cylinder

Type of electrode : Graphite (High density)

No of electrodes in 1 column : 3

Diameter of electrode : 457 mm

Heating rate : 3 - 5 °C / min of arcing

Electrical Power HT : 11 KV

Electrical Power LT : 415 V

Industrial waterPressure : 4 Kg / Cm2


Circulation rate : 260 M3 / Hr

Make up rate : 15 M3 / Hr

Emergency requirement : 100 M3

Soft WaterPressure : 4 Kg / Cm2

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Circulation rate : 60 M3 / Hr

Make up rate : 3.5 M3 / Hr

Compressed AirPressure : 3 - 4 Kg / Cm2

Requirement : 235 M3 / Hr

ArgonPressure : 4 ~ 16 Kg / Cm2

Requirement : 48 NM3 / Hr

NitrogenPressure : 4 ~ 8 Kg / Cm2

Requirement (Normal) : 35 NM3 / Hr

Requirement (Intermittent) : 48 NM3 / Hr

RH-DEGASSER

The state of the art RH Degasser unit was supplied, erected and commissionedby M/s Technometal, Germany and M/s Voest Alpine India on a turn key basis. Theunit was started on 30th March'2000.

RH Degasser is basically a degassing unit. The principle of creating vacuum is similar tothat of VAD unit but there is basic difference in the working principle of the two. VAD is atank degasser while RH Degasser belongs to circulating degassing system.

There is a vessel with inlet and outlet snorkels both lined with refractory. Thevessel is immersed into the liquid steel. Inside the inlet snorkel two layers of inert gassupply lines are installed. The vessel is subjected to low vacuum. The metal levelrises in both the snorkels due to barometric pressure. Inert gas stirring via the lift gasnozzles in the inlet snorkel causes a partial quantity of melt to be lifted into the RHvessel which subsequently comes back to ladle through down leg snorkel.Consequently a high turbulent flow from the inlet to the down leg snorkel takesplace. Once into the ladle, the steel flows quite slowly to the bottom of the ladle andturns back upwards to the uplid snorkel, when velocity is increased again. Thus therecirculation of molten steel is started and complete heat thus passes several timesthrough the RH vessel. The metal inside the RH vessel is exposed to vacuum level of1 millibar or less and so dissolved gasses (H2, N2, O2) in the steel is reduced. Thecirculation rate of molten steel is as high as 130 T / minute.

The RH process is thus faster and effective than VAD process. The process ismost suitable for making Rail Steel which requires H

2 concentration level less than

1.6 ppm. Also the obtained purity of Al-Si killed grade steel is very high due toeffective separation and removal of non-metallic inclusions during the process.

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GATEWAY

The unit is provided with ferro-alloy addition system for any trimming additionrequired during degassing.

A separate pump house along with cooling towers and settling tanks are providedto meet the water requirements of RH Degasser unit.

A unique swivel joint system is provided for lifting and lowering of RH vesselalong with its suction pipes.

An off line pre-heating burner is used for heating the vessel along with snorkelsafter fresh lining. An extremely sophisticated burner is provided for heating the vesselat the treatment place whenever required.

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GATEWAY

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CASTING BAY

In the casting bay all the continuous casting machines are located. This bay isdivided into two blocks. In one block there are three slab casters and in the otherblock one combi caster & one bloom caster are located. The casting bay is servicedby three 180 T / 50 T /15 T / EOT cranes and two 50 T semi-portal cranes. Theworking platform of the bay is at + 13.15 Metres elevation.

The rated capacity of Converter Shop & Continuous Casting Shop is raised to1.8 MT of cast steel production per annum.

GENERAL FEATURES OF SLAB CASTERS :

1. Radius of machine & mould : 12000 mm

2. Length of copper mould : 1000 mm

3. Maximum casting speed : 1.2 M / min

4. Metallurgical length of machine : 23 metres

5. Dummy bay insertion speed : 4 M / min (Max)

6. Range of frequency of mould oscillation : 6 to 13 mm

7. Range of frequency of mould oscillation : 15 - 100 cycles / min(Increasing with casting speed)

8. Grades of steel cast : Killed, structural & Alloy steel

9. Cross section of slabs produced : 200x1300, 200x1500, 250x1500

10. Total tonnage of cast from all the : 1.18slab casters

OPERATIONAL DATA FOR SLAB CASTER :

1. Rated casting speed : 0.5 - 1.0 M / min

2. Casting time for 120 T heat : 55 - 70 min

3. Water consumption mould : 350 - 500 Cu M / Hr

4. Total water consumption : 90 - 130 Cu.M / HrSecondary cooling zone

5. Length of slab cut at gas cutting machine : 6 - 10.5 M

GENERAL FEATURES OF BLOOM CASTER :

1. Radius of machine and mould : 12000 mm

2. Length of copper moulds : 1000 mm

3. Maximum casting speed of strands : 6 M / min

4. Metallurgical length : 24 M

5. Dummy bar insertion speed : 4 M / min

6. Range of amplitude of mould oscillation : 6 - 13 mm

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GATEWAY

7. Range of frequency of mould oscillation : 15 - 100 cycles / min

8. Grade of steel cast : Rail and structural steels.

9. Cross section of cast blooms : 300 x 340

TUNDISH PREPARATION BAY

Tundish preparation bay has been provided with the facilities for relining andpreparation of tundishes. The bay is serviced by two 50 T / 10 T EOT cranes.

Tundish capacity is of 10 Tons and 20 Tons, for slab and bloom casterrespectively.

MAINTENANCE BAY

In the maintenance bay of the shop, the withdrawal roll set dummy bar separationmechanism and gas cutting machines of casters are located where the strands (slab& bloom) are cut by oxy-acetylene torches as per requirement and sent to Slab &Bloom storage yard (SBS) by transfer car. The movement of cars is parallel to thebay. The Dummy bar is also inserted from the discharge bay by operating from GCMpulpits. This bay is serviced by one 50/10 T EOT crane.

SLAB & BLOOM STORAGE YARD (SBS) :

The slab & Bloom storage yard is 374 M long and 108 M wide arranged in 3bays, each 36 M wide. All the cast products of CCS are received here. Slabs for platemill are cut into desired size, inspected for visible surface defects and conditioned byscarfing. Accepted slabs are sent to plate mill for rolling as per rolling plan. Slabs fordespatch are inspected, conditioned and despatched to designated customers throughwagons placed on 4 different tracks laid perpendicular to bays. Blooms are despatchedthrough wagons to Rail & Structural Mill for rolling.

The yard consists of following facilities for handling, inspection, conditioning,storage & despatch of cast products.

1) Gas cutting Machine - 3 Nos for Slab, 1 No for Bloom

2) 5 EOT cranes of 46 T & 64 T hook capacity.Crane Nos 2106, 2107, 2108, 209 & 2110

3) 3 finger cranes 16 T each.Crane Nos F1, F2 & F3

4) 3 gripper cranes 18 T each.Crane Nos 1, 2, 4 with GCM's

5) 6 semiportal cranes 32 T each.Crane Nos 1 to 6

MOULD REPAIR SHOP (M.R.S.)

In the Mould repair shop, old (used) moulds for casting are repaired and newmoulds are also assembled.

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POWDER PLANTIn the Powder Plant, also called SFMPP (slag formation mixture preparation plant)

casting powder for slab and bloom casters is prepared by mechanical mixing ofingredients.

BRIEF DESCRIPTION OF CONTINUOUS CASTING SHOPAfter tapping of liquid steel into steel teeming ladle, the ladle is moved to the

Argon Rinsing Bay. Here the steel is rinsed for proper homogenisation and achievingdesired temperature of liquid steel for casting. After this the ladle is transferred tocasting bay by steel transfer car or sent to secondary steel units for further processing.The steel ladle received from Secondary steel units or Argon Bay is placed on the Lift& Turn Stand of Casting machines by means of Casting crane of 180 T capacity.Tundish is brought to the casting position and the sub-entry nozzle is aligned with thecentre of mould. The ladle is turned to the casting position and placed above thetundish. After this command from the casting In-charge is received for opening theladle slide gate. After the slide gate is opened metal from the ladle is taken into thetundish through a refractory lined pipe called the shroud. When the metal level intundish is attained, metal is taken into the mould of machine through a sub-entrynozzle. When the mould is filled to the working level, mould oscillation is started andthe casting is started at 0.2 m/min speed, and speed is increased gradually to aconstant working speed. When the dummy bay comes out of the roll zone the holdingdevice hook holds it. When the dummy bar head reaches the withdrawal roll stand, itis separated from the stand (slab or bloom).

The strand is cut at the gas cutting machine into the desired lengths and cutslabs / blooms are transported to SBS Yard. 10 minutes before the metal in the ladlefinishes, another ladle is placed on the reserve arm of L & T stand & kept ready. Assoon as the metal in the first ladle finishes, the L & T is rotated by 180 º and thesequence ladle comes to casting position and the ladle is opened for casting. Thussequence of casting is maintained. Sequence of casting is maintained depending onthe grade of steel being cast. At the end of casting, tail end of strand is quicklyremoved form the machine by increasing the speed and the machine is checked &prepared for next casting.

MAJOR IMPROVEMENTS & ACHIEVEMENTS (SINCE INCEPTION OF SMS-II) :- INCREASE IN LINING LIFE OF CONVERTER TO 6252 HEATS.

- PRODUCTION OF RAIL STEEL WITH LESS THAN 2 PPM HYDROGEN ANDLOW SULPHUR STEELS LIKE API AND BS GRADES.

- IN-HOUSE IMPROVEMENT IN CASTING MACHINES TO IMPROVE QUALITYOF STEEL AND YIELD.

- REDUCTION IN CONSUMPTION OF INPUTS LIKE HOT METAL, LIME AND FERROALLOYS.

- HIGHEST EVER PRODUCTION OF 84 HEATS ON 29-03-2005.

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GATEWAY

REFRACTORY MATERIALS PLANT-IRefractory Materials Plant-I (RMP-I) was installed along with other units in BHILAI

STEEL PLANT under 1.0 MT stage. The plant was expanded subsequently under2.5MT & 4.0 MT stage. RMP-I supplies sintered dolomite, calcined dolomite andvarious refractory mortars & castables to SMS-I, SMS-II & RED respectively. Firstunit of the shop, rotary kiln #01 was commissioned on 15/05/60 under 1 MT stagewhile rotary kiln #02 was commissioned on 28/12/66 under 2.5 MT stage.

RMP-I consists of following sections :

1) Raw material storage yard

2) Mortar shop

3) Dolomite shop

BRIEF WORKING OF THE SHOP:

Dolomite shop :

It produces sintered dolomite and calcined, lime/dolomite in two rotary kilns.Sintered dolomite is used for fettling in Twin Hearth Furnaces (THFs) of SMS-I. Calcineddolomite is used in SMS-II to increase the lining life of Convertors. Annual capacityof Dolomite shop is 70,000MT .Calcined lime is used in sintering plant to improvequality & productivity of sintering plants.

Product details-

a) Sintered dolomite :CaO 55-56%

MgO 36-38%

SiO2

1.2%

R2O

34-5%

LOI <1.0% (Loss On Ignition)

B D 2.8-3.0 g/cc (Bulk Density)

b) Calcined dolomite :CaO 52-54%

MgO 34-36%

LOI 4-5%

Reactivity 120-150ml of HCl (4N)

c) Calcined lime :Cao 88-89%

Mgo 2-2.5%

LOI 4-5%

Reactivity 330-360 ml of HCL(4N)

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RAW MATERIALS :

(i) Low silica raw dolomite chips (For producing sintered dolomite) :

Source Mandla areaSize 8-20 mmCaO 30% minMgO 20% minSiO

21.0% max

Al2O

32.5% max

(ii) Raw dolomite chips (For producing Calcined dolomite) :

Source HirriSize 10-25 mm

CaO 30% min

MgO 20% min

SiO2

3.0% max

Al2O

32.5% max

(iii) Low Silica Limestone

Source Jaisalmer

Size 10-35 mm

CaO 53% min

SiO2

1.6% max

Fuel : Mix of Coke Oven & LD gas along with PCM

PROCESS DETAILS :

Dolomite shop can be divided into following major sections:

- Dolomite production units

- Dolomite despatch section

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GATEWAY

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Dolomite production units :There are two rotary kilns of 60-meter length & 3 meter diameter. The inclination

of kilns is 3.5 % towards discharging end. Each kiln is driven by 125 KW motor.Cooler length is 25 meters while its diameter is 2.5 meters. Low silica chips arecharged into Rotary kilns by means of the receiving bin, vibratory feeder, skips hoist,charging bunker and Belt Weigh Feeder. The materials are charged into Rotary kiln-Iwith the help of charging pipe and scooping device in Rotary kiln -II. Sintered dolomiteis produced in Rotary kilns by calcining & sintering the raw low silica dolomite chipsat 1620-1650 0°C. While calcined lime is produced by calcining the limestone chipsat 1300-1350 0 0C. The kiln operates on counter current flow principle.

Mixed gas (CO+LD) alongwith air is charged from one end and raw dolomitechips descend from other end. Sintered/calcined dolomite is discharged from thefurnace into the cooler. Material is cooled to atmospheric temperature in the coolerbefore it is discharged.

Dolomite Despatch Section :The end product is transferred to silos via skip hoist. There are four silos, each

having a capacity of 800 MT. The sintered dolomite is screened on a double deckscreen of 1 mm & 15 mm, (+) 15 mm fraction is sent to roller crusher for recrushinginto (-) 15 mm fraction. 1-15 mm fraction is conveyed to high line bunker situated inbulk charging yard of SMS-I. It is loaded into hoppers through chutes. Calcined limeFrom RMP-II, calcined lime is conveyed to SMS-II /SP-3for use. Depending upon therequirement, production of sintered dolomite& lime is carried out in rotary kilns.Under normal circumstances, one kiln produces sintered dolomite while the otherproduces calcined lime is screemed on 5mm screen,undersize goes to dust bunkerwhile +5mm is passed through impact mill & output is again screened. The materialis stored in dust bunker & sent to SP-3 for RMP-2, material is directly loaded fromsilos into haulpacks.

OPERATING PARAMETERS :The norms of operation parameters are maintained for achieving high productiv-

ity & good quality of sintered /calcined dolomite. The important operating parametersof rotary kiln operation are.

Sl Parameters Sintered dolomite Calcinedl Lime1 Kiln speed 75-80 sec/ rotation 78-80 sec/ rotation

2 Sintering/calcinations temp. 1620-1650 deg C 1350-1400 deg C

3 Dust chamber temp 760-780 deg C 700-760 deg C

4 Gas flow 3000 cu M/Hr 3200 cu M/Hr

5 GCP draft (-) 4 to (-) 6 mmWC (-)4 to (-) 6 mmWC

6 Gas pressure 220-300 Kg/m2 220-300 Kg/m2

7 PCM flow 650-750 kg/hr ---

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GATEWAY

Mortar Shop

Mortar shop produces different types of mortar and castables after crushing,grinding and mixing the refractory materials. Annual capacity is to produce 18000MT of mortars & castables. The shop started production on 10/11/61.

Products and raw materials used are as below :

S. No. PRODUCT INGRADIENTS USED

1 FIRE CLAY MORTAR FIRE BRICK/ HIGH ALUMINA BRICK GROG,

PLASTIC FIRECLAY (PFC)

2 CHROME MORTAR CHR-MAG BRICK GROG, PFC

3 STEEL LADLE MORTAR HIGH ALUMINA BRICK GROG, KYANITE, PFC

4 HAM-70 MORTAR LOW FERRIC HIGH ALUMINA CAL.

BAUXITE (LFHACB), KYANITE, PFC

5 VAD MORTAR LFHACB, KYANITE, PFC

6 BT-1 MORTAR LFHACB, KYANITE, PFC

7 BT-2 MORTAR LFHACB, KYANITE, PFC

8 MAGNESITE MORTAR DEAD BURNT MAGNESITE, PFC

9 SP. KYANITE MORTAR FIRE BRICK GROG (FBG), KYANITE, PFC

10. SP.COR -1 FBG, KYANITE, PFC

11 LAUNDER RAMMING

MASS

CHR-MAG GROG, DEAD BURNT

MAGNESITE, PFC

12 60% ALUMINA CASTABLE

(HAM-K)

CALCINED FIRECLAY GROG,

13 FIRE BRICK GROG (0-1mm)

FIRE BRICK GROG

14 CHR-MAG GROG (0-10mm)

CHR-MAG GROG

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INDEX

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GATEWAY

PROCESS DETAILS :

The shop can be divided into following sections:

- Primary crushing section

- Grinding section

- Mixing & dispatch section

Primary crushing section : Two jaw crushers have been installed for primary crushingof dry materials. They crush firebricks, high alumina bricks, mag-carb bricks, basicbricks and kyanite ore. Material is fed from receiving bins by tray feeder to thecrusher and crushed material is taken into storage bunkers through chain bucketelevators. Size of crushed material is 0-25 mm.

One toothed-roller-crusher is also there for primary crushing of plastic fire clay from0-100 mm to 0-25 mm size.

Grinding section : The equipment available are -

(i) Tube mill

(ii) Ball mill

(iii) Pan mill

(iv) Impact mill

Tube mill is a double-chamber ball mill using 90,70, & 45 mm dia balls as grindingmedia. The length & diameter of mill is 5.6 meters and 1.4 meters respectively. It ispowered with 165 KW motor which rotates the mill at 29 rpm. Grinding action takesplace because of the cascading of the balls in the mill. The ground material of (-) 0.1mm size is taken to storage bunkers via belt elevators and screw conveyor. Rate offeed, RPM of mill, rate of discharge, retention time of material, amount of balls in themill are important operating parameters of tube mill. Capacity of mill is to produce atthe rate of 2-3 t/hr depending upon the type of material being crushed.

On the other hand, ball mill is used for grinding of pea magnesite only. It is asingle chamber ball mill of 0.5 t/hr capacity. It uses 45mm dia balls as grindingmedia. In this mill manual charging is done and discharged material is bagged ingunny bags.

Pan mill is used for grinding of plastic fire clay to (-) 1 mm size from 0-25 mmsize. Mill is equipped with two rollers of 1.6 meter diameter. Pan is rotated at 19 rpmby 55 KW motor. Mill capacity is one t/hr. Ground plastic fire clay is conveyed by beltelevator to a suspended screen of 1 mm opening. Oversize material is returned to panmill for re-grinding. 0-1 mm size material is taken to storage bins with help of screwconveyors.

Impact mill is utilized for coarse grinding of materials. The mill has two sets ofhammers, which crush the material by impact force while rotating at high speed(1200 rpm). A 30KW motor has been provided to give drive to mill. The material is

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fed from top and discharged from bottom after crushing & conveyed to double deckvibratory screen by belt elevator. After screening, desired size fractions are stored inrespective storage bins, while oversize is recycled to mill for crushing. The capacityof the mill is 4-5 t/hr depending upon the type of material being crushed. The productsof impact mill are as below :

PRODUCT USE0-2 mm chrome/mag grog In LRM production

2-5 mm chrome/mag grog In LRM production

Mixing & dispatch section :

Mortars are prepared by mixing the ingredients in predetermined proportion inthe mixer. There are four mixers. The mixer operator adds ingredients with the helpof weighing scales, in edge wheel mixer, through a belt conveyor. The refractorypowders are mixed in the batch type mixer with a system of rotating scrappers. Themortar is discharged into six tons or two tons capacity containers. Loaded containeris emptied out in bins with the help of crane. Mortars are bagged and sent to differentconsumer departments by trucks.

Products of mortar shop and their use is as below :

SL. PPRODUCT USAGE AT1. FIRE CLAY MORTAR GENERAL PURPOSE

2. CHROME MORTAR SMS-1

3. STEEL LADLE MORTAR BF LADLES

4. VAD MORTAR SMS-II LADLES

5. BT-I MORTAR BF STOVES

6. BT-II MORTAR BF STOVES

7. MAGNESITE MORTAR SMS-II

8. SPL. KYANITE MORTAR SOAKING PITS

9. LAUNDER RAMMING MASS SMS-I

10. HAM-C CASTABLE GENERAL PURPOSE

11. FIRE BRICK GROG (0-1mm) THMS OF BF

12. SPCOR-I COKE OVENS

(0-1&1-3.2mm)

Raw Materials Yard :

It is 312 meters long and has capacity to store raw materials for fifteen daysrequirement. Three grab bucket EOT cranes (span-28.5M) are provided for unloadingand loading of different materials. Capacity of each crane is 10 tons (inclusive ofgrab bucket weight of 6.5 tons). The different materials, unloaded in the yard are :

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GATEWAY

1) Kyanite ore

2) Mag-carbon brick bats

3) Fire brick bats

4) High alumina brick bats

5) Basic brick bats

6) Plastic fire clay

7) Coal for CDI of BF

8) Low silica limestone from Jaisalmer

9) Low silica raw dolomite chips from Mandala

10) Hot dolo dust from dust chambers of rotary kilns.

Also following materials are loaded at this yard :

(i) CDI coal for BFs

(ii) Lime - Dolomite dust for use in SPs

ENVIRONMENT CONTROL IN RMP-I :

Dolomite shop :

Two gas-cleaning plants (GCP) have been installed for both the rotary kilns. TheGCP consists of two stage venturi scrubbers in series, followed by centrifugal moistureseparator and radial bladed centrifugal exhaust fan. The capacity of fan is 76,000M3/hr. First venturi acts as a quencher cum primary dust removal equipment. Finalcleaning of waste gas is done in second venturi resulting the stack emission level inthe range of 150 mg/Nm3.

Total 12 numbers of dust extraction systems are installed in dolomite shop havingcumulative installed capacity of ID fans of 1,33,800 M3/hr. These are pulse jet typesystems. Dry dust is sucked through individual ID fan and taken to hopper consistingof number of filter bags and then collected dust is discharged to desired bunkers bymeans of rotary air lock (RAL) system, resulting in fugitive emission level in the rangeof 5mg/Nm3.

Mortar shop:

Mortar shop generates a lot of dust in the process of making mortars. A centralizeddedusting unit has been installed to control pollution. It consists of three nos. of IDfans (capacity of each fan is 1,00,000 m3/hr) and two nos. air compressors of highercapacity, covering major equipments, pits, screens and bunkers etc.

RMP-I is also having one stationary and one mobile industrial vacuum cleaner,which help in keeping different work floors clean.

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REFRACTORY MATERIALS PLANT-II

Refractory Materials Plant (RMP-II) was set up during 4 MT expansion of BSP toprepare and supply the required quantity of Lime, Sintered Dolomite and Tar BondedDolomite Bricks to SMS-II.

It has three main units :

1. Lime Shop

2. Rotary Kiln

3. Brick Shop

1.0 Lime Shop :

1.1 The Kilns :

There are two nos. of identical vertical shaft kilns commissioned in the year1984,with capacity 330 T /DAY for each kiln.One kiln is to make Lime and otherCalcined Dolomite for Converters.

1.2 The process :

Low Silica lime stone of feed size (30-50 mm) or Dolomite having feed size 30-60mm are weighed and charged to skip charging bunker.

The limestone is charged at common service hopper at kiln top, and from thismaterial is fed into kiln shaft. The charged limestone burns in parallel flow, while thecombustion air get heated when passing through column of limestone above theburners. The waste gases are conducted to the other shaft, which pass their sensibleheat to the limestone in the preheating zone. The burning in parallel flow allows avery high heat exchange. The hot flame comes in contact with the crude limestoneavoiding over burning. Final calcination of charge is carried out by waste gases. Limeis soft-burnt. High combustion air temperature and a very favourable fuel consumptionare achieved through regenerative preheating where waste heat is almost completelyutilized.

The two shafts are filled with the charge and connected to each other by achannel. Only one of the shafts is heated by fuel and other is heated by the wastegases coming out through the channel from fuel-heated shaft. Lime is simultaneouslyburnt in both the shafts. At fixed intervals reversal takes place. During reversal, thetwo shafts are alternately charged and burnt lime is continuously discharged fromboth shafts. Since the temperature is high, cool air is blown from below in both theshafts for cooling the product, which is then discharged.

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1.3 Kiln Operation

PARAMETERS OF KILN OPERATION

The operation of MAERZ kiln is characterized by the following parameters:

A) BURNING TIME

B) AIR VOLUME

C) FUEL RATE

D) WEIGHT OF CHARGE

A) BURNING TIME

With a MAERZ kiln the shafts are heated periodically. Fuel is fed always to onlyone shaft (as well as the combustion air), whereas through the other shaft wastegases flow to the stack.

The burning time is the time during which fuel is fed to the shaft, i.e. the timebetween opening and closing of the fuel valves.

The time required for reversing from one shaft to the other is called REVERSINGTIME. This is the time between closing the fuel valve (S) of the shaft which has beenfired last and opening the fuel valves of the following shaft to be fired. Burning timeplus reversing time is called CYCLE TIME.

The adjustment of a determined burning time is by means of the kiln automationby adjusting the Digital Counter.

B) AIR VOLUME

As regards the air volume, we distinguish between combustion air volume andcooling air volume.

Combustion air and cooling air are supplied by volumetric blowers. The controlof the air volume is function of the driving system of the blowers. With MAERZ Kilnsthere are following possibilities.

Combustion air as well as cooling air blowers are driven independently from eachother by motors which.

(i) run only with one speed

(ii) run with determined speed stages.

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Combustion air and cooling air blowers are coupled (pulleys) and are driven bymotors according to item (i). The volume of combustion and cooling air can thus becontrolled by the choice of determined speed stages or by varying the speed of thecontinuously variable speed motor.

C) FUEL RATE:

The fuel admitted is determined by the specific heat consumption of the kiln.The control of the fuel input is affected by adjusting the flow rate of the dozing pumpin case of fuel oil fired kilns, and by adjusting the gas flow control valve in case ofgas fired kilns.

D) WEIGHT OF CHARGE

This is the quantity of limestone charged into one shaft during a reversing period.The weight of charge is determined by the cycle time to be fixed during kilncommissioning.

1.4 Quality (Specification of R/M & Product)

S.No. Che. Compo. Limestone Lime for SMS-II1. CaO 53% (Min.) 88% (Min.)

2. MgO 2.5% (Max.) 4% (Max.)

3. SiO2 1.5% (Max.) 2.5% (Max.)

4. Al2O3 1.7% (Max.) 3% (Max.)

5. L.O.I. 42.5% 6% (Max.)

6. Reactivity - >320 ml with 4 N HCL in 4 min.

7. Sisze 30-50 mm 5-50 mm

2.0 Rotary Kiln :

2.1 Brief description :

There is one Rotary kiln for production of calcined lime for SP-3 Rotary kiln wascommissioned in the year 1985. The capacity of kiln is 200 T/day of calcined limeand other details of kiln are as below :

A. Length of Rotary kiln = 82.5 M

B. Dia of Rotary kiln = 3 M

C. Length of Rotary cooler = 22.5 M

D. Dia of Rotary cooler = 3 M

E. Charging system = by scooping device

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2.2 Principle of working :

Weighed raw material is fed with the help of scooping device and fuel is firedfrom discharge end. Material travels during slow rotation of kiln and heat is transferredto material due to radiation from refractory, final product is discharged into Rotarycooler and after cooling, product is continuously discharged on conveyor belt.

2.3 Kiln operation :

Various operating parameters of kiln operation are :

A. Quantity of feed material.

B. Rotation of kiln.

C. Quantity of fuel.

D. Combustion air volume.

A. Quantity of feed material

Rate of feed material (T/hr) depends on the production rate. It can vary 0-20 T/hr. Feed quantity is weighed by belt weigh system called "Merrick feeder".

B. Rotation of Rotary kiln

Maximum rotation of kiln is 0.9 RPM and it depends upon the kiln production andproduct also. Kiln rotation is more in case of calcinations and lower in case of sintering.More retention time is required for sintered process. Rotation of Rotary cooler is fixed(2 RPM).

C. Quantity of fuel

PCM, C.O. gas & both at a time can be used. Rate of flow of fuel is depending onthe production and process. Duplex burner has been installed to feed PCM or gas.Flue gas after burning, passes through rotary kiln and goes to chimney by naturaldraught or forced draught. ±5 mm WC draught is maintained.

D. Combustion air volume

Two blowers have been installed to supply combustion air for initial firing of fuel(20% of total combustion air). Rest of combustion is supplemented by controllingdraught.

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MATERIAL FLOW DIAGRAM OF ROTARY KILN CIRCUIT

D1 D4

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2.4. Quality : Calcined Lime to SP-3

S.NO. Che.Composition Lime Stone Calcined Lime1 Cao 53.0 %(min) 88 % (min)

2 MgO 2.5% (max) 4 % (max)

3 SiO2 1.5 % (max) 2.5 % (max)

4 Al203 1.7 %(max) --

5 LOI -- 6 % (max)

6 Size 10-35 mm (-) 3 mm

7 Reactivity - 320 ml ( Min.)

3 Brick Shop

3.1 INTRODUCTION :

Brick Shop was commissioned in the year 1985. The main function was toproduce Tar Bonded Dolomite Bricks for converter vessel of Steel Melting Shop No.2.The production of tar bonded dolomite bricks for converter was stopped in the year1987 because of poor life and production of Magnesia-Carbon Bricks started in theyear 1996. Some refractory masses were developed in the year 1990. At presentshop is producing following refractory items which affect cost savings.

S.No. Item/Product Used at1. MagnesiteMass SMS-II

2. Runner Mass B.F.

3. Twin Hearth sleeve SMS-I

4. Well filler Mass SMS I

5. Magnesia Carbon Bricks SMS-II

3.2 MAIN EQUIPMENTS :

S.No. Equipment Nos.1 Hydraulic Press 02

2 Mixer (Planetary type) 02

3 Tube Mill 01

4 Curing kiln 02

5 E.O.T. Crane 01

3.3 PROCESS OF MANUFACTURING OF MAGNESIA CARBON BRICKS :

Manufacturing activities are divided into following steps (as written below) :

a) Mixing

b) Ageing

c) Pressing

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d) Curing

e) Testing

a) Mixing :

Fraction of 2.5-3.5 mm sea water magnesia along with resin are mixed in LAEISmixer for one minute and then lower fractions of sea water magnesia are added andmixed for few minutes in the mixer. Subsequently pitch and graphite powder areadded and thoroughly mixed for required duration of time.

b) Ageing :

After getting homogeneous mix, it is stored for 16-24 hours depending uponweather temperature. In this way resin is better absorbed by refractory ingredientsand this helps in elimination of lamination formation during pressing.

c) Pressing :

Mix so prepared after uniform ageing is pressed at 1400 kgs/cm2 in the available1600 T Russian presses. Cold crushing strength is between 200 to 220 kg/cm2 andbulk density is 2.75 to 2.80 gm/cc in green condition. Neither cracking nor peelingoff of layer is observed. Size is uniform between ± 2mm tolerance. Rejection duringproduction is negligible.

d) Curing :

In order to develop strength these bricks were required to be heat-treated. Inabsentia of tempering furnace it was decided to construct curing furnace with in-house resources and curing technology was decided to get maximum crushing strength.

3.4 TESTING :

Testing & inspection play vital role for success of any product. These bricks aretested Regularly by RCL.

3.4.1 BRICK QUALITY NORM:

1. Apparent Porosity - 4 % (max)

2. Bulk density - 2.9 (min ) gm / cc

3. Cold crushing strength - 400 kgs /cm2 (min)

4. Dimensional check - ±2mm in length & ±1 mm in width & thickness

5. Coked Porosity - 10 -12 %

II) Coked Porosity :

Coked Porosity test is conducted as follows:

A sample is covered with petroleum coke from all sides and kept in a mufflefurnace. It is kept in the furnace for 1hour at 1000 °C. Furnace in then switched off.After natural cooling at room temperature the sample is tested for porosity.

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4. SALIENT FEATURES OF RMP-II :

a) Screening facilities for the limestone have been provided for smooth operationof the shaft kilns.

b) The temperature of the waste gases coming out of the lime shaft kiln is lessthan 150 °C.

c) All the raw materials and products are transported by means of belt conveyorsand there is no storage yard separately for RMP-2 adjacent to the shop.

d) In-house development of curing kiln for MgO-C bricks.

e) Modification of Rotary burner : burning of C.O. gas, PCM & both.

In-house developments / Achievements.

a) Developed many refractory items as written below :

* Runner Mass.

* Well filler Mass.

* Mag-C bricks.

* Twin hearth Sleeves.

* Magnesite Mass.

b) Enhanced the production of lime kiln (330 T/day to 410 T/day).

c) Commissioning of Duplex burner at Rotary Kiln.

d) Record life of 6252 Converter Heats with in-house produced Magnesia Carbonbricks. in the year 2006-07.

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REFRACTORY ENGINEERING DEPARTMENTThe main function of Refractory .Engg. Deptt is to ensure adequate & desired

availability of metallurgical units of the whole plant, except Coke Ovens, to meetproduction plan, such as furnace and ladles etc in time with proper quality & reliability.There are two wings of the department, RED-I & RED-II. RED-I takes care the refractorymaintenance of 2.5 MT area including Blast Furnace & Stoves etc. RED-II looks afterthe expansion units under 4.00MT area.

The function of the department is as given below.Refractory Engineering Department-I

Brick Laying Section (BLS)

a) Furnace Repair Shop: FRS is responsible for maintenance & repair of TwinHearth furnaces. Hot metal mixer of SMS-I, Rotary Kiln & cooler of RMP-I. HotMetal Chute & bottom pouring, refractories.

b) Ladle Repair Shop: LRS is responsible for repair and relining of teeming ladles &launders. Tap hole repair of Twin Hearth Furnaces, slag runner and ladle coversetc.

c) General Refractory Maintenance (GRM) : GRM is responsible for repair &maintenance of Soaking Pits, Reheating Furnaces of Rail Mill, Merchant Mill,Wire Rod Mill, Hot Metal Ladles of Blast Furnaces, SP-I & SP-III machines,Auxiliaries like cupola, heat treatment furnace, forging furnace, AnnealingFurnaces, electric arc furnaces, tap hole & monkeys repair of Blast Furnaces.

The quantity of work involved is of order of: -

a) FRS: About 20,000 tons of shaped refractories & 160 tons of granularrefractories per year.

b) LRS: About 13,000 tons of shaped refractories & 4500 tons of granularrefractories per year.

c) GRM: About 6500 tons of shaped refractories & 3500 tons of granular per year.

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Capital Repair Refractories (CRR)

CRR is mainly responsible for capital repair of Blast Furnaces & Stoves. It alsotakes repair of twin hearth furnaces.

When Blast Furnace repair is not going on, this crew works in different areas ofthe department wherever is needed e.g. Soaking Pit and RED-II area.

Blast Furnace capital repair tonnage is in order of 2300 tons to 3600 tonsdepending upon the size and category of blast furnaces & stoves consumption variesfrom 2800 to 3800 tons depending on size of stoves:

Stove (1-9) - Per stove / 3000 tonsStove (10-17) - Per stove / 2800 tonsStove of BF-7 - Per stove / 3800 tons

Consumption of granular refractories is about 200 tons / year

MECHANICAL SECTION (RED-I)

1. Processing the indents & work orders for various consumable items & spares.

2. Maintains the tools & equipments used for repair work of different sections ofBLS (RED-I) e.g. Belt Conveyors, Mortar Mixers, Diamond brick cutting machinesetc.

The section has a well-equipped mechanical workshop consisting of lathes, drillingmachines, shaping machines etc to manufacture spare parts required for theequipments so that the dependence on engineering shops and local industries arereduced. It also has a fabrication wing to fabricate scaffoldings etc.

Section has a good automobile crew, which carries out maintenance and overloadtesting of BEML Excavators, Forklift trucks, Diesel Engine, Batteries etc. The workingis oriented to effect substitution by modifying various imported spare parts, to reducedependence on imports.

PLANNING & PROCUREMENT SECTION (RED)

(Common for RED-I & RED-II both)

1. Plans the procurement of various refractory bricks for the whole plant.

2. Advising refractory stores for proper storage of all the refractory items. Thereare over 800 makes varying in shapes, size, quality and specification. Eachmarks being lakhs of pieces for use all over the plant.

3. Up gradation of specification & implementation of newer generation ofrefractories to achieve better life & better techno-economics.

4. Study and rationalization of shapes, sizes & specifications of range of refractoriesused in different steel plants of India.

5. Computerized monitoring of receipts, issues and consumption, release, stock &order balance of various brick marks.

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REFRACTORY ENGINEERING DEPARTMENT-II

Total consumption of refractories is of the order of 20,000 MT/Year of shapedbricks & 8400 tons / year of granular refractories.

RED-II is mainly responsible for repair & maintenance of 4.0MT area. It has gottwo main sections as given below: -

1. Brick laying Section:

It is responsible for repair & maintenance of 130 Ton converters & 130 Tonssteel ladles, Hot metal mixers of SMS-II, VAD heat shield, R.H.Degasser, Hot metaltransfer ladles, transfer cars, slag pots, tundishes, containers etc.

This crew is also responsible for repair of Reheating furnaces of Plate Mill,Normalizing Furnace, Rotary Kiln & Lime Kiln of RMP-II & SP-II Machines.

2. Mechanical Section :

The section is processing the indents & work orders for consumable items &spares for RED-II.

The section maintains equipments like Belt conveyors, Pn hammers, Mortar mixers,Diamond brick cutting machines, Jacks for RMP-II Kiln repair & other equipments etc.

The automobile crew of the section maintains the rock brackers, forklift trucks,tap hole drilling machine of converter and other equipments as required by RED-II forrepair work.

Forklift trucks of SMS-II & RMP-II are also maintained by RED-II Mechanicalsection. The section also has a small machine shop like RED-I Mechanical for makingessential & necessary spare parts required by the section.

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MATERIAL RECOVERY DEPARTMENTAN OVERVIEW

Material recovery department is primarily concerned with the recovery of scrapfrom the various areas of the plant for use in melting at SMS-I & II and sale assecondary products. Beside this it also contributes in steel making process byfacilitating empty thimbles after slag dumping and slag handling in its slag yards.Among multifarious activities the sale of secondary product and scrap from Boria andStructural area bear imminent importance. The operations of the yards/sections arecarried out in 10 different locations, diversely spread out in the extreme periphery ofthe plant. The various sections are as given below:

1. Slag Yard-I

2. Open Slag Yard

3. Slag Yard-II

4. Flame Cutting Yard

5. New Skull Breaker Yard

6. Scrap Processing Yard

7. Boria-Complex (Secondary Product Area)

8. New Open Hearth Muck Dump)

9. Blast Furnace Slag Dump Area

10. NSBY (FSNL area)

11. Structural-8

12. Scrap Collection

The working of the yards/sections is enumerated as given under:

SLAG YARD-I:During the process of Steel making, slag generated at SMS-I is collected into slag

pots (thimbles) and is brought in this yard. After thimble dumping, a thin layer of limecoating is done in the empty thimbles to minimize sticker generation and it is provided toSMS-I for further collection of steel slag. Sticker thimbles from SMS-I are also releasedhere with the help of EOT Cranes. Slag is loaded on dump cars after cooling and is sentto muck dump for disposal. Generated skulls, pit jams and scrap pieces are loaded on flatwagons and are sent to Muck dump for processing by FSNL/NSBY etc.

OPEN SLAG YARD:Slag thimbles of SMS-II are dumped at Open Slag Yard. Liquid slag gets emptied

& residual like solid/semi-solid slag thimbles are sent to Slag Yard-II. Also, in this yardrecycling of LD Slag (Slag generated in Converter is called LD Slag) is carried out toenhance solid waste utilization. Crushing and screening of LD Slag is done in thisyard by FSNL. The recycled LD Slag is mainly used as a substitute of lime stone atSP-I & II and Blast Furnace and raw dolomite at SMS-I.

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SLAG YARD-II:

Slag thimbles of SMS-II, after partial dumping at open slag yard, are brought inthis yard. After thimble dumping, a thin layer of lime coating is done in the emptythimbles to minimize sticker generation and it is provided to SMS-II for further collectionof steel slag. Sticker thimbles from SMS-II are also released here with the help ofEOT Cranes. Slag is loaded in the dump cars and is sent to open slag yard for recycling.Generated skulls, pit jams and scrap pieces are loaded on flat wagons and are sent toMuck dump for processing by FSNL.

FLAME CUTTING YARD:

Light scrap & wear scrap from all over the plant is brought into this yard thoughwagon and trucks. Scrap is processed in to chargeable size by gas cutting & sent toSMS-I through wagons for melting.

NEW SKULL BRAKER YARD (NSBY):

Rejected moulds & bottom plates, sticker molds from SMS-I; tundish skull,emergency container scrap, small jam pieces from SMS-II; defective moulds/ bottomplates and chills from Foundry are received in this yard. After processing intochargeable size by balling & oxygen lancing, scrap is sent to SMS-I through wagonsfor melting.

SCRAP PROCESSING SHOP:

Slag thimbles from ladle repair shop of blast furnace are dumped/ released hereby knocking operation with the help of EOT cranes. Generated iron skulls are processedinto chargeable size by balling and are sent to SMS-I by wagons for melting. Biggersize skulls are sold to private parties as per the release order issued by the marketingdeptt. Slag is loaded on dump cars and disposed at specified area of BF dump post.

BORIA COMPLEX (SECONDARY PRODUCT AREA)

Secondary products from mills and scrap items such as defective/ rejected/ mis-rolled, end cuttings are sold from Boria yard as per the delivery order issued by themarketing deptt after on line forward auction. Other items like mill scale, turning &borings, used refractory bricks steel rolls are also sold from this yard with the sameprocedure.

NEW OPEN HEARTH MUCK DUMP:

Heavy scrap (i.e heavy Ladle skull, Ladle Bottom, long jams, thimble stickers,etc) generated from SMS-I, SMS-II are sent to NOHMD through wagons. M/S FSNLrecovers & processes the scrap into chargeable size and sent back to SMS-I bywagons for melting.

Slag generated in SMS-I is also sent to NOHMD through D/Cars for dumping.FSNL also recover the scrap from this slag & after processing, sent it back to SMS-I. Other muck, debris etc generated in the Plant are also dumped here.

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BF Dump post:

Slag thimbles from blast furnaces are received in this area. Unprocessed blastfurnace slag is sold to private parties through marketing sale orders whereas BF Ironscrap recovered from the slag is sold through a sales contract.

NSBY (FSNL) AREA:

M/S FSNL has been assigned the job of processing of scrap in the followingcategories from this area, under a long term agreement:

WEAR SCRAP: The type of wear scrap, which is difficult to be processed in MRDyards, is processed by FSNL here and sent to SMS-II for melting by road.

RSM/BBM COBBLES: Cobbles of RSM (from line no.173) & BBM are transportedfrom the generation points of these mills & unloaded at NSBY (FSNL) area. Afterprocessing by gas cutting, into chargeable size, the scrap is sent to SMS-II for meltingby road.

SLAB CUTTINGS: End cuttings of slabs are brought to NSBY (FSNL) area & afterprocessing into chargeable size are sent to SMS-II for melting by road.

OH SCRAP: Jams, Small Skull which are difficult to process in MRD yards are processedby O2 lancing at 482 T area into chargeable size & sent to SMS-II for melting byroad.

STRUCTURAL-8 :

BF Iron Scrap, Unprocessed blast furnace slag, CI Skull etc. are sold to out sideparties as per the release order issued by the marketing deptt from Structural-8.

SCRAP COLLECTION

To maintain smooth operation of Mills area such as BBM, RSM, MM and WRM,scrap and secondary products are collected and unloaded at Boria complex & Disposalstore for sale, through contractual agency. In addition to it, for better house keepingof the plant premises, unserviceable equipments, unusable spare parts and otherscattered scrap pieces are collected from various deptts of the plant and processedinto chargeable size used in melting for SMS-I & II.

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BLOOMING & BILLET MILL

Blooming & Billet Mill popularly known as "Mother Mill", is a primary mill designedto roll 2.5 MT/ Annum of ingots into semies in the form of blooms & billets. A twohigh reversingblooming mill and 12 stands continuous billet mill are part of thisdepartment. The 1150mm two high reversing Blooming Mill is designed to roll steelingots into blooms for Continuous Billet Mill and Rail & Structural Mill. Average weightof steel ingots which are used for rolling is 8 to 9 Ton. Major sections are describedbelow :

SOAKING PITS

Heating of the ingots and soaking at a particular temperature is done in thesoaking pits. There are 14 groups of recuperative type soaking pits. Each groupconsists of 2 pits. Each pit is heated bytwo burners situated diagonally oppositein the upper part of the lateral wall ofthe pit. The fuel burnt is mixture of cokeoven gas and blast furnace gas with acalorific value of 1600 KCal./Cu.M. Airis preheated in ceramic recuperators andthe gas in the metallic recuperators. Theingots are placed in the pits in such away so that proper circulation of theflame around the ingot is ensured.

Generally 16 ingots are placed in onechamber at a time. Strict records aremaintained to avoid mix-up. After 4th to5th round of rolling, cleaning of the pit is done by scrapper bar held by the tongscrane and bottom is made with two buckets of Coke Breeze. Out of the 28 pits(14x2), 25 to 26 pits are under operation depending on requirement and the balanceare under repair/reserve.

Operational data of Soaking Pits

Dimensions of the pit

Length : 6.7m

Width : 4.2m

Depth : 4.5m

Soaking temp. : 1300 °C

Pit pressure : + 0.2/0.3mm w.c.

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BLOOMING MILL

The heated ingot are placed on the ingot buggy (two ingots at a time) by meansof tongs crane which delivers it on to the receiving roller table of Blooming Mill.

The Blooming Mill is a 2-High horizontal stand, equipped with individually drivenrolls. Each roll of the Blooming Mill is driven by 930 V, 8000 KW, 0-20-80 rpmmotor.

Length of Roll - 2800 mm

Dia. of Roll - 1150 mm (Min.1100mm & Max.1180mm)

Rolls are used in pairs. Each roll set is ground with the required pass design (4including the shaped beam pass). After rolling of about 1 lakh ton, the rolls arecharged. The used rolls are sent for redressing in Roll Turning Shop. After redressingthey are assembled and reused.

The Top Roll is balanced by counter weights. It is moved up and down by screwdown mechanism driven by two motors mounted on the top of the stand. There aremanipulator side guards on both sides of the Roll stand. This is to manipulate therolling stock on to the required pass section of the roll. Tilters are fitted in the frontmanipulator for tilting the rolling stock whenever required. The total rolls from ingotto bloom is done in 11 - 17 passes.

After rolling, the bloom proceeds to the shear where the front and back ends arecropped off to eliminate defects and the bloom is cut into required length. Bloomsintended for further rolling in Billet Mill are sent directly after cutting the front andback end. The shear is of the up-cut crank shaft type with maximum cutting force of1000 Ton and operating speed of upto 10 cuts per minute. Crop ends are pusheddown and conveyed to crop pit for cooling.

The Mill can roll square and rectangular blooms and also narrow width slab.Common Sizes of Blooms and Narrow Width Slabs

i) 320 x 320 mmii) 265 x 340 mmiii) 260 x 300 mmiv) Shaped blooms for Beam-450mm & Beam-600mmv) Narrow Width Slab 200 x 320 mmvi) Narrow Width Slab 200 x 420 mm

BLOOM STORAGE

Blooms assigned for Rolling in the Rail & Structural Mill and requiring inspectionand conditioning are transported hot, by 15 ton over-head cranes and stacked inspecified areas depending on quality of steel.

BILLET MILL

The Billet Mill has been designed to roll billets from blooms of cross section325x325 sq.mm in 6 to 12 passes depending on cross section of billets to be producedin the Mill. The capacity of the Mill was designed to roll 15,01,000 Tonns/Year. But

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with modified output size of billets the mill is now capable of rolling to million tonnesper year

The Mill consists of 12 working stands arranged in three groups.

a. The First group contains Two 2-High Horizontal stands with a 90 deg. tilter inbetween. These stands are equipped with rolls of diameter 1000mm and length1200mm.

b. The Second group called the roughing group contains 4 stand - 2 each ofHorizontal and Vertical stands arranged alternately. These stands are equippedwith rolls of diameter 700mm.

c. The Third group called the finishing group located after the transfer table contains6 stands - 3 horizontal and 3 vertical stands arranged alternately. These standsare equipped with rolls of diameter 500mm.

Rolled billets after the roughing group of stands which are not to be rolled furtherare transported by transfer table and by pass roll table to the stationary 800T shearwhere they are cut into required length. The billets are gathered and transported tocooling bed by roll tables.

Billets from roughing group intended for further rolling in finishing group aretransfered to the last group of stands. If necessary, the front end of billet can becropped off by 250 T shears installed in front of the group.

After rolling in the finishing group, the billets are cut by flying shears into billetsof length 5 to 12m. End arisings are controlled by a computer installed in the Mill.

After cutting, the billets are transported to cooling beds by roll tables and transferskids.

SECTION OF BILLETS ROLLED ARE

1. 150 x 150 mm 2. 110 x 110 mm

3. 105 x 105 mm 4. 100 x 100 mm

5. 90 x 90 mm

MILESTONES OF BBM

- COMMISSIONING : 12th NOV'59

- AUGMENTATION OF RATED : OCT'67CAPACITY TO 2.5 MT

- CHANGEOVER OF BILLET : APR'75MILL INPUT SECTION TO325 x 325 MM²

- INTRODUCTION OF EXTRA : OCT'76PAIR OF S/PITS

- REPLACEMENT OF MAIN : JUN'86DRIVE MOTORS OF 1150MM STAND

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- REPLACEMENT OF 10 T : JUL'90CAPACITY TONGS CRANENO. 7 & 8 WITH 20/50TCAPACITY CRANE

- EXTENSION OF RECEIVING : JUL'91ROLL TABLE

- THYRISTORISATIN OF : OCT'94MAIN DRIVE

- ISO-9002 CERTIFICATION : FEB'97

- PRODUCTION

A. COMPLETION OF 25 MT : MAR'76

B. COMPLETION OF 50 MT : JUN'88

C. COMPLETION OF 75 MT : 10th AUG'99

D. RATED CAPACITY EXCEEDED : TWICE

IN BLOOMING MILL : 2003-04 - 2521740 T2005-06 - 2585490 T

IN CONTINUOUS BILLET MILL : 2003-04 - 2018065 T2005-06 - 2018865 T

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PLATE MILL

With the commissioning of 3600 mm Plate Mill under 4 MT expansion programme,Bhilai has entered into the area of flat products in a big way. This giant rolling millcomplex which extends to over a kilometer in length has an overall covered area ofabout 15680 m². It consists of six main bays; 1-3 bays of span 36 meters each, 2bays of span 30 meters each and one bay of 18 meters span, also, two open gantriesfor scrap removal. The mill is intended for an annual production of 0.95 million tonnesof finished plates in 5600 operating hours. The thickness of the plates range from 5-120 mm. It is called 3600 mm Plate Mill because the barrel length of the work roll is3600 mm.

Continuously cast slabs in the length range of 5.6-10.2 M are delivered in hotcondition to the slab yard. These slabs are cut to smaller lengths in 3 non flamecutting machines as per requirement. Inspection and conditioning is carried out aftercutting of the slabs to the required sizes. Inspected slabs with proper identificationare supplied to Plate Mill.

The sequence of operations are : Slab heating, descaling, rolling, levelling, cooling,inspection and shearing to required size. Heating of slabs is done in three continuousdouble row pusher type furnaces with an estimated capacity of 120 T/hr each. Thesefurnaces have five heating zones : Soaking Zone, top and bottom preheating zone,top and bottom heating zone. The soaking zone has a flat roof with sixteen smallcapacity vertical burners through the roof. The other four zones have six burnerseach. Mixed gas of calorific value 2500 K cal/cum is used as a fuel. In time of gasshortage, provision for oil firing is also there in the four zones, heating and preheatingzones. Air for combustion is supplied by individual blowers. This is preheated inmulticellular cross paralled flow type of metallic recuperators. The slabs move onskid pipes in the heating and preheating zones and over a solid hearth in the soakingzone. The skid pipes are cooled by evaporative cooling system instead of theconventional water cooling system. The solid hearth in the soaking zone is made ofelectro cast corundum blocks.

Programmed slabs from the slab yard are placed by the means of overhead craneof the lifting and lowering table. The slabs are pushed one by one on the chargingside roller table. The slabs are positioned with respect to the furnace skids with thehelp of movable hydraulic stopper. They are pushed in to the furnace in cold conditionfor heating up to the required temperature. The first slab on the delivery side ispushed to pre-determined position by the pusher and then it is extracted by shockfree slab extractors.

Heated slabs are passed through the Hydraulic descaler. Here the scale formedduring the process of heating will be washed off by means of water spray at apressure of about 150170 atm. The sprays impinge on both top and bottom of the

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slab. Additional hydraulic descalers are also provided in the stands.

The rolling complex consists of one reversible vertical edger, one reversible fourhigh roughing and one four high reversible finishing stand. The vertical edger placedbefore the roughing stand helps in the production of plates with good edges. Thisensures minimum side trimming losses and increases net yield. The vertical edger isdriven by two 1800 KW motors placed on top of the stand itself.

The roughing and finishing stands are made of stationery closed top roof housings.These are designed for a maximum rolling force of 4500 tonnes. The working rolls ofthe roughing and finishing stands are driven by two 4000 KW and two 6300 KWmotors. The maximum speed of rolling in these stands are 3.5 m and 6 m/secrespectively. Back-up rolls are not power driven. They rotate due to friction. The rollsand spindles are balanced hydraulically. Working rolls are mounted on conventionalroller type bearings. Backup rolls are mounted on oil film bearings. Since the housingsare of closed top type, roll changing is carried out through the sides. The rolls arepushed in and out by electrically driven carriages and roll changing is effected by atraverse attached to the over head crane. Since the weight of back up roll, chocksand traverse is around 300 tons, a 320 ton crane with motorised hook rotation isprovided in the mill bay.

Heavy plates (63-120mm) are finished in the roughing stand and they are drawnaway from the rolling line to the heavy plate bay with the help of transfer cars. Theseare cooled and then cut to required size by flame cutting machines.

Lighter plates (5-60 mm) are rolled to the required thickness in the finishingstand. After rolling the front and back ends are cut using the hot crop shear, which isa cross cut shear with a cutting force of 1250 T is of down cut type. The shear canalso be used to cut the plate into two pieces so as to accommodate them in thecooling beds. The crop ends are further cut into small pieces by a crop shear and areremoved by the crop conveyor to the crop hopper.

After hot shearing the plates are levelled, cooled, inspected and cut to requiredwidths and lengths. Levelling is also done by roller type levellers with small workingrolls supported by back-up rolls. Lighter gauges (5-20mm) cools fast and hence theyare levelled at leveller-1 placed immediately after hot shear. Heavier gauge plates(21-60mm) do not cool faster and hence these are levelled at leveller-II placed afterthe hot transfer bed. This process also helps in reducing the internal stresses devel-oped during rolling.

For accurate cooling to the desired levelling temperature, spray coolers are keptimmediately after finishing stand . This reduces secondary scale formation resultingin improvement of the plate surface.

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After levelling the plates are cooled in grid type cooling beds with special liftingchains. The plates are lifted by this hydraulic lifting chains and are moved along thecooling bed. This will ensure a scratch free surface of plate. After cooling the platesare transferred to the inspection beds. The inspection beds are provided with tiltersso that underside of plates can be inspected easily. Plates having surface defects arerectified during the normal movement on inspection bed by using high frequencygrinders. However on special demand from the custormer ultrasonic testing is alsocarried out at the inspection beds.

Shearing of plates is done in two shearing lines.

Shearing line 1 consists of

1. Guillotine Double side trimming shear for 5 - 40 mm thicknesss plate

2. Cross cut shear for 5 - 40 mm thickness and to required length (2.5 to 15 mtrs)

Shearing line 2 consits of

1. Disc type Side trimming Shear for side trimming of plates upto 20 mm thickness

2. Disc type Slitting Shear for cutting of plates which are rolled to double theirrequired width and thickness upto 20 mm

3. Cross Cut Shear for 5 - 40 mm thickness. Both the cross cut shear are identicalin nature.

Medium duty shearing line also contains three shears. It contains double cutedge trimming for side trimming and shear for slitting of plates. A slumber type ofcross cut shear is provided of cutting required lengths. Scrap generated by the sidetrimming shears in both the lines is transferred to the open gantry for removal. Scrapfrom the cross cut shear is further cut into small pieces and collected in a scrap box.After shearing the plates are sent to plate pilers and to the shipping bay. Paint markingon the plates are being done before shearing operation whereas cold stamping isdone after shearing.

Finally finished plates are piled in pilers and transferred to despatch section.Plates requiring heat treatment are sent to the normalising section. The heat treatmentarea consists of a roller hearth type normalising furnace, cooling bed, levelling andcross cut shear.

PRODUCT MIX

A. Input sizes of slabs are :

200 x 1300

200 x 1500 length from 1800-3350 mm

250 x 1500

Depending on the order position sometimes 320 x 1500 mm size is also beingused.

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B. Plates sizes produced are :

Thickness : 07 -120 mm

Width : 1500-3200 mm

Length : 4500-12500 mm

C. Grades produced are :

Boiler qualityIS 2062 : ASTM/ASME-A/SA-515 Gr. 60, 70

Gr I,II,III ASTM/ASME-A/SA-516 Gr. 60, 70

ASTM/ASME-A/SA-285 Gr. "C"

DIN 17155, Atmosperic Corrosion Resistance Steel

IS 2002 : Gr I, II & III

High tensile : SAILMA, 300, 350 HI, 410 HI, 450 HI

IS-961Fe

540, HTW IS-

961 Fe 570,

HT DIN

17100 ST

52.3 Gost -

5521

NCD, API X 52, 60, 65, 70

DMR 49A, SAIL HiTen, Fire Resistance Steel

Mild steel : Mild steel quality plates are being produced

To different Indian and International specifications

Ship building : SBQ Lloyd Gr. A

Quality ABS Gr. A

SALIENT FEATURES

Cost of construction : Rs 800/- crores(Approx.)

Capacity : 950,000 T/year

Length : 1056 meter

Width : 256 meter

Mech Equipments : 76,452 T

Elect Equipments : 35,200 T

Date of commissioning : 29th March 1983

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TECHNICAL SPECIFICATIONS

1 Reheating furnace

a. Number : 03

b. Type : Five zone pusher type continuous slab

reheating furnaces

c. Capacity : 120 T/hr

d. Width : 7700 mm

e. Length : 28000 mm

f. Charging rows : 2 in each furnace

g. Fuel : Mixed gas (CO+BF), 1:1 CV = 2500 K cal

cum Oil with low sulphur content

h. Number of burners : 56

* Bottom preheating zone : 6

* Top preheating zone : 6

* Bottom heating zone : 6

* Top heating zone : 16

* Soaking zone : 16

* Extractor slots : 6

i. Pressure in header-DAS = 400 - 800 mm wc

2 Hydraulic descaler

a. Pressure of water in : 135-160 Kg/cm²hydraulic system

b. Pressure of air in : 4-6 Kg/cm²Pneumatic system

c. No. of jets : Top header = 15Bottom header = 15

3 Vertical stand

a. Rolling speed : upto 3.5 M/sec

b. Work roll dia : 1000 (Max)/900(Min)mm

c. Barrel length : 1150 mm

d. Roll separating force : 950 T max

e. Roll drive : 2 Nos motors 1800 kw each

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4 Levellers

# PARTICULARS LEVELLER LEVELLER1 & 3 2

1 Plate thickness 05-20 mm 21-40 mm

2 Levelling temp. 600-800°C 600-800°C

3 Work Rolls 5 pcs 7 pcs

Diameter 300 mm 500 mm

Barrel length 3600 mm 3600 mm

4 Backup rolls 10 pcs 14 pcs

Diameter 340 mm 640 mm


5 Horizontal stands

# PARTICULARS ROUGHING FINISHINGSTANDS STANDS

1 Rolling speed(max) 3.5 M/sec 6.0 M/sec

2 Roll separating 4500 T 4500 Tforce (max)

3 Work Rolls

Diameter(max/min) 1120/1050mm 1120/1050mm


Balancing Hydraulic Hydraulic

Drive (kw) 2x4000 2x6300

4 Backup rolls

Diameter(max/min) 1900/1800mm 1900/1800mm


Balancing Hydraulic Hydraulic

5 Shearing lines

# PARTICULARS LINE No-1 LINE No-2

1 Double side Trimming shear

a. Type Guillotine Rotary

b. Dimension of plates

Thickness 05-40 mm 05-40 mm

Width before cutting 1050-3450mm 1050-3450mm

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Width after cutting 1000-3200mm 1000-3200mm

Length 05-30 M 05-30 M

c. Mech properties(max)TS=80 kg/cm² TS=80 kg/cm²

d. Max shearing force 1000 T

2 Slitting shear

a. Type Rotary

b. Max shearing force 1500 T

c. Width before shearing 1000-3200mm

d. Width after shearing 0900-1600mm

e. Mech properties TS=80 kg/cm²

3 Cross cut shears

a. Type Guillotine Guillotine

b. Dimension of plates

Thickness 05-40 mm 05-20 mm

Width 3200 mm(max) 3200 mm(max)

c. Mech properties TS=80 kg/cm² TS=80 kg/cm²

d. Max shearing force 1500 T 1500 T

# PARTICULARS LINE No-1 LINE No-24 Normalising furnace

a. Type Roller Hearth Continuous

Normalising furnace

b. Dimension

Length 72 M

Width 3510 mm

c. Hearth Rollers

Quantity 144 Nos arranged in 8 groups

Linear speed 15-20 mm/sec

Drive Chain drive, Elect motor-7.5 kw

d. Max temperature 950°C at 9th zone

e. Capacity 35 T/hr (for 25x1888x8000 plates)

f. No of heating zone 9

g. No of burners 117

h. Fuel Mixed gas (CO+BF in 1:4 ratio)

CV = 1500 K cal/cum

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ACHIEVEMENTS & HIGHLIGHTS

- Production of 10 MT of finished plates. (by Dec 01)

- Export of 3 MT of finished plates. (till Dec 01)

- Achievement of 88.91% ever best yield (July 02) and going up further.

- Lubricant consumption reduced to 1466 barrels per year from 1536 barrels.

- Achievement of ever best specific fuel consumption of 593 M Cal/T. (July 02onwards)

- Certification of ISO:9000 Quality Management System.(Dec 94)

- Certification of ISO:14001 Environment Management System. (July 99)

- Production of 7.1 mm thick wider plates.

- Increase in production of special steel by 35 % of the total production.

- Saving of 50 crores in power consumption through various energy conservationmeasures since inception.

- Hot charging of slabs in July 01.

- Commercial production of API 5Lx60/65 grades of plates.

- Successful trial production of API 5Lx70 grades of plates.

- Supply of Boron Quality Plates to International Market.

- Development and supply of normalised rolled, Temperature controlled rolled,and controlled cooled plates to home sales and international market.

- Supply of ultrasonic tested chicker plates in the market :

* Mild steel upto 80 mm thick.

* Boiler Quality and high tensile upto 60 mm thick.

- Development and commercial supply of ASTM A 537 C1-I and BS-1501-224Gr. 490 A LT-50 grades of plates in the market.

- Major and regular exporter of plates in SAIL.

- Achievement of mill diversion equivalent to International standard. (below 1.5%)

- Minimum power consumption for such type of Plate Mill.

MAJOR MODIFICATIONS- Thyristorisation of vertical stand.

- Conversion of mech pusher before cross cut shear into hydraulic pusher.

- Modification of lubrication system of reheating furnace blower providing individuallubrication system.

- Conversion of crane no. 23 from hook type to magnet type.

- Replacement of all USSR made hydraulic distributors by German made distributors.

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- Modification of pilers from mech. drive into hydraulic drive for its lifting mechanism.

- In-house development and commissioning of hot reserves for various roll tablesof Plate Mill.

- Provision of width digital display in CP-8 for measuring post to achieve betterwidth control.

- Modification of Cold Punching Machine line No. 2 by providing compressednitrogen supply as an additional source of energy.

- Development, fabrication and installation of rescue ladder for roof top of Plate Mill.

- Revamping of crane nos. 30, 31, 27, 26 & 20.

- Provision of water U-seal in the gas pipe line of normalising furnace for gas safety.

- Reduction of noise level in reheating furnace no. 3 by providing acoustic panels.

- In-house repair of nine stage high pressure pump of P.A. station for descaling.

- In-house development of high pressure discharge pneumatic operated grease pump.

- In-house development of circulatory oil system in Cumbustion Air Blower

- Development of line filtering system to improve quality of lubricating oil of OilSystem-5

- Modification of chute of rotary side trimming shear.

- Desiging and implementing cascading system of drives for transmissing device,transfer beds to avoid breakdowns due to chain failure.

- Installation of 3 nos of CCTV cameras to monitor the scrap movement in trimmingshear conveyors & at exit side of finishing stand for profile control.

- In-house development of hot reserve facility for furnace extraction drives.

- Design and implementation of improved transversal plate sensor and sensorplate of Lo:117

- Development of dedicated 3 KW ventilation system in place of 75 KW forleveler 2

- Provision of Low voltage (145 V) to armature of 18 nos charging side roll tableoperating on 220 V DC

- Slow speed scheme in conveyor under cross cut in normalizing area.

- In-house installation of Electric magent at Crane No. 8

CHRONOLOGY (PLATE MILL)

- 1972 : Signing of contract with V/O TPE

- August 1975 : Start of foundation work

- March 1983 : Lighting up of reheating Fce No 3

- 29th March 1983 : Rolling of first plate

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- 4th February 1984 : Start of shearing line-1Dedication of Plate Mill

- March 1984 : Lighting up of reheating Fce No 2

- 27th March 1985 : Starting of normalising Fce

- 28th August 1985 : Starting of shear line-II

- November 1985 : Lighting of reheating Fce No 1

- September 1986 : Start of export

- August 1988 : Commissioning of hot stamping m/c

- March 1990 : Commissioning of paint marking m/c

- 29th July 1993 : Commissioning of cold stamping m/c

- December 1994 : ISO-9002 Certification

- June 1995 : Production of controlled cooled plate

- June 1996 : Production of normalised rolling plate

- October 1996 : Production of TCR rolling

- February 1998 : Commissioning of cold stamping m/c-2

- July 1999 : ISO-14001 Certification

- April 2000 : Production of 3 MT of export plates

- May 2001 : Commercial production of APIx60/65 plates

- July 2001 : Hot charging of slabs

- December 2001 : Production of 10 MT of finished plates

- 4th July 2002 : Thyristerisation of vertical stand drives

- Oct 2003 : Comm. of PLC base control in RH Fce 1 & 3

- March 2004 : Production of 1 MT of finished in one year. (1.04)

- Dec 2004 : Production of DMR249 Gr.A plates for Indian Navy

- 30 March 2006 : Commissioning of On Line Ultrasonic machine

- April 2006 : Production of ATM safe plates

- June 2006 : Production of fire reistance quality plates

- 18th Nov 2006 : Commissioning of HAGC & PVR

- Nov 2006 : Production atmospheric corrosion resistance plates

- March 2007 : Ever Best production of finished plate 11,38,207 T

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RAIL AND STRUCTURAL MILL

Rail and Structural Mill of Bhilai Steel Plant, SAIL is the world's largest producerof rails with an installed capacity to produce 500,000 tons of rails and 250 000 tonsof structurals. Bhilai is also the sole supplier of the country's longest rail tracks of260 metres. The length of rails produced so far since inception is sufficient to encirclethe globe more than 8 times.

The major profiles produced in the mill are:

1. RAILS 4. ANGLES

a. IRS 52 Kg/m a. 200 * 200 * 20/16 mm

b. UIC 60 b. 150 * 150 * 20/16 mm

c. Thick Web Asymmetric Rail Zu1-60

2. HEAVY BEAMS 5. CRANE RAILS

a. 600 * 210 * 12mm a. CR 120

b. 500 * 180 * 10.2 mm b. CR 100

c. 450 * 150 * 9.4 mm c. CR 80

d. 400 * 140 * 8.9 mm

e. 350 * 140 * 7.5 mm 6. CROSSING SLEEPERS

f. 250 * 125 * 6.9 mm

3. CHANNELS

a. 400 * 100 * 8.8 mm

b. 300 * 90 * 7.6 mm

c. 250 * 82 * 7.6 mm

The steel grades produced in these products are:

Rails:

IRS T-12/ 96 Grade 880 (90 UTS)

Cu Mo corrosion resistant rails

High Conductivity Metro Rails

High YS/UTS Vanadium Micro-alloyed Rails

Copper-Chromium alloyed High strength Rails

Heavy Structurals:

IS 2062 Grade A & B

SAILMA 300,350,410(with & without Hi)

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II) PROCESS FLOW AT RAIL AND STRUCTURAL MILL:

I) STEEL INPUTS OF RSM:

The Rail Steel making process at Bhilai Steel Plant is one of the most advanced.Rail steel is made in BOF converters at SMS 2 and processed through RH degasserand ladle furnace etc. The steel thus obtained is very clean and has hydrogen in liquidsteel less than 1.6 ppm a world benchmark. It is continuously cast into blooms,which are flame cut to specified length & weight, and sent to Rail and Structural Millfor rolling. Steel for structurals is made at SMS 1 in twin hearth furnaces and is castinto ingots, which are rolled into blooms at the blooming mill.

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III) ROLLING MILL AREA

It constitutes of the following areas:

1. Reheating furnaces

2. Roughing Stand

3. Intermediate Stands

4. Finishing Stands

5. Hot saws, Stamping Machine & Cooling beds

1. Reheating Furnaces

Blooms from BBM route and continuous casting route are supplied to chargingroll table of Reheating Furnaces, through 3 nos. of Bloom Feeders.

The blooms are the reheated in three reheating furnaces of 75T/hr capacityeach. These furnaces are continuous pusher type, end-charging end-discharging typeinjection burner type furnaces with three zones. These furnaces use a mixture ofcoke oven and blast furnace gas of~1900 Kcal/NM3 as fuel. They use natural draftfor air source and natural draft for flue gas exit. The fuel gas is preheated in metallicrecuperators and the combustion air is heated in ceramic recuperators. The furnaceinstrumentation and control is automated with micro processor based processcontrollers .

The furnace is divided into three zones: the preheating zone, the heating zoneand the soaking zone. Bloom enters the preheating zone and in the process of passingthrough heating zone attains desired temperature. In soaking zone (which has solidhearth) the temperature of bloom is equalized throughout its length & cross section.

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2. Roughing Stand

The blooms after re-heating are first rolledin the 950 mm roughing stand. This is a 2 highreversing stand and the reduction to the bar isgiven in forward as well as backward directions.The roll gap for each pass is adjusted by top rollscrew down and the blooms guided into thepasses by manipulators. The rolling schemes fordifferent profiles employ different number ofpasses and different pass gaps in these passes.The maximum reduction to the bloom is givenin this stand and the rough shape of profile is made. The distance between thepinions of top and bottom rolls is 950mm and rolls have a barrel length of 2300mm.The rolls are driven by a 4000 KW DC motor by thyristor converters. The workingrolls have water cooled and lubricated textolite bearings. In rails primary descaling ofbloom is done prior to its rolling in roughing stand.

3. Intermediate Stands

The 800 mm intermediate mill is the only oneof its kind in India in that, that it is a 3 high non-reversing mill. The mill has two 3 high standscoupled together and driven by a single drivemotor. The scheme employs 3 passes in eachstand. Lifting tables lift the rolling bar up to theupper passes for reversal of direction. The distancebetween the pinions is 800 mm and a barrel lengthof rolls is1900 mm.

The top rolls are hydraulically balanced for reducing the mill spring and alongwith the high rigidity housings ensure high degree of consistency in the dimensionalaccuracy of the rolled profile. The drive motor is a fully compensated DC motorpower supplied by thyristor converters. The 930V, 7100 kW 100 / 180 rpm motor iscoupled to the rolls by a 3 high pinion roll set. In rails secondary descaling is done insome passes and roll pass lubrication is employed for better surface finish andincreasing pass life.

4. Finishing Stand

The 2 high finishing stand provides the final shapeand dimensional accuracy to the rolled profile. Railsare branded with month, year, profile, grade of steeland manufacturer's name at the finishing stand. Theworking rolls are mounted on anti friction bearingsand have hydraulic roll balancing and a closed top

Roughing stand

Intermediate and finishing stand

Hot Saw

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housing to minimize mill spring and roll gap variations. The distance between thepinions is 850 mm and a barrel length of rolls is 1200 mm. The drive motor is a fullycompensated DC motor supplied by thyristor converters. The 750V, 1800 kW, 90/180 rpm motor is coupled to the rolls by a 2 high pinion roll set.

5. Hot Saw, Stamping Machine and Cooling Bed

Rails and structurals after rolling are cut to specific lengths by rotary hot sawswith tempered tips. Rails are cut in 13.5, 27,65 and 78 metre lengths and structuralsto ordered lengths. The end crops, samples for destructive tests and for profilemeasurement are also cut here.

Rails & Structurals after cutting are stamped by a hot stamping machine. Thestamping data supplied by the bloom tracking system consisting of the cast numberof the bloom, the strand number of the caster which produced the bloom, CC/CO isstamped on the web of the rail. Structurals are stamped with the cast number at theweb.

Rolled profile (13/26 m rails and structurals) are taken on cooling beds for coolingbefore finishing. The rails are tilted in head up condition. Long Rails (65 & 78 m) aresend to a separate cooling bed in long rail finishing area.

IV) RAIL FINISHING AREA

There are two rail finishing areas one for finishing of 13 & 26 m rails and one forfinishing long rails. The details of both are elaborated below:

A. 13/26 M FINISHING AREA

It constitutes of the following areas:

1. Rail straightening

2. Online NDT

3. Rail finishing and inspection

1. Rail Straightening

Rails after cooling are straightened in a bi-planer straightening machine. Themachine consists of a six horizontal roller and a six vertical roller biplanar straighteningmachine. The semi automatic machine has digital thyristor converters supplying tothe drive motors of the rolls. Each roll being individually driven and the converterscontrolled by a PLC ensure constant and uniform linear speed of the working rolls.

2. Online NDT

The rails after straightening are tested by on-line eddy current tester (ECT) forsurface defects and by ultrasonic testing machine (UTM) for internal defects. TheECT uses eddy current loops generated on the rail surface by probe windings tocheck the surface finish. Any defect on the surface causes a distortion of the eddycurrent loops which is sensed by the detection probes. The ultrasonic testing machine

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has piezo-electric probes mounted on a housing to check all the areas of the railprofile. The ultrasonic pulses produced by the probe travel through the steel and getreflected at the end of the path. Any inside defect causes a pre-mature reflection andan extra echo is generated and detected. The defects sensed by the testing systemsare paint marked with color codes in the region of the fault. The defective rails arerejected.

3. Rail Finishing & Inspection

Rails are sent to Indian Railways in 13 metre and 26 metre lengths. The railsafter online testing are processed in six finishing groups where the ends are milledand cut to length by carbide tipped milling and cutting machines. This ensures fineend surface finish and square-ness.

Each rail produced at RSM is inspected by RITES - the inspecting agency forIndian Railways before classification and shipping. Rails are visually inspected forsurface defects, measured by gauges for dimensional accuracy, checked with straightedges and feeler gauges for end straightness. Rails are classified as accepted, rejectedor marked for end straightening or cutting. Accepted rails are color coded as perlength, stamped on the end with the seal of the inspecting agency and sent to shippingsection. In case of defects the rails are either cut or refinished to salvage the rails.Straightening is done in 4 directional hydraulic presses and end cutting at carbidesaws in the re-finishing area

Profile dimensions of rails

Profile Height Flange Head WebUIC 60 172 +0.8/-0.4 150 +1.2/-1.0 74.3 +/-0.5 16.5 +1.0/-0.5

IRS 52 156 +0.8/-0.4 136 +/- 1.0 67 +/-0.5 15.5 +1.0/-0.5

B. LONG RAIL FINISHING AREA

The Long rail complex of Bhilai Steel Plant has the most modern rail processingequipment from all over the world. The rail straightening machine from Germany, theultrasonic and eddy current rail testing systems from Canada, the laser basedstraightness measurement and 4 directional hydraulic press from Germany, precisioncut to length carbide saws from Austria and the computer controlled automation andrail mapping systems designed by VAI, Austria being installed are the best in theworld.

Centre for Engineering and Technology, SAIL was the consultant for the projectwith M/s Corus consultants, UK providing the technological consultancy

Why long Rails

Concerns of safety and economy of operations have necessitated railroads theworld over to switch to long rails with very few weld joints. The longer the length ofthe rail, the lesser the number of welds per kilometer length. The commuter enjoys a

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safe and bump-less ride and the railroad company saves on track life and maintenance.Bhilai Steel Plant has established long rail production facilities at a cost of Rs 400crore to cater to the demand for long rails from Indian Railways. Long rail complexproduces rails upto 80 meter length and welded rail panels of upto 260 meter lengths.This results in ready to use being sent to site directly.

Milestones in supply of Long rail

o Inauguration of long Rail complex-27.6.04

o Dispatch of 65 m rail-20.9.04




Long Rail finishing complex constitutes of the following areas:

1. Precambering and walking beam cooling bed

2. Rail straightening

3. Online NDT

4. End finishing/ straightening and inspection

5. Welding

6. Rail Handling

1. Precambering and walking beam cooling bed

The process flow line starts with the insulatedroll tables taking the hot rails to the cooling bed.Rail has asymmetrical shape. Maximum mass is athead and the foot is thin. When the hot rail coolsdown the foot gets cold very fast and the headcools very slowly. During cooling the head shrinksand the foot gets elongated. Therefore the railacquires a parabolic camber after cooling. In longerrails this camber is very large. So rails are given apre-camber in opposite direction while they are hotso that they become almost straight after coolingdown. The reverse camber is given to rails by aset of 29 position controlled carriages. Theprogramming of the carriages produces pre-cambering of the rails. The rails are clamped firmly,lifted from roller table and placed on to the walkingbeam cooling bed with the help of hydrauliccylinders. These rails move on the cooling bed &are also cooled in the process. Precambering of rails at Bhilai

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2. Rail Straightening

To meet straightness requirement, the rails arestraightened by roller straightening machine whereinthe rails are passed through series of rollers Thecooled rails are passed through most advancedstraightening machine of the world supplied by M/s SMS MEER, Germany. This bi-planar straighteningmachine has 9 horizontal rollers and 8 verticalrollers. These horizontal and vertical roller machinescollectively are capable of straightening in verticalas well as horizontal plane. The machine with off-line straightening model enables development ofstraightening parameters and straightening models. The straightening machine alsocommunicates online with laser straightness machine such that timely correctiveaction for straightness can be taken up

3. Online NDT

Non-destructive test carried out forlong rail comprise of Ultrasonic, EddyCurrent and Laser Geometry test.Ultrasonic test is carried out to detect anysub-surface anomalies. Eddy Current testis used to detect surface defects. Anintegrated paint marking station indicatesthe position of the defect found.

The Laser Geometry test measuresthe straightness and top flatness of therail. Laser Geometry Station is used tomeasure the body straightness and top flatness. This system comprises of a laserbeam incident on the railhead and a CCD as a receiver capable of highly accuratedisplacement measurement, and generation of the test results. The top flatness ofthe rail is measured using thrubeam laser sensor.

4. End Cutting/ Straightening & Inspection

Rails are cut to length by carbide saws from M/s Linsinger Austria. These sawscut downwards from head, give a good finish without inducing any out of squaredefect. They are automated to cut rails in any length.

These rails are then visually inspected and tested for dimensions with gauges attwo online visual stations equipped with mirror inspection.

If required the rails are sent to hydraulic presses to ensure 100 percent straightnessof the rail ends in all directions.

Straightening machine

Laser Straightness measurement

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GATEWAY

5. Welding

Rails of 65 m are welded to 130 or260 m The welding machine supplied byESAB, Sweden is has integral strippingsystem & is fully automated withdedicated micro-controller for the weldprocess control and PLC for sequencingof operations. The anti twist clamps andautomatic alignment ensure perfect profilematching of rail ends while welding. Thedistributed clamping ensures highly rigidand slippage free clamping of rails while welding. The profile-grinding machine grindsboth the running faces and top of the rail with a very high precision and finish.Ultrasonic testing ensures flawless joints.

6. Rail Handling

Handling and loading of rails upto quartera kilometer requires specialized equipment. Therails are handled by an automatic computercontrolled telphers. The rails are loaded inspecial rakes of flat bottom wagons calledEUR's(End unloading rakes).

V) RAIL TESTING

A number of tests are carried out to ensure that the rail conforms to the productspecification. Falling weight test, tensile test, hardness tests, micro examination,chemical analysis, hydrogen content test and sulphur print are carried out at BhilaiSteel Plant whereas residual stress, fracture toughness, fatigue strength and inclusionrating level are carried out at Research and Development Centre for Iron and Steel,the in-house research centre of SAIL.

STRUCTURAL FINISHING AREA

The heavy structurals produced in the mill are straightened in the structural rollerstraightening machine. They are then inspected for dimensional accuracy, surfacefinish, branding. Testing of mechanical properties is done and these are dispatchedto customers.

Welding of Rails

Loading of long Rails

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MERCHANT MILL

The "350 mm" Merchant Mill is a semi continuous high capacity mill designed toroll 500,000 tones of finished products per year as per present market demand. Mainproducts are :

Rounds Bars 28,32,36,40,50,53,56,60,63 & 67 mm dia; TMT bars of 28,32, 36, 40 and 45 mm are also being rolled.

Angles 50x50, 65x65, 75x75, 80x80 and 90x90 mm leg lengths andthickness ranging from 5 to 10 mm.

Channels 100x50, 75x40 mm.

Raw materials

Raw materials used are billets of size 100x100, 105x105, 110x110, 150x150and shaped billet of size 122x135x80, length ranging from 5 M to 6 M. Billets aresupplied from billet yards by magnetic cranes on to the charging device. Three chargingdevices are installed one in each of the three bays of billet yard. Approach tables atthe billet shipment in the first, second and the third bays are designed to push thebillets on the furnace approach roll table. Furnace approach table, which extendsupto the first bay in billet shipment, is designed to receive billets from the chargingdevices and deliver them to the furnaces. The furnace pusher installed at the chargingside of the reheating furnace, pushes the billets after leveling from the approach rolltable into the furnace and moves the entire charge in the furnace pushing the heatedbillets on to the delivery roll table at the discharge end of the furnace.

The Merchant Mill consists of three main sections :

1. Re-heating furnaces.

2. The mill stands and cooling beds.

3. Finishing zone & shipping.

Reheating furnaces :

There are three re-heating furnaces installed in the mill to heat the billets to therequired temperature necessary for hot rolling . Furnaces are continuous, end charging/ discharging type. The capacity of each furnace is 60 ton per hour.

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GATEWAY

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Important technical parameters of the furnace are :

Breadth of furnace 6.5 m No. of burners 16Effective width 6.1 m (a) top zone 05 burnersLength 20 m (b) bottom zone 05 burners

(c) soaking zone 06 burners

There are three zones of heating, preheating, heating and soaking zones. In thefirst part of the furnace (preheating and heating zones), the billets move over thewater cooled skids and are heated by top and bottom zone burners.

The burners are injector type which suck air automatically. In the second part(soaking zone) the furnace has a solid chrome magnesite brick bottom with solidskids, where the billets are soaked to a uniform temperature. The fuel used in thefurnace is a mixture of coke oven and blast furnace gas in the ratio of 20:80 withcalorific valve of 1350 kcal/Cu M and at a pressure of 1500 mm water column.

Normally air is preheated in ceramic recuperators to 400°C - 500°C and gas inmetallic recuperators to 250-300°C.

The temperature of the metal to be heated depends on the following factors.

1. Quality of steel

2. Rate of rolling

3. Size of the billet

4. Profile being rolled

5. Calorific value etc.

While rolling beams, the soaking zone temperature is maintained at 1250-1280°Capprox and while rolling rounds, the soaking zone temp. is maintained in the rangefrom 1220 to 1250°C.

The working of the mill :

As the billets from furnace are discharged, they fall on the furnace delivery sideroll table approaching stand No.1 at themill side.

The turn-over devices or tilters areinstalled on the rolling lines beforestands 1, 2, 6 and 10, and are used forturning over billets by 90° beforedelivering them to the respective stands(as per requirement).

There are 12 working stands in themill, out of which 9 stands are horizontaland 3 are vertical.

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GATEWAY

Roughing group comprises of stands 1,2,3,5 being 500 mm two high horizontalstands and 4th stand is a 400 mm, 2 high vertical stand.

Intermediate group comprises 6,8,9 stands of 400 mm 2 high horizontal and 7thstand 400 mm two high vertical. Finishing group consists of 10th stand of 400 mmand 12th of 350 mm 2 high horizontal stands and 11th being 350 mm 2 high vertical.The first line of rolling consists of 8 stands. After the 8th stand there is a chaintransfer to deliver the bar from 1st line to 2nd line of rolling i.e. from stand 8 to stand9. There is a second chain transfer after 10th stand for delivering the bar fromsecond line to third line of rolling. The third line of rolling consists of two stands 11and 12, connected by the approach and delivery roll tables respectively. The chaintransfers are used while rolling structures only.

All stands are of non reversing type and driven individually by d.c. motors. Workingstand consists of pinion stand, universal spindles(except stand 6 which has gearedspindle), splined transmission shaft, reducer stand, main drive displacement mechanismand clamping mechanism. The top roll adjustment mechanism with individual screwdown drives are located on the housing cap of horizontal stand. The mechanism isdriven by two electric motors through double reduction worm reducers. An indicatoris coupled to each of the worm reducers to indicate the distance through which eachend of the top roll is displaced. The level of bottom roll is adjusted by putting differentsize of packings as required.

Work rolls are mounted on oil film bearings. Balancing of the top roll isaccomplished by the aid of springs resting on the transverse beam. Axial adjustmentmechanism located on the idle side of the stand with double balanced lever system.The bottom roll is fixed in the axial positions clamping idle side.

In the case of vertical stands, the roll stand can be moved up and down by thehousing lifting mechanism. The roll stand has mono block housing. The rolls areplaced in the housing and are clamped. There are two repeaters in between 8th and9th stand and in between 10th and 11th stand. When the repeaters are used, chaintransfers are not used. Repeaters are used for rounds upto 67 mm dia. and TMT barsupto 45 mm.

The length of the body of rolls used for different stands are given below

1,2,3 & 5 1000 mm

4,7,11 & 12 600 mm

6,8,9 & 10 800 mm

The finished bar (except TMT bars) from stand 12 travels on the delivery rolltable through the switch point bifurcator to the cooling bed. The bifurcator distributesthe flow of bars to both side of cooling bed. Just before the left cooling bed, there isa sample cutting circular saw. In case of TMT, the finished bar from stand 12 travelsthrough Thermax pipes in which this is subjected to rapid water quenching system.

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(at a water pressure more than 16 kgf/cm2) There are 10 pipes for this out of which5 pipes are RE-50 type & the other 5 pipes are of RE-60 type. At a time, maximum 5pipes are used. This system is kept out of line of rolling while rolling structurals andplain rounds.

After cooling, the bars are fed (while rolling structurals) to the straighteningmachine, one at a time. The length of cooling bed is 90 m.

To facilitate single piece feeding to straightening machine, the bars are distributedone ahead of other on cooling bed. Adjustable guides are provided at the end of theroll table for directing the bar to the vertical guides before straightener. There aretwo machines one on each side of the cooling bed to straighten the fed bars. Acantilever crane is provided on each machine for changing the rollers. After thestraightening machine there are shear approach roll tables from where bars aretransferred to the cold shear approach table by the rope transfer.

There are two cold shears installed in the line of rolling, one on each side to cut,the rolled bars into desired lengths. The lengths are adjusted by the shear adjustablegauge before cutting into suitable lengths.

The bars are weighed and bundled. A card indicating the heat no., weight, &quality is attached to the binding wire and kept on the stack.

Stage inspection for the rolled profile is carried out during the process of rollingfor finding out rolling defects, surface defects, steel defects and any other mechanicaldefects. Samples from each cast are sent to laboratory for mechanical testing andfor ascertaining chemical composition.

There are fifteen cranes in the mill provided on the different bays for load lifting,roll changing etc. The oil film bearings are used to support the rolls of the workingstands. Each roll is supported on two bearings fitted on the roll necks. The roll assemblyis supported in the stand housing.

The bearings are of precision type totally enclosed and well proportioned . Thecoefficient of friction is between 0.0001 & 0.0003. The sleeve or conical journal isalloy steel forging, hardened and ground to a mirror finish fitted and keyed to thetapered roll neck. The bushing has a special bore of displaced centers. The shape anddimensions of the bore are such that the bearing clearance has a wedge shape.Hydrodynamic pressure takes place in the oil layer dragged into this clearance by therevolving shaft due to wedge shape of the clearance. This pressure raises the sleeveand creates an oil film between the rubbing parts of the bearing and balances theouter pressure.

The thickness of the film depends upon operating conditions, oil etc. Adjacent tothe outward end of the sleeve is a thrust bearing. In case of bearings of horizontalstands two thrust rings, (one full ring and one half ring) provided on the sleeve collarto take up the axial loads.

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GATEWAY

In case of vertical stand bearing, a radial thrust ball bearing is provided instead ofthrust rings for taking up axial loads.Notes on important modifications :

1. Both the chain transfers are working in auto. This has been achieved by usingphoto sensors after stand VIII and before stand-10.

2. Earlier Mercury Arc Rectifiers were used for the drive of main motors of stands,which has been replaced by thyrister converters.

3. While rolling of TMT bars, operation of lifting valve mechanism is carried out in"Auto". This is achieved by using HMD (Hot Metal Detector) installed at section201,301 on either sides of cooling bed. For other profiles, operation of liftingvalve mechanism is done manually through control pulpit no. 6.

4. The old straightening machines have been replaced by BRONX straightening M/c.(England). These machines are capable of straightening the bars with higheraccuracy.

5. Conventional Russian Stands 9,10,12 have been replaced by "Housing less"stands supplied by Morgard Sahammers, Sweden.

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WIRE ROD MILL

The 4 strand 250mm continuous Wire Rod Mill, commissioned on September 11967, was designed to roll 6, 7, 8, 10mm diameter wire rods from square billets of80mm x 80mm cross section (of length 11 to 11.8 meters) with rated capacity of4,00,000 T per annum. The billet size was further enhanced to 85 mm2, 90 mm2,100 mm2, 105 mm2 to improve in coil weight from 540 Kgs. to 930 Kgs. After therevamping of Right Side, sections 5.5 - 12 mm dia. wire rods are rolled in B , C&Dstrands, whereas 8mm & 10mm are rolled on left side (A strand).

BRIEF DESCRIPTION OF THE MILL

Inspected billets are fed on the charging grate of the furnace by magnetic fingercranes. The billets are fed one by one to the furnace, through roll table and draw-in-roller mechanism. Billets are moved into the furnace by means of pushers at thecharging end. Soaked billets are ejected out by means of Ejector Ram from thedischarging end.

The reheating furnace of the size 18Mx 12M is having 28 burners, which includes14 in the heating zone and 14 in the soaking zone. Mixed (Coke Oven & Blast Furnace)gas with calorific value of 1800 K Cal/Cum is used in the furnace as fuel. Capacity ofthe furnace is 120T/Hr. Gas and air is preheated to 250°c and 450°c in metallic andceramic recuperators respectively.

The roughing group consists of nine horizontal stands in which combined drive isprovided for stands 2-3 and 4-5; whereas stands 1, 6, 7, 8 and 9 are individuallydriven. All the drives are controlled by thyristor converter. Flying Shear is providedafter stand no. 9 for front-end cutting & cobble cutting.

First intermediate group has 6 horizontal stands, out of which stand No. 12 & 13are not being used. Stand No. 10 & 11/14 & 15 are used for rolling on all the strands.

After stand No. 15, the Mill is divided in four strands, old line (A) and Modernisedline (B,C&D).

A STRAND

Second intermediate group has 4 horizontal strands. Vertical loopers are providedafter stand No. 15 & Stand No. 19. Pneumatically operated snap shears are locatedat the entry of second intermediate group and the finishing group, so as to cut thebar when cobble takes place; thereby reducing accumulation of metal in the workingstands.

Finishing group consists of 4 stands; in which stand No. 20 & 22 are verticalstands and stand No. 21 & 23 are horizontal stands.

Rolling is done in 4 strands in the roughing group and first intermediate group, inone strand in the second intermediate group and finishing group of stands.

Wire rods coming out of the finishing group enter the coiler for reeling whereclose laying of coil is done through PLC control. Two coilers are present in A strand.

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GATEWAY

The coil thus formed are transported to hook conveyors via Plate Conveyors. Aftergetting air cooled on the hook conveyors, the coils, with trailing end trimmed, areinspected, strapped at three places and then identification tags and colour coding isprovided. These finished coils are off-loaded to the Piling Machines from where theyare lifted by over-head cranes and kept in stock yard.

PRODUCT MIX

Plain 8 mm, Ribbed 8mm , Plain 10mm and Ribbed 10mm.

QUALITIES ROLLED

Rimming steel , SWR -14 , IS 2062A ,Ribbed bar , Low Carbon etc.

QUALITY PARAMETERS OF ROLLED WIRE RODS

Tolerance on diameter : + 0.3 mmOvality : 0.35m (max)Secondary Scale loss : 1.5. - 2.0%Coil Dimensions : ID 850 mm,OD 1250 mm,Height 450- 500 mmYield : 8 mm, 10 mm; 95.5 - 95.7%

REVAMPED B , C & D STRANDS

The rod exiting from stand no.15 is fed to stand no.16 located at a height of 5.1meters above ground level through a series of feed guides. Before stand no 16, aUniversal Shear is provided for cutting front end and cobbles I in C and D strand anddrum shear in B strand. Intermediate cooling line is provided after stand no. 15 toensure that the rod temperature does not exceed 970°c.

After Universal Shear/Drum shear , one Horizontal (# 16) and one Vertical (#17)rolling ring stand are present. One Vertical Looper is present after Universal Shear andafter stand no. 16. One Horizontal Looper is present after stand no. 17 and before NTBlock. One eight stand Rod Mill Block (No Twist Block) comprises stands 18 to 25.

The product from the rod mill block is fed to the Laying Head through the feedguide (primary cooling line). The laying temperature of the rod should not exceed750°c. The rod convolutions formed by the Laying Head fall on the Loop Conveyors/Roller conveyor, that carries the overlapping rings to the reforming tub. The overlappingrings moving over the loop conveyors get cooled by air flow generated by blowers.The rings fall into the Reforming Tub which consists of an auxiliary mandrel with twocatcher arm levels.

The convolutions dropping over the mandrel get collected onto a pallet placedbelow the reforming tub. The loaded coil pallet then moves to the compacting andstrapping installations where the coil is compacted and then strapped at four places.The pallet with the compacted coils are then unloaded at the Tilter and placed on tothe Coil Collector with the help of Load Car. Coils from the coil collector are removedby cranes for storage. After stand 15 the rolling in B C and D strand is totally underlevel -II automation

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PRODUCT MIX

Plain 5.5mm, 6mm, 7mm, 8mm , 10mm & 12mmRibbed bars /TMT 8mm, 10mm & 12mm

QUALITIES ROLLED

Rimming steel, SWR -14 , SAE 1008 , TMT BARS , IS 2062 "A", SA 12 , ColdHeaded Steel etc.

QUALITY PARAMETERS OF ROLLED WIRE RODS

Tolerance on diameter : +/- 0.15 mm for 5.5 & 6mm+/- 0.20 mm for 7, 8 & 10mm+/- 0.25 mm for 12 mm

Ovaity : 50% of total diameter variation

Secondary Scale loss : 0.6 to 0.8%

Coil Dimensions : ID 950 mm,OD 1250 mm,Height 550 - 650mm (after Compacting)

Yield : 95.6 - 95.7 % for all sections

PERFORMANCE TABLE

Billet dimensions : 105 x 105 x 11600mmFurnace capacity : 120T/Hr.Actual discharge capacity : 90 -93 T/Hr.Billet weight : 960 Kgs.Coil weight : 930 Kgs.

Rolling Stock Final Length (m) Final Seed(m/s)5.5 mm 4890 55.06 mm 4220 45.07 mm 3100 35.08 mm 2350 26.010 mm 1500 16.512 mm 1050 12.0

ADVANTAGES OF REVAMPING OF WIRE ROD MILL :1. Increase in mill capacity by 20 -25%.2. Rolling of wider range of steel grades :

Mild Steel , Rimming Steel, Low Carbon, High Carbon, TMT Bars, Tyre Bead &Cold Heating Quality etc.

3. Rolling of wider range of profiles: 5.5, 6, 7, 8, 10 & 12mm & 8, 10, 12 TMTBars.

4. Better surface finish.5. Improved dimensional tolerances.6. Better shape and packaging of coils.7. Reduction in secondary scale formation.8. Improved rod drawability.

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GATEWAY

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GATEWAY

ROLL TURNING & REPAIR SHOP ANDROLL PASS DESIGN BUREAU

Vijay Kumar, DGM , Nagesh Ramteke, Mgr.

RTS & RPDB is a highly specialized department which takes care of design,manufacture & repair of rolls of various profiles required for the rolling of differentsections in 2.5. MT area Mills. The shop is laid out in an area of 8880 sq.M and hasfollowing sections

1. Roll Turning Shop2. Repair Shop3. Roll Welding section4. Roll Pass Design Bureau

1. Roll Turning Shop

Facilities available :

a. Roll turning Lathes

1. Conventional in main shop 20

2. Conventional in RSM site 03

3. CNC (Computerized numerical control) 03

35 Ton, 25 Ton & 1 Ton

b. Roll neck grinding machine 02

c. Groove / Rib cutting machine (CNC retrofitted) 01

d. EDM Branding machine for TMT Bar 01

The Shop also includes :

Templates section for making roll pass templates and go-no-go check gauges forproduct inspections. CNC EDM wire cut machine is installed for making new templatesand gauges.

a. Forge section with gas fired furnaces and pneumatic hammer for forging specialprofiled tools.

b. Tools grinding section.

c. Machine tools and repair shop.

d. Maintenance Section : Mechanical & Electrical

Capacity :

a. Turning of 4,830 tonnes of new rolls.

b. Redressing of 35,500 tonnes of used rolls

The rolls are made of forged steel, cast steel and cast iron. Presently the biggersize forged steel rolls are imported and other types of rolls of different material are

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purchased from indigenous sources. The profiles are cut in these roll blank and sentto the mills for service. Rectifiable defects on rolls if developed during service, aretaken up in Roll neck grinding machines to make them further usable. Grooves arecut on the rolls according to the roll design developed for converting input steel intovarious products. Templates are made accurate to the size of the designed passes tocheck the grooves. The tools are ground to desired shapes as per template for cuttingthe grooves on rolls.

2. REPAIR SHOP :

The shop serves the purpose of quickly replacing/reclaiming/rectifying the smallbroken parts of the mill equipment and Roll Turning Shop. The average reclamation isapproximately 35 to 40 tonnes per month.

The equipments in the Repair Shop are:

Lathes 05

Milling Machine 01

Shaping Machine 02

Radial drilling machine 01

3. ROLL WELDING SECTION :

This section has come to existence under the 2.5 million tonne programme. Thesteel rolls, which would have been otherwise scrapped, are reclaimed for further useby building up the worn out grooves, by automatic submerged arc welding process.Dump car wheels, RMP rollers, Crane wheels, Crusher drums, Wire Rope drums andmill rollers are also reclaimed by this method.

Facilities available :

Two automatic submerged Arc Welding Machines. One of 8 tonnes job weightcapacity and the other of 40 tonnes capacity.

Technology :

Rolls are preheated and then welded as per the roll building-up technology. AlloySteel and copper coated mild steel electrodes in coil form are used with suitablefluxes.

This reclamation of rolls has brought a lot of saving in foreign exchange.

Forge Section :The equipments in this section are :

Pneumatic Hammer 01

Brazing Furnace 01

Forging Furnace 01

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GATEWAY

CNC Roll Turning Lathes :

(a) 35T CNC Roll Turning Lathe :

Technical Features :

Max. work piece weight between centres

35 Ton

Max. turning dia 1400 mm

Max. distance between centres 6000 mm

Tools used Tungsten carbide and ceramic inserts

CNC control system Sinumerik 840 D

Make Herkules, Germany.

Model WD 600 Le-CNC x 6000 Commissioned in 1997

Application Turning of passes of Roll of Blooming Mill and Rail & Structural Mill

Benefits :

Reduction in turning time by half or more compared to conventional lathe.

Higher hardness rolls (beyond 60 degree shore C) can be turned resulting inincrease of rolling tonnage.

Tool movement and Roll rotation are controlled by computerized turningprogramme

(b) One Ton CNC Roll Turning Lathe :

Make HMT Lathe retrofitted by Kirloskar control. Model HMT B-32 Commissioned in RTS in 2001.

(Shifted from M/c Shop) Application Turning of passes of Wire Rod Mill Roll

Technical Features :

Max. work piece weight between centres 1 Ton

Max. turning dia 400 mm

Max. distance between centres 1500 mm

Tools used Tungsten carbide and ceramic inserts

CNC control system Kirloskar - Crusader II L

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GATEWAY

4. ROLL PASS DESIGN BUREAU :

Roll Pass Design Bureau is usually known as the nerve centre of Rolling Mills. Allthe activities concerned with the rolling of various profiles start in the department.Pass Design is a highly specialized job. The pass designs for various profiles havebeen developed by engineering and finalised based on Shop floor experience. In Bhilai,more than 200 profiles have been designed and developed by our designers in thelast 30 years. Further modifications in design are also carried out as and when thenecessity is felt.

Rail and Structural Sections such as Beams, Channels and Angles as per variousforeign specification have also been developed in Bhilai for export to various countries.We have exported rails to IRAN, GHANA, SUDAN, ARGENTINA, MALAYSIA, SOUTHKOREA, NEWZELAND, BANGLA DESH, IRAN & NEPAL as per their specification.

In the Bureau, the design of pass grooves, to be cut on rolls are first worked out.Then the roll diagrams showing the position of passes on rolls are made. Roll TurningShop makes the templates as per the pass design drawings and cuts the grooves onrolls as per the roll diagrams given by R.P.D.B. The design of rolling tackles are alsomade in this department.

SOME SPECIAL MACINES & HIGHLIGHTS

RTS commissioned on 19th August, 1959, supplies turned rolls to all the 2.5 MTMills, Apart from 23 conventional lathe machines, following need special mention :

35 Ton CNC lathe :

CNC Roll turning lathe of 35 Ton capacity (Make Herkules, Germany) installedand commissioned in Oct.'1997. Blooming Mill rolls and Rail Mill rolls are turned onthis machine.

25 Ton CNC lathe :

CNC Roll turning lathe of 25 Ton capacity (Make Hankook, Korea) installed andcommissioned in January 2007. Rail Mill rolls are turned on this machine.

One Ton CNC lathe :

CNC retrofitted turning lathe (one ton capacity) has been shifted from MachineShop and commissioned in RTS in June 2001 for turning Wire Rod Mill rolls

Revamping of Inductors :

1200 mm size inductors are now being used for pre - heating of jobs. This is atechnological requirement for submerged arc welding for reclamation of rolls andother jobs. These inductors have been revamped in-house in RTS.

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Heating arrangement by CO Gas :

Gas heating arrangement has been developed in-house in RTS. Burners havebeen designed and fabricated and Pipe lines installed. These are used for heatinglarge size rolls (Blooming Mill Rolls and 950 stand RSM rolls) on machine E9 forsubmerged arc welding.

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GATEWAY

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RESEARCH & CONTROL LABORATORY

This is the most important central department for quality control of variousincoming materials,intermediateproducts and finished products of Bhilai Steel Plant.The basic functions of Research & Control Laboratory (RCL) can be broadly describedas under:

To maintain a close control on the quality of raw materials purchased / receivedfrom external agencies / captive mines.

To impose necessary control measures on metallurgical processes for productionof quality materials with cost effectiveness.

To plan and work out the technological instructions for the processes, inconsultation with shops.

To test all finished products as peer customers requirement to examine theirsuitability .

To maximise the plant yield and to minimize the rejections at different stages.

To ensure supply of quality materials as per specified requirements of thecustomers, by developing new products.

To investigate the causes of any material failures occurring within the shops,and to recommend substitute materials (including import substitutions).

To plan and conduct the development programmes in collaboration with shop,and to introduce innovations in the methods of manufacture.

To advise the management regarding suitability of steel orders for manufacture& supply.

To take active part in R & D Activities

The main function of RCL can be divided into three parts as under.

(A) PROCESS CONTROL:

1. Ore Handling Plant Process Control

The main function of this section is to control the quality of incoming raw materialsthrough Wagon Tipplers in Ore Handling Plant.

2. Coke Oven Process Control

The main objectives of this section are (a) to ensure the production of highquality metallurgical coke and (b) to bring any processaberration to the notice ofconcerned authorities for rectification.

3. Blast Furnace Process Control

Function of this section is to have a check and control on the quality of liquid pigiron produced. This includes regular sampling and testing of raw materials, ensuringproper blending and charging, checking whether correct technological regime is adhered

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GATEWAY

to or not, and to ensure solid pig iron of proper grade for salet. This group also playsan important role during blowing out and blowing in of the furnaces. Sample collectionof Top and Radial gas in Blast Furnace and their analysis and also done by them.

4. Sintering Plant Process Control

The functions of this section are to collect and prepare samples of all raw materialsand sinter, and to carry out physical and chemical tests for these samples andmonitoring and control of the process.

5. Steel Melting Shop - I & Ii Process Control

The main objective of this section is to achieve production of righ quality prooneat reasonable economical levels. With this aim, the process control organisation isresponsible for evalution and standardization of technical norms for raw materials,technological instructions for the various process stages in the melting and teemingof steel in Steel Melting Shop-I, blowing and casting and secondary refining of steelin Steel Melting Shop-II. The Process Control is responsible to fix the grades of steeltapped as per prevalent standards, and certify their fitness for rolling. In addition tothis, it takes up short term and long term projects to develop and improve upon thequalitative level of production, keeping an eye on the cost indices.

6. Foundry Process Control

Function of this section is to test all raw materials required to ensure propermoulding. It also controls the pouring and fettling of castings. Inspection of importantcastings like ingot moulds and bottom stools is conducted by this section. It alsosuggests alteration and modification in technology and casting design to meet changesin service conditions and demand so as to improve service life, quality, and yield ofproducts.

7. Rolling Mill Process Control

The function of this section is to ensure an effective metallurgical control atvarious stages of the process to get sound quality products, with maximum possibleeconomy in the rolling mills. This enables manufacturing of semis and finished productsconforming to the steel orders for the specified physical, chemical and mechanicalproperties. It works for the optimization of yields at various stages of the processand analyse the loss in yield. It also conducts experimental study and investigationalwork for the development of the process as well as for improvement of the quality.

8. Plate Mill Process Control

The function of this section is to monitor the heating regime, control of qualityduring rolling of slabs into plates of different grades and sections.

(B) TESTING

1. Mechanical Testing Laboratory - I & II

Testing of all the saleable steel products to various specifications and theircertification is the main function of this section. It plays an important role in thequick despatch of our rolled products. Mechanical Testing Laboratories are having

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tensile, impact, hardness and bend testing machines. Mechanical testing includeshardness test, impact test, tensile test, bend test etc. for various samples. Thissection plays a key role in salvaging the cases of any mix-up in our mill products.

2. Metallography Laboratory

The metallography laboratory functions as a quality control unit as well as atesting laboratory for various rolled products for export, defence, railways etc. It alsocarries out investigations of service failures of equipment, rolls, machine parts etc,and sulphur printing of rails in three shifts on regular basis. Modern instruments likeScanning Electron Microscope, Micro Hardness Tester, are being used for the pur-pose.

LIST OF CHEMICAL INSTRUMENTS IN DIFFERENT LABORATORIES

Sl. No.

SECTION NAME OF INSTRUMENT

MAKE QTY. USE

OPTICAL EMISSION SPECTROMETER

SHIMADZU 2

STEEL-PLAIN & LOW ALLOY

1 CENTRAL CHEMICAL LABORATORY

ATOMIC ABSORPTION SPECTROMETER

PERKIN ELMER

1

R M ANALYSIS, NON FERROUS METALS


SHIMADZU 2


2 SMS – 1 LABORATORY


ARL SWITZERLAND 2



SHIMADZU 2



ARL SWITZERLAND 2


3 SMS – 2 LABORATORY

XRF SPECTROMETER

PHILIPS

1

VARIOUS RAW MATERIALS & FERRO ALLOYS

4 BF EXPRESS LABORATORY

XRF SPECTROMETER

PHILIPS

1

ALL RAW MATERIALS, HOT METAL & SLAG

5 FOUNDARY LABORATORY

MANUAL ANALYSIS

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MELT DOWN SAMPLES OF ELECTRICAL FURNACE

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3. Non-Destructive Testing Laboratory

The main function of this section is testing & inspection for internal soundnessand surface cracks of rails, plates and various components working under severeconditions like crane hooks, boiler plates & tubes, rolls, spindles, shafts, weldedjoints etc. by utilizing one or more of the following :

Radiography (using X-Rays & Gamma Rays)

Ultrasonic testing of plates in Plate Mill.

Magnetic particle inspection.

On-line and manual ultrasonic testing of rails in Rail & Structural Mill.

On-line eddy current testing of rails in Rail & Structural Mill.

Control of nucleonic gauges working in RMP-II, Blast Furnace-7, Coke

Ovens & Sintering Plant-III departments for level gauges.

4. Refractory Testing LaboratoriesREFRACTORY TESTING LABORATORY - I & II

The function of RTL is to conduct :

Joint testing of refractory bricks, castables and mortars at party's premises ifrequired.

Secondary inspection and testing of all the refractory materials used in BhilaiSteel Plant (after receiving at our premises);

Quality Control of lime in RMP-I & II;

Quality Control of Tap Hole Mass and Runner Sand used in Blast Furnaces;

Investigation jobs in cases of premature failure of refractories, slag test etc.

Major tests done are Refractoriness under load, pyrometeric cone equivalent,permanent linear change, app. porosity, bulk density, specific ravity, etc.

2. CHEMICAL LABORATORIES:

The principal functions of chemical laboratories are to determine the chemicalcomposition of various raw materials and products. RCL is equipped with expresslaboratories at Coke Ovens, Blast Furnaces, Steel Melting Shop, I&I, Oxygen Plantand Foundry Shop along with a few laboratories at the Central chemical Laboratoryitself. The express laboratories make quick analysis of raw materials and finishedproducts and help produce uniform quality, especially with regard to chemicalcomposition. These sections have also been equipped with modern instruments likeOptical Emission Spectrometers, x-ray Fluoroscence Spectrometers, BrookfieldViscometer, Astro Graphite Furnace for determination of viscosity at highertemperatures, Carbolite Furnaces, Gas Chromatograph, Atomic AbsorptionSpectrometer, Leco Gas analyser for Hydrogen, Nitrogen, Oxygen, Carbon & Sulphur.Wet method of analysis is being replaced by instrumental analysis in many cases.

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3. INSPECTION :

The main function of this wing is to check the quality of semi-finished products,to control the quality during rolling and finishing in all the finishing mills and to finallyinspect the finished products before despatch to customer. In case of semi-finishedproducts (blooms, billets and slabs) the conditioning prior to further rolling is alsocontrolled. The conditioning methods followed are hand or pneumatic chipping, orcutting of small fins etc. and scarfing with oxy-acetylene gas flame. Conditioninghelps to minimize the defects in the finished products from blooms billets and slabs.Inspection of finished products is carried by BSP inspectors. For products like rails,plates etc, where outside inspecting agencies are involved, the product is inspectedby BSP inspectors prior to offering for joint inspection with outside agencies. Inspectiondepartment also works as a co-ordinator for carrying out different types of testsrequired as per specifications.

DIFFERENT SECTIONS OF R & C LABORATORY

A. Process Control

1. BFPC Blast Furnace Process Control

2. COPC Coke Oven Process Control Foundry Process Control

3. FDY. PC Foundry Process Control

4. OHPPC Ore Handling Plant Process Control Plate Mill Process Control

5. PMPC Plate Mill Process Control

6. RMPC Rolling Mill Process Control

7. SMS-1 PC Steel Melting Shop-1 Process Control

8. SMS-2 PC Steel Melting Shop-2 Process Control

B. Testing Laboratories :

1. Blast Furnace Laboratory

2. Coke Oven Laboratory

3. Foundry Laboratory

4. RMP-1&2 Laboratory

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5. Central Chemical Laboratory

6. Oxygen Plant -1 Laboratory

7. Oxygen Plant - 2 Laboratory

8. Raw Materials Laboratory

9. SMS -1 Laboratory

10. SMS - 2 Laboratory

11. Refractory Testing Laboratory

12. Mechanical Testing Laboratory I&II

13. Metallographic Laboratory

14. NDT Laboratory

15. Machine Shops I&II

C. Inspection

1. Billet

2. Bloom Yard

3. Plate

4. Slab Storage Yard

5. Rail Mill

6. Wire Rod Mill, & Merchant Mill

7. Calibration Cell

D. Technical Services

1. Planning

2. Training & Safety

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TOTAL QUALITY MANAGEMENT DEPARTMENT (TQM)Total Quality Management was introduced in Bhilai Steel Plant as a business

philosophy in the year 1989. While committing to this concept, focus was on orientingourselves internally as well as externally to the needs of customers. A full time TQMGroup with officers drawn from various disciplines exists for promoting and facilitatingTotal Quality movement across the organization. Following are the main activities ofTotal Quality Management department at Bhilai Steel Plant:

Implementation and maintenance of Quality Management Systems (ISO9001:2000 standard)

Internal Customer Satisfaction (ICS) Model

Six Sigma

Knowledge Management

Under the Quality Management System of BSP based on ISO 9001:2000 standardfollowing is the Quality Policy and Quality Objective of BSP :

Quality Policy of Bhilai Steel Plant

BSP has formulated Quality Policy which aims at -

Attaining market leadership through enhancing customer satisfaction

Achieving continual improvement in productivity, quality and saleability of ourproducts

Active involvement of all our people in achieving our goals, objectives and targets.

Adherence to a quality management system, based on ISO:9001:2000 and itsperiodic review for continued effectiveness.

Organisational Objectives :

The organizational objectives of BSP are to enhance customer satisfaction through:

Improvement in productivity and product quality

Skill enhancement of our people by competence, commitment and culture building

Productions as per Customer Requirements

ISO:9000 CERTIFICATIONi) Installation of Quality Management System :

An approach plan for implementation of ISO:9000 Quality System was preparedand presented before the management in April, 1992. The head of TQM Deptt. wasappointed as Management Representative by the Managing Director. In the first phase,the Quality System was installed in Steel Melting Shop-II and Plate Mill, along withassociated service departments (M&SP, PPC, RCL, HRD, Instmn.&WBs, INCOS, RMD,Materials Management and MR's office). BSP obtained ISO-9002 certificate for thesetwo areas on 6th Jan., 1994.

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During the 2nd phase, the scope of the Quality System was extended to SteelMelting Shop-I, Blooming & Billet Mill and Rail & Structural Mill, and these units werecertified by LRQA in Jan., 1997 along with 1st triennial re-certification of SMS-II andPlate Mill.

In the 3rd phase, QMS was installed at Merchant Mill & Wire Rod Mill andISO:9002 certification was obtained in July '97.

In the 4th phase, the ISO:9002 certification was obtained for CO&CCD andBlast Furnaces in July '98.

With this, BSP had the distinction of becoming the first integrated steel plant inIndia to cover all its major production shops under ISO-9002 certification.

The final scope of certification for Quality Management System of BSP Worksarea became :

"Manufacturing of Blast Furnace, Coke and Coal Chemicals and production ofhot metal and pig iron, steel making through Open Hearth, twin hearth and basicOxygen process, manufacture of steel slabs and blooms by continuous casting andproduction of hot rolled steel blooms, billets and rails structural, plates, steel sectionsand wire rods."

In the 5th phase ISO 9001:2000 certification was obtained for OHP,SP-II&SP-IIIalongwith the triennial re-certification during Aug,2005.

The final scope of certification for Quality Management System of BSP Worksarea now reads as follows :

"Handling of raw materials at Ore Handling Plant, Manufacturing of Blast FurnaceCoke and Coal Chemicals , production of sinter at Sinter Plant II &III , production ofhot metal and pig iron , steel making through Twin hearth and Basic Oxygen process,manufacture of steel slabs and blooms by Continuous casting and production of hotrolled steel blooms, billets and rails, structurals, plates, steel sections and wire rods."

The entire Quality Management system was audited for the 2nd triennial re-certification by LRQA in Jan., 2000, and certified for 3 years period, upto Jan. 2003.In between, the ISO 9000 standard got revised in December 2000. The QMS wasthen aligned to the revised ISO 9001:2000 Standard and re-certified by LRQA duringJune 2002 which was again re-certified in Aug 2005. At present the QMS certificationof BSP Works area is valid upto June,2008.

A separate ISO 9001:2000 certification of the QMS of BSP Personnel deptt.was obtained from LRQA in Aug,04.

Efforts are continuing to install the QMS in other areas of works and non-worksdeptts. of BSP like Electrical Org., F&A zone, etc.

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ii) Maintenance of Quality Management System :

A great effort is required to install and maintain a Quality Management Systemin a multi dimensional organization like Bhilai Steel Plant. To achieve this a largenumber of "Internal Auditors" & "Lead Assessors" have been trained for carrying outmonthly audits of the QMS installed and to give regular feed back to the HODs fortaking all necessary corrective actions.

Effectiveness of the Quality Management System is reviewed through regularmeetings held by different levels like weekly Shop Corrective Action Meetings chairedby respective HODs, monthly Quality Improvement Committee Meeting under thechairmanship of Head of Quality, and quarterly Management Review meetings chairedby MD.

The system has proved its effectiveness by recording consistent improvement inall identified Quality Parameters such as Quality objectives, Delivery Fulfillment,Diversions, Defectives, NCO arisings, ICS agreements, Customer Complaints, CSIratings, etc.

Other intangible benefits which have been achieved due to installation andmaintenance of the QMS are as below:

1. Role clarity and high degree of involvement of the employees.

2. Documentation and record keeping (have got streamlined).

3. Reliability of measuring and test instruments has improved due to periodiccalibration by using masters of national / international standard.

4. Inculcated Quality culture and brought down instances of norm violations.

5. Helped in better training coverage of all related personnel as per identified trainingneeds.

6. Commitment from departmental heads in maintaining the system by timelycorrective actions.

7. Lowering instances of Quality mix-ups of products.

8. Helped in establishing a well-defined system to promptly redress CustomerComplaints and ensure corrective / preventive action.

9. Helped in establishing a well-defined system to assess the capability of sub-suppliers supplying the Quality critical items and communicating them forimprovements.

10. Improvement in Housekeeping of all associated departments.

11. Improvement in internal and external customer satisfaction.

ICS MODEL

In today's competitive scenario, an organization has to demonstrate its ability toconsistently meet the requirements of its customers and should aim to enhancecustomer satisfaction through continual improvement in processes. In order to satisfy

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external customers, BSP has taken up an initiative to ensure that each departmentsatisfies requirements of its internal customers because external customer can besatisfied only if the entire chain of internal customers is satisfied. The model is aimedat understanding the true requirements of internal customer, identifying bottlenecks/ gaps and developing suitable action plans for de-bottlenecking / overcoming thegaps and building capability to ensure 100% internal customer satisfaction.

Each supplier department invites its internal customers to project their requirementsfor the financial year. Once the requirements are discussed and agreed upon, an agreementis signed by the supplier and internal customer department. This agreement helps thesupplier department to select suitable targets / quality objectives and make action plansto achieve the same. Micro plans are developed in all the areas and used for monitoringthe implementation of the ICS Model. This ensures involvement and commitment of allemployees towards meeting the requirements of their internal customers.

BSP has formulated Internal Customer Satisfaction Indices for each supplierdepartment where a customer department evaluates supplier departments throughratings based on their level of satisfaction on the fulfillment of ICS agreement by theconcerned supplier department. This has led to an improved system of monitoring byHeads of Departments in their respective areas. For the year 2007-08 there are 102ICS agreements under the ICS Model.

SIX SIGMA

The Six Sigma methodology is more ofan evolutionary development in the scienceof continuous improvement that combinesthe best elements from many earlier qualityinitiatives. The combination of theseelements with a rigorous, disciplinedapproach and well-publicized, provenbusiness successes makes Six Sigma a verypowerful tool for Breakthrough Improvement.

Six Sigma is a committed managementapproach to quantifiably solve problems andoptimize critical processes. Adapting and applying Six Sigma methodologies can leadto dramatically improved business performance and bottom-line profitability. It is amanagement strategy for improving a business and a high performance data drivenapproach focused on analyzing the root causes of business problems and solvingthem. It ties the outputs of a business directly to market place / bottom line. SixSigma deployments revolve around Six Sigma Projects. Projects are defined that willconcentrate on one or more key areas: cost, schedule, and quality.

Two popular approaches for deploying Six Sigma are DMAIC (Define-Measure-Analyze-Improve-Control) and DFSS (Design for Six Sigma) for structured problem

Impact of Six Sigma

The Six Sigma strategy affects fivefundamental areas of business :-

1. Process improvement2. Product & service improvement3. Customer satisfaction4. Design methodology5. Supplier improvement

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solving roadmap & tools. Whereas DMAIC methodology is used for minimizing thevariation in the processes, DFSS is used during new Product and Process Development.BSP personnel have been trained at present on D-M-A-I-C Methodology.

Aspects of Six Sigma

Six Sigma approach integrates the human and process elements of improvementto produce breakthrough results.

Human elements

Strong leadership

Training

Customer focus

Project teams

Culture change

Process elements

Analysis of variation

Disciplined approach

Quantitative measures

Statistical methods

Process improvement

Implementation Strategy for deployment of Six Sigma in Bhilai Steel Plant :

Six Sigma initiative was launched in Bhilai Steel Plant with the objective tocreate a self sustaining infrastructure for implementation of Six Sigma, selection ofprojects and executives for different roles, v.i.z., Champions, Black Belts, GreenBelts.

Approach

It was decided to engage a reputed consultant for deploying Six Sigma in theorganization with the objective of providing appropriate training /certification to theexecutives as Champions, Black Belts and Green Belts as well as support to theManagement and the members of Six Sigma community for successful deploymentof Six Sigma in BSP with measurable improvements in Quality, Productivity, Deliveryand Costs.

BMG India, the leading Six Sigma service provider in the country and a part ofBreakthrough Management Group Inc. USA was engaged for complete deploymentof Six Sigma in BSP.

Implementation

A roadmap for the deployment of Six Sigma in one year was prepared. 104senior executives were developed as Champions. The champions identified projects

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in their respective areas. 25 projects were selected as Black-Belt projects in the firstphase. Accordingly 25 executives were selected to handle these projects as BlackBelts. Since Six Sigma training is project based learning, the DMAIC principles, toolsand techniques were simultaneously applied to these projects as the trainingprogressed.

Apart from this a separate pool of 90 executives was also developed as GreenBelts to assist Black Belts in their projects and also independently handle the projectswhich do not require the rigorous methodology as required in Black Belt projects.

In the first year of implementation of Six Sigma, a total of 71 projects (46 BBproject and 25 GB projects) were identified which were handled by various BlackBelts and Green Belt executives. Most of these projects proved instrumental inimproving the process parameters in various departments of BSP.

KNOWLEDGE MANAGEMENT

It was decided in October, 2004 to implement KM in BSP. Initially the focus wasgiven on communication and training. Around 100 officers were exposed to KMconcept by MTI faculty in the initial months. The KM group members carried out anextensive communication through a series of awareness workshop across theorganization. A total of 13 workshops were organized covering around 750 executivesin the last week of November 04 to increase awareness about the concept and itsusefulness.

Electrical Community was the first to start Knowledge Management initiativefollowed by Engineering Shops, Mechanical, Utility, Quality, Long Rolling, and CokeOvens. 22 Communities of Practice were formed in BSP and Community Champions,as well as Coordinators identified for the different Communities. This was done througha formal communication from ED (W), Head of Task Force vide letter dated, 17.2.05.Personnel became 23rd CoP.

KM site

KM site facilities include fundamental of KM, Case Studies, facilities for sharingKnowledge Piece, facility for searching Knowledge Piece, facility for visiting Communitypages, real time performance graphs and other features. The repository has around5000 knowledge pieces in various categories viz. Experience, Literature, SOPs andStandards

Recent Achievement

A two-day inter-plant Knowledge Management workshop to Evolve BestMaintenance Practices of Large D.C. Machines was conducted at Bhilai Steel Plantby the Electrical Community of Practice on 9th and 10th January 2007. The workshopwas organized with the objective of pooling the knowledge and expertise availableacross the industry by sharing experiences to evolve the best practices in maintenanceof large DC

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The workshop had active participation from all SAIL units as well as RashtriyaIspat Nigam Ltd (RINL). 30 delegates from nine steel plants discussed their maintenancepractices across seven sessions and sought solutions to their problems. The sessionsdealt with Maintenance Practice of Large DC machines, Brush grade selection andtype of brushes, Case studies on typical sparking problems, Testing and protectionof large DC machines, Mechanical aspects of large DC Machines, Repair aspects oflarge DC machines and Typical breakdown case studies.

Future Plans

BSP has developed a KM websitethrough in house resources, which haslimited facilities. We do not have featureslike personalization of portal, expertisesearch, role and rule based access andautomatic taxonomy management. Alsopresently, BSP neither have IT packagefor Work Flow & Document ManagementSystem nor collaborative tools which arethe basic building blocks for any IT enabledKM system.The present IT system for KMhas limitations and accordingly a tenderdocument for KM System for BSP hasbeen made and put up for approval of themanagement. The major objective of theproposed KM system is to capture,manage, retrieve and share the structuredand unstructured knowledge of the peoplein the organization. The aim is to provide a robust IT infrastructure to facilitate KMprocess in the organization. The proposed system will be integrated with otherfunctional legacy systems and also with proposed ERP and MES systems which arebeing planned for implementation simultaneously.

Technology Infrastructure for KMS

Single-sign-onTaxonomy ManagementFederated/ unified SearchSecurity and access control includingfirewallBackup and Recovery capabilitiesTracking usage AnalysisWeb Content ManagementWeb Portals and personalizationDocument ManagementWork FlowCollaborative toolsRecords management

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PRODUCTION PLANNING & CONTROLIn order to ensure harmonious functioning of various production shops and service

units of an Integrated Steel Plant like ours, it is essential to have a central coordinatingagency.

Production Planning & Control department performs this function of centralcoordinating agency at Bhilai Steel Plant by coordinating all production related activitieswithin each major production unit as well as providing an essential link for facilitatinginter-departmental movements of materials and related services having internalcustomer supplier relationship.

The work allocation amongst the different groups/wings and sections of ProductionPlanning & Control department is as indicated below :

The main functions of PPC are: Preparation of Production Plans, Programming &Scheduling of various rolling Mills, follow-up and monitoring for achieving productiontargets, compiling various data/information and preparing MIS reports. In addition toabove, PPC is also associated with 'Despatch coordination' for Despatch of Iron &Steel from the Plant.

1. PLANNING

Planning section of PPC Department is responsible for formulating the productionplans related with all the areas of operation of the plant starting right from the Captive

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Mines, Procurement of Raw Materials from outside sources including Coking Coalthrough CCSO, production and performance plans for each of the shops in the plant.The plans necessarily include the stage -wise material balances based on techno-economic parameters, which become the yardstick for evaluating the performance ofeach production unit. The various plans in vogue are the Annual Business Plan (ABP),Monthly Operative Plan and Contingency Plans.

All plans are essentially sales-oriented and based on the projections of marketdemand given by the Central Marketing Organisation (CMO). The formulation of theABP is based on the following considerations:

Market demand projections as given by CMO

Production Targets for the Major Products/ Potential for production

Availability of production equipments based on capital repairs and maintenanceschedules for the year.

Techno-economic parameters and their norms.

Overall and stage-wise, process-wise Material Balances.

Other major functions of Planning section are:

Preparation of Monthly Operative Plans considering availability of orders indicatedby CMO based on Sales Co-ordination/Pre Sales Co-ordination meeting and productioncapability linked with equipment availability.

The date-wise rolling plan of Rail & Structural Mill, Merchant Mill, and Wire RodMill are worked out by Finishing Mills taking into account the targets for the month,rolls availability, priority & availability of orders, availability of input materials andrepair programme. The date-wise rolling plan of RSM, Mer.Mill & WRM includesProfiles/Sections to be rolled, quantities to be rolled and the date on which these areto be rolled.

Planning of special quality heats for SMS-1 and planning for placement of steelorder on SMS-1 as per requirements of BBM, RSM, Merchant Mill & Wire Rod Mill.The daily steel order for the next day is decided in the meeting chaired by GM(Mills)or his representative. The meeting is attended by representatives of 2.5 MT Mills,SMS-1, RCL and PPC. The Steel Order so decided is then issued by GM (Mills) underhis signature.

Facilitating the procurement of Coking Coal, Boiler Coal and other raw materialsas per requirement and stocks available in the Plant.

Monitoring the production and despatch of orders of all special quality products,Key Account orders, Direct despatch orders for Home Sales and Export of long products(semis and finished).

Preparation of contingency plan in case of crisis situations causing shortage ofmajor inputs like Coking Coal or Power and major break down of essential equipmentsin the plant.

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2. PROGRAMMING

PPC (Programming) is responsible for real time planning for production of SMS-2 and Plate Mill.

Slabs are produced in the Converter Continuous Casting route of SMS-2, whichis input material for the Plate Mill. "Slab Programming" is the a vital activity for PlateMill and has direct bearing on Plate Mill productivity and yield. This is very complexbecause of divergent customer requirements in terms of sizes, specifications andtechnical delivery conditions. More complexity is added to the job of programming asthe slabs are produced through Continuous Casting route due to "fixed-slab crosssection" and the concept of "optimum reduction ratio". For every order (size andquality) of plate, slab length is to be decided right at the time of planning for productionof steel.

In addition to meeting the requirement of Plate Mill the production capacity ofconverter and continuous casting shop is to be fully utilised by properly planning forproduction of blooms for UTS-90 rails and production of slabs for inter Plant Transfer/Sale/ Export.

From this, it is evident that in order to maintain a smooth and steady materialflow, it is necessary to have a well knit dynamic planning system (real time basis) forthe Converter And Continuous Casting Shop (SMS-2) and Plate Mill.

2.1 Computerised Plate Monitoring System

Programming for SMS-2 and Plate Mill involves handling of voluminous data.Manual handling of such system would be tedious, time consuming and error prone.In view of these limitations of manual data processing, "computerized productioninformation system in 4.0 MT area" has been developed in Bhilai Steel Plant with in-house expertise.

The system is based on "Distributed Data Processing" on the Local Area Network(LAN) of personal computers placed at 28 nodal points of SMS-2 , Plate Mill andPPC(programming). This system is working very efficiently for processing of plateorders, faster decision making, monitoring of order fulfillment for better customersatisfaction and other MIS related activities.

2.2 Functions of Programming Section

Production Planning for SMS-2, keeping in view the requirement of Rail Blooms,Slabs for Plate Mill and Slabs for IPT & Sale.

Participating in meeting for enquiry and internal review of customer requirementfor Plate and Slab orders for acceptability as per production range & capabilityof plant.

Processing of orders for plates and slabs for Home Sales and Export.

Placement of 'Daily steel order on SMS-2.

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Round the clock monitoring of steel order compliance and updating of stockposition of slabs for Plate Mill.

Programming of production of plates.

Monitoring of production/despatches of Plates and Slabs for Home Sales andExport.

2.2.1 Production Planning for SMS-2

Overall production of Slabs and Blooms from SMS-2 is decided by Programmingsection keeping in view the optimum utilisation of resources of SMS-2 and therequirement of Rail Blooms, Slabs for Plate Mill and Slabs for Inter plant transfer &Sale both export and home sales. Considering this, total number of heats grade-wiseto be ordered in a day on SMS-2 is decided.

2.2.2 Enquiry and Internal Review of orders

Customers give their orders to Central marketing Organisation for booking theorders. If the requirement given by the customers are not within the standard productrange of BSP either in terms of Technical Delivery Conditions or size, then beforebooking the orders these requirements are referred to plant for confirmation.

Acceptability of these orders is decided by the 'plate /slab enquiry ' committee,Representatives of shop (Plate Mill/SMS-2), RCL, M&SP and PPC (Programming)participate in the `Enquiry Committee' meetings for Plate/Slabs.

Before issue of final Movement plans /Export orders , CMO/ITD issue the draftmovement plans/draft Work order for examination of size, technical delivery conditionsand decide the delivery schedule in the ̀ Internal Review Meeting' where representativesof PPC (Programming), M&SP, Shops (Plate Mill/SMS-2) and RCL participate.

2.2.3 Processing of Plate Orders

Home sales plate orders in the form of "MOVEMENT-PLANS" (MPs) issued bySRM Bhilai of Central Marketing Organisation (CMO) and Export Orders in the form of"Work Order" issued by International Trade Division of CMO are received throughMarketing Department. Like-wise Internal Transfer Order (ITO) is issued by Marketing& Strategic Planning Department for Plant consumption. All these orders after, scrutiny,are transferred to the LAN order file.

These orders are processed in the computer system to decide the slab sectionand slab length required for each order.

2.2.4 Steel Ordering

The Daily Steel Order is placed on SMS-2 for heat making at Converter andcutting of the Continuous Cast Slabs and Blooms to desired lengths to meet thedown stream requirement.

While placing the steel order on SMS 2 fulfillment of following down streamrequirements are to be ensured.

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i) Requirement of slabs for Plate Mill to meet the commitment in respect of qualityand delivery schedule.

ii) Inter Plant Transfer (IPT) order for slabs.

iii) Slab order for both Export and Domestic Market.

iv) Bloom requirement for Rail & Structural Mill.

While placing the steel order on SMS-2, following points are considered :

i) Availability of Casters in the Continuous Casting Shop and their uniform loading.

ii) Stocks of deferent grades of slabs in "Slab & Bloom Storage Yard".

iii) Plate Sections to be rolled in Plate Mill.

iv) Rake movement plan for particular destinatio.

After finalising the total number of heats and the grade-wise and caster-wiseheats to be ordered, 'Daily Steel Order' is fed in the LAN computer.

2.2.5 Round the clock monitoring of steel making

Round the clock monitoring of steel making at Converter and Casting at CCSw.r.t. Steel order, continuous interaction with Process Control (SMS-2) is done toensure the heats are made as per ordered grade and slabs are cut in the requiredlength. In case of diversion at heat making stage alternate cut length is given and theheat is fitted into suitable order.

Preparation of 'Heat balance for Plate Mill heats' and its updating is done oncontinuous basis by adding heats made, deleting heats supplied to Plate Mill forrolling and indicating the status of heats which are inspected and made ready forrolling.

Continuous monitoring and follow up of status of ready heats in "Slab & BloomStorage yard" is done to ensure balance availability of ready heats in different gradesand for different sections of plate to be rolled for timely fulfillment of orders, effectiveutilisation of Plate Mill roll set life and optimum yield in Plate Mill.

2.2.6 Programming of production (rolling) in Plate Mill

It consists of preparation of "Slab supply sequence" "Slab discharging Programme"and "Rolling Programme".

i) Slab supply sequence is prepared to facilitate planned rolling of ready heats,selected and sequence on the basis of thickness to be rolled, ultrasonic testrequirement, other technical delivery conditions and conditions prevailing atdifferent areas of Plate Mill.

ii) Slab discharging programme is prepared for discharging of slabs from reheatingfurnaces of Plate Mill.

iii) Rolling programme is prepared for rolling of slabs discharged from the reheatingfurnaces of Plate Mill to ensure rolling of the slabs into plates of size and

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technical delivery conditions strictly as per "Movement Plan" (Customer'srequirement).

Details of "Rolling Programme" are fed into the LAN computer in the prescribedformat. Rolling Programme contains the following particulars.

(a) Running Slab No. (b) Heat No., (c) Slab size, (d) Slab weight, (e) MovementPlan No., (f) Grade, (g) Destination. (h) Technical conditions, (i) Rolled length, (j)Finished Plate size, (k) Tolerance on plate dimensions etc.

2.2.7 Monitoring of production / despatches of Plate and Slab

Monitoring is carried out on continuous basis to ensure that orders are fulfilledboth in terms of quality and delivery schedule.

i) Home Sales and Export Plate Orders

In the beginning of every month, based on requirement indicated by CMO, list ofHome sales orders of plates to be executed during the month is decided jointly by M&SP Department. Plate Mill & PPC (Prog.).

For Export orders, delivery schedule is decided in internal review (when order isreceived from ITD). Grouping of order in terms of grade and plate size is done manuallyto work out the heat requirement on daily basis. After the heats are made and suppliedto Plate Mill for rolling and further processing, the stage-wise status (like tonnagerolled, finished, normalized, tested, passed in final inspection and despatch) of eachorder is updated in the LAN computer system by the respective agencies. The updatedstatus, as can be had from the computer, forms the basis for review and planning offurther heat making and rolling. This process continues till the order is completed.

ii) Slab orders for Home sales and Exports

Delivery date is decided at the time of receipt of order in internal review.Compilations of data and updating are done in the LAN computer for each order ondaily basis. Heat making is decided on the basis of inspection result.

This continues till the order is completed.

iii) Slab for Inter-Plant Transfer (IPT)

Plan for IPT is issued by "Corporate Office". Heat making and inspection dataare compiled on daily basis to decide further heat making to ensure fulfillment of IPTrequirements for the month.

Plates produced are despatched from the shipping section of Plate Mill after theplates are cleared in Testing and Final inspection. PPC (Programming) monitorsavailability of order-wise and destination-wise ready material to facilitate fasterdespatch. When despatch can be in rakes, PPC interacts with the despatchcoordination, to ensure availability of material for faster completion of rakes. In caseof failure of plates in MTL or Final Inspection, further planning of production is takencare of.

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3. SHOP PRODUCTION CONTROLS

3.1 The shop level coordination and follow-up of production is carried out by PPCShop Controls situated at the major production shops. The following shopshave such Production Controls manned round the clock by PPC personnel:

Blast Furnaces.

Steel Melting Shop-I

Steel Melting Shop-II.

Blooming & Billet Mill.

The main functions of the shop control are:

Co-ordination of all production-related activities within the shop and relatedshops necessary for smooth functioning of the shop.

In case of any breakdown , intimating to all concerned for early liquidation ofbreakdown, so as to ensure minimum disruption of the production cycle.

Co-ordination for timely placement of Ladles, Mould Trains and Slag Ladles asrequired for tapping, flushing or teeming at the furnaces.

Follow-up of Hot Metal Ladles to both Steel Melting Shops, Foundry and PCMso as to avoid hold-up and ensure quick turn-around.

Monitoring of Coke position in the Blast Furnace bunkers.

Recording of production related data in the daily log sheets.

Giving hourly report to Plant Control for giving feedback to Plant management.

Reporting to the HOD's and other senior officers of the shop.

To facilitate quick and reliable communication, all-important controls are equippedwith special despatcher sets. Each set has direct telephone lines connected to individualsection of the unit and controlling officers. This is in addition to the general telephonenetwork provided for plant.

3.2 HEAT MOVEMENT CELL

A special cell formed as 'Heat movement cell' works round the clock and acts asan independent agency to regulate the activities involving supply of hot heats fromSMS-1 to Soaking Pits of BBM with a view to maximise the number of heats suppliedat temperature above 800°C.

Heat Movement Cell works round the clock and is manned in each shift. Themain functions of the Heat Movement Cell are to co-ordinate for :

Supply of heats made at SMS-1 to Blooming & Billet Mill (Soaking Pits) atmaximum possible temperature by timely removal of Heats from the Pit side.

Regular supply of cold Ingots to Soaking Pits as and when required.

Timely return of Hot Mould sets to Mould yard.

Timely removal of Bottom Plate Trains from the Soaking Pits for facilitatingfurther preparation of Mould Trains.

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4. PLANT CONTROL

Plant Control is the central agency for round-the-clock monitoring of all the plantprocesses and coordination between the major production units including follow-upof all the Internal Movement circuits in the plant for smooth and effective functioningby proper integration and least disruption to over-all working. The main functions ofPlant Control are:

Round the clock monitoring of plant performance.

Hour to hour co-ordination with various shops for production related activities.

Follow-up of internal movement of wagons.

Reporting the performance of the plant to different levels of Management.

Follow-up of in-coming/receipt and out-going/despatch of material.

Direct Telephone Communication System with dedicated lines to all senior officersof the plant including MD, ED (Works), GMs and HODs in the offices as well asresidences; provide the important infrastructure for instantaneously getting in touch,as and when required. Plant control , at present , has a sophisticated directtelecommunication set having 1 0 0 subscribers with an in-built conference facility.This facility is utilized daily by ED (Works)/MD for morning conference. The previousday's performance of Plant is reviewed and directives for improvement or change aregiven during this conference by ED (Works)/Managing Director.

Plant control works round the clock. There is an elaborate system of reporting ofthe progress of shop/plant operations, delays, breakdowns, operational parametersand connected problems. Detailed log sheets are maintained, which provide an overallinsight into the working of plant. Important operations are indicated in a chart formagainst the corresponding schedules to locate deviations. All delays are analysed andconcerned persons/agencies are appraised promptly, so that remedial measures canbe taken for the liquidation of breakdowns in the shortest possible time to limitdisruptions of process of the integrated working of Bhilai Steel Plant.

Formulating weekly tasks and daily schedules : One important function of Plant Controlis to formulate shop-wise weekly schedules and targets based on guidelines prescribedin the monthly plan. Availability of plant equipment and facilities on day-to-day basisand other prevailing limitations and priorities are considered in detail. Plannedmaintenance and shutdowns are detailed to ensure proper integration and leastdisruption to overall working. The weekly tasks are discussed every Monday in ameeting chaired by ED (Works). Production performance is reviewed every weekagainst the approved tasks. Achievements are highlighted and weak areas arepinpointed. Resources needed to make up the short-fall and improve performance arediscussed and decided upon. These are pursued further for implementation.

Plant Control MIS reports : Plant Control prepares the daily Plant performance (PlantControl MIS) which is a gist of the previous day's performance of whole Plant (fromMines to Despatches). It also prepares A Shift Plant performance report. These are

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available in the Plant intranet for easy accessibility of the top management and otherusers. Internal movement material, movement and date-wise production Gists areavailable to top management for ready reference and analysis.

Plant Control prepares the weekly Production performance review reports with delayanalysis for the shortfalls in the targets (shop-wise) for discussion, reviews, analysis andfuture action plans/ measures are decided in Monday ED(W) ABP meeting.

Major Plant Exigencies : During major crisis situations like Voltage dip, Power failure,Water logging due to excessive rains, Pump house failures etc., Plant Control co-ordinates, monitors and controls all the activities that are desired at that point as perthe guides of the Controlling despartment and its hierarchy.

5. STATISTICS SECTION

5.1 The statistics section is responsible for collecting , compiling , maintaining andsubmitting authentic data /information on production , despatch and operationalcharacteristics of the various units. Data for incentive calculation and costingare prepared and forwarded to the Accounts Department.

The section prepares various types of MIS reports on daily, weekly, monthly,quarterly & yearly basis regarding production, stock, despatch, techno-economicparameters/ operational indices etc. for evaluating performance of the entirePlant in respect of both volume and financial impact.

"Operational Statistics" covering operational data for all shops is publishedevery year by this section, which is widely referred to for authentic informationon plant operations.

Other activities include furnishing data for various incentive schemes & costing,analysis of data, stage-wise material balances and other specific information asper requirement of Top Management as and when required.

The section also brings out, a booklet on "Technological Norms" every year forthe next year, which spells out target for various Techno-economic parametersto be achieved by major production shops. "Technological Norms" provideguidelines for operation at every stage of production.

Correspondence : Statistical section of PPC is the authorised agency for furnishinginformation regarding production, stock, Techno-Economic Parameters etc. tocorporate office, sister plants, Govt. organizations etc. Reply to parliamentaryqueries pertaining to technical area is furnished after taking approval of themanagement.

5.2 Technical Audit Cell : The technical audit cell is primarily responsible forprocessing the replies to technical queries raised by Government Audit (ResidentAudit Officer) in consultation with the concerned departments. The finalisedreplies for Draft Audit Paras are put up to the Management for approval beforeonward communication.

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6. DESPATCH CO-ORDINATION

Despatch Co-ordination is responsible for planning of loading and despatch ofsaleable steel (Semi finished & Finished) from BSP on daily basis in coordination withSRM, Bhilai (CMO), all production/loading units (Blooming Mill, Billet Mill, SBS yard ofSMS-2, Rail & Structural Mill, Merchant Mill, Wire Rod Mill and Plate Mill), Marketing& Strategic Planning department (M&SP), PPC and Transport & Diesel department(T&D). The main functions of Despatch Co-ordination are:

Conducting daily meeting for planning of loading and despatch of Saleable Steel with therepresentatives of all loading units, M&SP, PPC, T&D department and SRM, Bhilai.

Organising meetings from time to time, with SRM and representatives of allloading units, M&SP, PPC and T&D department for formation of rakes.

Follow-up and co-ordination for fulfillment of daily loading plan and rake-despatchplan. Bhilai Steel Plant despatches about 350 thousand tonnes of Iron & Steel everymonth. Out of this, about 80-85% are despatched by rail in rakes for CMO, Exportand IPT, 10-15% by road for CMO and about 5-6% in internal wagons for Plant Salesand internal consumption.

Rake formation : Raek for mation is a crucial step towards planning for despatchof saleable steel. Efforts are continuously being made to despatch saleable steel inrakes to various destinations for which rake formation is not possible, despatches aremade in loose wagons or by road also.

CMO network of SAIL has 38 stockyards/ Branch Sales offices spread out allover the country and is divided into 4 regions viz., Eastern, Western, Northern andSouthern region. Customers book their orders with CMO through these Branch SalesOffices, the orders which subsequently come to SRM, Bhilai, who ultimately releasesorders to the Plant through M&SP department. Some customers receive delivery ofmaterial through stockyards and some receive the material directly at desireddestinations at private/ railway sidings. Orders released by SRM to Plant are in theform of Movement Plan for stockyards or Direct despatch for production and despatchof material by rail/ road. Rakes are formed for various stockyards, or direct despatchdestinations, or both combined, for despatch of material in railway wagons; consideringthe destination-wise orders availability matching with material available in stock andthe rolling plan in coming days. Combination rakes are formed for destinations approvedby Railways to avail concessional freight.

Rails for Railways are despatched in independent rakes as per priority given byRailways. Export Material is despatched mostly to Vishakhapatnam port and IPTmaterials are despatched to Sister Steel Plants.

Daily loading plan and Rake Despatch Plan is made in the daily meeting inconsultation with the representatives of all loading units, M&SP, PPC and T&Ddepartments. Target for daily loading is kept around 12,000 T. Loading of rakes is

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planned in such away that the rakes are despatched within free time allowed byRailways to avoid demurrage due to detention of railway wagons. Augmenting of theloading against orders for Special Steel, Key Accounts and Direct Customers is alsotaken care of.

Loading and despatch of saleable steel to required destinations is done in rakesconsisting of various type of wagons. Flat wagons-BRN, BFN are used mostly forloading of Rails, Heavy Structurals, Light Structurals, Rounds & bars, Plates. HeavyBlooms and Killed Slabs. BOX/ BOST/ BOXN wagons are used mostly for loading ofWire Rods and Billets. BOX/ BOST wagons are also used for loading of Light Structurals,Rounds & Bars and Plates as per type of rake. For loading of Pig Iron and Hard Coke,BOXN wagons are used.

Standard rake size and Type of Wagons approved by Railways are as under :

Type of Wagons Size of Rake (no. of wagons)

BRN : 35 to 40

BOX : 35

BOST : 42

BOXN : 58

BOST + BRN : 35 (minimum 10 wagons of BOST or BRN)

BOXN + BRN : 35 (minimum 10 wagons of BOXN or BRN)

: 40 (20 BOXN + 20 BRN)

: 50 (30 BOXN + 20 BRN)

Considering the type and number of wagon available, loading plan is made forvarious shops as per rake plan already decided.

7. ORDER MONITORING :

Monitoring of despatches is carried out on daily basis against the orders forSpecial Quality Steel, Key Accounts, Direct Customers, Committed Delivery, Railwaysand Export.

On-line status of orders is available for long products in 'Sun' computer systemfor 2.5 MT area and for plates in "computerized production information system (localarea network-LAN)" for 4.0 MT area. These systems are also helpful for generatingvarious reports, which are used for monitoring the availability of orders as per monthlyproduction/despatch plan. Party-wise, destination-wise & item-wise reports aregenerated with the help of these systems, which help in rake formation and prioritisingloading of available material. PPC monitors fulfillment of orders for Special QualitySteel, Key Accounts, Direct Customers, Committed Delivery, Railways and Exportand availability of order-wise and destination-wise ready material to facilitate loadingin the planned rakes.

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COST CONTROL DEPARTMENT

Cost Control Deptt. has been setup to help bring in a turnaround by reduction ofcost of production by way of assisting the production shops as well as servicedepartments in maximizing Cost Reduction efforts in all fronts, like:

Improving Techno Economics

Reducing Maintenance Cost

Effecting Wastage Elimination

Recycling Metallurgical Wastes

Reducing Power Consumption

Optimising Asset utilization, etc.

To achieve Cost Reduction, we have to tap the innovative potential of theemployees and need to follow the "Quality & Cost- Route". In fact, the job of CostControl & Cost Reduction of every department is like functioning as a member of anorchestra. It depends on the team whether the result is MUSIC or NOISE.

CONCEPTS:

The determination and control of costs incurred by a business enterprise is ofmajor importance to enhance its profitability. The basic equation summarizing thetrading activities of a business is:

SALES - COST = PROFIT

The level of sales income depends ultimately on the customers of the business.To some extent, their actions can be influenced by the QUALITY & PRICE of theproducts we offer them.

Control can not be exercised without reference to a certain plan of action and anAction Plan can never be rigid and has to be dynamic, in a sense it needs continuousreview in the course of implementation.

The basic step to be taken is to find out what precisely needs to be controlledand who is responsible for controlling. Before proceeding to access the efficiency ofcontrol, it should be ascertained that tools of control are right in every respect. A'Cost Centre' is the smallest area of responsibility. The performance Report is a toolin the search for devising better methods for accomplishment of given objectives. Itis not possible to categorize costs and expenses rigidly as controllable andun-controllable. All costs are controllable in the long term, anyway

Cost Control :

- Principles of Cost Control : The mechanism of controlling costs lies in:Cost ascertainment, Cost analysis & Control action.

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An effective control scheme needs a clear definition of the objective . Controlpresupposes measurement and needs engineering & costing norms / standards. Actualaccomplishment has to be measured against the standard. When actual divergesfrom the norm, the control scheme should include an automatic system of investigation& determination of the reasons for the discrepancy for taking appropriate actions.Various techniques like setting standards, standard costing & budgetary control areused for the purpose of COST CONTROL.

Cost Reduction :

Cost Reduction is the achievement of real and permanent reduction in the unitcosts of products manufactured or services rendered without impairing their suitabilityfor the use intended.

Therefore, the essentials of Cost Reduction are :

Reduction must be real in the course of manufacture or services rendered.

The Reduction must arise from within the organisation by improved efficiency

and innovative means.

Reduction must be a permanent one.

Essential characteristics and quality of the products should be retained.

THE BASIC IDEA BEHIND COST REDUCTION IS THAT: THERE IS A BETTERWAY OF DOING EVERYTHING. Also, we should remember Cost Reduction startswhere Cost Control ends!

Fixed Costs & Variable Costs :

The portion of total expenditure which remains fixed and continue to be incurred,irrespective of the level of Production is called FIXED Cost e.g. Basic Salary, DA &other Perquisites as paid to the employees, etc.

The portion of the total expenditure which changes with the level of productionis known as VARIABLE Cost. e.g. raw materials, incentive bonus, direct supplies &services, etc.

Cost Variance :

It means the difference between the standard cost and actual cost incurredduring a period. If the cost variance is favourable - it is an indication of "Efficiency".

It is prudent to examine minutely the courses of favourable or adverse variance.This helps in exercising proper control by taking appropriate corrective actions.

Type of variance practised: Works Cost Variance, Volume Variance, ExpenditureVariance, Usage Variance & Rate Variance.

EVERY ONE SHOULD HAVE THE KNOWLEDGE OF RELEVANT COSTS IN HISAREA AND SHOULD IDENTIFY WHAT COSTS CAN BE CONTROLLED BY HIM ANDSHOULD ACCORDINGLY FUNCTION COST-EFFECTIVELY!

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*PICTORIAL REPRESENTATION OF COST MREDUCTION PROCESS

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REQUIREMENT :

Every individual is one of the most important links in our total chain of HumanResources. Everyone is experienced and know the best in his area of working. Underpresent business scenario, we need to change as per the requirement of times. Ourendevour is to stress the need for this change and impress upon individuals to payattention on the following :

Moulding the attitudes to become positive & take up challenges to achievebetter performance .

Inculcating Quality and Cost Consciousness.

Fulfilling obligations towards customer satisfaction both for internal and externalcustomers.

Encouraging to use innovative potential in Processes, Methods & Systems soas to achieve excellence.

Using benchmarks to be competitive and survive even in harsh Businessenvironment.

Any Cost Reduction effort in the Company requires TOTAL involvement, initiativeand support of the entire collective at each level.

CONCLUSION :

Managing radical performance improvement is vital, since the changes aheadare so radical that incremental improvement in performance, though necessary, isinsufficient. One of the most important issues as now, facing the Steel industry isthat of BUILDING COST CULTURE among the Employees.The Cost Control Deptt.endeavors to act as a catalyst in tapping the potential of the work force to meet thechallenges of the times and achieve collective excellence in performance which shalllead to sustained Cost Reduction for the Company, thus attaining the GOAL of CostLeadership.

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TRAFFIC DEPARTMENT

Traffic Department is a vital department which takes care of all internal andexternal movement on Rails of various raw materials, procces materials, semi-finishedand finished materials involved in running of a steel plant. This movement starts rightfrom Railway Exchange Yards to material handling points of user shops. It takes careof movement of hot metal, ingots,blooms, slabs and also slag, muck, scrap, coke-fractions, flue-dust, used refractories etc. which are generated during various processesin the plant. Collection of empties from Railways and supply to different loadingpoints, like various mills and despatch of loads to Railways, is also the job of thisdepartment.

Traffic Department comprises of two main sections :

1. Traffic Section (Rail Transport).

2. Maintenance wing.

1. TRAFFIC SECTION :

Rail Transport is linked up with the technological process of steel making fromthe beginning of the process and continues till the completion of the process. Receiptof raw materials, dispatch of semi finished and finished products, removal of industrialwastes, internal process materials movements etc., should maintain a strict continuitywith the technological process of a Steel Plant. Thus, the objective of the TrafficDepartment is to establish and maintain the continuity of the process from the stageof input to the finished stage (at the speed defined by the process), dispose offwastes and despatch of finished materials with a view to reach places of consumption.About 7.5 MT of traffic (External & Internal) is handled for production of 1 MT crudesteel, as shown under -

External Traffic : I/Ore- 1.65 MT

Flux - 0.55 MT

Coal - 0.90 MT

B/Coal - 0.20 MT

External Despatch - 1.00 MT

Total - 4.30 MT

Internal Traffic : Hot Metal, Ingot, Bloom, Scrap, Bloom Butt, Slag,

Muck, Flue Dust, Coke-fraction, etc. 3.20 MT

Total Traffic : External + Internal- 7.5 MT

(A) External Traffic :

Receipt of Raw Materials and despatch of finished products in association withIndian Railways. The movement is linked up on one side with Bhilai Exchange Yard

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and on the other side with Maroda Railway Station both of South Eastern Railway.Most of the raw materials for the plant are received directly through Peripheral Yardand Maroda Station link. Receipt of low silica lime stone for SMS-1 , empty wagonsfor outward loading and dispatch of finished and semi finished products are carriedout through Bhilai Exchange Yard link. Works Station is the main exchange yard ofour plant connected with double lines to Bhilai Exchange Yard.

(B) Internal Traffic :

It is mainly for inter-shop movement of various process material and semi finishedgoods, raw material, scrap, and all other miscellaneous traffic inside the plant. It isorganized in a modern style of contact schedule system.

All traffic activities are controlled by five stations and one Peripheral Yard. Thefunction of each of the stations is given below :

(a) Works Station and Rolling Mills Post :

(i) Interchange of pilots from SE Railway.

(ii) Receipt of raw materials such as low silica lime stone, ferro alloys,manganese ore etc. and their transfer to unloading points.

(iii) Formation and sorting of trains, both for outward despatch and internaltransfers.

(iv) Despatches of finished products and empty wagons to Bhilai Exchange Yard.

(v) Supply of empty wagons to various loading bays of rolling mills and coldpig yard and collection of loads from there.

(vi) Services to auxiliary plant area, disposal stores and Bhilai Stock Yard.

(vii) Services to Peripheral Yard.

(viii) Co-ordinating commercial activities with SE Railway.

(b) Raw Material Station & Plate Mill Post :

(i) Receipt of raw materials like lime stone, sulpher & manganese etc. fromWorks Station, and Iron ore from Maroda Railway Station in Ore Trench.

(ii) Formation and shunting of trains for empty wagons, or mix trains of loadsfrom coal chemicals plant.

(iii) Transport services to Coke Ovens & Coal Chemical Plant, BF highlines,Ore Trenches, Sintering Plants 1, 2 & 3, and Plate Mill.

(iv) Supply of coke to BF highlines in case of conveyor belt shutdown / breakdown.

(v) Movement of finished plates and slabs to Works Station, for despatch.

(vi) Supply of wagons to Plate Mill and Slab Yard, for loading.

(c) Blast Furnace Station and Cold Pig Yard :

(i) Provide transport facilities to Blast Furnaces and Pig Casting Machines.

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(ii) Transportation of liquid hot metal to mixers of SMS-I & II, PCM, Foundry,and disposal of BF slag to Slag Granulation Plant and BF Slag Dump.

(iii) Disposal of BF waste products like flue dust, coke breeze, nut coke, muckfrom hearths, lime sludge and iron scraps from PCM.

(iv) Formation of trains in Cold Pig Yard and dispatch to Works Station.

(v) Supply of boiler coal to power generation hopper at PP-I.

(vi) Transport facility to scrap preparation shop.

(d) Steel Station :

(i) Provides transport facility to Steel Melting Shop.

(ii) Movements of heat and mould trains to & from SMS-I.

(iii) Movement of hot ingots from stripper yards to soaking pit.

(iv) Supply of bulk charge and magnetic charge material to OH furnace.

(v) Disposal of slag from furnaces, O.H. scrap from Mould Yard, and otherwaste materials.

(vi) Supply of new mould from foundry and insert-plates from steel structuralshop to mould yards of SMS-I.

(vii) Supply of Ferro Manganese and Ferro Silicon to furnaces.

(e) Open Hearth Station and Muck Dump :

(i) Provides raw material to bulk charge yard, and scrap to the magnetic yardof SMS-I highlines.

(ii) Transport facilities for auxiliary shops , liquid fuel station and RefractoryMaterials Plant.

(iii) Collection of scrap from rolling mills, skull breaker yards, slag yards, muckdump etc.

(iv) Dumping of dump car loads from slag yard, and supply empty dump cars.

(v) Services to wagon depot & expansion stores.

(vi) Provides transport facility to Converter Shop, Slag Yard, Ferro Alloy Depots& Continuous Casting Shop.

(vii) Bloom movement from SBS to Bloom Storage Yard.

(viii) Movement of scrap to Convertor Shop.

(ix) Placement & withdrawal of OH grade Iron Ore, Lime stone , Dolomite,Ferro Alloys.

(f) Peripheral Yard :

(i) Receipt and handling of raw materials for SP-II, RMP-II, Convertor Shopand BF-7 through O.H.P. using 1 Ore Tippler and 2 sets of Track Hoppers.

(ii) Receipt of boiler coal for PP-2 and PP-1.

(iii) Receipt and handling of coking coal through 3 wagon tipplers for theCoke Ovens.

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(iv) Receives train of coal, boiler coal, lime stone, low silica limestone, dolomiteand manganese ore from Railways.

(v) Transfers boiler coal for Power Plant-I, Coal for CDI (Coal Dust Injection),Dolomite & Lime Stone for RMP-I & SMS-I.

(vi) Despatch of empty wagons to SE Railway.

TRAFFIC HANDLING FACILITIES IN TRAFFIC DEPARTMENT.

A. Control :

There are five control sections to co-ordinate and to expedite the movement,round the clock, all over spread and number of activities of Traffic Department fromone end to other end of the works. These controls are as follows :

(i) Train Control : Co-ordinate and control all the external traffic activities of theworks viz. exchange of trains with Railway; handling of railway wagons insideplant and inter station movement etc.

(ii) Commercial Control : Co-ordinates for commercial requirements with Railwaysand plant viz. supply of empties, wagon loading, despatch advises, booking oftrains, invoice, railway permission etc.

(iii) Power Control : Field operation of locomotive, deputation of staff, daily inspection& movement of locos for maintenance, attending to minor repairs of power(Locomotive) are centrally controlled and coordinated from this control.

(iv) Permanent Way Control : Coordinates all the day to day maintenance, repairand inspection of permanent ways as well as emergency repairs of tracks.

(v) Railway Signalling Control : Coordinates all the day to day maintenance, repairand inspection of Railway Signalling and communication equipment of TrafficDepartment.

B. (i)Locomotives :

The department has a fleet of 79 locomotives comprising the following varioustypes of locomotives :

S.No. Make Nos Type Horse Power1. Russian (Caterpillar) 23 Diesel Electric 750

2. Czech Repowered 9 " 650/700

3. WDS-6 41 " 1400

4. G.E. 6 " 670

Total Locomotives 79

For transfer of rakes (pilot movement) from Bhilai Exchange Yard, PeripheralYard and Maroda Station, WDS-6 locomotives (of Higher HP) are exclusively used;these have been equipped with vacuum brakes.

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The area wise break up of locomotives working for transport services (at present)are as follows :

1. Works Station & Rolling Mills Post - 7 + 1 (Control) + 1 standby

2. Raw Material Station - 6

3. Open Hearth Station - 8 + 2 (Compresor Loco) + 1 standby

4. Blast Furnace Station - 21 + 1 standby

5. Steel Station - 12 + 1 standby

6. Peripheral Yard - 5

7. Wagon Depot - 160+1(Control)+2 (Comp. Lo.)+4 stand by locos

(ii) Rail Cranes :

To meet the various requirements of production shops, and to attend toderailments, the plant has the following types of Rail Cranes.

S.No. Make Nos. Lifting Capacity1. Hitachi 1 100 tons.

2. American Braithwaite 4 50 tons.

C. TRAMS :

TRAMS is an acronym for "Traffic Management System". It is a computerisedsystem and the first system of its kind in India. It has been developed indigenously,with very little imported hardware components.

OBJECTIVES

The major objectives of TRAMS are as follows:

(i) Capturing of information regarding various activities of railway wagons, internalrolling stock and locomotive inside the plant for monitoring and analysis,abnormalities and operational bottlenecks such as derailments, track damagesand loco failures.

(ii) Computerization of commercial activities like weight capturing, wagon to DAlinking, shadow demurrage calculation, forwarding note preparation .

(iii) Capturing activity-wise data of each railway wagon to help negotiations withrailways and providing analysis for improvement.

(iv) Generating various reports and graphs to help decision-making processes in theorganization.

(v) Maintaining of web pages of Traffic Organization.

HARD-WARE CONFIGURATION

The system constitutes of the following hardware:

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MAIN COMPUTER

SYSTEM : SUN 450 (SOLARIS)

DATABASE : ORACLE 9i

TERMINALS

50 Nos of PCs including few thin clients with printers located at 18 locations

COMMUNICATION

Fiber Optic Network integrated with plant wide networking.

POWER SUPPLY

100% redundancy in power availability by two feeders.

SOFTWARE CONFIGURATION

The data resides on Oracle database. The database server is at C&IT and isconnected through fiber optic networking. Users interact with the system using GUIdeveloped in Developer 2000, Java and ASP.

The configuration consists of following major segment:

External Wagon Module

Internal wagon Module

MIS Module

Control Module

PPY Module

TXR Module

Weighbridge computerized data capturing and DA linking system (EasyWeigh)

Forwarding Note generation and RR feeding.

OPERATIONAL OVERVIEW

The various terminals of TRAMS have been located taking into consideration theactivities undertaken on any rolling stock. These activities include pilot interchange,yard shunting, wagon transfers, wagon placements and withdrawals, loading,unloading, weighment, booking and other commercial activities. There are terminalsat all stations and posts, all shipping bays and at all controls and offices.

TRAMS activities start with the train arrival at the exchange yard and all thefollowing activities are continuously captured after it has occured, which in turn isused by the system to respond to user queries about the wagons. Post dispatchinformation about the wagons is preserved in the historical database for analysis andenquiries.

TRAMS does not have any automatic data acquisition system and every input toit has to be given by manual data-entry.

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2. MAINTENANCE WING :

Maintenance of the plant locomotives and the rolling stock (for internal traffichandling) are carried out in the Loco and Wagon Depots of Transport & DieselOrganisation.

A. Loco Depot :

The locomotive are subjected to periodical examination and repairs at prescribedtime intervals which are adhered to, for reliable service. The following types of repairsare carried out in the Loco Depot. The service time and maximum intervals mentionedbelow are for diesel/ electrical locomotives.

For Medium Horsepower Locos (Below 750 H.P.)

Type Repair Time IntervalR-1 Prophylactic Inspections 15 ± 7 days

R-2 Minor Periodical Repairs 30 ± 7 days

R-3 Extensive Periodical Repairs 9 ± 3 months

R-4 Disassembly Repairs 18 ± 6 months

R-5 Capital Overhauls 54 ± 9 months

For High Horsepower Locos (Above 750 H.P.)

Type Repair Time IntervalRBM Repair Bimonthly 15 ± 7 days

RM Repair Monthly 30 ± 7 days

RY Repair Yearly 12 ± 3 months

R3Y Repair Three Yearly 36 ± 9 months

R6Y Repair Six Yearly 6 ± 1 year

The Loco Depot comprises the following main sections -

(a) Loco Maintenance :

This section carries out prophylactic repairs titled R1, R2 and R3 repairs, ofdiesel electric locomotives. There are 7 repairs pits to accommodate 14 locomotivesat a time. The section is supplemented with a battery room, E.O.T. cranes, capacity- mainhost - 15T, auxiliary hoist 3T.

(b) Engine Overhauling Section :

Reconditioning and overhauling of diesel engines is undertaken here. Facilitiesare also provided for testing of the overhauled engines. The section is equipped withhighly sophisticated equipments for :

(i) Calibrating fuel pumps.

(ii) Testing of oil and fuel lift pumps.

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(iii) Testing of water pump.

In addition the section has :

(i) WDS 6 engine governor test bench.

(ii) Dynamic balancing machine, machine for turbo-rotors.

(iii) PT fuel pump test bench.

(c) Loco Overhauling Section :

Lifting repairs and capital overhauls of diesel locomotives are carried out in thissection. It has five pits with lifting jacks. The section is supplemented with compressoroverhauling room, and an electrical repair section. Overhead cranes of capacity 30T/5T/ & 15/3T cater to all necessary work of loco overhauling.

(d) Electrical repair section :

Testing of electrical switchgears and electrical machines.

(e) Machine Shop :

A well equipped machine shop is provided to repair / reclaim old parts and tomanufacture small new parts too. Wheel turning lathe, horizontal boring machine and650 tonnes hydraulic press are the important machines in use in this area.

B. Planning& Procurement Group :

The group deals with the procurement of spare parts pertaining to loco andwagon depot and is responsible for planning maintenance schedule and overhaulingschedule of locos and wagons in consultation with the shops. Drawings of thecomponents for import substitutions & procurement are also made in this section.

C. Wagon Depot :

For the internal rolling stock (belonging to the T&D organisation) scheduled andpreventive maintenance are carried out in this depot. For this purpose, the wagondepot is equipped with most updated facilities near Boria Complex. It has its ownmachine shop, black smithy shop and bearing moulding shop.

Different types of Rolling Stock - Under T&D Organisation

Dump Car - 105

N.P.C. - 53

S.P.C. - 6

H.D.W. - 187

BOBX - 46

BOBS - 22

C.R.T. - 33

T.T.C. + F.T.C. + BTC - 13

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BOX - 59

BOBC - 33

M.S.W. - 7

BRH - 13

TOTAL 577Special Rolling Stock - Under Traffic Department

Plough Car - 3

Track Slewing M/c - 2

D. Permanent Ways :

The total length of the railway track inside steel plant is, at present, 234 kms,with 975 points and crossings, and 26 diamond crossings. For purpose of maintenance,the entire trackage has been divided into 13 maintenance zones and 2 dumps. Tocater to the needs of maintenance, capital repair groups have also been formed.

E. Railway Signaling and Communication :

Most of the external traffic movement and communication are conducted througha system of Central Traffic Control (C.T.C.) which envisages Route Relay Interlockingand Automatic Signaling. Four stations, namely Works Station, R.M. Station, O.H.Station and B.F. Station are provided with C.T.C. facility covering 330 points in theplant. The route relay interlocking for each station comprises an illuminated controlpanel with necessary switches, push-buttons etc. for operating the points and signallingin its area. Coal Tippler Yard will soon have a panel with locking system on IndianRailways pattern.

The Yard equipment consists of :

1. Electric point machines which set the route for running trains.

2. Track circuits for supervision, control and indication of presence and passageof trains through different sections.

3. Signals for displaying permits to move or to stop.

All signals are placed on the right hand side of railway track. The manipulation ofcontrol panel in the stations is simple. Signal for train is intiated by pressing just twobutton (1) Start button and (2) End / route button. Once a signal is open for a particularroute, the interlock is provided as follows :

(i) All points over the routes are locked and become free only after the passage ofthe train.

(ii) No conflicting entry into this line is possible unless the signals are disregarded.

As the movement takes place, a white light indicating a set route transformsinto red showing the progress of movement, and extinguishes in the rear and clearsthe section for subsequent movements.

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Facilities are also provided for emergency working such as canceling of incompletemovements, electrical operation of points under track circuit failure and manual workingof points under total failure. The other field equipment are :

(i) Level crossing warning signals. (17 Nos. of Blinker Lights installed on 75 autorisedRail Road crossings all over works area).

(ii) Loudspeaker communication in CTC Yards.

(iii) VHF & WLL Communication.

Communication with control and adjacent stations.

All the station yards, posts and control rooms have been provided with necessarycommunication connections to the central traffic control room. In all, 8 EPABXs (4Nos. each of 40 line, 2 Nos, each of 50 line, 1 No. of 100 line & 1 No. of 8linecapacity) are installed at stations and control to ensure smooth internal communicationof Traffic Organizion. The Railway communication lines can be accessed through theEPABX installed at Train Control.

SOME HIGHLIGHTS OF T & D ORGANISATION

Lowest ever overall Wagon Detention of 17.2 hrs. achieved in the year 2005-06.

Outward Traffic for Saleable Steel increased form 3.16 MT to 3.29 MT,registering a growth of 4.10 % in the year 2006-07.

Total Outward traffic increased from 3.91 MT to 4.34 MT, registering a growthof 13 % in the year 2006-07.

100 % wagon were released within free time allowed for loading and unloadingin Feb-2007.

Zero Reportable Accidents in Wagon Repair Shop since Dec-2003 and RailwaySignalling Section completing 1304 days of 'Accidents free period' on 1st March2007

Mr. Inderjeet Singh Sr. P.W.I was awarded the "Best Safety Man" in plant forthe year 2006.

Zero reportable Accidents in Wagon Repair Shop since Dec-2003 and RailwaySignaling Section completing 1304 days of 'Accident free period' on 1st Mar-2007.

Re-commissioning of A-02 Rail Crane by in house efforts in the year 2006-07-Deferred an investment of Rs. 16 Crores.

In house Repair / revamping of 45 no.Wagons in the year 2006-07 - saving Rs.4.25 Crores.

68 sets sleeper and 17281 nos. BG Sleeper were made in the year 2006-07 -saving Rs. 6 Crooes.

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SAFETY ENGINEERING DEPARTMENT

1.0 INTRODUCTION

Accidents in a plant affect productivity and morale of workforce. All accidents,regardless of their consequences are symptoms of production inefficiency. Accidentfree production is regarded as an efficient production. Many activities and processesin a steel plant can present situations which involve risk to Safety and Health ofemployees and risk of damage and loss to plant equipment and product. Hence, it isa moral, economic as welll as legal duty of all especially the front line executives - toprevent, control or guard against such risks and their possible ill effects with anobjective to achieve elimination of human suffering, damage to material and equipmentand resultant loss of production, the Hindustan Steel Limited (HSL) laid a policy foraccident prevention which was adopted by the committee of management in themeeting held at Durgapur on 25th August, 1972. Based on the principles expressedin that policy, the organisation of Safety activities and programme for accidentprevention in the plants of Hindustan Steel Limited and at the Head office wereoutlined. It was stated that there should be a dynamic Safety Department in eachplant and a suitable organisation at the head office to implement the Safety policyand programmes and that the Safety department should have the status necessaryfor effective discharge of its functions.

After formation of the Steel Authority of India Ltd. the same policy was acceptedin principle with a view to achieve year by year, a continuing reduction in the numberof accidents and provide health working environments, the policy of accident preventionwas revised and the revised Safety and Health policy of Steel Authority of IndiaLimited was approved by the Board of Directors of SAIL in their 96th meeting held on20-07-1983. This Safety Policy is applicable all units of SAIL. Bhilai Steel Plant is anOHSAS-18001 certified plant and it has developed its own Occupational Health &Safety Policy in addition to the SAIL Safety Policy.

2.0 OCCUPATIONAL HEALTH & SAFETY POLICY

Bhilai Steel Plant is committed to:

☯ Create worksite free from Occupational Health & Safety Hazards for its employees,

☯ The Safety of the people associated with it, those living in the neighbourhoodof its plants, mines and units,

☯ Pursue the Safety efforts by adhering to Occupational Health & SafetyManagement System based on the requirements of internationally recognizedOHSAS-18001 standard and its periodic review at works,

☯ Demand accountability for Safety performance and provide the resource tomake safety program work,

☯ Involve all employees for continual improvement in OH&S,

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☯ Comply with the applicable legislation and other requirements of OH&S.

3.0 OBJECTIVES OF SAFETY ENGINEERING DEPARTMENT :

Although Safety is established as the direct responsibility of the line managers,the Safety Engineering Department is vitally concerned with all aspects of Safetyand is available at all times to perform services that will enable the plant to achievethe best possible Safety performance. It functions as a staff department assistingthe management in accident prevention, by:

☯ Apprising the managers where they are falling short of Safety standards

☯ Creating Safety awareness amongst all the employees both executives andnon-executives.

☯ Recommending to managers latest appropriate safe practices, procedures andSafety aids that will give protection to employees from Occupational Hazard atall times.

☯ Assisting the managers to maintain their shop in compliance with legal regulations.

☯ Furnishing statistics on Safety aspects to SAIL, other plants, local managementand managers so as to improve on past performance.

4.0 ORGANISATIONAL STRUCTURE OF SED :

The department in the operation side is headed by GM (Safety & FS) and isfunctionally categorized in four main zones i.e.

a) Iron

b) Steel

c) Mills

d) Maintenance & Services and

e) Power, Energy & Electrical each headed by a DGM / AGM to look after technicalaspects of Safety and enquiry related issues for all Fatal and Road accidentcases. Besides these, separate working groups are formed to look after otheractivities eg. Road Safety, Training of regular employees (Executives and Non-Executives) as well as contractual workers, Safety Control, Safety statisticsand Procurement and inventory Control of PPEs.

The department consists of qualified Engineers, Office Staff, Engineering Operativesand Statistical staff to perform various Safety activities spread all over the plant.

5.0 FUNCTIONAL ACTIVITIES OF THE DEPARTMENT :

5.1 ACCIDENT PREVENTION ACTIVITIES :

☯ Implementation of OHSAS-18001 management system

☯ Implementation of 5-S concept of house keeping at shop floor

☯ Adherence to accident prevention plan, to control accidents

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☯ Total auditing of major departments twice in a year and monitoringimplementation of Safety Audit points.

☯ Assisting maintenance departments in preparation of protocols for jobs carriedout by multi-departmental agencies and Safety supervision during Capital repairand during break-down jobs for enforcement of job Safety.

☯ Investigation of all serious accidents.

☯ Enforcing use of PPEs (Personal Protective Equipment) at shop floor.

☯ Monitoring implementation of recommendations of enquiry committees for alltypes of accidents.

☯ Identify & conduct of special studies of major hazards and develop preventivesteps for elimination and assist in preparation of job Safety rules (incorporationin SOP / SMP) and revision from time to time.

☯ Regular inspection of unsafe conditions/acts at the shop floor, as per scheduleand check-lists.

☯ Organising special campaigns for the inspection of cranes, telphers, cablegalleries, ladle cars, slag thimbles, hot metal tracks, conveyor galleries etc.

☯ Review & revision of GRA of pervious year Fatal accident.

☯ Participate in apex committee inspections and monitor implementation ofidentified unsafe conditions / acts for their elimination.

☯ Administration of basic safety induction training to all new recruits and conductsafety appreciation courses for front line executives and regular / contractualworkers and supervisors.

☯ Organising Mass communication exercises on different safety related topicsevery year.

☯ Organising refresher safety training programs for all employees.

☯ Organising safety training program for executives on specialised topics

☯ Assist all departments in organising Safety Week celebrations, Safety ModelExhibitions and display of Safety related posters and slogans at various locationsin the plant to generate Safety awareness for accident prevention.

☯ Organise Safety Audit of major accident hazard (MAH) units by inter plant auditteams as per statutory requirements.

5.2 POST ACCIDENT ACTIVITIES :

(a) INVESTIGATION AND ENQUIRIES :

As soon as an accident or a dangerous occurrence takes place or immediatelyafter the knowledge of such occurrence the Safety Engineering Departmentinvestigates jointly with the shop representatives / line supervisors to find out thecause and recommends steps to prevent the recurrences and participates as memberin various committees which enquire into serious disabling injury accidents and serious

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near miss accidents to find out the facts and causes of the accidents and to recommendpreventive measures.

N.B.: The investigations and enquiries are fact finding and not fault finding. As such,the front line executives should go into details of the accident occurring in theirjurisdiction and should keep first hand information of all the evidences and cases toprevent the recurrence.

(b) REPORTING OF ACCIDENTS :

☯ All the accidents resulting in injuries are reported to ED (Works)

☯ In case of serious / Fatal accidents and dangerous occurrences after theinvestigation immediate information is sent to MD & ED(Works)

☯ As soon as the occurrences of such serious / fatal accidents or immediatelyafter the knowledge of such accidents, the messages are forwarded to thelegal authorities. The reports on Form-22 and in case of Electrical accidents onForm No.44A received from the departmental heads are forwarded to the legalauthorities concerned.

(c) ACCIDENT STATISTICS AND ANALYSIS :

☯ Develop database on Safety activities and the accidents which occurred in theplant and maintain individual Safety cards through HRIS system.

☯ Analysis the statistics in different departments to strike at the root cause of the accidentsand thereby suggest concrete Safety programme to reduce the accidents.

☯ Based on these statistics and analysis, participation in competitions conductedby National Safety Council / SAIL Safety Organisation.

☯ Statistical analysis is compared with those of other steel plants to find out ourposition and to improve upon it.

☯ These statistical analyses are discussed in Departmental Safety Committeeand Zonal Safety committees and Weekly coordination meetings of DSOs forcorrective measures.

(d) REVIEW :

The performance of each department based on statistical record is reviewed byGM (Safety & FS) in Monthly Review meeting with HOD, Line Managers and DSO(Departmental Safety Officer) of concerned department for corrective action to achievethe target of Zero accident

5.3 JOINT PARTICIPATION :

Various committees are formed eg. Joint Safety Audit committee, DepartmentalSafety committee and Zonal Safety committees. Safety Engineering Departmentparticipates in all these committees as a member to discuss safety related problemsand arrive at solutions to strengthen Safety.

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The department also participates in various Departmental trade test committeesto test the knowledge of persons to be promoted regarding Safety.

5.4 RAIL-ROAD SAFETY :

☯ Restricting & Monitoring of timings, movement and parking of heavy vehiclesinside plant.

☯ Checking of road worthiness of Contractors transport vehicles inside the plant.

☯ Imparting training to transporters' workers engaged in road transport

☯ Monitoring of rail traffic at rail road crossings inside the plant

☯ Conducting special campaigns to enforce use of crash helmets by two wheelersriders inside plant.

5.5 LIAISON ACTIVITIES :

The department maintains close liaison with statutory authorities such as Directorof Industrial Health & Safety, Electrical Inspector, SAIL Safety Organisation and otherSafety Organisations to fulfill legal obligations and corporate Safety action plans.

6.0 HIGHLIGHTS/OTHER IMPORTANT ACTIVITIES :

6.1 Accident data has been incorporated in the HRIS database maintained by personneldepartment for each employee. Accident cases from January 2001 have beenrecorded in this database and it covers the employee of all departments.

6.2 Conducting mock drills as per the Disaster Management Plan in all the registeredhazardous factories.

6.3 Composite Safety training programmes are being organised by Safety EngineeringDepartment in BSP's Higher Secondary Schools and some selected PrivateSchools on General Safety, Civil Defence, Road Safety, Fire Safety and First-Aid treatment for the benefit of School children since last nine years.

6.4 Parking places were developed at Boria Gate, Khursipara gate and inside thepremises of Refractory Stores for parking of heavy vehicles to dilute trafficcongestion.

6.5 For generating Safety awareness amongst employees, eleven Safety flags foreleven zone of the plant and one Safety flag representing whole work areawere hoisted at the main entrance gate of the Plant.

6.6 Full body harness, Fall arrestor and Safety nets are introduced for Safeperformance of height jobs.

6.7 PG Diploma course in Industrial Safety has been started in BIT Durg and SafetyPersonnel are being sent to acquire PG Diploma in Industrial Safety and are postedas Qualified Safety Officers in various departments as Departmental Safety Officersto fulfill the requirement against Section 40 B of Factories Act, 1948.

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FIRE SERVICE DEPARTMENT

In our country, it has been noticed that awareness about fire hazards amongcommon people is very less. We being the Steel Industry, fire hazards /fire risks aremultifarious. We must also understand that ours is an integrated steel plant andhence one big fire can stop whole plant production. Therefore our main stress shouldalways be on preventing fire risks at designing stage itself. Some of the fire hazards/ fire risks which need top most concern are :-

1. Coke Oven gas, Blast Furnace gas, LD, gas and other gases in use such asHydrogen, Acetylene etc.

2. Benzene, Toluene, Xylene, Naphtha, PCM, Muck (containing flammableingredients), Naphthalene, Anthracene, CS2, Tar, H.S.Diesel, Petrol, storagesof other flammable liquids, etc.

3. Cables (PVC - high tension / low tension) laid in tunnels and trenches.

4. Coal dust, coal, coke.

5. Power plants where cables, conveyers, and coal are handled.

6. Oxygen Plants where cryogenic liquids are handled.

7. Liquid Metals, Scales, Sparks, Hot Spots etc. (These can also lead to fire).

8. Short circuits.

9. Gas Boosters and Liquid Fuel Stations are fire prone areas.

All mentioned above can lead to total destruction if we are not careful about firesafety. Statistics show that most instances of fire in the plant are in the areas whereoil & grease, gas, dry bushes, wooden materials, flammable liquids, cables, electricalmotors etc. are present. Cause can be static electricity, short circuit, sparks, hotspots, radiated heat/ spark from liquid metals, careless smoking, friction, spontaneousignition, shortcuts in process, etc. Bhilai Fire Service has tackled explosions of CokeOven Gas/ Blast Furnace Gas; Flammable Liquids; Dust Explosion; fires due to DryBushes, Cable Bursts etc. Due to these, there have been occasions when we lostsome of our valuable human resource, including expert hands. Therefore it is theresponsibility of every person in the plant to be fully alert and aware of fire hazards.

Bhilai Fire Service is the biggest industrial fire brigade in the country today. Theirservices are not confined to the plant; they are also rendering services within an areaof two hundred kms radius from Bhilai. Apart from fire and rescue, services are givenfor helipad safety of VIPs, disturbed law and order situation, threats of self immolation,election duties, and also at every other place where there is likelihood of burn loss tonational property by public. Fire consultancy is also rendered as and when required,to the Govt. of Chhattisgarh.

Other than fighting fire, rescue operations, prevention of fire, maintenance offire equipment and HRD, the department performs as many as 35 other duties: one

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such is the emergency dewatering in cable tunnels, ECRs, oil cellars, belt conveyordrums etc. If timely dewatering is not done, the unit can come to a halt. Other dutiesinclude cooling of tuyers in blast furnaces in case of emergency, cooling of furnacesduring laying of new refractory lining, flushing of pipelines, hydraulic testing of pipelines,hazardous blanking/ deblanking of gas lines, cutting/welding, filling of 'U' seals, roll tableflushing etc. The department also plays an important role during capital repairs. Out ofevery ten special service calls from the plant, eight are for such duties.

ORIGIN :

Bhilai Fire Service was established on 26th Dec.1956. At that time it was one ofthe wings of security organisation, "HINDUSTAN STEEL SECURITY FORCE". In theyear 1972, when Central Industrial Security Force (CISF) was introduced (on09.02.1972), fire service was formed as a separate department. Since then, BhilaiFire Service department has been performing its duties in the highest tradition and isstriving hard to maintain reputation as one of the finest fire service in the country.

The organizational structure of this department is identical to any major FireService in the country, which is as per the directives of Government of India, Ministryof Home Affairs.

The Fire Service Department is headed by Chief Fire Officer, under GM (Safety& Fire Services) and overall supervision of ED (Works).

FIRE STATIONS :Bhilai fire service comprises five fire stations :

(1) Central Fire Station (Head Quarter),(2) Coke Oven Fire Station,(3) Plate Mill Fire station,(4) Rolling Mill Fire Station,(5) Rajhara Fire Station (For Mines area)

These fire stations are self contained in all respects and are equipped with modernappliances and equipment, and well qualified trained staff.

The operational activities of Bhilai Fire Service have been formulated as per thenorms in protocol stipulated by the Standing Fire Advisory Council of Govt. of India,Ministry of Home Affairs.

WINGS OF FIRE SERVICE DEPARTMENT :There are four wings of fire servicedepartment :

1. OPERATION WING :To attend any Fire Calls, Special Service Calls,

Rescue Calls, Emergency Dewatering, Mock Drillsin the plant, township and outside areas.

2. FIRE PREVENTION WING :

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Following are some important jobs of the Fire Prevention Wing.

- Fire preventive inspection of hazardous areas.

- Checking and maintenance of extinguishers.

- Checking of fixed fire-fighting installations.

- Checking of fire detection systems.

- Maintenance of static tanks (with the help of CED & WSD).

- Demonstration of first aid and fire fighting equipment to plant workers.

3. MAINTENANCE WING :

A well established workshop to repair the vehicles and pumps of the departmentis available at Central Fire Station. Fire men are trained as a mechanics under multiskilltraining to attend day-to-day problems and maintenance of the vehicles. Major repairsof vehicles are carried out at plant Garage.

Following are some important jobs of the Maintenance Wings.

- Maintenance of all fire appliances & vehicles is carried out in coordination withPlant Garage.

- Repairs of Portable Fire Pumps & TPL are carried out in Maintenance workshop.

- Deep lift test, Vacuum test of all fire pumps.

- Repairs of delivery hose, suction hose & fire fighting equipment.

- Preventive Maintenance of Vehicles & Pumps.

- Painting of Fire Appliances.

4. TRAINING WING :

Following are some important jobs carried out by the training wing.

- Hydrants checking.

- FAFF (First Aid Fire Fighting Equipment) training to the plant employee.

- Refresher course for fire brigade personal.

- Physical test for new recruitment to the plant.

- Need base First Aid Fire Fighting training for school children, NCC scouts, CISF& Police.

- New recruit training for Fire Man, Fire Engine Driver, Supervisory officers &MTT (Fire Engg).

FIRE PROTECTION SYSTEM IN BSP:

A) PASSIVE FIRE PROTECTION SYSTEM

Passive fire protection is an integral part of a complete fire protection systemand is essential for prevention of spread of fire through openings in walls or floors.These measures are intended to contain a fire in the fire compartment of origin, thus

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limiting the spread of fire, excessive heat and corrosive, re-ignitable and toxic gasesfor a rated fire resistance period (Fire Resistance).

- Fire Retardant Coating/Painting :

For vertical run of cables & PVC conduits, fire retardant coating is provided forthe whole length. For horizontal run of cables, 1 m length of fire retardant coating isprovided at every 20 m interval wherever cables cross any partition wall, floor orpass through any opening, it is provided for 1 m length on either side.

- Sealing of Cable Openings :

Cable fire stops/barriers are provided in following cases;

a) Entry/Exit area of cable/cable trays in various compartments of cable gallery/basement/tunnels having different fire loads

b) Under control panel/any other panel where cables are entering or going out.

c) In floor openings

B) ACTIVE FIRE PROTECTION SYSTEM

Fire Alarm & Detection (FDA) System

Water Spray System(HVWS & MVWS)

Sprinkler System

Foam Pourer

Fixed Foam System

Clean Agent Total Flooding System

External Hydrant System

Internal Hydrant System(Landing Valve)

Dry riser System

Fire Tress Tube System

Nitrogen purging system

Water Curtain

Static Tanks

Mulsifier system

Portable Fire Extinguishers

Modulars

# HIGH VELOCITY WATER SPRAY SYSTEM (HVWS) AND MEDIUM VELOCITY

WATER SPRAY SYSTEM (MVWS)

HVWS & MVWS is a special fixed pipe system connected to a reliable supply ofadequate quantity of water and equipped with spray nozzles (projectors) for specificwater discharge and impingement over the surface or area to be protected. Thepiping system is to be connected to the water supply through an automatically actuatedvalve (deluge valve) which can initiate flow of water. Deluge valves for the spray

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system are to be actuated by an automatic detection system which in the case oftransformers consists of quartzite bulb detectors mounted around the protected areaand for cable galleries these are part of fire detection & alarm (FDA) system. HVWS/Water Mist system is being installed for protection of transformer. Cable galleries/basements are protected by MVWS system. All instrumentation points actuated bythe FDA system are addressable and controlled by FDA panel.

# GAS BASED/CLEAN AGENT SYSTEM SYSTEM

The total flooding system of Gas based / Clean agents work on the principle ofmaking the premises non-conducive to sustenance of fire therein by injecting sufficientquantity of gas. The rapid injection of sufficient volume of gas into an enclosure, sothat an inert atmosphere is created, extinguishes fire, which is named as total floodingsystem.

Clean agent gas conforming to NFPA l2 & 2001, is a colorless electrically non-conductive gas that is suitable for extinguishing fire in Computer rooms and importantcontrol rooms, where water or foam can not be used.

The discharge of this gas may create hazards to personnel especially in the caseof total flooding system. It is necessary to provide suitable safeguards to ensureprompt evacuation from and prevention of entry into the space where this extinguishingmedia will be discharged.

When a detector detects fire, the signal is communicated to the main controlpanel, which shows the address (along with location) of the actuated detector. Ondetection of fire the respective hooters of the zone will also be actuated. Onconfirmation of fire by detectors the respective Air-conditioning & Ventilation systemwill trip and evacuation alarm signal will appear in the premises provided with thissystem. There will be a selector switch for manual and automatic actuation of thesystem. Gas will be discharged automatically in the affected premises after a timelag of 30 seconds. In case of manual operation, after time lag of 30 seconds thepush button switch of the affected premises shall be manually operated which willactuate the discharge of extinguishing media developing required concentration andthere by extinguishing the fire.

CRITICAL EQUIPMENT:

Following are the special equipment used during any emergency operation likefire fighting or rescue.

High Expansion Foam Generator.

Generator for emergency power supply

Blower/Exhauster

Power Cutter

Circular Saw

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Pneumatic lifting bags

Lock -Cutters

Hydraulic Jacks

Cutting Set

Breathing Apparatus(B.A.) Set

Wireless Set

Spreader

Mist Technology Extinguisher

Life Saving Jackets

Fire Entry Suit

Light Mast

Foam Making Equipment

Search Light

Aluminum Extension Ladder

Vertical rescue Stretcher

Roll Glees

Safety Goggles

Live Casualty Detector

Multi Gas Detector

Oscillating Monitor

Full Body Harness

Combi Tool

Inflatable Light Tower

Diamond Saw

Bullet Saw

MAJOR FIRE APPLIANCES:

TYPE Nos.1. Water Tender 15

2. Snorkel 01

3. Foam Tender 04

4. Hyd.Platform (Hydramake) 01

5. Combined Tender 02

6. DCP Tender 01

7. Emergency Tender 01

8. Truck 01

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9. Pick-up Van 02

10. Towing Vehicle 10

11. Station Wagon 01

12. Trailer Pump Large (TPL) 07

13. Water Bouzer 01

14. Portable Pump 25

CALL RECEIVING PROCEDURE :

The fire calls are received by three means :-

1. By phone.

2. By alarm.

3. By running messenger.

BSP Telephone nos. of fire brigade control rooms :

1. Central Fire Station : 2222,2223,3090101

2. Coke Oven Fire Station : 2666,4499.

3. Rolling Mill Fire Station : 2668.

4. Plate Mill Fire Station : 4444.

5. Rajhara Fire Station : 3333.(07748)285655

To get better help from fire brigade the person calling to fire brigade shall givefollowing information.

1. Name

2. Phone no.

3. Type of fire (Material involved in fire)

4. Correct location or address.

ALWAYS REMEMBER :

- Whatever burns never returns.

- Reduce fire to produce more.

- Match stick has head but no brain.

- Housekeeping has to be of very high order.

- Extinguishers shall be regularly checked.

- Regular mock drill shall be conducted.

- Leakage of oil to be avoided at any cost.

- Fires don't happen, they are caused.

- Availability of fire extinguishers in the premises do not prevent outbreak of fire.They help in minimising the losses due to fire if operated immediately.

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- Cutting & welding jobs should be carried out with proper protocol.

- Avoid spillage of oil or any flammable materials.

- Train employees, in fire prevention & responsive techniques.

- Fire safety is for all irrespective of position held.

- Carelessness is the biggest cause of fire.

- Pick the right extinguisher for fire.

- Fire - easy to light, hard to fight.

- Cleaning of conveyor galleries should be done regularly.

- Roller jamming should be avoided to prevent fire due to over heating.

- The welding cables should not have any joint while being used for work.

- Electrical cables and wiring should be maintained in a healthy condition.

- Ensure the availability of water supply at hydrants, and landing valves.

- Never blank the landing valve point.

- Don't delay in calling fire brigade in case of fire.

- Smoking has to avoid in plant area.

- Dry bushes to be cleared regularly.

- "Prevention is better than cure", PREVENT FIRE.

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CHM, GMG, CRM (MECH/STRL) & RVC

Maintenance organisation plays a vital role in achieving the production targets.Maintaining a good health and optimum availability of equipments is the responsibilityof Maintenance Organisation. In the beginning of the year, the Capital Repair plan isprepared keeping in view the production targets for the financial year. Approvedschedule for capital repair becomes the guideline for the year. Monthly / weeklyrepairs are planned based upon the condition of the equipment and productionrequirement as per APP. Objective of Maintenance Organisation is to perform qualityrepairs at minimum cost.

This chapter covers Central Heavy Maintenance(CHM), General MaintenanceGroup (GMG), Capital Repair & Modification Mech/Strl (CRM-M/Strl) and RevampingCell (RVC): the four important central mechanical maintenance Groups.

CENTRAL HEAVY MAINTENANCE (CHM)

CHM broadly maintains the major mechanical equipments in all the productionshops of BSP to increase their availability and reliability. It carries out planned preventivemaintenance, capital repairs, conditioned-based maintenance and liquidates any breakdowns also. It has five zones located at different areas inside the plant to facilitatequick response. But as such there is no fixed boundary as far as its working isconcerned. As per need, the manpower of any zone can be deployed in any otherarea for the optimal utilisation of manpower. The 5 zones are as follows:

1) CHM-I (Mill zone), (2.5 M.T. Area) : Located near BBM , it carries out repairactivities primarily in BBM, RSM, MM& WRM.

2) CHM-II (Steel Zone) : Located near flyover, it takes care ofmaintenance activities in SMS-I andEngineering Shops.

3) CHM-III (Iron Zone) : Located near CO &CCD, this zonemaintains the equipment of CO &CCD,BFs, SP-2 SP-3, OHP, RMP-1 & RMP-2.

4) CHM-IV (Expansion), (4 MT. Area) : Located near Plate Mill, Maintenanceof equipment in Plate Mill and SMS -II(Converter & Continuous Casting Shop)are being taken care of by this zone.

5) Belt Maint. Group : Located near CO&CCD, A total lengthof about 145 KM of conveyor beltsare in use in BSP, consisting of 750nos conveyors at different locations.Belt replacements & making of coldvulcanising joints is done by this group,through-out the plant.

CHM-Planning :

It prepares yearly, monthly, weekly maintenance schedules and sees to the

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fulfillment of same. Weekly repair schedules are finalised on Mondays for ensuingweek and are monitored daily. CHM Base Store ensures smooth supply of storeitems, tools and tackles to various CHM groups.

During the Capital Repair of BBM, MM, PM & RSM depending upon the volumeof job, man-power from all the above zones of CHMs are redistributed & redeployed.The above division of areas is only to facilitate quick response to the job. Thus anyzone can take up any job inside the plant to meet any emergency. The division ofareas among CHM has the advantage of having special skill for the particular equipmentof a particular shop.

GENERAL MAINTENANCE GROUP (G.M.G.)

G.M.G. is headed by a Chief Engineer I/c at present. Consisting of 3 executives& 21 non-executives, this group helps in carrying out preventive maintenance andCapital Repair jobs in 2.5 MT stage area i.e BBM, RSM, MM, WRM, BFs, etc.

CAPITAL REPAIR & MODIFICATION (CRM-MECH./STRL.)

This department was established in 1971 primarily to carry out capital repairs ofBlast Furnaces and Open Hearth Furnaces. Later on it got involved in capital repair ofother units also, like Rolling Mills, RMP-1, Coal Chemicals Department etc. Presentlythe department is primarily made responsible for organising capital repairs of BlastFurnaces. Jobs are executed partly through contractual agencies, while carrying outvarious assignments during all preventive maintenance shutdowns in different unitsby central maintenance organisation as also for carrying out riveting jobs at site.

At present the department is having three sections namely Mech.-1, Mech.-IIand Planning. Manpower of the department is 175, including 9 executives.

SOME SPECIAL ACHIEVEMENTS

Replacement of Converter-A, B&C vessel at SMS-2.Installation of Hanging Platform Insertion arrangement in Bell -less Top of BlastFurnacesReplacement of well of stripper Crane-3.Capital Repair of BF-4 and BF-3Major repair of RH Degasser, VAD and Ladle Furnace of SMS-II

CORE COMPETENCIES :

Planning organising and executing the various categories of capital repair of BFs.Fabrication & Erection of technological structures like, girders, beams columnetc in various work areas.Capacity to complete replacement of various units of 1000T shear of BBM,800 pinion stand of R&S MillAbility to meet the maintainance and major repair needs of various E.O.T. cranes.Provision of technological solution to some of the critical problems of BFcsusing six sigma & T.P.M. techniques.Repair and upkeep of enabling equipment like winches, pulleys etc.

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REVAMPING CELL (RVC) :

REVAMPING Cell department was formed in the year 1989 with a view to takeup revamping of major equipment including EOT Cranes of the plant-which werenearing the end of their life spans. The equipments identified for revamping are takenup either departmentally or through contractual agencies.

This department plans and monitors execution of revamping of old equipment.Besides revamping, the department manufactures new EOT cranes and equipment aswell. Moreover, the department is engaged in processing HSCL work orders for supplyof manpower to plant and also processes Rate Contract work order for mechanicaljobs. The department also participates in scheduled maintenance & Capital Repairsof 2.5 MT mills & Plate Mill.

Department has been undertaking revamping work over last 15 years and isengaged in manufacture of cranes/equipment over last 10 years. The department hasso far manufactured around 25 new cranes/equipment and revamped around 75cranes/equipment.

(A) Major cranes/equipment revamped are as under :- Gantry Cranes # 1&3 of CO&CCD.- OBC # 1&3 of B.Fs.- Revamping of OTC of B.Fs.- Charging Machine of SMS-I.- Mould Yard & Magnetic Yard cranes of SMS-I.- Finger Cranes in BBM.- Magnet Cranes in R&SM.- EOT Cranes in P.MILL.- Forging Hammer (5 T).

(B) Major Cranes/Equipment manufactured are as under :- Coal Charging Car and Door Extractor of CO&CCD.- LRS Crane and Cast House Crane of B.Fs.- Ingot Storage Yard Crane of SMS-I.- Teeming Ladle & Fettling M/c of SMS-I- Cantilever Crane of SMS-I.- Ingot Buggy of BBM.- Pit Cover Cranes of BBM - 5 nos.- Scrap Bay Crane of BBM.- EOT Cranes of R&SM - 5 nos.- Main Bay EOT Crane of M.Mill.- Foundry Crane.

Revamping of equipment/cranes has averted purchase of a large number of cranes/equipment and hence resulted in huge saving. Around 100 equipment and craneshave been manufactured/revamped so far which has resulted in a net saving of aroundRs.80 crores.

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CRANE ENGINEERING DEPARTMENT

Crane Engineering Department was set up at 1 MT stage itself, under the centralmechanical organization. This department exercises effective technical control overthe operation and maintenance of EOT cranes, installed in the plant, in order toensure their proper upkeep and use.

MAIN FUNCTIONS OF THE DEPARTMENT

1. To prepare annual inspection / load testing schedule for all EOT cranes & Liftsand to inspect all the cranes & lifts as per the approved schedule; and also toindicate the shop concerned where is action is required.

2. To conduct dynamic and static load testing of all EOT cranes in service, once ayear and for newly erected cranes before commissioning: for ensuring theirfitness for operation.

3. To keep watch on the 'proper' operation of EOT cranes and to highlight thecases of misuse & violations to GM(Mech) / shop management.

4. To standardize important crane spares, procure them and to control theirconsumption by various shops by proper scrutiny.

5. To analyze the crane breakdowns and damages and suggest remedial measures.

6. To assist the shops in giving training in crane operation and also in promotingsuitable persons for the post of crane operators by judging their skill knowledge.

7. To keep a close watch on the performance of important production cranes andto appraise GM (Mech) for taking timely actions.

8. To conduct feasibility studies and give specific recommendations in all technicalmatters concerning EOT cranes like Capital Repairs/ Revamping of cranes.

The department is at present looking after about 440 cranes. Presently thedepartment is divided into four zones:

a. Iron zone : CO & CCD, Bfces. & Mines

b. Steel zone : SMS-I, RMP-I, MRD & Auxiliary Shops

c. Rolling Mills : BBM, R&SM, WRM & RTS

d. Expansion : SMS-II, Plate Mill, OHP, RMP-II & SP-II & III etc.

HIGHLIGHTS

The Crane Engineering Department has helped in revamping of important cranes like:

SMS-I Mould yard Cranes, Stock yard Cranes, Ingot Storage Cranes, Stripper Cranes.

BBM Pit Cover Cranes, Finger Cranes.

RSM Magnet Cranes in Shipping area.

Blast Furnace OBC Cranes, Cold Pig Yard Cranes etc.

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DESIGN & DRAWING DEPARTMENT

1. INTRODUCTION

Design & Drawing Department is one of the most important technical departments,under GM (M&U)'s organization. This department was established in 60's and itcaters to the needs in respect of design , modification , repair & development ofspare part drawings pertaining to different equipment all over the plant.

In a running plant there is always a need for modifications, repairs and newprojects utilizing in house facility. Liquidating breakdowns, tackling bottlenecks andcombating obsolescence can increasing the productivity of the plant. Design & DrawingDepartment plays a major role in all such situations. It also renders services to differentshops by developing drawings for procurement of costly and imported spares throughindigenous sources. Design & Drawing Department furnishes essential designdocuments, drawings, and specifications for achieving the reliability of equipment soas to ensure uninterrupted production.

2. MAIN FUNCTIONS/ACTIVITIES

a. Development of drawings for- Equipment modification and repair schemes.- Additions/Alterations and Innovations in the plant limited to mechanical

equipment.- Spares of equipment for in-house/local/indigenous manufacture.- Approval of drawings and tracings prepared by various shops.

b. Preparation of technical specification for indigenous procurement of spares,assemblies & sub-assemblies.

c. Technical Archives and Library

BSP was created out of Indo-Soviet collaboration. Various Russian documents &drawings pertaining to mechanical equipment/structures of different metallurgical shopsunder 1MT/2.5 MT stages are kept in this section of D&D. Apart from this, variousdrawings and documents brought from various sources are also kept in this section.

A small library has been created containing technical books of various disciplines.Various IS Standards which are required for day to day reference, are also kept.

d. Printing Section

The purpose of this section is to generate consumable ammonia prints fromreproducible drawings so that shops can use them for various purposes likedevelopment of inhouse technologies, for assembling, or in-house manufacture atBSP. The consumable prints are produced on Ammonia papers with the help of 2Ammonia printing machines and 3 Ammonia gas chambers.

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Printing section plays a vital role in the storage of drawings prepared by Design& Drawing Department and they are documented department -wise and year -wise ,with rationalized drawing numbers for ease of locating drawings, for ready reference.

e. Photocopy section

This section generates reproducible tracings from scarce documents, with thehelp of Modi Xerox Engineering Plan Printer on 1:1 scale.

f. CADD System

CADD system comprises a PC, a Graphtec plotter and a printer. Drawings can begenerated on the PC by drafting through AutoCAD software package, and plotterhelps in plotting the drawings on reproducible tracing paper. The present system willbe upgraded by including facilities of latest version to prepare e-drgs i.e in digitizedform and to convert existing manual drags in e-form (digitized).

g. Digitization of Drags

In the days to come the material procurement system will be in paper - lessmode replacing conventional manual drag & Ammonia prints. In view of this, e-procurement system will come and to faciliate the drags are to be prepared in e-form. To enforce this faster a large number of old manual drags will be digitized fromoutside sources and also from the upgraded system as described earlier.

3. DEPARTMENTAL ACHIEVEMENTS

Some of the achievements in recent past :

Design of 70 mm Plate bending machine for Steel Structural Shop.

Developments of drawings for in-house manufacture of four-directional hydraulicpress for Rail finishing.

Layout of technological equipment , and development of related drawings forconveyerisation of return sinter fines from Blast furnace to Sintering Plant III.

Development of manufacturing drawings for in-house manufacture of carbidesaw for Rail finishing.

Design & Development of manufacturing drawings for in-house manufacture ofEOT cranes like crane no 16 of RSM, 10/10T scrap bay crane of BBM, DE baycrane of CCS etc.

Design & development of drags for 4 dehydrators to refurbish health ofdehydrators required for BF-7 Modernisation.

Modification of 8 - roll section to 10 - roll section and overall modification ofslab caster I & II.

Equipment layout, and development of manufacturing drawings for 6.5 lakhton Rail finishing complex.

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CENTRAL HYDRAULICS

During 4 MT expansion of BSP, new Units and Equipments like Continuous CastingMachines, Lift & Turn Mechanisms of CCS, Plate Mill Equipments, Bell Less TopSystems of the premiere Blast Furnace 7, Blast Furnace 4, 5 & 6 and Lime Kilns ofRMP II came into existence. All these equipments were powered by the state of theart hydraulics technology.

At that time, necessity was felt to develop a Central Expert Group in the field ofIndustrial Hydraulics to cope with the advancements in the technology and the CentralHydraulics Section was formed in 1986 under GM (M & U).

MAJOR ACTIVITIES

The Central Hydraulic Section carries out the following major activities:

A. HOSE ASSEMBLY SHOP : The section runs a Hose Assembly making Unit tocater to the needs of the Plant for hydraulics, lubrication and other criticalapplications. The hose assemblies are made with quality materials and strictquality norms are maintained during assembling and testing. It is ensured thatthe hose assemblies supplied to the consumers are 100 % reliable. The timelyavailability of the hose assemblies, reduces the breakdown time of the equipmentand increases the equipment availability. Since the hose assemblies are suppliedcentrally, the inventory cost is also low.

B. FAULT DIAGNOSIS & TROUBLE - SHOOTING : During modernization of thePlant, the new equipments have come with latest technologies involvinghydraulics.Understanding the operation and developing the skills to maintainthese equipments are very important.

The Central Hydraulics team assists in diagnosis of fault and trouble-shooting ofproblems in hydraulic systems installed all over the Plant. Routine maintenancein the hydraulic systems is done by the concerned shop hydraulic maintenancecrew and if a problem of complex nature arises in the hydraulic system, theCentral Hydraulics team helps in trouble shooting and liquidating the problem.

C. CENTRALIZED Planning, Procurement and Consumption Control : The planning,procurement and consumption control of hydraulic spares are done centrally bythis section. The high standards of quality for spares is kept to ensure 100%reliability of the equipment. The inventory cost of spares is also maintained low.

D. Standardization and Variety Reduction : Continuous efforts are put to standardizethe hydraulic components and reduce their varieties.

E. Technical Support to the Customers : Technical support and guidance is providedto various Units in the matters of Industrial Hydraulics.

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F. Monitoring : Capital Repair of various Units of the Plant are carried out everyyear. During these capital repairs a lot of jobs are done on hydraulic systems.The capital repair jobs done on hydraulic systems are monitored by CentralHydraulics for quality of work.

G. MODIFICATION OF THE EXISTING HYDRAULIC SYSTEMS : To improve theperformance and reliability of the equipment, modification in hydraulic circuit isdone in association with the concerned shop for improving the system.

H. INSTALLATION, COMMISSIONING AND TESTING OF NEW HYDRAULICSYSTEMS : The Section involves in TS preparation, Technical Scrutiny of tenders,installation, commissioning, trial and testing of new hydraulic systems of thePlant.

I. HRD ACTIVITIES: As the training and development of its personnel is one of theimportant activity for any organization, the Central Hydraulic Section has alsotaken up the responsibility of imparting training to the Plant People in the field ofIndustrial Hydraulics. An exhaustive training schedule has been made, coveringbot Executives and Non-executives working in the related areas of the Plant.

The state of the art computer animation technique with projector and hydraulictraining lab are used by the expert faculty to impart quality training to theparticipants to make them understand better.

Leading Hydraulic System and Component Manufacturers are invited forinteraction on latest practices and developments in this field. This helps in betterunderstanding of our requirements and bridging gap between customers andmanufacturers.

Apart from above, continuous interactions are held with the internal customersand necessary technical support is provided by the Section.

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LUBRICATION DEPARTMENT

Large quantities of various types of lubricants are used in a steel plant for itsnormal working. A central department takes care of the arrangement and managementof lubricants for the whole plant and is known as Lubrication Deptt. It has followingsections:

(a) Lubrication Repair Shop

(b) Oil Reclamation Unit

(c) Inspection Group

(d) Planning Section

MAIN FUNCTIONS OF LUBRICATION DEPTT :

Planning & procurement of Lubricants & Lubrication Spares.

Co-Ordination of Centralized Procurement of Lubricants for BSP, BSL, RSP,DSP under PCRM.

Collection and reclamation of Used Oil and its re-use.

Condition Monitoring of Oils in -use in the Lubrication Systems and to suggestCorrective Measures to Increase their life.

Recommending the Grade of Lubricants for New Equipment Installed in thePlant.

Inspection & monitoring of Lubrication Systems of various units of Plant and tofollow-up The Rectification of Defects Noticed.

Analysis of lubrication systems failure.

Provide 'Technical Support' and 'Guidance' to various Units of Plant for properMaintenance of Lubrication Systems.

Liaison on Technical Matters with major Oil Companies. To plan trial of NewProducts to Improve performance of the Equipment & conservation of Lubricants.

Standardization Activities related to Lubricants and Lubricating Equipments asper BSPS, IPSS, BIS, etc.

Repair of Lubrication Equipment from Plant and Mines (in Lubrication RepairShop).

Promotion of Lubricant Conservation activities and Monitoring /Controllingconsumption of Lubricants.

In-house training programmes for non-executives.

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BEARING ENGG. DEPTT. MECHANICAL SERVICESOF 4MT (MECH) AREA

Bearing Engg.Deptt. is one of the most important related to the maintenance andavailability of equipment throughout the Plant and Mines.

Main Functions :

1. Procurement of centrally controlled items (bearings ) from Overseas andIndigenous manufacturers.

2. Judicious release of bearings strictly as per the requisition of shops.

3. Technical assistance in case of mounting, clearance setting and analysis ofpremature failures of bearings to ensure smooth running of equipments.

4. Technical knowledge sharing for bearing selections; substitutions for betterreliability of equipments.

5. Inventory Management - maintaining proper stock level.

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TOOLS AND TACKLES

This department regulates the use of Tools & Tackles in the entire plant, andsupplies tested wire rope slings which are a very common requirement. The groupexercises control over the inventory as well as quality of tools.

To ensure maximum utility and to minimize the procurement of Tools and otheritems, norms are fixed for each shop, and inter-shop transfer of these item isimplemented. Besided this, reconditioning and repairs of worn out and damaged tools& tackles are undertaken for greater economy. The department comprises a smallworkshop of its own.

Following are the main jobs handled by this department :

1. Manufacture and supply of mechanically spliced tested wire rope slings up to38mm dia.

2. Repair and reconditioning of the follwoing :

a. Hydraulic jacks

b. Hand operated chain pulley blocks

c. Lifting and pulling machine

d. Portable maintenance tools like portable pneumatic tools and portable

e. electrical tools, dieless hydraulically operated crimping tools, etc.

3. Planning & procurement of centrally controlled lifting tackles & portable toolsfor maintenance.

FACILITIES PROVIDED AT TOOLS & TACKLES (WORKSHOP) :

a. Radial drilling machine - 1 nos.

b. HMT Lathe Model H-22 - 2 nos.

c. Shaper - 1 nos.

d. Welding Machine - 2 nos.

e. Pedestal grinder - 2 nos.

f. Abrasive cut-off machine - 2 nos.

g. Sling making machine 500T - 1 nos.

h. Sling making machine 1000T - 1 nos.

i. Proof load testing machine Cap.-50T/12m - 1 nos.

j. Proof load testing machine Cap.-100/16m - 1 nos.

The department also exercises control over the consumption of various toolsand tackles numbering to around six thousand items used in the plant by variousshops. Also, it undertakes the standardization of these items regarding their size,type and quality.

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CENTRAL PLANNING DEPARTMENT

FUNCTION

The main function of Central Planning Department (CPD) is to formulate monthlyPlans for manufacture of spares for the Plant in the Engineering Shops. Items/ sparesrequired for day to day running and Capital Repairs of all production departments ofthe Plant are planned in the concerned Engineering Shops by CPD taking dueconsideration of the capacity of the Shops, requirement of customers and feasibilityof manufacture.

CPD is also the central agency for progress monitoring of manufacturing processof spares in Engineering Shops and provide related reports on the status to managementfrom time to time. In addition to planning CPD also facilitates the manufacture/ repairof items in Engineering Shops to the satisfaction of the customer departments.

OBJECTIVES

1. To ensure timely availability of quality spares to the customer Department.

2. To help in cost reduction by facilitating manufacturing/ repair/ reclamation ofcostly spares in Engg. Shops.

3. To earn revenue for the Plant through Planning, coordinating, and help in providingthe required resources for manufacture of spares for other Steel Plants.

4. To provide required inputs to Management for taking Make - Buy decisions.

PLANNING PROCESS

CPD formulates the monthly production Plans for all Engineering Shops viz.Foundry & Pattern Shop, Forge Shop, Steel Structural Shop, Reclamation Shop,Machining & Re - engineering Services (MARS) - 1, 2 & 3 and also provided the Planfor Construction Workshop under Projects Department. While providing these monthlymanufacturing programs to Shops, full attention is paid to all maintenance & CapitalRepair schedules of the Production units alongside exercising an inventory controlover the semi- finished jobs in Engg. Shops. These Plans are set, reviewed & monitoredto achieve to fulfill the Plant's requirement.

MAKE - BUY DECISIONS

ALL requisitions of spares requirement of the Plant are routed through CPD forscrutiny and to provide inputs to the management to make the Make - Buy decisionfor any spare. On the basis of the capabilities available in the Engineering Shops,feasibility and existing loads on them, CPD recommends the next course of action tothe Screening Committee. The Screening Committee takes a decision to either buythe item or to make it in-house in the Engineering Shops. In case of a make decision,a requisition for manufacture in Engineering Shops is sent by the Indenter and theitems are processed for manufacture. Otherwise the customer department may move

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for purchase of the item through Material Management Department. All these activitiesare done through a computerize system developed by CMMS Department.

MONTHLY PLANS

Monthly Plans are a guideline for the month's Production in Engineering Shopsand Construction Workshop. The Plans ensure that the full potential of the EngineeringShops are exploited. The Plans, which are generated through a CMMS module arebased on the following underlying factors:

Production capacity of individual Shops.

Backlog from previous month's Plan.

Current requirement of the customer department.

Commitment for Capital Repairs.

Other Priorities.

SEMI-FINISHED AND IN - PROCESS STORES

The open storage area for semi-finished and in - process spares is popularlyknown as Open Gantry (OG). Here the un machined blanks from Foundry, ForgeShop, Steel Structural Shop & Reclamation Shops are stacked and issued to MachineShops on demand. OG also takes care of the inter - Shop transportation of semifinished spares. OG plays a vital role in ensuring smooth flow of materials betweenthe various Engineering Shops. This section strives to keep the inventory low andtries to meet the urgent needs by using alternate blanks of slow and non - movingitems. It also handles shipment of jobs for various external parties & sister SteelPlants.

All blanks/ semi-finished items are kept in a distinctive way to ensure safety andeasy retrieval. All receipts and issues are entered into the computer against therespective work orders, thus updating the status of the work order. There are twoEOT Cranes of 20/5 ton capacity for handling materials. There are 28 columns witha span of 20 Mtrs. The materials are stacked according to the user department. OGalso has a 8 Ton Hydromoc and a Trailer of 20 Ton capacity for the purpose oftransportation, handling and storage.

RATE CONTRACT GROUP

This group was started in 1983 in a very humble manner to offload various smalljobs in view of certain limitations and to tide over crisis to meet exigencies. Additionally,it supports 42 Local registered ancillary units by giving them simple orders of machining.RCG has however now become indispensable having an annual budget of Rs. 50lakhs Approx. Rates for various operations/ jobs ae fixed with the help of IndustrialEngg. Department. These rates take into account the following factors:

1. Blanking technology.

2. Machining technology.

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3. Norms, etc.

The jobs are allocated to various Parties by a small committee consisting of:

Heads of Engg. Shops.

Head of Central Planning Department.

Official in charge of RCG.

It decided the party to be awarded based on the following criteria:

- Capacity and competence of the Party.

- Performance record of the Party in terms of adherence to delivery schedule andquality.

- Orders already with the Party.

- Furnishing of appropriate Bank guarantee.

RCG issues Blanks to the selected Parties and receives finished products fromthem. It also gives intimation to user for collection of finished items.

PROGRESS & RECORD KEEPING

Main tools for control of engineering shops:

- Day to day progress of monthly plan / critical items / Capital Repair Schedules.

- Performance reporting Daily, Monthly, Quarterly, Yearly - tonnage, itemfulfillment, machine hours utilization.

- Review discussion on Capital Repair schedules / Monthly plans.

- Suggestion in modification / replacement.

- Reports of purchase diverted items / High Value reclamation items.

THERMIT WELDING CONTRACTS SECTION

Repair of important jobs by Thermit Welding is got done by Central PlanningDepartment on contract basis. The major and important jobs being repaired by thermitwelding are Peel assemblies, Bottom Boxes with core barrels, RSM feeder beams,various sizes of electrical armatures, Rail joint during capital repair of RSM etc. Thetechnique is found fast, sound, dependable and economical in salvaging broken parts.The budget allocation for current financial year is around Rs.5 lakhs.

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MACHINING ASSEMBLY & RE-ENGINEERING SERVICES-1( MARS-1)

MARS-1 has a vital role to play in maintaining the plant equipment so for as itsupplies the bulk of spare parts required by the various units. It acquires an addedsignificance by virtue of the finishing line of manufacturing activities of engineeringshop . The product mix so arranged so as to meet the demand of both heavy andsmall spares. The shop is housed in three machining bays, 21 meters x182 meterseach with an assembly bay of 24 meters x 96 meters .A total of 196 machine -toolsare engaged in direct production of spares, whereas the remaining contribute indi-rectly towards shop production. Apart from these, there are 12 Heat Treatment /Heating furnaces 22 material handling equipment (cranes,jib cranes transfer cars).The Annual production plan for MARS-1 during 2007-2008 is 6,40,000 credit hours.

MAIN ACTIVITIES:-

Functionwise MARS-1 carries out the following activities:

1. Manufacture of spares, changables, tools, tackles etc. Required for maintenanceand operation of various departments.

2. Overhauling and repair of equipment sub - assemblies to the extent of thosethat can be transported to MARS-1.

3. Reclamation of worn-out spares .

4. Repair of certain equipment at site-especially where machining at site is required.

5. Manufacturing and modification of equipment / spares for development workfrom the point of view of import substitution,cost reduction ,etc.

FLOW PROCESS:-

A brief description of process for spares manufacture from the order stage to thedespatch stage is given below:-

Work order for a group of jobs is placed on the shop by the cental planningdepartment(CPD). The CPD prepares a monthly plan ,enlisting the jobs to be carriedout in a particular month , after necessary discussion ,review of previous month'splan , requirement of new item etc; with the help of shop planning section andordering departments. Jobs are categorised in the order of priorities .

This plan is processed for execution by the shop planning section. The technologyprepares calculations, tooling is prepared in advance by tool room . These mastercards are numbered and stored by planning section for future reference , and copiesmade out for execution taking into account priorities if any , blank availability etc.Simultaneously the blanks (forgings , castings or fabrications ) stored in an open

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gantry storage (controlled by CPD ) are taken in and after preparatory work, if any ,are supplied to the concerned machines . The route card, drawing and job card areissued to the machine when the job is taken up . After completion, inspection iscarried out by the inspection department for quality control . The completed jobs arecollected by the ordering department.

SECTIONS :-

MARS-1 is divided in to following sections:-

1. Machining Section:-

The machning section carries out the following function :-

(i) Manufacture of various spares of a wide variety, out of forged , casting andfabricated blanks.

(ii) Finishing of reclamed parts.

(iii) Modisfication of various spares by machining.

For performing the above , apart from the general purpose machine tool rangingfrom extra heavy duty to light duty nature are used which are :

a) Lathes (Max dia -2000mm,length 12000mm)

b) Shapers (Max stroke 1000mm)

c) Planning M/cs (Max table size 6000x2000mm)

d) Slotter (Max stroke 1000mm)

e) Vertical Boring M/cs (Max dia -5000mm)

f) Pillar & Radial Drilling M/cs (Max drill size 80mm)

g) Horizontal boring M/cs (Max spindl dia 175mm)

h) Plano milling M/cs (Max table size 6300x2000mm)

The section is provided with a versatile gear cutting group comprising GearHobblers (max. Module 36 ,dia 3000mm), gear slotter (max, module 8, dia 500), aMAAG Gear shapers with rack cutting unit (Max module 15, dia 1450) , straight levelgear generators (Max. Module 24) , and a spiral bevel gear generators (Max. Module1, dia 500). Other machines of special intrest are a ROD Threading Machine andvertical Boring machine with copying attachment.

The section is housed in three bays Heavy Machine Bay, Lihgt & MediumMachineBay and Expansion Bay. Handling equipments are provided in all the threebays which include 8 EOT cranes ( Max. Capacity 30T/5T), 6 Electrical transfer cars(Max. Capacity 20T) connecting the three bays to open gantry and assembly section.T rollys of 2T capacity are also provided for material transfer , stores collection etc.

2. Planning Section

Guided by the monthly plan given by CPD , the shop planning section proceeds

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with various steps in processing the jobs . The functions of planning section are:

1. Receipt , document and storage of work- orders received and master cardsdepartment-wise.

2. Collection preparation of finished products . A sub - section called productioncontrol group (PCG) executes these jobs .

3. Scheduling of jobs operation-wise with a view to take up the various work ondifferent machines as per sequence of operation specified , and to distributethe workload on machine in optimum manner

4. Issue and receipt of jobs cards for each operation .

5. Assessment of progress of jobs , maintaining statistics of production and otherrelevant data.

6. Advance preparation of co-ordination with tool room.

7. Co-ordination with CPD and maintenance/ planning section of various orderingdepartment for assemblies etc. The section has been provided with PCs forstorage of master carde and copies preparation .

The preparation of blanks machining includes and cutting of shafts , riser cuttingon casting , marking out jobs etc. For these P.C.G. Is provided with 4 circular sawmachining and 2 power back saws , layout tables for marking etc.

3. Technology Section : -

The section is responsible for working out the technological processing of jobsto be manufactured . The responsibilities of the section are .

1. Preparation of master card , detailing sequence of operations , type of machinetool to be employed , sequence of machining on eatch machine , cutting toolsto be used necessary shop calculations , tooling required etc. Along with allother relevant and special instruction .

2. Design, manifacture in coordination with tool room and try out of jigs andfixtures where - ever applicable

4. Assembly Section :-

1. Planned manufacture of new assemblies i.e. Crane wheels of various types andsize for different department . Hammer crusher rotors for coke oven and sinteringplant, peel assembly for SMS , transfer chains for Mill etc.

2. Planned periodcal repair/overhauling of equipment like B.F.Top equipments(charge distributor , bells , hoppers etc.) skip cars , mud gun ,OBC trolley travelaxle for SMS , stripper yard crane traverse , charging machine spindle , crusherroters for coke ovens , various transmission shofts and rollers for mill etc.

3. Repairs / reconditioning of parts / equipment of various department duringscheduled repairs , capital repair or at the time of breakdowns .

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GATEWAY

4. Repair of babbitt bearings for various shops.

The assembly work involves extensive material handling for which three E.O.T.Cranes ( max. Capacity 50 /10 ton) , one 3 ton telpher and a mechanincal chain block& job crane are provided . Railway wagons can enter in to assembly bay at one end,enabling heavy assemblies to be brought in . Dismantling and assembly work aredone with the help of two horizontal hydraulic presses (max. Cap 630 tons )& hydraulicjacks up to 200 tons capacity . A gas fired furnace for heating of components forshrunk fitted assemblies.

(5) Tool Room & Treatment Section :-

The Tool Room is intended to

i. produce & Recondition various metal cutting tools & cutters

ii. Repair measuring instruments/ tools , hand tools etc.

iii. Manufacture jigs , fixtures , gauges , templates ,and special cutters.

iv. Manufacture of machine tool accessories , and various other tackles.

v. Manufacture precision where high accuracy is demanded .

Also, tool room controls all the grinding operations carried out on various producedin MARS-1.

To perform above functions addition to general purpose machine tools , toolroom is equipped with a relleving lathe , a jig boring m/c with location accuracy ofone micron pantograph engraving m/c, cylindrical & surface grinding machine ofvarious capacities , tool & cutter grinders & hob grinding machine (to grind up tomodule 36), a drill grinding m/c and a circular saw grinder .

Proper heat treatment of spares is an absolute for improving their performanceand life . The heat treatment section is set up to effect this and is equipped to carryout general heat treatment process like hardening and tempering for increasing hardnessor improving structural and mechanical properties , normalizing for relieving stressesinduced in forging etc, annealing to improve machinability . Facility exist for casehardening .Equipments installed are gas fired annealing furnaces, brazing furnace forbrazing tools , electrically heated annealling of gears , gears shafts , crane wheelsetc. And a high freqency induction heating brazing of carbide tipped tool are alsoavailabile . An auto welding machine installed in heavy bay does the reclamation ofworn out crane wheels , shafts etc,using submerged arc welding .A sorbitising f/c forsurface hardening is also provided .A forging section is also provided with a gas firedheating furnace and a pneumatic hammer , for forging of tools & tool shanks .

6. Maintenance Section

The upkeep & maintenance of machine tools and all other installations of MARS-1 is as vital to the shop performance as the production itself. This is carried out by

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electrical & mechanical maintenance section which have the following responsibilities.

i. Regular check up of condition of machine tools.

ii. Planned preventive maint. Of machine tools , with the objective of minimizingbreakdowns by rectifying possible defects in advance .

iii. Attending day to day minor breakdowns.

iv. Attending to major breakdowns in such way so as to curtail the down time ofmachines to minimum.

7. Store Section

Controlled by the Incharge tool room, this section ensures the supply of toolitems & consumable required by MARS-1. These are normally collected from variouscentralized store of plant & stocked as per requirement . This section is also responsibilefor procurement of all items specially required by MARS-1.

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MARS - II

MARS-II is the new machine shop which is built under 4 MT expansion of BSP tocater to the spares and assemblies requirements of Convertor Shop, ContinuousCasting Shop, and Plate Mill. The shop has got two machining bays (Light bay andHeavy & Medium bay 78 x 24 M each), and one Assembly bay (72 x 24 M) whichforms a Tee with the machining bays.

Working Area of the shop : 5161 M2

Electrical Power : 1 MVA

CAPACITY

Annual machining capacity : 2200 TAnnual assembly capacity : 6000 T

Main assemblies done are 5-roll set, 8-roll set,10-roll set, and Pinch rolls used inSlab Caster of Continuous Casting Shop.

MAIN EQUIPMENT

1 Vertical Bording machine : 1 No

2 Horizontal Bording Machine : 1 No

3 HMT Lathe : 8 Nos

4 Cylindrical Grinding Machine : 1 No

5 Heavy Duty Lathe : 1 No

6 Plano Milling Machine : 1 No

7 HMT Horizontal Milling Machine : 1 No

8 HMT Universal Milling Machine : 1 No

9 Slotting Machine : 2 Nos

10 Shaping Machine : 1 No

11 Thread Cutting Machine : 1 No

12 Auto Welding Machine 10 T : 1 No

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MACHINE ASSEMBLY & RE-ENGINEERING SERVICES-III

In the beginning, this shop was known as Area Repair Shop-Rolling Mills, lateron as Zonal Repair Shop then as Machine Shop III and now as MARS-III. It was builtto cater to the need of spares and assemblies required for Rolling Mills.

This Shop is housed in two bays (21x75M and 11M X 54m) Total area is 2169sq. Meters.

Annual Capacity :- Machined parts - 500 T

Assemblies - 2000 T

EQUIPMENTS INSTALLED ARE :

Main Machine Tools:

1. Horizontal Hydraulic Press Capacity 630 T - 1 No.

2. Horizontal Boring Machine spindle 100 - 1 No.

3. Vertical Boring and Turning Machine table symbol 0 1250 - 1 No.

4. Precision lathes - H22/H26 - 530 DBC 3000 - 1 No.

1600 - 2 No.

5. Open side planing machine : Table size 900 x 3000 - 1 No.

6. Shaping Machine stroke 630 - 1 No.

7. Slotting machine stroke 250 - 1 No.

8. Vertical Milling machine : Table size 1325 x 310 - 1 No.

9. Radial Drilling Machine DR 80 mm in steel - 1 No.

10. Vertical Drilling Machine 40 - 1 No.

11. Bench Drilling Machine 12 - 1 No.

12. Submerged Arc Welding Machine : Job 1000 x 3000, Cap 4 T - 1 No.

13. Radial drill Machine 100 mm DR10 in steel - 1 No.

Other Equipment

1. Power Hack saw - stroke 400, stock to be cut 250 mm - 1 No.

2. Double ended Pedestal Grinder wheel 400 - 1 No.

3. Heating furnace (CO-gas fired) - 1 No.

4. Electric Transfer Car 10 T - 1 No.

5. EOT crane 30/5 T (20 M span) - 1 No.

6. Telpher 4 T (10 M span) - 1 No.

Surface plate, marking plate, welding tables : one no each are provided.

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GATEWAY

3 welding transformers are also installed.

Jobs carried out are :

- Tongs crane column assembly

- Mould Bogie, charging and slag car wheel assembly & dismantling

- Rack drilling and dismantling for BBM

- Crane wheel & 700welding & Machining

- Transmission shafts for BBM, RSM and cranes.

- Mechanical spares for Rolling Mill etc.

- Various rollers Assly. for mills

- Various gas valves for BFc's

- Cross pieces for 500 STD of CBM

- Cassette frame for CCS. etc.

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FORGE SHOP

Forge Shop is housed in a single bay building with an area of 120m x 21m, andan open gantry of size 12m x 11m is provided to stock raw materials required for theshop. It has been designed to produce semifinished and finished jobs.

The finished products are subjected to close inspection by :

a. Engineering Shops Inspection Department : for dimensional accuracy.

b. R & C Lab process control : for metallurgical quality.

Setup at 2.5 MT stage, the shop is designed to produce 3200 tonnes of forgings,300 T Balls and 50 T of non standard items. There is no change in the capacity under4 MT expansion of the plant.

Maximum single weight that can be forged is 4.5 tonnes.

MAIN EQUIPMENT

Forge Shop has been equipped with the following machines:

3 Tonne Pneumatic Hammer : 1 No



0.4 Tonne Pneumatic Hammer : 2 Nos

250 Tonne Friction Press : 1 No

160 Tonne Electric Press : 1 No

100 Tonne Eccentric Press : 1 No

1 Tonne Forging Manipulator : 1 No

250 Tonne Bar Cropper : 1 No

CO Gas Fired Furnaces

a. Annealing Furnace 6 x 1.5m (car bottom) : 1 No

b. Reheating Furnace (Batch type) : 9 Nos

c. Band saw machine (max. dia. 400 mm) : 1 No

MATERIAL HANDLING EQUIPMENT

3 Overhead Travelling Cranes of 5 T capacity each 4 cantilever Cranes of 3 Tcapacity each

1 cantilever Crane of 1.5 T capacity and

1 Transfer Car of 10 T capacity are provided for handling of materials.

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GATEWAY

RAW MATERIALS

Various raw materials and sections used for forgings :

a. Materials

Mild Steel

Medium Carbon Steel

High Carbon Steel

Low Alloy Chrome Steel

Nickel Steel

Die Steel etc.

b. Sections

Billets : Sq. 60, 85, 100 & 125 mm

Blooms : Sq. 160, 200, 280, 350, 380 & 400 mm

Rounds : Dia 28, 32, 36, 40, 50, 56 & 63 mm

The losses during forging are :

a. Scale Loss

b. Scrap Loss

c. Cutting Loss

MAIN FORGING OPERATIONS

Following are the main forging operations in the shop:

a. Drawing out

b. Upsetting

c. Cutting off

d. Bending

e. Punching and piercing holes

f. Ring rolling

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FOUNDRY & PATTERN SHOP

Foundry & Pattern shop is an important Engineering Shop, set up to meet therequirement of various ferrous and non-ferrous castings and cast blanks required forthe plant and other Engineering Shops especially machine shops, for manufacture ofspares. It comprises two major parts, the Pattern Shop and the Foundry Shop.

THE PATTERN SHOP:

The pattern shop is designed to produce patterns for foundry needs. The annualoutput is rated at 220 Cu. meters. The shop works in G shift. It is equipped withmodern set of working machine tools. Handling of heavy patterns at the shop andstorage is carried out by overhead travelling crane operated from floor level. Thepatterns are painted according to a code, ticked, labelled and stored, to enable thepatterns to be issued to foundry as and when required, according to a well-laid outprocedure. The pattern storage room is protected against any fire hazards.

FOUNDRY SHOP

The foundry shop is laid out in five bays, each of length 270 meters. Varioustypes of castings and their usage is as follows :

Iron Castings : ( Capacity 79000 T/year)

i) Spare parts for machines / equipments.

ii) Ingot moulds.

iii) Bottom Stools.

Steel Castings : ( Capacity 6500 T/ year)

i) Spare parts for machines / equipments.

ii) Twin hearth-charging boxes.

iii) Skull cracker balls.

iv) Spares for Mould bogie.

v) Ladle covers for SMS, Lip ring for CCS.

vi) Pig casting moulds.

vii) Alloy steel Ingots.

Non - Ferrous Castings : ( Capacity 515 T/ Year)

i) Bushings, slide blocks for machines/ equipments.

ii) Monkey for BF & Hollow shaft for SMS.

iii) L.N. body & covers.

iv) Al. Cubes & Al. Shots for SMS-I & SMS-II.

Main Sections of Foundry Shop :

1) Charging and Moulding Material Store :

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GATEWAY

The charging and moulding material storage is designed to hold 15 days supplyof all raw material used in foundry. The storage bay is served by overhead travellingcranes with removable magnets. With the help of electric grabs, all the raw materialsare stored in bins & bunkers.

2) Sand Preparation Section :

In this section, preparation of moulding sands and core sand mixture for all typesof castings is done. The raw silica sand is received from Sambalpur and Allahabad.Quartzite sand is supplied by Crushing Plant. The new sand, if wet, is dried in arotary dryer in which sand is heated to 200-250 deg.C. The dried sand is fed in thefeeding hoppers, over the sand mixers of 20 cu.m/hr capacity.

In the sand mixer ; various moulding materials like fire clay, bentonite, molasses,saw dust etc. are added and mixed. The sand so prepared is distributed by thesystem of conveyor belts throughout the cast-iron, steel and core section. 130 T ofmixed sand is produced by sand mixers for preparing different types of sand mixturesfor core section (about 5 T per day).

3) Iron Foundry :

The Iron foundry can be divided in to the following sub-sections.

i) Cast Iron section.

ii) Mixer section

iii) Moulding section

iv) Ingot Moulds

v) Mould drying chambers.

The estimated annual requirement of the metal is about 1,00,000 tons and thedaily requirements is 270 tons.

The moulding section prepares moulds for all types of castings required underthe schedule or special work requiring upto 30 tons liquid metal.

The Ingot Mould section produces the Ingot Moulds required by the plant. EachIngot Mould weights 8.8. T or 9.3 T and the daily production of Ingot Moulds are 17nos. on average. Ingot Moulds are rammed on two 30 tones jolting machines in theIngot Mould section.

Top box is prepared for using at top of Ingot Mould for pouring. The mould dryingchambers are used for drying the moulds in the chamber type drying ovens at thetemperature of 300-350 degree cel. There are 6 drying ovens. The 4 drying ovens are of130 Cu.m. capacity and the other 2 of 60 cu.m. capacity for drying small castings.These ovens have been provided with an arrangement for the re-circulation of the productsof combustion. Coke oven gas is used for heating purpose.

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Moulding of Bottom Stools in Cast Iron section :

Apart from rammed moulds with bottom chills, "Chill bottom stools" mouldingsare done by chill mould i.e. in the C.I. section. A better type of bottom stools areknow as "Chill bottom Stools"- these give more life, and are of better quality.

The 30 ton jolting machine in the CI section: At present this is being used formaking self core of charging boxes.

The Iron foundry is serviced by overhead travelling cranes (75 T, 50 T, 30 T) andcantilever cranes (5T). This section of the foundry is also equipped with ladle preheatingburners.

For the inter bay transfer of materials (castings, moulding boxes, containersetc.) there are 4 transfer cars of 50T capacity each.

4) Steel Foundry

This section is located in line with the Iron casting section. It is divided into thefollowing sub-sections:

I) Steel Melting Section

II) Moulding Section.

The steel melting section is provided with two 5 T direct arc furnaces with 3-phase supply. Melting and moulding section operate in 3 shifts on parallel schedule.The furnaces are lined with mangnesite on the silica bricks on the roof, Water coolingis provided at electrode holders, roofing, economisers, door frame and tap hole arc.To charge the furnace its roof is lifted and shell is rolled out. A pointer attached tothe body of the furnace indicates the amount of forward fill during the slagging andtapping time. 3 nos of 300 mm diameter electrodes passing through the roof, supplythe electrical energy to the furnace. Transformer capacity is 28 KVA. Heat timevaries from 2-2.30 hrs. for plain carbon steel and 3 -3 1/2 hrs. for alloys steels.Castings around 10 T. are made by running the furnaces simultaneously.

The moulding section operates in 3 shifts. Preparation of moulds is carried outon the foundry floor as well as, for moulding the PCMS (pig castings moulds), inboxes. Two 2.5 T moulding machines are also provided in this section. There are twocranes one of 30 T. one of 15 T and one cantilever crane of 15 T capacity.

The mould drying is carried out in mould drying chamber of 60 cu. meters capacitylocated in this section. Some moulds are also dried in bigger ovens in IM section.

The section is provided with two 50 T. transfer cars to bring charge materialsand to despatch castings to fettling section.

5) Non - Ferrous foundry

The Non-ferrous foundry is meant to produce liners, bearings, slide blocks, bushesand other small castings of different types from brass and bronze.

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Besides 1 Ton Induction furnace two indirect arc electric furnaces are for meltingnonferrous metals. These are of 0.5 Ton capacity and are scheduled to produces 515Tones of nonferrous metal. The furnace is of cylindrical shape having two electrodes.The furnace is rocking type lined with high alumina fire blocks. Moulds are dried in 11cu.m. oven.

Aluminum Shots and Cubes section consists of 3 Al. melting and pouring unitsand 3 melting crucibles for Al. Cube making.

6) Fettling section :This section is equipped with the following equipment

I) Knock-Out Machine :After solidification of the metal in the mould, the moulds are placed on the 20 T

knockout machine for the separation of mould box, sand and the casting. From theknock-out machine., the casting is removed and if necessary washed in the hydraulicchamber.

II) Hydro cleaning chambers : 2 nos.The hydro cleaning chamber is equipped with central rotating table and jet of

water operating on high pressure of 150 atm. When the casting is placed on the tablewith the water jets hitting the casting, all sand is removed. Two such chambers areprovided in this section.

III) Milling Machines : 2 nos.For machining the bottom of Ingot Moulds, two mould milling machines have

been provided. Each machine has provision of mounting two ingots at a time forcontinuous milling.

7) Cranes :There are in all 24 E.O.T cranes, including the crane in the new bay (towards SMSstripper yard)

Additional facility of 4 mt. stage :

1. The Open DE bay in the existing shop has been covered over a length of 71meters from column row 20 to 32 in order to provide additional space forproduction of steel castings. A small sand preparation unit, a drying oven ofcapacity 100 cu. m. and a paint mixer have been installed in this area.

2. A fully covered new bay measuring 12 x 168 m with 10 T EOT crane has beenconstructed towards steel melting shop's stripper yard for storing mouldingtackles and moulding materials. This bay connecting with the existing AB bayby extending the 50 T transfer car line form BC Bay.

3. 1 Ton capacity induction furnaces 2 nos. installed in Non-ferrous section, fornon-ferrous & alloy cast iron melting : commissioned in Dec. 1995.

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STEEL STRUCTURAL SHOP

Steel Structural Shop (SSS ) is one of the major engineering shops in the plantfor manufacturing spares through the process of fabrication. It was expanded in 2stages.

From 1 MT to 2.5 MT stage and from 2.5 MT to 4 MT stage. At present the shophas an open gantry for material storage and 3 bays parallel to it. One 30 M bayperpendicular to the existing bays was added during 4 MT stage. Total working areaat present is 12960 M2.

SSS has the following roles to play :

1. Caters to all the departments / shops of the plant for :

a) Capital Repairs jobs.

b) Schedule maintenance jobs (fabricated and gas cut items)

c) Break down jobs.

d) Modification and addition of new facilities as and when required in plant.

2. It also acts as a blanking shop for machine shops.

Infrastructure / facilities provided are :

i) EOT Cranes with capacities ranging from 5 T to 50 T ..................09 nos.

ii) Transfer Cars, connecting different bays. ...................................03 nos.

iii) Radial drilling machines ............................................................03 nos.

iv) 63 T Crank press ..................................................................... 01 no.

v) 80 T Punching machine ............................................................ 01 no.

vi) 200 T Vertical press ................................................................. 01 no.

vii) 200 T Capacity hydraulic press brake ......................................... 01 no.

viii) Shearing machines various capacities ........................................06 nos.

ix) Combination Shear (punching machine) ....................................... 01 no.

x) Profile gas cutting machine (Photo tracer type) ...........................01 nos.

xi) Welding Transformer & Rectifier ...............................................55 nos.

xii) MIG / MAG Welding machines ..................................................18 nos.

xiii) CNC Oxy-fuel Profile Gas Cutting machine .................................02 nos.

xiv) Plate Straightening machine ( up-to 25 mm Capacity) ................... 01 no.

xv) Plate Bending machine ( up-to 32 mm Capacity)........................... 01 no.

xvi) Heavy Plate bending machine (up-to 70 mm Capacity) .................. 01 no.

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GATEWAY

xvii) Plasma Gas Cutting Machine ..................................................... 01 no.

xviii) Portable Gas Cutting Machines .................................................30 nos.

Job Profile :

Steel Structural Shop manufactures assemblies for Converter Vessels of BSPand other units of SAIL; Ladles for BFs, SMS-I, SMS-II; various types of LaminatedHooks for SMS-I and SMS-II; Pusher Racks of BBM; Leveller Bars, Pusher racks,Mother Liquor Tanks for CO&CCD; Water Cooled equipments for Rolling Mills andStructural Details for Capital Repairs of different Departments of BSP. Apart fromthis, repairs of Slag Cars, Hot Metal Ladle Cars, Slag Cups, Ladles and othermiscellaneous structures during Capital Repairs are also done.

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RECLAMATION SHOP

Reclamation in general means economical sense of a used / damaged waste itemby value addition, which otherwise would have been useless. Reclamation Shop wasset up in the year 1991 with this idea of reducing procurement of mechanical sparesand assemblies by reclaiming the work out, damaged or broken items by welding &mechanical repairs.

Range of services offered by Reclamation Shop-

- Reclaims old spares / assemblies.

- Development of repair welding procedures & execution of repair.

- On site reclamation work.

- Testing of new welding consumables.

- Reclamation of crane wheels by submerged arc welding.

- Reclamation of discarded conveyor idlers of various departments of BSP includingmines.

- Mechanical repairs of different assemblies.

Reclamation Shop caters to the need of all departments of BSP including mines.Reclamation Shop has specialization in all types of welding like MMAW, GMAW,FCAW, SAW. Shop has expertise in repair of all types of gear teeth and all types ofwelding like MS, SS, Cast Iron, Brass, Aluminum etc.

Some of the high value & procurement diverted items repaired by ReclamationShop are as follows-

1. Grab Bucket - ARS

2. Dozer Blades - ARS

3. Main Drive Universal Spindle - BBM

4. BLT Chute - B.F.

5. Dehydrator Segments - B.F.

6. Hot Blast Valves - B.F.

7. Hammer Crusher Rotor Assly - Coke Oven, SP-I & SP-II

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GATEWAY

8 Bottom Frame of Jolting Machine - Fdy. Shop

9 Normalising Roller - Plate Mill

10 Work Roll - Plate Mill

11 Insitu Repair of Roughing Stand & Finishing Stand - Plate Mill

12 Apron Feeder Shaft - Rajhara Mines

13 G.C.P. Impeller - SMS-I

14 Rack & Pinion of Mixer - SMS-I & II

15 Impeller - SP-I

16 Sinter Crusher Rotor Assly - SP-I, SP-II & SP-III

17 Adjusting Sleeve - WRM

18 Roll Shaft - WRM

The shop consist of two bays "AB" & "BC". AB Bay comprises of SAW Machine,Conveyor Idler Repair Section, Roller Rotating Device & Auto Welding Section, whilethe BC bay is used for Hand Welding and mechanical repairs.

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GARAGES & VEHICLE POOLS A large fleet of light & heavy vehicles, alongwith good number of Earth Moving

Equipments, are required to be maintained for working of Bhilai Steel Plant. Therequirement is taken care of by following shops :

A. Plant Vehicle Pool (PVP)

B. Automobile Repair Shop (ARS)

C. Mobile Equipment Repair Shop (MERS)

D. Township Vehicle Pool (TVP)

PVP, ARS & MERS are situated in the plant works area, whereas TVP is locatedin Sector-7 of BSP Township.

A. PLANT VEHICLE POOL

This pool caters to the need of movement of store items ( spares andconsumables), raw materials, waste products, etc. by road. A number of earth movingequipment are also being maintained .

Deploying Earth Moving Equipment (EME) in production departments, eliminatesuse of excessive labour force and in better upkeep of shops. The jobs done by EMEsare as follows :

i) Removal of wastes from SMS-I, SMS-II, Blast Furnaces, Convertor Shop etc.

ii) Removal of microfine dust from Blast Furnaces

iii) Removal of lime sludge from acetylene plant

iv) Slag removal, by using payloader and dozer, in converter shop slag yard

v) Loading of coke into wagons at coke dump yard

vi) Removal of coal from coal handling plant

vii) Removal of mill scale from BBM, RSM, MM, WRM, PM & CCS

viii) Transportation of raw materials from RMP-I & RMP-II

Various Vehicles available are :

Light Vehicles

Cars, Jeeps, and Pickups are mainly utilised to coordinate the various activitiesof service departments of the plant (such as Plant Control, T&D Organisation,Telecommunications, Water Supply, EMD etc.). Vehicles are used for movement ofpeople as well as materials such as spares, tools, tackles etc. Cars are mainly usedfor movement of senior executives of the plant.

Trucks / Tippers

Used mainly for transportation of spares/consumable for stores and also forvarious operational requirements. They are also used for transportation of productsfrom one department to another, such as lime from dolomite shop to convertor shopand sintering plants.

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GATEWAY

Dumpers

Dumpers transfer return sinter and nut coke from Blast Furnaces to SP-II & SP-III; CDI coal from Yard to BF-6, and raw materials like lime, mill scale, dolomite fromvarious areas to SP-II & SP-III. These are also deployed for shifting of coal, coke,slag, and burnt sand of Foundry, etc.

Dozers

These are deployed for coal feeding in Power Plants, removal of slag in Slag Yard- I, Slag Yard - II, Open Slag Yard & Convertor Shop.

These are also used for coke shifting in the mechanised Coke Yard I & II, andCoal Yard of Coke Ovens.

Excavators

These are used for removal of waste from SMS-I Pit Side, Acetylene Plant, SlagYard-I, Open Slag Yard, SMS-II (Ladle Bay & Tundish Bay), Ladle Repair Shop-II, etc.

Front End Loaders

These are used for removal of waste from Convertor Shop, CCS, Blast Furnace,Coke Sorting Plant, Foundry Shop etc.

Tractors / Trailers

These equipment move assemblies, long jobs, raw materials such as ferro alloysfor Convertor Shop, etc. They are also deployed for mould shifting to CCS, Tar toRMP - II, Diesel to OHP and Acid to PP-II.

The P.V.P has been entrusted with the operation of all above mentionedequipment. It also caters to the need of shops during capital repairs.

The total number of Vehicles and Earth Moving Equipment pertaining to PlantGarage are as follows :

S.NO. TYPE OF VEHICLE / EQPT. FLEET STRENGTH

1 BUS 8

2 TRUCKS 88

3 CASH VAN 3

4 EXPLOSIVE VAN 1

5 TIPPERS 23

6 GARBAGES 8

7 ELECTRICAL VAN (HOIST P/F) 3

8 WATER TANKERS 9

9 WATER TENDERS 23

10 AMBULANCE 14

11 CARS 53

12 JEEPS 84

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13 PICKUPS 38

14 MINIBUS 10

15 DOZERS 12

16 DUMPERS 13

17 EXCAVATORS 16

18 FRONT END LOADERS 8

19 TRACTORS 7

20 CRANES 4

21 SNORKEL (FB) 1

22 HYDRAMOC CRANES (CAPTIVE) 41

23 CRAWLER PAY LOADERS 5

TOTAL 469

B. AUTOMOBILE REPAIR SHOP (ARS)

Automobile Repair Shop undertakes the maintenance and repair of all types ofroad transport vehicles, earth moving equipment and small mobile cranes belongingto the plant. To cope with the above functions, A.R.S. has been provided with modernfacilities.

This shop is broadly divided into the following major sections.

01. Light Vehicle Running Repair Section.

02. Servicing Section.

03. Heavy Vehicle Running Repair Section.

04. Electrical Repair Section.

05. Body and Chassis Repair Section

06. Pump Room.

07. Machine Shop.

08. Painting Section

09. Upholstery Section.

10. Engine Overhauling Section.

11. Battery Room.

12. Tin/ Blacksmithy Room.

13. Carpentry Section.

14. EME (PM) Section.

15. EME (CR) Section.

16. Tyre Section.

17. Planning and Procurement Section.

18. Imprest Stores.

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GATEWAY

C. MOBILE EQUIPMENT REPAIR SHOP (MERS)

This shop is situated near RMP- II. It started functioning in 1989 with the idea ofquicker service on important production equipment which are under breakdown . Itcaters to maintenance and repair of Crawler Equipment like Dozers, Cranes and CrawlerPay Loaders.

D. TOWNSHIP VEHICLE POOL (TVP)

It caters to the need of township, VIPs and also helps State Govt. in maintaininglaw and order in the town by providing vehicles whenever required.

It facilitates transportation of employees, and also artistes etc. during culturalfunctions of the plant..

There are cleaning facilities for washing of vehicles, and also arrangements forminor repair of the vehicles.

The fleet consist of cars, jeeps, pickups, buses etc.

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SHOP INSPECTION (ENGG. SHOPS)

Engineering Shops produce spares and changeables for day to day maintenanceand repairs, and replacement of worn out assemblies of the equipment and machineryin the form of castings, forgings, fabrications, machined products and heat treatedproducts, beside carrying out repair, overhauling, dismantling and assembly jobs.Any defective or out specification job is bound to create problems in the running ofequipment, and production. Hence, it is essential that spares produced be inspectedbefore they are sent for use. For the purpose, this department (falling under CentralMaintenance Organisation) was set up.

Broad Functions :

1. To inspect the semi finished/ finished products from the engineering shops andcontrol the spares quality in accordance with technical specifications andtechnical documents.

2. All deviations from approved specifications are accepted only after consultingthe indenter and with the concurrence of design bureau.

3. It ensures control over the operations by stage inspections during technicalprocess in production as per demand of work.

4. Together with the departments, it does documentation of all inspected andrejected products manufactured in engineering shops, for future consultations.It checks on operation allowances, machining allowances, and tolerances oncastings, forgings and fabrications as approved by competent authority.

5. It ensures quality of all out-going finished parts, heat-treated parts and assemblyproducts and declares the factual production of shops in the engineeringorganisation on the basis of which the incentive payment is done in the shop.

6. Check the quality of wire rope slings during manufacturing process and finallytest them for strength.

7. Inspects repaired tools and lifting tackles.

8. In Auto Repair Shop, checks old tyres before and after retreading.

9. Inspection of certain critical items is carried out time to time at different sites inthe plant for timely change of worn-out parts of equipment.

10. Inspection is arranged at site during repairs/breakdown to facilitate changing/modifying/manufacturing of any worn-out/damaged parts.

11. Inspection is carried out for parts' thermit welding for its alignment.

12. Inspection is also carried out on the spares coming for reclamation.

OTHER IMPORTANT ROLE :

This inspection Department is concerned not only with checking for faults in

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spares produced but also takes preventive steps to reduce recurrence of defects. Itcontrols and guarantees the quality and accuracy of parts and helps in minimisingrejections, subsequent rectifications and reworking.

Department is entrusted with not only checking of spares made in EngineeringShops but also many spares which are purchased (purchase diverted - i.e; divertedby purchase department for inspection) like 270 T steel ladle of SMS-I, 130 T steelladle of SMS-II, convertor shells, mould bogie assembly of SMS-I, manipulator guardof BBM, various types of pusher racks for BBM, RSM & Plate Mill etc. In addition,other jobs such as fabrication of V.A.D. heat shield, modification of pinch rollerassembly, coolers of Blast Furnaces etc which have a direct bearing on cost to theplant.

Various Stages of Inspection :

1. Incoming material inspection

2. On process or stage inspection

3. Final inspection

By adopting this method, spares found out off specification at any stage arequickly rectified. If the quantity of job is in hundreds or thousands, then samplingmethod is used to decide the lot to be passed.

It is economical for the plant - especially during austerity drives - to use repaired/rectified parts. A committee comprising indentor and representatives from engineeringshop and inspection decide the possibility of economical repairs. Here inspectionplays a very vital role in taking measurement of worn-out parts, which makes it easyto decide towards repair or new fabrication.

Time to time inspection/measurement is arranged at site so as to know thewearout of vital equipments and plan for its changing to avoid breakdown.

Many reducers in the plants have been in use for 30 years and have no spares ordrawings available. Design & Drawing department takes help of this department - toget correct dimensions for making new drawings for manufacture.

Preventive maintenance is a phenomenon now most adopted. To increase thelife of a spares, various welding methods are in existence. Inspection by nondestructivetesting checks hardness measurements and reducing maching defects are generalmethods.

In the current competitive world, the Shop Inspection Department is playing avery vital role ensuring quality and good maintenance which makes plant efficientand profit oriented, to face the market challenges.

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OXYGEN PLANT NO - I

Oxygen from OP-1 is used for enhancing the process of steel making in open/twin hearth furnaces. It is also used for scarfing, gas cutting, welding, cylinder filling,for opening the tap hole and medicinal uses.

There are many ways in which oxygen can be produced. All over the world O2 isproduced by separating the air into Nitrogen and Oxygen. Large plants for industrialproduction of oxygen are called tonnage oxygen plants as the capacity is measuredin tons of oxygen produced in one day.

Here in Bhilai Steel Plant, in Oxygen Plant No - 1, we have three air separationunitseach having a capacity of 5000 NM3/hr. Of this 95 % oxygen is 4700 NM3/hrand remaining 300 NM3/hr is 99.2 % pure. 95 % pure oxygen which is known astechnological oxygen is used in Steel Melting Shop for Steel production and 99.2 %is used for Medicinal purpose. Two of these units have come in 1 MT stage and thirdcame under 2.5 MT expansion of BSP.

For manufacture of huge quantity of oxygen three types of processes are used :

1 High Pressure

2 Mixed Pressure

3 Low Pressure

In our plant we are using low pressure process. Air is compressed to a pressureof 6 Atm. and then it is led to Air Separation Unit (ASU).

This air goes to regenerators. There are two oxygen and three nitrogenregenerators which operate on a three minute cycle. In oxygen regenerator out-goingoxygen passes for three minute when it is getting cooled and then air for threeminutes when air gets cooled. Similarly in nitrogen generator, every regenerator iscooled for three minutes by Nitrogen and then heated for three minutes by air. Loopair enters regenerator at the bottom and comes out at the middle, cooling theregenerator further. Air temperature at the bottom of the regenerator outlet is 173°C.Regenerators are packed with aluminium foils.

Cold air from regenerators enters the bottom column which is a rectificationcolumn. Liquid nitrogen travels from top through the rectification trays. Air travelsfrom bottom of the column to top and through the holes in rectification trays. Whenthis air reaches of the top it is about 97% nitrogen liquid which travels on the traysand falls on the lower tray. It contains 40% oxygen when it reaches at the bottom ofthe column. During the mixing up of liquid and gas, Nitrogen being more volatile goeswith gas by evaporating from liquid, and oxygen condenses.

Liquid air from bottom column passes through filter adsorber and goes to columns

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after getting cooled in liquid air section of sub cooler condenser by nitrogen. Filteradsorber consists of porous bronze filter which arrests solid CO2 and ice particlesand adsorbing section is filled with silica get which adsorbs acetylene.

A part of air from bottom of bottom column passes through liquid separatorwhere liquid air particles are separated from gaseous air and go to turbo expanderheat exchanger. When it is heated by loop air going to bottom column and comes outat -150°C. This air goes to turbo expander where it is expanded from 5 Atm to 1.4Atm. Also, in the process of expansion this air runs a generator which produceselectricity. This power is fed to the mains. During expansion the temperature of airdrops to -186°C.

Air, after turbo expander passes through gas-adsorber filled with silica gel forremoval of acetylene and goes to top column. Top column is a rectification column oflow pressure. (0.4 to 0.5 Atm) in which rectification takes place and nitrogen collectsat the top and liquid oxygen 95% pure collects at the bottom. This liquid oxygen iscontinuously boiling in main condenser (which has a shell and tube construction) inthe tubes and nitrogen from bottom column will be circulating around the tubes andgoing back to top of bottom column.

This 95% liquid oxygen is then taken to additional condenser which also hasshell and tube construction. Here also liquid oxygen gets evaporated and nitrogenfrom bottom column liquefies and is sent to top column through expansion valve.Gaseous oxygen passes through acetylene separator and goes to oxygen regeneratorsafter passing through additional condenser.

For 99.2% oxygen production 95% pure liquid oxygen is taken to anotherrectification column known as technical column. Oxygen coming out of this columnwill have a purity of 99.2%. A part of this oxygen is liquefied (75 M3) and compressedin liquid oxygen pump to a pressure of 130 Kg/cm2, evaporated and filled in cylinders.99.2% pure oxygen is known as Technical Oxygen. At present cylinder filling in OP-I is stopped and cylinders are filled in OP-II.

MAIN EQUIPMENT IN OP-1

ATCs

There are 3 Nos air turbo compressors in OP-1 having a compressor capacity of30000 M3/hr at 6 Kg/cm2. All these are run by synchronus motors of 3 MW each.Function of these air compressors is to compress air upto 6 Kg/cm2 which is sent todistillation column.

OTCs

There are 3 Nos oxygen compressors to compress oxygen upto 12 Kg/cm2 andthe oxygen is sent to SMS-I through pipe line.

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Capacity of oxygen compressor is 7000 M3/hr,1 No & 6000 M3/hr 2 Nos. Theseare high speed equipments (speed 13,700 rpm) and run by synchronus motors.

GAS HOLDER

A gas holder (oxygen) is installed in the synchronus line of OTC's and wheneverconsumption in the SMS-I reducess oxygen is stored. Storing capacity 10000 M3/hr.Whenever there is a oxygen pressure drop at SMS-I oxygen to some extent is suppliedfrom gas holder.

MAJOR CONSUMERS

1 SMS-I

2 Blast Furnances

3 Service Oxygen @1000 M3/hr is supplied to 1 MT area.

Although the plant (OP-I) is nearly 47 years old but still it is contributing towardssteel production with a slightly reduced capacity (around 80%)

It is being maintained by continuous efforts of OP-1 staff. Some critical sparesare being reclaimed inhouse also.

One Oxygen line drawn from OP-2 feeds leakage oxygen from OP-II to the suctionof OTC's at the rate of around 3000 NM3/hr.

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OXYGEN PLANT - IIOxygen Plant-II is one of the major auxiliary units of 4 M.T. expansion of Bhilai

Steel Plant.

The plant has three Air Separation Units, each having Capacity of 550 tons/day

of Oxygen (maximum). The Main products are Oxygen, Nitrogen and Argon. Apart

from these products the following cylinders are also filled in Oxygen Plant-II.

(i) Oxygen Cylinders : Technical : 130 Kg/Cm2; Medical : 130 Kg/Cm2

(ii) Nitrogen Cylinders : 130 Kg/Cm2

(iii) Argon Cylinders : 130 Kg/Cm2

Main equipment in OP-II are described below :

AIR CENTRIFUGAL COMPRESSOR

Air is sucked from the atmosphere through a suction filter. Here dust and foreign

particles are removed from air. It is then compressed in Air Centrifugal Compressor

up to a pressure of 7.35 kg/cm2 abs (temp.40 deg.).

PRECOOLING UNIT

This consists of Nitrogen water tower and Air water tower with moisture separator.

Waste Nitrogen which is coming from Air Separation Unit at 25 deg.C is used to cool

soft water by direct contact in the Nitrogen water tower. Chilled soft water at 20

deg.C is then used to cool compressed Air from Air centrifugal compressor in Air

water tower some traces of moisture are removed in moisture separator. Warm soft

water from air water tower is returned to Nitrogen water tower for cooling.

AIR SEPARATION UNITS :

There are three Air Separation Units 1, 2 and 3 (ASU-1, ASU-2 & ASU-3)

PARTICULARS OF PROCESS FOR ASU 1 & 2:

Compressed Air after being cooled to 22 deg .C enters set of reversing heat

exchangers. In these, passages for out going oxygen & pure Nitrogen are fixed &

passages for in coming Air & out going waste Nitrogen are reversed periodically. The

main function of reversible heat exchanger is to cool incoming Air by heat exchange

with outgoing products & consequently moisture & Carbon dioxide are deposited in

the reversing passages. During reversal period (switch over of waste Nitrogen stream

& air stream) the solid deposits of CO2 and H2O sublime in the WN2 stream and are

carried away. Therefore compressed Air leaves the cold end of reversing heat exchanger

free of moisture and carbon di-oxide, and at a temperature slightly above its dew

point.

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MEDIUM PRESSURE COLUMN K-50

Air from reversing heat exchanger is fed into bottom portion of medium pressurecolumn (K-50). This column consists of 35 no. of trays. Air is bubbled through a richliquid at the bottom of column. Air stream rising up becomes poorer in oxygen bycontact with descending flow of liquid stream on trays. At the top of medium pressurecolumn we get medium pressure pure nitrogen. Part of which is liquefied in vaporiser(E61) to produce lean liquid with high nitrogen content liquid. Down flow liquid becomesricher in oxygen and produces rich liquid at the bottom, (which contain 40% oxygen).

VAPORISER (E61)

Works as a condenser for medium pr. column K50 to Nitrogen & works as vaporiserfor low pressure column to vaporise liquid oxygen.

LIQUID OXYGEN PUMPING AND FILTRATION

Liquid Oxygen from Separator (B61) is re-circulated by Lox circulating pumpsthrough Lox filter where acetylene & other hydrocarbon gases gets adsorbed withthe help of silica gel. Which other wise may causes an explosion of very severeimplications.

LOW PRESSURE COLUMN (K51)

Liquid N2 which contains (10% O2) called as lean liquid is tapped from 19th trayof M.P. column, K-50, is passed through a sub cooler where heat exchange takeplace with outgoing waste N2 and then expanded through expansion valve and fed totop of low pr. column as a reflux. Rich liquid (40% O2) from the bottom of M.P.column is passed through rich liquid filters (T94/T95) to remove acetylene and thenexpanded through expansion valves and fed to top of low pressure column.

Pure gaseous oxygen is drawn from the bottom of low pr. column. & sent tooxygen turbo compressor through reversing heat exchangers. Waste Nitrogen comingfrom top of lowpressure column goes to atmosphere via subcooler, Reversing heatexchanger & Nitrogen Water Tower.

EXPANSION TURBINE :

Medium pressure Nitrogen is tapped from the top of vaporiser E 61 (shell side)part of medium pressure Nitrogen is used in the expansion turbine for expansion afterpassing through cold section of reversing heat exchanger. This low pr. Nitrogen thenpasses through Reversing Heat Exchanger and comes out as a product LP N2. Coldbalance of Air Separation unit is made by expansion of pure nitrogen in expansionturbine.

CRUDE ARGON COLUMN :

In the atmosphere Argon content is 0.9% by volume. Boiling point of Argon is -185.7 deg.C. So it gets concentrated in the stream of lower section of low-pressure

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column (K-51). A gaseous about 10% Argon is withdrawn from low-pressure column(K-51) & fed to the bottom of crude Argon column (K-55), where it is bubbled throughrich liquid. Crude Argon purity of 97% is obtained at the top of crude Argon column.Part of it is condensed to form reflux liquid in the condenser (E75) with help ofevaporating rich liquid.

AIR SEPARATION UNIT NO.3 :

GENERAL :

Air is a gaseous mixture containing oxygen, nitrogen, argon (and certain raregases) in fixed quantities. These components are separated through the use of lowtemperature distillation.

The air separation process follows these steps:

1. Compression

2. Pre-purification

3. Cooling to cryogenic temperature

4. Separation into component parts by low temperature distillation

5. Re-warming of separated components

The refrigeration process used to develop liquid air temperatures is regenerative.Warm process air entering the plant is cooled by the separated products as theyleave. In order to compensate for warm end loss heat in leak to the plant and toprovide for any liquid production, refrigeration must be provided. Process considerationother than refrigeration requires that air entering the distillation system must be at anelevated pressure. Inlet air is compressed in the main air compressor and a sidestream is boosted to a higher pressure via a booster compressor.

Air also contains variable quantities of dust, water, carbon dioxide andhydrocarbons. These impurities must be removed from the system to ensure safeand efficient operation. Dust is removed by filtering the inlet to the air compressor.Some of the atmospheric water is removed by adsorption on to the molecular sieveand alumina in molecular sieve adsorbers (MSA).

The following paragraph covers some of the important details of the air separationplant.

PROCESS AIR SYSTEM :

Air is drawn into the a filter (F-10), compressed in the main air compressor(CP-11A or B) to a pressure of about 6.2 kg/cm2 (a) and then fed into the directcooler (C-13) for cooling and partial dehumidification. This operation serves the functionof moisture removal through compression and cooling and provides pressurised airfor the air separation process.

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DIRECT COOLER AND EVAPORATIVE COOLER

The warm air is cooled by counter-current contact in the direct cooler (C-13),firstly in the lower packed section with treated water from pumps (P-131 A/B) andthen in the upper packed section with chilled treated cooling water from the evaporativecooler (HE- 17).

The vap. cooler (HE-17) generates chilled water by cooling treated water throughcounter current contact with dry waste nitrogen (WN) and low pressure product nitrogen(LPPN) from the cold box. The chilled water is pumped by the Vap. Cooler Pumps (P-171A/B) to the direct cooler (C-13) while the humid nitrogen thus created exits to atmospherefrom the top of the cooler. The warm water exiting the direct cooler is cooled in thecooling water tower before returning to the cooling water pond (CT-91).

PRE-PURIFICATION

Pre-purification is accomplished by feeding compressed and pre-cooled air fromthe air compressor (CP-11A or B) and direct cooler (C-13) to the pre-purification unit(PPU). The pre-purification unit consists of a switching valve skid, two vertical adsorbervessels D- 16A/B, two after-filters F-162 A & B, and an electrical regeneration heater(HE-163). The pre-cooled air enters the on-stream adsorber vessel via the switchingvalves. In the adsorber vessel water, carbon dioxide and some trace hydrocarbonsare removed down to extremely low levels. The adsorbent bed consists of two layers- activated alumina which forms the bottom layer and removes water vapour andmolecular sieve which forms the top layer and removes carbon dioxide. After theadsorber vessels are fitted two after filters (F-162 A & B) which prevent escape ofany molecular sieve dust to the rest of the plant. Dry waste nitrogen (WN) from thecold box is used to regenerate the adsorbers. The waste nitrogen is heated in theregeneration heater (HE - 1 6 3 ) before being passed through the off -stream bed atlow pressure . The previously collected impurities are desorbed and removed fromthe bed by the passage of the hot low-pressure waste nitrogen gas. The impurity-laden waste nitrogen stream is vented to atmosphere on leaving the bed. Whenregeneration is complete the bed is cooled by turning off the heater while continuingthe flow of cool nitrogen waste through the bed . Once the regenerated bed has beencooled to ambient temperature it can be switched to adsorption duty and the bedwhich was previously on-stream can then be regenerated.

AIR SEPARATION UNIT

Dry purified air from the PPU splits into three streams. The main stream from thePPU passes to the main heat exchangers, HE-21 and 22, in which it is cooled tocryogenic temperatures by heat exchange against returning product streams. Thesecond stream from the PPU passes to the compression side of the expandercompressor, CE-35A or B. A third stream is taken off the PPU as dry air to BhilaiSteel. At the outlet of the compression section of CE- 35A or B, the air stream iscooled and passed to the main heat exchanger from where it is taken out at an

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intermediate temperature and passed to the inlet of the expander side of CE-35A orB. From here the air stream splits, part going back to the main exchanger as a coolingstream, part going to the upper, low pressure, column. The air stream at the cold endof HE-21 and 22 passes to the base of the HP column C-25. In the HP column, C-25,air is separated by distillation into high purity nitrogen at the top and oxygen richliquid at the bottom. Reflux for the HP column is provided by condensation in thecondenser/reboiler, RB-31, which also provides Reboil for the LP column. Mediumpressure nitrogen product is taken from the top of C-25 and passed to the mainexchangers, HE 21 and 22. The rich liquid stream is taken from the bottom of the HPcolumn under level control and is expanded into the LP column after flowing throughthe subcooler HE-26/36/33, the pure argon column reboiler RB-284 and condensercans for RB-282 and RB-28. The outlet from the reboiler and the vapour liquid returnsfrom the condenser cans form the five rich liquid feeds to the LP Column C-30 wherefinal separation takes place. Liquid Nitrogen is provided by a pure nitrogen streamfrom the top of the HP column condensing in the LP column reboiler RB-31. Thisprovides both the refluxes to the HP column and liquid product via the product subcoolerHE-26/36/33. Reflux is also provided to the top LP column in the main exchangersHE-21/22. Waste nitrogen (WN) is taken from a point near the top of C-30 and likethe LPN is heated in the exchangers HE-26/36/33 and HE-21/22. The waste streamis then used for regeneration of the PPU unit. A stream rich in argon is taken frompartway down the LP column to the crude argon system (see section 4.1.5). Pureliquid oxygen collects at the bottom of C-30. Most of this liquid oxygen is reboiled inthe main condenser reboiler. However there is a significant flow of liquid oxygen (LO)taken under level control to the LO transfer pumps, P-371 A & B. Here the LO ispumped through the LO absorbers D-37 A & B, where any hydrocarbons are adsorbed.A small stream then leaves for storage via the product subcooler, the remainderreturning to the sump of the LP column. High purity gaseous oxygen (GO) is withdrawnfrom the gas space above the reboiler, heated in the main exchanger, and then formslow pressure GO.

PURE ARGON PRODUCTION

The argon distillation duty is split between two columns, the lower column,

C-29, and the upper column, C-294. The upper argon column sits on the floor of thecold box, whereas the lower argon column is, in fact, higher up the cold box. The

words 'upper' and 'lower' refer to the process duty and not the physical position.Argon enriched vapour is taken from an intermediate elevation on the LP column,

C-30, and is passed to the lower argon column, C-29. The vapour rises up the columnwhich effect separation primarily of argon and oxygen by contact with liquid descending

the column. Overhead vapour from C-29 flows to the base of the upper argon column,C-294 and rises up the column to the condenser, RB-28. Reflux liquid flows down

C-294 and is pumped up to the top of C-29 by the argon reflux return pumps, P-291A/B. The discharge pressure of the reflux return pumps is kept constant by controlling

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the recycled liquid to C-294 and the level of C-294 sump controls the liquid sent to

C-29. Overhead vapour from C-294 is condensed in RB- 28 by heat exchange withsub-cooled RL originating from the HP column. Argon depleted liquid from the base of

C-29 returns under gravity to the LP column at the same elevation as the argon richvapour is withdrawn. A stream of liquid argon is taken from the liquid leaving the

argon condenser, RB-28, and passed to a mid point in the nitrogen removal column,C-292, where final traces of nitrogen are removed and vented to atmosphere. This

liquid is flow controlled with the controller set point fixed by the purity at the top ofthe upper argon column. Reboil and the RL stream provide condensing duties for

C-292. RL leaving the subcooler, passes first through the reboiler, RB-284, to supplycolumn Reboil and then some of the RL is expanded into the nitrogen removal column

condenser, RB-282, to supply the condensing duty. The remainder of the RL isexpanded into the main argon condenser, RB-28. The pressure of the nitrogen removal

column is controlled by venting gas at the top of the column. The column re-boil isadjusted by adjustment of the reboiler bypass. The pressure in the nitrogen removal

column condenser is controlled by the temperature at the top of the column cascadingto a pressure controller and the condenser level is kept constant by control of the

inlet valve. The pressure of the main argon condenser, RB-28, is controlled by thedifferential pressure across the lower and upper argon columns and RB-28 level

controlled by the liquid outlet valve. The inlet valve to RB-28 is controlled by the HPcolumn level. Pure liquid argon product flows from the base of the nitrogen removal

column, C-292, to storage under level control.

Thawing and Liquid Disposal System

The thawing of the air separation unit is achieved by passing dry air directly fromthe PPU into the plant. A thawing header is provided so that dry air can be delivered

to individual machines (argon recycle pumps P-291 A/B, LO pumps P-371 A/B andcompressor/expanders CE-35 A & B). If the plant is shut down, thawing air is admitted

via the normal process route to the plant, and also to the argon columns and nitrogenstripper column via the thawing header. At plant shut down, cryogenic liquids can be

drained via manual valves to the disposal system, which leads to the disposal vesselWD- 96.

STORAGE AND DISTRIBUTION OF PRODUCTS:OXYGEN :

Low pr. Oxygen (99.5% PURITY) from A.S.U. is compressed up to 31kg/cm2 inoxygen centrifugal compressors. The compressed oxygen is then fed into 16 receivers

(100 M3 vol.) in parallel with pressure regulating & metering station. In PRMS pressureof oxygen is reduced from 31kg/cm2 to 16kg/cm2 and fed to SMS-II and service line.

Gaseous Oxygen/storage vessels act as a buffer vessels for continuous production &fluctuating consumption.

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NITROGEN :

MEDIUM PRESSURE NITROGEN :

Medium pressure Nitrogen at 4 Kg/cm2 and ambient temperature is used forsealing of Lox circulating pumps and expansion Turbines of A.S.U.

NITROGEN TURBO COMPRESSOR :

Low pr. Nitrogen from Air Separation unit is compressed in Two Nitrogen TurboCompressor (Max. pr.-16kg/cm2) and fed to converter shop at 10-14 kg/cm2 andother consumers. Part of compressed nitrogen is fed to BF-7 for gearbox cooling &other blast furnaces (BF-7 4,5,6) after regulating pr. at 3.5 kg/cm2.

PURE ARGON :

Gaseous Argon is supplied to RH Degasser, Ladle Furnace, Converter bottompurging etc. through pipeline after regulating pr. at 16.0 kg/cm2.

Gaseous Argon is filled into VAD tank up to 16-kg/cm2 pressure (max.) formaking special steel.

LIQUID STORAGE TANKS :

2000 TON LIQUID OXYGEN (LOX) TANK : (2 NOS)

Liquid oxygen from Air Separation Units is stored in a spherical Aluminium tank& cylindrical tank insulated by expanded perlite. The insulation is covered by mildsteel sheet and the annular space is purged by low pr. pure nitrogen. When one of AirSeparation unit is under shutdown, Lox is drawn from these storage tanks & pumpedup to 31 kg/cm2 by reciprocating pumps & vaporised in a vaporiser by stream heatedcirculating water. This gaseous oxygen is then supplied to discharge header of oxygencentrifugal compressors.

200 TON LIQUID NITROGEN (LIN) TANK : ( 1 NO.)

High purity Liquid Nitrogen from Air Separation Unit No.3 is stored in a 200 MTcylindrical tank insulated by expanded perlite. The insulation is covered by mild steelsheet and the annular space is purged by low pr. pure nitrogen. When one of AirSeparation unit is under shutdown or when one of nitrogen turbo compressor tripsLIN is drawn from this storage tank & pumped up to 17 kg/cm2 by reciprocatingpumps & vaporised in a vaporiser by stream heated circulating water. This gaseousnitrogen is then supplied to discharge header of Nitrogen Turbo compressors and alsoused as a backup instrument air during total power failure for quick start-up ofmachines.

200 TON LIQUID ARGON (LAR) TANK : ( 1 NO.)

High purity Liquid Argon from Air Separation Unit No.3 is stored in a 200 MTvacuum insulated cylindrical tank and is provided with two reciprocating pumps andvaporisation system. LAR is drawn from this storage tank & pumped up to

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130 kg/cm2 for filling cylinders by reciprocating pumps & also supplied through directpipeline to various consumers viz. RH Degasser, Ladle furnace, VAD etc for makingspecial quality of steel.

OXYGEN / NITROGEN /ARGON CYLINDER FILLING & STORAGE STATION :

Liquid oxygen pump installed in 2000 Ton Lox Tank I area of make CryopumpAsia is pumped up to 130 kg/cm2 and after passing through atmospheric vaporiser,filled in cylinders and given to customers.

OXYGEN Liquid nitrogen is pumped form Liquid nitrogen tank upto 130 Kg/cm2

and after passing through atmospheric vaporiser, filled in cylinders and given tocustomers.

Liquid argon is pumped (2 nos. LAR Pump) form Liquid argon tank upto130 Kg/cm2 and after passing through atmospheric vaporiser is supplied to consumersthrough pipeline and sometimes filled in cylinders and given to customers.

SAFETY ASPECTS :

1. OXYGEN :

a. Oxygen Gas is without odour taste and colour.

b. The atmosphere normally contains 21% Oxygen, An increase in Oxygen contentabove this figure is known as enrichment the decrease below this figure isdeficiency.

c. Oxygen is slightly heavier than air and will accumulate in cavities, trenches andpits.

d. Although not it self-combustible, Oxygen supports combustion fiercely.

e. Liquid Oxygen causes cold burn if it is allowed to come in contact with skin.

f. In areas where oxygen enrichment can occur smoking and naked flames areforbidden.

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CONSUMERSSl.No. DEPARTMENT APPLICATIONCONSUMERS OF OXYGEN :1. STEEL MELTING SHOP STEEL MAKING, BOTTOM REPAIRS OF

FURNACES, WELDING ETC.

2. CONVERTER SHOP STEEL MAKING, CONVERTER LINING &

PRE-HEATING

3. CONTINUOUS CASTING SHOP OXYGEN ACETYLENE TORCH FOR

SLAB & BLOOM CUTTING

4. SLAB & BLOOM STORAGE YARD SLAB & BLOOM CUTTING/ SCARFING

5. PLATE MILL PLATE FINISHING

6. BLAST FURNACE 4,5,6, & 7 BLAST ENRICHMENT

7. FERRO SCRAP NIGAM LTD. SCRAP CUTTING

8. ALL OVER B.S.P CUTTING & WELDING

9. HOSPITAL MEDICAL CYLINDERS

CONSUMERS OF NITROGEN :

1. CONVERTER SHOP HOOD SEALING, GAS RECOVERY &

SLAG SPLASHING

2. PLATE MILL HYDRAULIC SYSTEMS

3. ACETYLENE PLANT INERT PURGING

4. CCS VAD, RH DEGASSER & LADLE

FURNACE

5. BLAST FURNACE 4,5,6, 7 BIN PURGING & FURNACE TOP

SEALING

6. BLAST FURNACE 7 GEAR BOX COOLING

7. LIN FOR VETERINARY FOR ARTIFICIAL INSEMINATION

8. LIN IN TANKERS FOR SELLING TO OUTSIDE PARTIES

CONSUMERS OF ARGON :

1. STEEL MELTING SHOP - 2 STEEL REFINING THROUGH VAD, RH

DEGASSER, LADLE FURNACE &

RINSING

2. R & C LABORATORY FOR OPTICAL EMISSION

SPECTROMETERS OF SMS-2, PM ETC.

3. LIQUID ARGON IN TANKERS FOR SELLING TO OUTSIDE PARTIES &

STEEL REFINING

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1. OXYGEN PLANT-II

If you have been in oxygen enriched atmosphere you must ventilate your clothingin the open air for atleast 15 minutes before smoking or going near a source ofignition.(flames or sparks)

2. NITROGEN/ARGON :

a. Nitrogen and Argon arecolourless, odourless andtasteless Gases.

b. They are non-toxic but don'tsupport l ife and acts asasphyxiants.

c. They are non-flammable inertgases and are essential partsof atmosphere.

d. Rooms where inert gases arehandled or stored must havegood ventilation.

h. Liquid Nitrogen/ Argon causes cold burn if it is allowed to come in contact with skin.

e. When liquid nitrogen / argon evaporate the gas produced is very cold and ismuch heavier than air. Thus it can collect in low-lying areas and confined spacessuch as pits and trenches where they may be slow to disperse.

SOME HIGHLIGHTS OF OXYGEN PLANT-II

- Uninterrupted supply of Oxygen & Nitrogen For Iron & Steel production :

- Uninterrupted supply of high purity argon for VAD, RH Degasser, ladle furnace& rinsing

- Production of Lox, Lin & Lar forcaptive consumption and formarketing

- In-situ plugging of the 4 leakingtubes of ASU-1 was done. Thisprocedure was evolved andexecuted with in-houseresources. Pressure tests & coldtests were conducted afterrepairs and performance issatisfactory after commissioningon 16.01.2001.

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- Complete overhauling of the two 15000-rpm expansion turbines of ASU-I.

- Achievement of 18,000 nm3//h of gaseous oxygen production from ASU-3against rated production of 16,200 nm3/h @ 112 %

- Marketing of products (LAR, LIN & LOX)

- Program for quick & automatic change in Oxygen production from Air SeparationUnit III as per demand was prepared and implemented . Our InstrumentationDeptt incorporated this program in the Distributed Control System through In -house resources for achieving power saving.

- ASU-2 : Stopped on 16.01.2001 after start-up of ASU-1. Leakage's observedin 9 out of 12 Warm Cores of the Reversing Heat Exchanger. One warm corehas been replaced by In-house resources in December, 2001. Pressure test &cold Test has been carried out & found satisfactory. ASU-II is commissioned on29th May 2002 performance is satisfactory.

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ACETYLENE & PROPANE PLANTS

INTRODUCTION :The Operation & Maintenance of an integrated Steel Plant involves huge quantities

of metal cutting/welding works. Normally Oxy Acetylene flame is used for this. Nowa days LPG, Bharat cutting gas. Propane gas are also being used in place of Acetylenedue to their cost economy. Till 2.5 MT stage BSP's requirement of Acetylene gaswas of the order of 80-100 Nos. DA cylinders per day. As there was no captiveAcetylene Plant the required DA cylinders were procured from out side. A captiveAcetylene Plant was commissioned under 4.0 MT stage on 22.07.1982 at BSP tomeet the increased requirement of DA cylinders. With the commissioning of 4.0 MTunits the requirement of DA cylinders has increased to 300 to 350 Nos/day, due toscarffing of slabs and operation of Gas cutting Machines in SMS-II. With increasedVolume of production at SMS-II the total requirement of DA cylinders during the year2003 & 2004 was of the order of 400-450 Nos per day. This increased requirementof DA cylinders was successfully met by the Acetylene Plant.

As propane gas is an alternative gas for Acetylene and it is quite cheaper comparedto cost of Acetylene gas a "Propane Storage & Distribution Plant " was commissionedin BSP in Jan 2005 to cater to the needs of SMS-II. After this the requirement ofAcetylene gas from various units BSP has come down to 80-90 DA cylinders perday:ACETYLENE PLANTEQUIPMENT INSTALLED AT ACETYLEN PLANT

# DESCRIPTION MAKE NO.OF EQPTS. CAPACITY(EACH)

1 D.A. Generators. IOL,Calcutta 3 50 NM3/H

2 Hydraulic washer and IOL,Calcutta 3 50 NM3/Hhydraulic mains.

3 Gas holders IOL,Calcutta 2 550 ft3

4 Purifiers IOL,Calcutta 4 -

5 Low pressure driers IOL,Calcutta 2 -

6 Balance gas holders IOL,Calcutta 1 -

7 D.A. compressors IOL,Calcutta 4 35NM3/H

8 D.A. cooler and HP driers IOL,Calcutta 4 -

9 Gas distribution header IOL,Calcutta 1 -

10 Dissolved acetylene IOL,Calcutta 8 racks -gas filling racks. 352 points

11 Chilled water plant Frick India Ltd 1 20 T

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RAW MATERIALS

Raw Material Quality Quantity

1. CALCIUM - Conforming to ISI 50-60 MT/MonthCARBIDE specification IS 1040-1978

Size 25 mm to 50 mm

2. ACETONE Conforming to IS 170-1987 10-14 T/Year

3. a) L.K.MIXTURE Brand names of Chemicals 3 T/Year

b) REGENETAL-2 for using in DA gas purifiers 1 T/Year

4. a) FUSED CAL. For using in low pressure 2 T/YearCHLORIDE and High pressure driers.

b) ANHYDROUS 1 T/YearCAL. CHLORIDE

DESCRIPTION OF ACETYLENE PLANT EQUIPMENTS

1. GENERATOR

300 Kgs of Calcium Carbide is Charged at a time into the Generator Hopper byopening the lid cover. After charging, the lid covers are kept closed by tightening thefly nuts. During carbide charging, all safety precautions are taken including the NitrogenGas blanketing. The carbide chargings are done using a filling hopper and pneumatichoist. The carbide lumps are fed in the Generator by helical conveyer (helix). Theentire lumps are gradually fed in the generator by rotation of the helix. The generatordrive consists of a motor, coupled with reduction gear box.

The Generator inside consists of a wire grid where the carbide falls and reactswith water. The exothermic reaction starts within the generator and the gas C2H2 isproduced by Reaction - CaC2+2H2O=C2H2+Ca(OH)2 i.e. the Acetylene gas+CalciumHydroxide (Lime sludge ) . The lime sludge is continuously drained through an overflowpipe. The temperature is maintained in the generators from 60°C to 70°C for betteryield. 3 way valves are fitted on the Generator's top. Acetylene gas passes through3-way valve to the Hydraulic washers where the impurities are cleaned and gas iscooled.

The water tank portion of the generator contains no mechanically driven partand circulation of sludge / water is affected by thermal convection current. The ferrosilicon lumps are cleaned from the Generator from time to time for proper yield.

The temperature of the generator is controlled by water (adding or lowering) asper requirement. The temperature min. 60°C to 70°C is controlled & recorded by aThermograph.

Thus the Acetylene gas is produced by exothermic reaction in the Generators.The Calcium carbide is charged in the generator's hopper as per requirements. The

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generator temperature is brought to 48-50° C before charging. The drain valves arekept opened for 1-2 minutes and sludge is drained, then valve again closed. The freshwater is supplied in the generator inside through water tank and level is maintainedfor the fresh charge.

2. HYDRAULIC WASHER & HYDRAULIC MAIN

The main function of the Hydraulic washer is to wash and remove the impurities

(Ammonia) from the Gas (C 2 H2) and cooling the gas to normal temperature. Acetylene

gas from the generator enters the main and bubbles through the water and passes

into gas holder.

3. GAS HOLDERS

The utility of the Gas holders is to hold (collect) the C2H2 Gas inside the Bell

which is lifted by pressure at top upto certain standard level. These are water sealed

type and have capacity of 550 Cubic Ft. each. The G.H. Bell is provided with counter

weight to give the required pressure. Syphon pots (seal pots) are provided in the inlet

and outlet of gas holder for draining out water. There is a limit switch (Electr.) provided

on the top channel of the gas holders. When the maximum level is reached the limit

switch automatically trips the motor of the generator drive for safety.

4. PURIFIER

The main function of the purifier is to further purify the C2 H2 gas. The impurities

in the gas are H2S gas & Phosphine, which are adsorbed in the purifier material.

5. LOW PRESSURE DRIERS

This is a cylindrical vessel mounted vertically on stool and fitted with three trays

equispaced. The bottom tray support a cooling coil and the other two trays have

wooden grids to hold fused solid calcium chloride (CaCl2). Gas enters the bottom

tray and comes out from the top tray. One drain valve is provided at the bottom to

drain out water from time to time.

6. BALANCE GAS HOLDER

This is a small gas holder interpassed in between L.P. Drier and Acetylene

compressor and fitted with a trip switch (limit switch) to ensure positive pressure on

the compressor suction and thus prevent ingress of atmospheric air to form an explosive

mixture. It trips the compressor in the event of non-availability of Acetylene gas. The

balance gas holder is also sealed with water. It is a very important device for safety.

If there is lack of C2H2 gas in the main gas holder, chances of air coming by water

seal breaking, then the Balance Gas holder will immediate function by tripping the

limit switch.

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7. D.A. COMPRESSOR

The main function of the D.A. compressor is to compress the DA gas to 21 Kg/

cm2 (Max) and feed in to the DA cylinders. The D.A. compressor runs on polytropic

process. The gas is sucked from the Balance gas holder through inlet valve and

comes to the first stage cylinder, where the gas is compressed 1.8 Kg/cm² - 2.2 Kg/

cm². The coils have been provided in the compressor which are inter connected with

1st stage, 2nd stage & 3rd stage cylinders. The gases are cooled by water in

intercooling system. The piston and cylinders of D.A compressors are also cooled by

water. The temperature is maintained at 35° to 38°C.

It is a 3-stage reciprocating type water cooled compressor, driven by flame

proof electric motor with reduction gear.

Adequate safety measures are incorporated in the design of the compressor.

The cylinders and the glands are lubricated by mechanical lubrication and the crank

case is lubricated by a gear pump. Bursting discs are provided in each stage. The

filling pressure is maintained at 21.0 Kg/cm². The Acetylene gas is passed to the H.P.

drier through cooler. The pressure of the D.A. compressor is recorded by the pressure

gauges provided at stages.

8. D.A.H.P. COOLER

The high pressure cooler is a shell & tube type exchanger where compressed gas

is cooled by chilled water for effective drying in H.P. drier. The chilled water after

cooling the gas is returned from the other end of the cooler to the hot sump. The gas

passes to the H.P. driers in 3 stages.

H.P. DRIER: - The H.P. drier consists of 3 nos. cylinders in series having buckets

inside to contain Anhydrous Calcium Chloride for drying compressed gas. Each cylinder

is provided with a drain valve at the bottom to drain out water periodically.

9. ACETYLENE DISTRIBUTION RACK

The Acetylene distribution rack is an attachment (round shape) where the valves

are connected in the manifold pipe. The gas after 3rd stage supply of the H.P. drier,

comes direct to the distribution manifold. In the same manifold there are six valves

(outgoing) for supply of C2H2 gas to the charging racks. The pressure gauge is provided

in the manifold to record the pressure of gas supply.

10. DISSOLVED ACETYLENE FILLING RACKS

The main function of the charging racks is to feed the C2H2 gas in the cylinders.

There are eight racks in the Acetylene plant. In each racks there are 44 charging

points. Each Rack is fitted with the Flash Back Arrestor Assembly, and is connected

with main shut off valves at both ends. One end being connected to H.P. line from

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the compressor and the other end connected to the gas Holder. Suitable pressure

gauges are fitted to indicate the rack pressure.

Water spraying arrangements side by side with the charging rack for each charging

point are provided so as to cool the cylinder under charge. Chilled water supply

would reduce the charging time of the cylinder. The chilled water temp. is maintained

at 6°C to 7°C. By chilling the D.A. cylinders properly the C2H2 gas is well dissolved

in the Acetone. When the charging is over & 24.0 Kg/cm² rack pressure is achieved,

the D.A cylinders valve keys are closed. The charging rack valves are also closed.

11. CHILLED WATER UNIT

This unit supplies chilled water at 10°to 12° C for usage in Acetylene Plant.

PROCESS DESCRIPTIONS

The acetylene generator is of carbide to water type and carbide is fed from the

top at the predetermined rate. Calcium hydroxide is collected in the sludge pit from

the bottom of the generator. Acetylene passes from the generators to wet gas holders.

Acetylene is purified in the low pressure chemical purifiers. The low pressure acetylene

is cooled in the low pressure coolers, dried in calcium chloride driers. Thereafter the

acetylene gas is compressed to a pressure of 21 Kg/cm² in the water cooled slow

speed compressors, it is further cooled with water in the high pressure coolers, dried

in high pressure calcium chloride driers and then filled in the cylinders. During filling

chilled water is sprayed on cylinders to control the raise in temperature. Gaseous

acetylene is absorbed in weighted quantities of acetone filled in the cylinders. A

comprehensive system of safety devices including nitrogen purging have been provided

in the acetylene plant as per statutory regulations.

The reaction between Calcium Carbide and water is appreciably exothermic. It is

governed by the equation

CaC2+2H2O=Ca(OH)2+C2H2+31.0 K.Cal.

FILLING PROCEDURE

Slow rate of filling results in better absorption of acetylene gas in Acetone.

Therefore, the following procedures is adopted for filling the cylinders.

RATE OF ACE- FILLING SETTLING EXPECTED NO. OFTYLENE GAS (HOURS) (HOURS) QTY OF GAS COMPRE-TO BE FILLED ABSORBED SSORS

TO BE RUN

1.0 Kg/hr 3.5-4.0 3-4 3.5-4.0 2

0.5 Kg/hr 1.5-2.0 1-2 1.0-1.1 2

0.5 Kg/hr 2.0-2.5 1.3-1.6 1

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FLOW SHEET OF ACETYLENE PLANTACETYLENE GAS

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Total filling time varies from 11 hours to 14.5 hours and quantity filled will varyfrom 5.8 to 6.7 Kg. For filling of cylinders, the following preparations are needed.

i) Weighment of empty cylinders.

ii) Replenishing the Acetone in each cylinder.

iii) Connection of Cylinders.

iv) Charging of the cylinders for 11 hours to 14.5 hours depending on thetemperature of the chilled water.

v) Disconnection and Weighment of the filled cylinders.

INFORMATION RELATED TO HAZARDS

1. Acetylene burns in air with smoking flame. When burning it develops a lot ofheat at high temperature. Mixture of acetylene and air is very easy to ignite orexplode by a spark, small flame or hot spot.

2. When heated or compressed above normal operating limits, Acetylene mayexplode as a result of violent decomposition.

3. Acetylene may form explosive compounds when in contact with some materialsfor example copper, silver and mercury.

4. Severe fire/Explosion in Acetylene cylinders can occur and result into flyingpieces falling up to a distance of 100 meters.

5. Possibility of Fire / explosion in the acetone storage (30 KL capacity) & Explosion/ fire in the carbide storage (500 Tons capacity)is there.

So far no major accident has occurred in this Acetylene Plant since inception.

Propane Storage & Distribution Plant

1. WHAT IS PROPANE?

Propane is a by product of natural gas processing and petroleum refining.

Propane is recovered from natural gas at atmospheric pressure but can beliquefied if subjected to moderately increased pressure. It is stored andtransported in its liquid from.

2. PROPERTIES OF PROPANE

Hydrocarbon - C3 H8

Composition (by volume)

98.47 % of Propane

1.23-2.00% of Ethane

0.30-0.60% of Butane & higher hydrocarbons

H2 S -1 PPM Max. by Weight

CO2 42.2 PPM Max. by Weight

Auto - ignition temp. 466°C.

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Specific gravity 0.49 at 15°C.

Calorific value 11945 Kcal/ kg.

Chemically stable.

☯oiling point: - -40°C.

Freezing point: - 188°C.

Fire - Extremely flammable.

3. STORAGE OF ☯ULK PROPANE:

Propane is stored in liquid and vapour form under pressure in specially designed

tanks known as Pressure Vessels (Unfired) of capacity 50 Tones.

4. DESCRIPTION OF PROCESS;

Propane liquid is purchased from suppliers like GAIL/ IOCL by ☯SP. The liquid

Propane is transported from gas terminals to Propane plant, ☯SP through licensed

road tankers. There after the liquid Propane is unloaded by Propane decanting pumps

and Propane vapour compressors. The liquid is stored in 2 nos. Propane bullets of 50

MT capacity each. From the Propane bullets the gas is transferred to vaporizer unit

where it is vaporized. The pressure of vapour Propane is 10kg/cm2 (approx). There

after the pressure is reduced by pressure reducing valves and Propane gas at 2.5-4.0

kg/cm2 pressure is transferred to various consumer points in SMS-II (S☯S & CCS).

5. MAJOR EQUIPMENT INSTALLED

S.NO. EQUIPMENT INSTALLED UNITSCAPACITY OF

EACH UNIT

1. Propane storage tanks 2 nos. 50 Tons.

2. Propane decanting pumps. 2 nos. 12 M3 / hr.

3. Propane vapour compressors. 2 nos. 200 Ltr/ min

4. Steam based vapourisers. 2 nos. 250 kg / hr.

5. Fire water storage tank. 1 no. 1500 M3

6. Electric driven fire water pumps. 2 nos. 273 M 3 / hr.

7. Diesel engine driven fire water pumps. 2 nos. 273 M 3 / hr.

8. Fire water monitors. 2 nos.

9. Gas leak detectore 4 nos.

6. DISCRIPTION OF PROPANE PLANT EQUPMENTS

1. Unloading pumps: - Propane is received in the Road Tanker and unloaded from

the Road Tanker by means of Pumps. Unloading is done by creating pressure

differential between Road Tank Liquid and Storage Tank Liquid.

2. Unloading compressor: - Pumps cannot handle the remaining Vapour in Road

Tanker to recover pressure vapour. Compressor creates pressure differential

between vapour space of the Road Tanker and Storage Tank. The Propane

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Vapour is forced from the Road Tanker by the Vapour Compressor into StorageTank by compression.

3. Vaporizer:- Propane is stored as a liquid and then by a relatively simple processis converted into a gas or vapour for ultimate consumption. This vapourisationprocess from the liquid phase to the gaseous phase is accomplished thought headdition of heat. Method of vapourisation employs a special apparatus called aVapouriser. In this process, liquid product is removed from the storage container,delivered into a vapouriser where the heat is applied to the liquid causingvapourisation within the device. The product is drawn from the vapouriser ingaseous form. Here steam is used as source of heat.

4. Fire Fighting pumps:- Water is used for fire extinguishments, fire control, coolingof vessels.

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AIR CONDITIONING AND WORKS ENVIRONMENT

In a Steel Plant there are hundreds of different processes involved which finallymake the raw material possible to be rolled into final products. All such processesinvolve heat emission, fume/ toxic gas emission and dust emission separately or incombination to each other. All such emission polute the environment and at the sametime adversely affect man, machine and method, health wise and performance wise.Such emissions are of course inherent in the method structure itself and it may notbe possible to stop them altogether, however it is possible to control them upto aprescribed limit. To ensure such controls and to maintain controlling equipment isACWE's business. Category wise there are 3 controllable factors.

1. Temperature

2. Dust

3. Environment.

1. TEMPERATURE : Temperature control is being done by 2 methods :

i. Air conditioning

ii. Air cooling.

Air Conditioning :

The ACWE department maintains 50 central Air Conditioning Plants, 350 Pack-age Air Conditioners, over 1500 Room Air Conditioners, 450 Water Coolers and 50Refrigerators 50 High ambient Crane A /Cs.

Central Air conditioning Plants of capacity 15 tons to 60 tons are installed incontrol rooms of Blast Furnaces, Power Plants, SP-III; Electronic Labs; ComputerRoom of Plate Mill; Assembly Hall of BTI; Process Water Chilling of Acetylene Plant.These plants maintain desired tempratures to safe-guard electronic cards, PLCs, ControlPanels etc. and provide comfortable working conditions.

Package A/Cs of capacities 3 tons to 15 tons are installed in control rooms ofvarious shops, control pulpits of Rolling Mills, cranes of Soaking Pits (Tongs Cranes),SMS-I Stripper Cranes, SMS-II Hot Metal Cranes, Casting Cranes, SBSY Cranes etc.;Mobile Equipment of C.O. B.9 & 10 viz. Pusher Cars, Charging Cars and Door extrac-tors, Railway Signalling, Express Labs etc.

Air Conditioner Functioning

An air conditioning machine essentially consists of an evaporator,a compressor,acondenser an expansion valve and the refrigeration medium. Freon 12, 21, 22, 124,134a or 142b are being used as refrigerating medium according to the prevailingambient conditions. A refrigerant gas has special characteristics to reject heat

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(condense) at high pressue and change the phase to gaseous form.

The pressurisation of gas is done in a suitable compressor according to the heatload which is then passed to the water cooled or air cooled condenser. Here incondenser, gas transfers heat at this pressure to condensing medium and change itsphase to liquid form; this liquid, under high pressure and low temperature is thenexpanded in a suitable expansion device which could be a capillary/expansion valveor thermostatic expansion valve. This low temperature, low pressure liquid is passedthrough a heat exchanging device known as 'evaporator'. Subsequently, due to heatload, the refrigerant again changes its phase to low temperature, low pressure gas onits way back to compressor in a closed cycle.

Air Cooling

The department maintains 317 nos.of medium to high capacity evaporative coolingsystems and 165 chilled water heat exchanger units for cooling the huge machinehalls of Rolling Mills, control cabins of SMS, BBM Soaking Pits, Convertor Shop,C.C.S Electric Control Rooms,Oxygen Plant-II and Pulpits of Rolling Mills.

154 Motor Cooling Fans supply cooled air to huge motors' stator winding tokeep the temperature within specified limits.

DUST CONTROL

Centrifugal exhaust fans are used to draw air from the source and exhaust theminto atmosphere after treating by one of the following methods.

a) Direct exhaust into atmosphere.

b) Dust Extraction System with cyclone dust collector

c) Dust Extraction System with scrubbers

d) Dust Extraction System with filter bag dust collectors, (D.E. Systems with filter

bags) installed in Blast Furnaces, RMP-I, RMP-II, SMS-II & SP-III

e) Multicyclone System installed in BF-7 Central Exhaust Fan Station

f) Dry fog dust suppression system installed in BF-4 Stock house.

ENVIRONMENT CONTROL :

Controlling of liberated dust, fumes and gases is done so as to provide a workable,hygienic atmosphere to man and machine and to control environment pollution. Thisis done by following methods:

a) Exhausting gases, fumes from working place.

b) Removal of dust by means of dust extraction systems and liberation of clean air

into atmosphere.

c) Supply of fresh air blast for people working near hot areas by means of ManCoolers.

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d) Supply of fresh air blast through viscous filters and air washing chambers toelectrical panel rooms and machine halls.

e) Exhausting contaminated air from underground tunnels.

Such forced ventilation can be broadly divided into 2 groups namely :

(i) Inflow system or plenum system

(ii) Exhaust system.

The inflow system, as name indicates, is used to supply air at slightly higherthan atmospheric pressure. Air is sucked from outside through suitable filters by acentrifugal fan.The suction and delivery of air is done through sheet metal ducts orRCC tunnels.

Air filters are provided at the suction end. These are used to remove dust, dirtand germs. There are two varieties of filters namely;

(a) Dry type

(b) Wet type

Some Highlights of ACWE :

(1) Import substitution of compressors of Mobile Air Conditioning units of PusherCars, Charging cars and Door Extractors of COB 9 & 10.

(2) Recycling of dust collected from D.E. Systems of Blast Furnaces to RMP-1.

(3) Erection of Chimney for B.F.1, D.E. System to provide clean environment asper pollution control norms.

(4) Providing air conditioned environment in RSM slow cooling bed Crane OperatorCabin to facilitate 6.5 Lakh Tons Rail production.

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COMPRESSED AIR STATIONS & CHILLED WATER PLANTS

Air is colourless , odorless and tasteless. It is a mixture of individual gases, majorconstituents being Nitrogen , Oxygen and Argon (78.09%, 20% & 0.93% by volume

respectively). Compressed air serves as an important medium for powertransmission systems. Compressed Air is used for operating various pneumatic toolsand apparatus. Compressed air is also employed for monitoring control and regulation,frequently in combination with electric and hydraulic systems in Bhilai Steel Plant. Avery vital role is played by Compressed Air in a metallurgical plant like Bhilai SteelPlant. 'Chilled Water' has also its role to play.

Brief about the Department :

Compressed Air Stations and Chilled Water Plants Department (CAS & CWP)has two Compressed Air stations, CAS-2 & CAS-3, and two Chilled Water PlantsCWP-1 & CWP-2. Compressed Air Stations supply compressed air to almost all thedepartments of B.S.P. through a complex network of interplant pipe lines. The'compressed air' is a form of energy being used in major production shops for operatingvarious types of instruments and for technological purposes. It is also widely used forgeneral purpose cleaning for maintenance of various equipments.

Chilled Water Plants supply chilled water to various consumers throughunderground and overhead pipelines, mainly for air conditioning of control pulpits andcontrol rooms in Mills, Labs etc.

COMPRESSED AIR STATIONS :

CAS-2 is located by the side of R & C Lab and mainly caters to the compressedair needs of 2.5 MT units i.e. Rolling Mills, SMS-1, Mech. Shops (Foundry Shop,Forge Shop, Machine Shop etc.), BFs 1 to 6, CO Bat. 1 to 6 & CCD.

CAS-3 is located in expansion area near Converter Shop and supplies compressedair to 4 MT units i.e. CO Bat. 9 & 10, Plate Mill, Converter Shop, PP-2, BF-7, ContinuousCasting Shop, SP-2, RMP-2 and other expansion units.

However the two Compressed Air Stations are interconnected through pipelinenetwork in SMS, BF and CO & CCD area.

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CAS-2 has 8 nos. centrifugal air compressors, each of capacity 250m3/min at 8kg/cm2 pressure. Main specifications of these compressors are given below:

Make & Type : USSR make K-250-61-5 model air compressors.

Capacity : Flow 250 m3/min, Pr. 8kg/cm2 at 20°C Ambient temp. and

50% relative humidity.

R.P.M. : 10935

Drive Motor : CAS-2: Synchronous Motor, 1600KW, 6.6 KV, 3000 r.p.m..

CAS-3 has 6 nos. centrifugal air compressors of same specifications and capacity,with 4 of 11 KV and 2 of 6.6 KV motors.

The average total load of CAS & CWP is about 13 MW, which is the 5th highestin BSP.

The average cost of production of compressed air is about Rs.405 per 1000m3,out of which energy accounts for Rs.376.

Normally 6 compressors are in operation at CAS-2, and station pressure of 5.2 -5.4 kg/cm2 is maintained, and 4 compressors are in operation at CAS-3 and stationpressure of 3.8 - 4.0 kg/cm2 is maintained.

The output and efficiency of compressors depend upon the ambient temp. andhumidity. In summer the efficiency goes down due to high ambient temp. (45°C) andin rainy season due to high humidity (90%), where-as in winter the efficiency is veryhigh since both temp. and humidity are low.

The requirement of compressed air is (about 2500 Normal m3/min) very high insummer and rainy seasons due to the above reasons . Apart from technological uses,compressed air requirement goes high in summer due to other requirements likecooling etc. Hence in summer and rainy season 11 compressors are required to berun and in winter 10.

Process:

Air is sucked through panel filters by first stage of compressor. The centrifugalturbo compressor consists of several rotating rings of curved blades (the completeblade ring is known as an impeller) keyed on to a common shaft. Each impeller issurrounded by a diffuser which converts the high velocity of the air leaving theimpeller into pressure energy. A vane in the outer casing then guides the air streaminto the next impeller of the series. Each impeller and its diffuser is known as a stage.Our compressors are having 6 stages. The impeller is rotated at 10,935 r.p.m. Air iscooled after every second stage, passes through a moisture separator after finalstage cooling (End coolers/After coolers) and finally goes to the main collectors.

Each centrifugal compressor is having its own lubrication system consisting ofan oil tank, oil pumps (one starting oil pump and one main oil pump), filters, by-passand pressure reducing valves, oil coolers and piping for lubrication of bearing. During

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normal course of operation, main oil pump works, which is directly coupled to thegear shaft. At the time of low pressure, "starting oil pump" comes into operation.

The heat exchangers are tube and shell type, having finned brass tubes. Coolingwater passes through the tubes and air remains in the inter-tube space.

The excitation to the synchronous motor is provided by rotary exciter in 2compressors at CAS-2 coupled to the motor NDE, and static exciter in rest of the 12compressors at CAS-2 & CAS-3. The synchronous motor has its own cooling systemconsisting of heat exchanger and fans. Motor rotor has two fans at its ends. Thesefans suck cold air from the cold air chambers, force it through the rotor and statorand the hot air goes to the heat exchanger where it is again cooled and goes to thecycle. The heat exchanger is made of wire finned brass tubes. Cooling water ispassed through these tubes.

The cooling water to the compressors at CAS-2 & CAS-3 is fed through a ringmain and cooling towers, supplied by dedicated pump house situated near each station.

Maintenance:

Each motor is overhauled once a year. The gear-box is opened and bearingschecked once in 2 years. The heat exchangers are replaced once in 6 months withcleaned ones. The compressor is opened every 2 years and checked.

CHILLED WATER PLANT NO-1

CWP-1 is situated between Battery Charging Station near PP-1 and Mould BogieRepair Shop of SMS-1 and has a Thermax make single effect Vapour AbsorptionChiller of 1050 TR capacity. This chiller provides about 500 m3 of chilled water perhour between 110°C and 130°C depending upon the season and heat load.

Details:

Type : Vapour Absorption Chiller

Model : 1400 VB

Capacity : 1050 TR

(A) Basic Principle :

1. Water boils at 3.7°C at 6 mm Hg Col.

2. Concentrated Lithium Bromide solution has the property to absorb water due toits chemical affinity. The temperature of Lithium Bromide solution adverselyaffects this property.

(B) Parts:

1. Upper Shell : Consists of condenser and generator.2. Lower Shell : Consists of evaporator and absorber3. Softner Pump : Loss in return water is made up by this pump

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4. Condensate Pump : To send condensate water (from steam) to PP-1.5. De-super Heater Pump : For bringing down the steam temp.to about 115 to

120°C. Condensate is injected into the steam by thispump.

Operation :

Refrigerant produced in the condenser is sent to the evaporator (lower shell)through which, water to be chilled is passed. Refrigerant absorbs heat from thewater to be chilled. The water to be chilled, therefore, gets cooled. The refrigerant byabsorbing heat gets evaporated at 3.7°C at 6 mm Hg in the evaporator. The refrigerantvapour is absorbed by the hot concentrated Lithium Bromide solution which is sent tothe absorber through which cooling water is circulated. Cooling water absorbs heatfrom Lithium Bromide. Thus Lithium Bromide gets cooled. Due to absorption ofrefrigerant vapour Lithium Bromide solution gets diluted. The cool and dilute LithiumBromide solution is pumped into the generator through which steam is passed. Steamloses its heat to cool and dilute Lithium Bromide solution. Thus Lithium Bromidesolution gets heated up and releases water vapour. Water vapour flows over to thecondenser. Lithium Bromide solution becomes hot and concentrated and is re-circulated.Steam in the generator is condensed and sent back to the boiler. Cooling water whilepassing through the condenser absorbs heat of the water vapour. Water vapourtherefore becomes refrigerant and is sent to the evaporator. Cooling water, afterpassing through absorber and condenser, becomes hot and is sent to cooling towers.

Chilled Water Pumps :

There are three chilled water pumps, with one working all the time for circulatingchilled water to 2.5MT area.

Details :Pump : Single Stage Centrifugal,Flow : 540 m3 / hr,Head : 74 mm water column,R.P.M. : 1500Motor : Induction motor 3 ph., 415V, 50 C/S, 160 KW, 1480 RPM, 287A.

Auxiliary Circulating Pumps:

There are 4 auxiliary circulating pumps of capacity about 300 m3 / hr. for feedingthe chiller with the return water from consumerssince the pressure is not enough togo to the chiller.

The cost of chilled water is about Rs. 2731/- per 1000 m3.

Maintenance:

The chiller is taken for maintenance once a year (in December) to clean all thetubes in Absorber, Evaporator, Condenser, Generator, for about 5 days.

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Flow :

1) Absorber :Concentrated absorbent sprayed on the tubes through which the cooling waterpasses, absorbs the vaporized refrigerant from the evaporator and is diluted.

2) Heat exchanger:Heat exchange takes place between hot concentrated absorbent and low

temperature dilute absorbent.

3) Generator:Diluted absorbent heated by steam (to boil out absorbent) is separated intovaporized refrigerant and concentrate absorbent. Former is sent to condenser,latter to absorber via heat exchanger.

4) Condenser:Condenser condenses vaporised refrigerant by using cooling water and producescondensed refrigerant.

5) Evaporator:Refrigerant, which is sprayed on the tubes, extracts the heat from the water inthe tubes and is vaporised.

6) Purge Unit:Purge unit expels non-condensable gases automatically and traps them in thechamber. These gases should be periodically removed by purge pump.

CHILLED WATER PLANT NO- 2

Chilled Water Plant No.-2 is situated by the side of CAS-3 and supplies chilledwater to all 4 MT units viz. Plate Mill, Con Cast etc. for control pulpits cooling. Hereone Blue Star make Centrifugal Chiller of 590 TR capacity is installed. It works onrefrigeration cycle using Freon-11 gas as refrigerant. This chiller provides about 300m3

of chilled water per hour between 11 & 13°C depending upon the season and load.

General Description of Process:

Single stage compressor (driven by 355 KW, 6.6 KV, 3000 RPM Induction motor)compresses refrigerant (Freon gas R-11) vapours and sends it to condenser. In thecondenser, refrigerant vapours are condensed by water flowing in the tubes and ischanged to liquid, giving heat to water. Therefore, outlet water temperature is morethan inlet water temperature in condenser. The condensed liquid refrigerant drainsfrom condenser into the flow control chamber, from where it flows to the evaporatorthrough an orifice.

In the evaporator, this low pressure liquid refrigerant vaporizes at 74.4°F due tovacuum and absorbs heat from return chilled water flowing inside the tubes thuslowering the temperature of water going out from the evaporator (chilled water). The

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refrigerant vapour produced by the boiling action, is sucked by the compressor tocomplete the refrigerant circuit.

Pre-rotation vanes from 10% to 100%, according to the chilled water temperature,control the opening of suction line of compressor. Temperature controller TM inelectronic control center gives signal for opening or closing the pre-rotation vanes.

The lubrication system of the chiller consists of oil pump which pumps the oilfrom oil tank and sends it to compressor bearings through oil filter and oil cooler.From bearings, oil returns to the oil tank.

Purge Unit:

There is a purge unit provided in the chiller to purge out air and other gases tothe atmosphere.

Chilled water from evaporator is collected in tank, known as chilled water tank.From there chilled water is sent to consumers by main circulating pump. Returnwater from consumers is again sent to evaporator and in this way water circulation ismaintained.

Service water from pump house - 4 4 is fed to condenser. The outlet water fromcondenser is sent to cooling tower and from there to pump house-44.

Protections provided in the chiller:

(i) High condenser pressure - If condenser pressure goes above 15 PSI(ii) Low service water and chiller water flow.(iii) Low oil pressure - below 15 PSI(iv) Low chilled water temperature - below 10°C.(v) Motor overload.

Chilled water is circulated to all the 4 MT areas by chilled water pumps (M.C.P.).There are 2 pumps, one working and one stand-by.

Chilled Water Pumps - (M.C.P.) :

Capacity : 352.8 m3/hr, Head : 65.6 M (W.C.), RPM 1450; Motor : 110 KW,150 HP, 194 A, 415 V, 1482 RPM, 3 ph. 50 C/S, induction motor.

Maintenance:The chiller is taken for maintenance for about 5 days during December. All heat

exchangers i.e. condenser and evaporator (coolers) are opened, and tubes and purgeunit are cleaned.

The cost of chilled water in Chilled Water Plant No.2 is about Rs. 6300/- per 103M3.

ACHIEVEMENTS & HIGHLIGHTS:

CAS-2:

Reciprocating Compressors 10 Nos., which were not dependable, have beenreplaced by Centrifugal Compressors (6 Nos.) at CAS-2 in 1991-92

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CWP-1 :

Russian Ejector Type Chiller has been replaced by more efficient and dependable1050 TR Vapour Absorption Machine in 1991.

CWP-2 :

Russian Ejector Type Chiller replaced by 590 TR Centrifugal Chiller Machine in1991.

More efficient and environment friendly Vapour Absorption machine of 350 TRat a cost of Rs. 55.00 Lakhs has been commissioned in Oct' 2002 at CWP-2 whichsaves approx. Rs. 30 Lakhs per year in operation and maintenance cost.

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WATER MANAGEMENT DEPARTMENT

Water is one of the most important inputs for steel making, as are iron ore, limestone,coal, power and transport. In Bhilai Steel Plant, water is used for cooling, quenching,dust collection, scale breaking, steam raising, lubrication, fire fighting etc.

Bhilai Steel Plant gets its water requirement from the reservoirs which are nowunder the jurisdiction of Chhattisgarh State Irrigation Department.

To meet the requirement of BSP at 1.0 MT stage, Gondli Reservoir of 3.4 TMCcapacity was developed in 1956 by the State (MP) Irrigation Department. In order tomeet the increased requirement of water at 2.5 MT stage , Kharkhara Reservoir of 4. 9 TMC capacity was constructed in 1966-67. With the commencement of 4.0 MTExpansion of the Plant in late seventies, necessity for additional source of water wasfelt and this additional water requirement of BSP was assured from Mahanadi Reservoircomplex.

Raw water is conveyed to BSP by open lined Tandula Main Canal which is 69kms. from Tandula Head Works. Tandula canal is connected to Kharkhara and MRPby respective feeder canals. Water released from irrigation reservoirs (Tandula &MRP complex) is received and stored in a site storage reservoir, having a capacity of36 million cubic meters, and is called Maroda-II.

The storage capacities of Reservoirs:

A. State Government Irrigation Department :

1. Kharkhara - 144.95 Million Cubic Meters.

2. Tandula - 302.27 Million Cubic Meters.

3. Gondli - 96.56 Million Cubic Meters.

4. Ravi Shankar - 767.00 Million Cubic Meters.

5. Dudhawa - 284.00 Million Cubic Meters.

6. Murrom Silli - 162.00 Million Cubic Meters.

7. Sondhur - 162.00 Million Cubic Meters.

B. Bhilai Steel Plant :

1. Maroda-I - 9.09

2. Maroda-II - 35.90

The annual requirement of water for BSP is 110 MM3 (3.8 TMC). This includesdrinking water for plant & Township (60 %) and industrial make-up water (40%).

For drinking water, raw water from Maroda-II is supplied to Raw Water PumpHouse. After prechlorination raw water is pumped to Maroda Treatment Plant, having

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maximum capacity of 6700 M3/hr. At Treatment Plant, alum is added to acceleratethe process of settlement of suspended solids. Then water is filtered through rapidgravity sand filters / pressure filters and is supplied to Township and Plant after(post) chlorination. Industrial water supply to the Plant has two distinct differentsystems viz. "once through system" & "re-circulating system". Industrial water supplyto 2.5 M T area is "once through" system (except to THF 1,2,3 (SMS-I) and CAS-II).It is a centralized supply system where water is drawn from Maroda -I through incomingchannel and travels to main pumping station known as Pump House-1, Pump House-2 & Pump House-11 complex. The chlorinated water is filtered through Rotary Screens(4 Nos.) and is pumped to all the consumers of 2.5 MT area. The major consumersare BF- 1 to 6, Rolling Mills (L.P.), SMS-I, OP-I, PBS (PP-I) , PCM,CO & CCD (Bat. 1 to8) & SP-II.

After use, wherever necessary, the return water is treated in settling tanks;where oil, sludge, scale etc. is removed and water flows back to Maroda-I forrecirculation.

Industrial water supply to 4.0MT area is recirculating system consisting of coolingtowers, settling tanks, filters etc. The water lost in the process is made up by tappingfrom make-up water line which is originating from Make-up water Pump House (PH-31) which draws water directly from Maroda-I.

The major units of water supply department are :

1. Pump Houses - 70 Nos.

2. Cooling towers - 85 Nos.

3. Radial Settling Tanks - 22 Nos.

4. Horizontal Settling tanks - 96 Nos.

5. Filter Houses - 02 Nos.

6. Oxidation Ponds - 04 Nos.

7. Water Chemical Treatment Plant - 02 Nos.

8. Chlorine Stations - 03 Nos.

9. Over Head Tanks - 12 Nos.

10. Ash Pond - 01 No.

11. Testing Laboratory - 02 Nos.

12. Rotary Screens - 10 Nos.

13. Fire Hydrants - 270 Nos.

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FLOW DIAGRAM OF WATER SUPPLY SYSTEM

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There are three major outlets for storm water and waste water :-

I. Outlet "A" near Sector-4. (Zero Discharge)II. Outlet "B" near RSM & Disposal store.III. Outlet "C" near Somani Village joining Purena Nallah.

Major Pump Houses of Water Supply Department

A. 2.5 MT Area :PUMP HOUSE NO.1

It feeds PBS (PP-I) and Chilled Water Plant-I. There are 4 pumps of capacity of12,000 to 15,000 Cu.M/hr. Normally three working and one reserve/ standby.

PUMP HOUSE NO.2

There are 5 groups of pumps in this pump house.

PUMP HOUSE NO. 11

There are two group of pumps. Group-I is for GPG and connected to group-I ofPH-2 system for boosting purpose. Group-I is having 2 pumps of capacity 6000Cu.M/hr. each. Normally one pump works in this group. Group-II is for PBS (PP-I) andis connected to PH-1 system for boosting purpose. This group of pumps works as perrequirement. This group-II is having 2 pumps of capacity 12500 Cu.M/hr. each.

PUMP HOUSE NO. 3 & 3A :

This handles the return water, from all the Mills, contaminated with oil and millscale. It delivers water to horizontal settling tanks. There are 11 pumps of capacity2000 Cu.M/hr. each.

Group I : This group supplies water to SMS-I, OP-I, PCM, BBM, RSM, MM, WRM, CO&CCD and various auxiliary shops of 2.5 MT area. There are 6 pumps of capacity 6000 Cu.M/hr. each. Normally 3 pumps work and 3 are kept in reserve. It is known as GPG group.

Group II : This group supplies water to BF- 1 to 6. There are 5 pumps of capacity 6000Cu.M/hr. each. Normally 2 pumps work and 3 are kept in reserve. It is known as BF group.

Group III : This group supplies water to GCPs of BF-1 to 6. There are 5 pumps of capacity 3420 Cu.M/hr. each. Normally 2 pumps work, and 3 are kept in reserve. It is known as GCP group.

Group IV : This group supplies BF-GCP return clarified water to cooling towers for cooling purpose. It is known as CT group.

Group V : This group supplies water to GCPs & BF 1 to 6, this group of pumps are run asand when required during Capital Repair. There are 2 pumps in this group of capacity 85 Cu.M/hr. It is known as High Pressure group.

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PUMP HOUSE NO. 26 :

It supplies water to Wire Rod Mill main motor coolers and oil coolers. There are3 pumps of capacity 190 Cu.M/hr.

PUMP HOUSE NO. 27 :

It supplies water to CAS-II for air and oil coolers. There are 5 pumps of capacity600 Cu.M/hr. each.

PUMP HOUSE NO. 56 :

There are two group of pumps.

Group "A" : Having pumps of capacity 400 Cu.M/hr. each for THF-I furnace,burner, lance & door cooling.

Group "B" : Having 2 pumps of capacity 500 Cu.M/hr.each for GCP of THF-I.

PUMP HOUSE NO. 59 :


Group-I : Having 2 pumps of capacity 1500 Cu.M/hr. each supplying coldwater to THF- 2 for furnace, burner, lance & door cooling.

Group-II : Is for supplying hot water to cooling towers for cooling purpose.

PUMP HOUSE NO. 62 :


Group-I : Having 2 pumps of capacity 1500 Cu.M/hr. each supplying coldwater to THF- 3 for furnace, burner, lance & door cooling.

Group-II : Is for supplying hot water to cooling towers for cooling purpose.

PUMP HOUSE NO. 67 :

2 Pumps of 1000 Cu.M/hr for recycling of SP-II water.

B . 4.0 MT Area :

PUMP HOUSE NO. 31 : ( Make-up water PH)


Group-I : Having 6 pumps of capacity 2500 Cu.M/hr. for supplying water tospray cooling devices of Plate Mill. Normally two pumps work.

Group-II : Having 6 pumps of capacity 2000 Cu.M/hr. for supplying chlorinatedwater to 4.0 MT area mainly for Make-Up purpose. Normally threepumps work. There are 6 Rotary Screens also in this Pump House.

PUMP HOUSE NO. 33 :

There are two group of pumps. (Group-I: clear water Gr and Group-II :conatminated water Gr.)

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Group-I : Having 5 pumps of capacity 1600 Cu.M/hr. each for supplying wa-ter to coolers of motor of main stand, re-heating furnace, descalingunit, oil coolers and ventilation chambers of Plate Mill.

Group-II : Having 6 pumps of capacity 1600 Cu.M/hr. for supplying water toRoll cooling.

PUMP HOUSE NO. 34 :


Group-I : Having 5 pumps of capacity 1250 Cu.M/hr. each for supplying wa-ter for scale flushing purpose in Plate Mill.

Group-II : Having 6 pumps of capacity 1800 Cu.M/hr. for supplying oil & Millscale contaminated water to settling tanks , which in turn returns toPH - 33 contaminated water group-II suction chamber.

PUMP HOUSE NO. 39 :

There are four groups of pumps.

Group-I : Having 5 pumps capacity 1250 Cu .M /hr. each for supplying waterto equipments of Concast.

Group-II : Having 5 pumps capacity 770 Cu.M/hr. each for supplying soft waterto moulds of Concast. Make up water is drawn from WCTP-3 softwater system.

Group-III : Having 5 pumps of capacity 225 Cu.M/hr. for supplying water tosecondary spray cooling devices of Concast. Make up water is drawnfrom WCTP-4 soft water system. It is a once through system.

Group-IV : Having 5 pumps of capacity 1000 Cu.M/hr. for supplying return hotwater to cooling towers.

PUMP HOUSE NO. 40 :

There are two groups of pumps.

Group-I : Having 7 pumps of capacity 900 Cu.M/hr. each for supplying oiland scale laden water to settling tank which in turn comes toPH-39/ Gr.-IV suction chambers via gravity sand filters.

Group-II : Having 3 pumps of capacity 450 Cu.M/hr. each for supplying waterto cooling tower.

PUMP HOUSE NO. 41 :

There are 6 pumps of capacity 780 Cu.M/hr. for supplying water to GCPs ofConverter in SMS-II.

PUMP HOUSE NO. 42 :

There are 5 pumps of capacity 170 Cu.M/hr. for supplying water to Lance ofConverter in SMS-II.

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PUMP HOUSE NO. 44 :

There are two groups of pumps.

Group-I : Having 5 pumps of capacity 1650 Cu.M/hr each for supplying toCAS-III and Chilled water Plant-II.

Group-II : Having 3 pumps of capacity 200 Cu.M/hr. for supplying drinkingwater to 4.0 MT area for boosting purpose.

PUMP HOUSE NO. 45 :

There are six pumps of capacity 4000 Cu.M/hr. each for supplying water toPower Plant-II.

PUMP HOUSE NO. 46 :

There are two groups of pumps .

Group-I : Having 6 pumps capacity 1350 Cu.M/hr. each for supplying waterto OP-II. Make up water is drawn from WCTP-4 soft water system.

Group-II : Having 6 pumps for supplying hot return water to cooling towersfor cooling purpose.

PUMP HOUSE NO. 46 A :

It is an additional pump house for OP-II. It is having six pumps capacity 1250Cu.M/hr. each. Make up water is drawn from WCTP-4 soft water system.

PUMP HOUSE NO. 53 :

There are five groups of pumps.

Primary : Having 4 pumps of capacity 2100 Cu.M/hr. each for supplying waterto BF-7.

Secondary : Having 4 pumps of capacity 1600 Cu.M/hr. each for supplying waterto BF-7.

GCP Supply : Having 4 pumps of capacity 800 Cu.M/hr. each for supplyingtoGCP of BF-7

GCP Return : Having 4 pumps of capacity 800 Cu.M each for supplying hot returnwater from GCP-7 to cooling tower for cooling purpose.

DM Water : Capacity !5 Cu.M/hr. Supply 5 CuM DM Water to BF-7 in a day oras per requirement.

L.F. PUMP HOUSE :

There are two groups in this pump house.

Group I : Having 2 pumps of capacity450 Cu.M/hr. each for supplying industrialwater to Ladle furnace.

Group II : Having 2 pumps of capacity 90 Cu.M/hr. each for supplying softwater to Ladle furnace.

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R.H. DEGASSING PUMP HOUSE :

There are two groups in this pump house.

Group I : Having 2 pumps of capacity 696 Cu.M/hr. each for supplying clarifiedwater to Degasser unit.

Group II : Having 2 pumps of capacity 30 Cu.M/hr. each for disposal of sludgesettled in suction chamber of the pump house.

DRINKING WATER PUMP HOUSESPUMP HOUSE NO. 4 :

It receives water from Water Treatment Plant Maroda, and supplies to 2.5 MTarea. In this pump house there are 2 UGRs and 5 pumps of capacity 250-360 Cu.M/hr.

PUMP HOUSE NO. 32 :

It receives water from Water Treatment Plant Maroda, and supplies to 4.0 MTarea. In this pump house there are 4 pumps of capacity 200 Cu.M/hr. each.

WATER CHEMICAL TREATMENT PLANT-3

The Plant is designed to supply 140 Cu.M/hr. softned water to continuous castingshop (PH-39 Mould Group [group-II]), 60 Cu.M/hr. deaerated soft water to Plate Mill( Reheating furnace) 40 Cu.M/hr. deaerated soft water to Converter Shop for skirtand hood cooling and 6 Cu.M/hr. deaerated soft water to BF-7 ( At present it is notin operation).

Raw water is drawn from the make up water grid of 4.0 MT area . Additionalsource of raw water is also made as second source from new raw water pumphouse.

The treatment given at this Plant is as follows :

i. Filtration through pressure sand filters. (4 Nos.)

ii. Major cation exchanging is done by weekly hydrogen based resin (acidic cation)in the exchangers (3 Nos.). Here, all the carbonate & bye- carbonate hardnessis removed by exchange with RH type resin.

iii. Breaking the carbonic acid in the degasser (2 Nos.) into water and carbondioxideand removing carbon dioxide.

iv. Making the degassed water alkaline to 9 pH, by addition of sodium hydroxide.

v. To remove the rest of the cations linked to strong acid, radicals like Cl--, SO4++with sodium based resin, thus converting all the harder salts into Sodium salts.The resultant water is soft water coming out from softeners (3 Nos.).

vi. The soft water is deaerated by spraying against the flow of steam in Deaerator(2 Nos.) which carries away the dissolved oxygen along with it, leaving thecollected water free from oxygen.

The soft and deaerated water is pumped to Plate Mill, Concast and Convertershops as per requirement.

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Water Chemical Treatment Plant-4

The Plant is designed to supply 850 Cu.M/hr. of soft water. Raw water is drawnfrom the make up water system of 4.0 MT area. The raw water is filtered throughAutomatic valve-less gravity filters (AVGF - 7 Nos.) . The filtered water is passedthrough softeners (7 Nos.) having sodium base resin. In the softener, hardness ofwater is removed and water becomes soft. Softened water is supplied to the consumersthrough two different groups, 700 Cu.M/hr. of soft water is supplied to Concastthrough secondary cooling group ( group-III) of pump house-39 and 150 Cu.M/hr. toOxygen Plant-II Pump House, PH-46 & PH-46 A as make up water.

Different types of water & their consumers :

1. Drinking water - For Drinking and Fire-Fighting.(Throughout the Plant & Township)

2. Industrial water - For Industrial use and Fire Fighting.(Through out the Plant)

3. Raw water - WCTP-1 (PBS), WCTP-2 (PP-II) &WCTP-3 (PM, Concast, Converter)

4. Soft water - Concast, Converter- 130T ladle furnace& Oxygen Plant-II.

5. Deaerated water - Plate Mill and Converter.

6. DM Water - BF-7

W S D : SOME HIGHLIGHTS

Recycling of high Fe content sludge arising from GCP of SMS-I, ETP of Converter,RST of BFs, and Settling Tanks of SP-I&II to RMP-I and SP-II.Desiltation of Maroda-I Reservoir (Cooling Pond), to improve the quality of watersbeing recycled back for plant operation.Commissioning and stabilizing of Ladle furnace & RH degasser water supply systemincluding pump houses, cooling towers and associated facilities at SMS-II.Reduction in arising of scale in the secondary settling tanks and the suctionchamber of PH-3&3A, thereby improving the life of return water pumps, bystrict monitoring for cleaning of scale pits at the Rolling Mills.Direct supply of soft water to CCS under system pressure and stoppage ofpump operation at WCTP-3, thereby saving electricity.Recycling of wastewater from storm water Outlet No.7 to Maroda-I and hencesaving of make-up water consumption for plant operation. Achieved Zeroodischarge at outlet 'A'Conservation of wastewater of the bed drainage PH of Plate Mill by divertingthe drainage system to Maroda-I.Removal & recycling of scale (100%) arising at the settling tanks of RollingMills, CCS, Plate Mill and ETP of Converter shop.Rain water harvesting of plate mill area and collecting it in Maroda - I.

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HEAVY MAINTENANCE (ELECTRICAL)

The Heavy Maintenance (Electrical) i.e. HM(E) is a centralised service agencyfunctioning under 'Electrical' organisation. It is setup to carry out preventive, break-down and specific maintenance work. It also facilitate other working agencies onlarge sized rotating electrical machines, i.e. motors and generators. (Machines above28 KW capacity are considered large sized for this purpose). In case of overheadcranes, electrical motors of all sizes and capacities are attended to by this department.A total of around 5600 machines are taken care of by HM(E) throughout the plant,functioning round the clock.

MAINTENANCE SCHEDULE

An annual maintenance schedule is drawn just before the beginning of eachyear. Following points are taken into consideration while making this schedule.

Backlog of jobs.

Planned major shutdowns/repairs in the shops. - Special/condition basedrequirement of shops.

This plan is further broken down into monthly and daily work schedules.

CLASSIFICATION OF THE MACHINES

Depending upon the type, application, and importance, machines under scope ofHM(E) are categorised into four groups :

VITAL/CRITICAL MACHINES

ESSENTIAL MACHINES

IMPORTANT MACHINES

ORDINARY MACHINES

This is to ensure that maintenance can be done priority-wise, as per requirement.

DETAILS OF MAINTENANCE DONE BY HM(E)Maintenance done by HM(E) mainly constitute :

Preventive scheduled maintenance

Breakdown maintenance

Condition based maintenance

Enabling and other works

PREVENTIVE SCHEDULED MAINTENANCEThis comprises :

(a) General checking

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(b) Overhauling or medium repair

(c) Babbit bearing maintenance

(d) Commutator & Brushgear maintenance

BREAK DOWN MAINTENANCEThis comprises :

(a) Replacement of defective motors

(b) Alignment of motors

(c) Attending breakdowns 'In-Situ'

CONDITION BASED MAINTENANCE

(a) Insulation Resistance Improvement

(b) Commutator & Brushgear maintenance due to sparking

(c) Motor / bearing replacement

ENABLING AND OTHER WORKSThese constitute :

(a) Proper matching and refitting of auxiliaries like Couplings, Pinions , Pulleys ,Brakedrums, heatexchangers , internal cooling fans etc.

(b) Dismantling / re-assembling of machines in the shop, for necessary repairs andtheir sub-assemblies.

(c) Making spare motors ready for use.

(d) Removal / installation of motors to fascilitate mechanical work.

To facilitate all these activities throughout the plant, HM(E) has site offices atthree locations in the plant: Rolling Mills Area, Iron & Steel Zone, and 4 M.T. ExpansionArea. The Executives and Non-executives for each area are earmarked, and theydirectly report at the respective site offices. Each zone has been allotted thedepartments to be attended to by them. This has been done to speed up deploymentof work force. In case of urgent and important requirements, work forces from differentzones are pooled by shifting from one zone to another during their working hours, oreven from several shifts depending upon the requirements.

Keeping in pace with the modernisation and advancement in maintenancemanagement techniques, exercises are being organised in HM(E) also for introducing"Condition Based Maintenance".

Untiring effort by Heavy Maint.(Elect.) collective (consisting of 10 executivesand 128 Non-executives ) is on to bring about improvement in work methods andtechniques of maintenance with problem oriented approach.

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CAPITAL REPAIR AND MODIFICATION (ELECT.)CRME, a section in Electrical Organization of Bhilai Steel Plant, is playing the role of

ensuring continuous availability of electrical equipment's, resulting in improvement inProduction, Quality and Operational Safety. CRME deals with maintenance and repairwork of all electrical equipment's and installations through out the plant. This includesreplacement, modernization and up-gradation of equipment and electrical schemes.

CRME department was formed in June 1971, viewing the need of a permanentgroup to cater to services for Blast Furnace Capital Repairs of different categories i.e. totake responsibility for repair of electrical equipment on one hand and on the other handto provide enabling facilitates by maintaining temporary Power Supply System for otherrepair agencies. Beside the activities related with BF Capital Repair, CRME is involved inthe planning of major repairs and capital repairs of all other major shops. This involvementhas provided great going ageing electrical equipments and sensed the fact that spareelectrical control panels were not easily available. Thus fabrication of electrical panels, aproduct oriented activity was conceived and first panel with Russian design componentswas fabricated in its centralized workshop. Here after a shift towards panel fabricationwas clearly visible in all its zonal electrical breakdowns ands has proved its ability tohandle critical situation in most organized and meticulous way within the cost savingparameters. CRME has diversified its activities to maximize savings by reducingCONTRACT COST and doing the job departmentally.

Recently a new turn has taken place where this small department was entrustedto supervise electrical related jobs of various important projects so that the same arecompleted in optimum duration to meet changing business scenario demand.

As a new initiative CRME is also doing cable reclamation, which is a major costsaving for coming days.

Highlights of Recent Major jobs1. BF-7 CR The CR of BF-7 was taken up after nearly 10 years and the volume of jobs in

BF- 7 is nearly double as compared to other furnace.

2. Conversion of ATL to single loop trailing cable system in cranes.

3. Route diversion of power and control cable of Teaming Crane-1 of SMS-I.

4. Rail Welding Plant re-commissioning for Indian Railways at KalyanEarlier this equipment was taken from railway and commissioned in RSM for weldingof 13 meter rails by in-house efforts. Now as per agreement with Indian Railways,re-commissioning of this plant is done successfully at their site.

5. Hot Saws of RSM - Cable Route modification

6. Laddle Furnace of CCS- Copper Hose Replacement

7. Provision Of Additional Proxy Switches In Bell-Less Top (BLT) Charging Systemin BF-7

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In all the above mentioned project activities, shops have achieved substantialsavings. CRME people have demonstrated a commitment to fulfill shops expectationsand have set high standards.

Employees of CRME are always at the forefront in acquiring knowledge andgrasping skill on the latest technologies. Today CRME is recognized as a preferredalliance for its commitments and productive approach.

ROUTINE JOB OF CRMERewiring of Cranes.

Replacement of panels.

Repair/Replacement of Main/Aux. Trolley lines & their supports.

Maintenance of trailing cables of cranes.

Modification of jobs rerouting and conducting.

Slag Dump Yard:- Shifting of power & lighting points which involve erection ofpoles, installation of cable-stands & laying of cables.

Fabrication of Electrical Panels.

Cost saving measures like reclamation of old cables.

BLAST FURNACE CAPITAL REPAIR JOBS:

a) Enabling facilities:Erection & commissioning of temporary power supply post and its regularmaintenance.

Connections & maintenance of electrical enabling equipments such aswinches, Welding Transformers Compressors, Telphers etc.

Providing lighting fixtures for proper illumination at the work spot.

b) Repair activities:Removal of motors from foundations and transportation to ERS for mediumrepair.

Transportation repaired motor back, and fixing on the foundation.

Alignment of all motors less than 28 kw. capacity.

Removal of limit switches and safety switches for overhauling.

Maintenance, repair & revamping of electrical control panels and control desks.

Replacement of cables, end termination and testing.

All electrical modification jobs.

Repair/Replacement of electrical conduits and Junction Boxes.

Testing and commissioning of electrical schemes..

Apart from these regular maintenance activities, Cable Management has becomean important responsibility of CRME. It is playing an important role in planning andindenting for all the cable requirements of Bhilai Steel Plant.

INDEX

Bhilai Steel Plant

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POWER SYSTEMS DEPARTMENTINTRODUCTION

Power Systems Department takes care of distribution of Electrical power to theentire production and service units of Bhilai Steel Plant and its township. This is

made possible through a large power system network consisting of 5 EHT (ExtraHigh Tension) sub-stations, 42 HT (High Tension) sub-stations and more than 150 LT

(Low Tension) sub-stations scattered through out the plant. We receive power fromChhattisgarh State Electricity Board (CSEB) at 220 and 132 kV at two EHT sub-

stations, which operate in synchronism with two captive power plants feeding thecritical processes of the integrated steel plant.

In order to ensure uninterrupted power supply to each unit, regular maintenance

and repair of all types of electrical equipments such as Circuit Breakers, Transformers,MG sets, Thyristor units, HT cables, Over-head lines, Batteries, Battery Chargers etc.

are carried out. Besides regular maintenance, condition based maintenance systemis also being implemented for some critical equipments to ensure smooth functioning

of the power system.

Close monitoring and analysis of Electrical Energy Consumption of all units andtownship is done and based upon these, many energy conservation measures have

been introduced to reduce the input cost of production. We have also been takingCost Control measures on a continuous basis to optimize our maintenance cost.

There is a separate section called General Services, which takes care of general

illumination inside the plant such as lighting towers, street lights etc.

BSP POWER SUPPLY SCHEME

Bhilai Steel Plant imports power supply from Chhattisgarh State Electricity Board(CSEB). The plant also has two generating stations Power Plant-1 and Power Plant-2.

PP-2 is under NSPCL.

BSP receives CSEB supply through two 132 KV lines at MSDS-1 (Main StepDown Sub-station) from BRSS (Bhilai Receiving Sub-station) and through two 220

KV lines at MSDS-II from Khedamara Sub-Station (S/S). MSDS-I and MSDS-II areinterconnected through a 132 KV Tie-Line called as Tie-Line-3. PP-I is connected to

MSDS-I through three 6.9 KV tie lines whereas PP-2 is connected to both MSDS-Iand MSDS-II through 132 KV tie lines called as Tie-Line-2 and Tie-Line-1 respectively.

MSDS-I and PP-1 cater power supply to entire 2.5 MT area including SP-3; MSDS-IIand PP-2 cater to entire 4.0 MT area.

The two power generating stations at BSP are of following capacities:

PP-I : 3 x 12 MW + 1 x 15 MW = 51 MW

INDEX

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GATEWAY

PP-II: 2 X 30 + 1 X 14 MW = 74 MW

There are 3 more MSDS at BSP namely MSDS-III, MSDS-IV and MSDS-VI, which

take care of power supply to Plate Mill, SP-3 and OP-2 respectively. MSDS-III andMSDS-VI receives supply at 132 KV from MSDS-II through two lines each whereas

MSDS-IV receives supply at 132 KV from MSDS-I through two lines.

The total average load of BSP including township is of the order of 260MW.

Normally an average of around 110 MW is generated in the captive power plants ofBSP and remaining 150 MW power is imported from CSEB. In case of power supply

failure from CSEB grid, power supply to all critical loads of BSP is ensured fromavailable generation at PP-I and PP-II.

FUNCTIONING

Most of the HT Sub-Stations are manned round the clock. Two Shift Managersat MSDS-I and MSDS-II control rooms, control and monitor all operations through

Switch Board Attendants / Substation Operators of various manned sub-stations.

Maintenance & Repair of all types of equipments of the department, such asTransformers, Switchgears, O/H lines, Isolators, Cables, Pumps, Compressors, MG

sets, Thyristors, Battery Chargers, Battery, CT, PT, LA etc., is done once or twice ayear as per the requirement for their better performance. For this, an Annual

Maintenance Schedule is prepared every year and all efforts are made to follow itstrictly.

In an effort to further minimize the downtime and avert breakdowns of theequipment, Condition Based Maintenance System is being practiced in several areas

theses days. For this, on-line monitoring of certain parameters such as temperature,physical condition etc. is done to assess the healthiness of the equipment. Temperature

is being monitored by Thermo-scanner gun and Thermo vision camera.

A daily/weekly energy statement is prepared giving details of import throughCSEB, power generated at power plants and power consumed by each and every

major unit. This serves as a guideline for all the energy conservation projects and tocalculate specific energy consumption.

PCMS (Power Consumption Monitoring System)

The load flow of BSP can be continuously monitored in real time using our SCADAsystem called as Power Consumption Monitoring System. Data regarding Maximum

Demand, Load Flow at PP-1 &2 can be obtained in real time from PCMS along withhourly, daily and monthly reports of power consumption of different shops.

SAFETY

All members of the department strictly adhere to standard safety norms. Onlyauthorised persons are allowed access to electrical equipments. Central Electricity

INDEX

Bhilai Steel Plant

- 345 -

Authority subjects all electrical equipments to regular inspection. Safety lectures are

given to every group by the respective area in-charges. Safety awareness amongemployees is created by regular safety meeting through safety circles, safety week

celebrations and safety training.

POWER FACTOR IMPROVEMENT

As per our power purchase agreement with CSEB, penalty has to be paid if the

import power factor for a given month goes below 0.9. But if the power factor goesabove 0.95, CSEB gives substantial incentive. Power factor of import power from

CSEB to BSP usually was somewhere between 0.90 and 0.92 depending upon theavailable captive generation and nature of load. With present arrangement, it was not

possible to avail power factor incentive; in fact there always use to be a threat to paya penalty for low power factor. Therefore, Capacitor banks were installed at BSP for

improving the import power factor to avail maximum incentive from CSEB.

Depending upon the load conditions of BSP, according to a careful study carriedout to improve the import power factor from 0.9 to 0.99 (maximum possible), 42

MVAR of Capacitors have been installed at various locations. After installation ofCapacitors bank, BSP is getting an incentive of 3 to 4 % (Rs. 30 lakhs per percent)

per month from CSEB.

PSD AT A GLANACE

No. of 132KV S/Ss. - 5

No.of 11KV Substations. - 14

No.of 6.6KV Substation. - 32

No.of LT.Substations. - 228

No.of H.T.Breaker panels - 1760

No.of Transformers - 748

Length of cable tunnel - 25 km

INDEX

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GATEWAY

* Figures indicated in italics (under lined) are 220 kV equipments.

There is one feeder from MSDS-I to PP-I for feeding auxiliaries of Power plant I in

case of emergency in PP-I auxiliary supply.

There are two station Transformer each of 320 KVA capacity, 6.9 KV/230V for

auxiliaries and lighting loads of MSDS-I.

The neutral of 6.9KV sections is grounded through Arc suppression coils (Peterson

coils) in order to neutralise the capacitance current flowing in case of 6.9KV system

earth fault.

MSDS-I (2.5 MT Area)

The power supply system of BSP is designed in such a way that a very reliable

supply to all the production units is ensured. There are at least two feeders for each

LOCATIONSEQUIPMENTS

M1 M2 M3 M4 M6

(A) Transformers

160 MVA

80 MVA

50 MVA

40.5 MVA

28 MVA

16 MVA

15 MVA

(B) Circuit Breakers

(i) ABCB

(ii) SF6

(C) Isolators

(D) Lightening Arrestor

(E) Potential transformer

(F) Current Transformers

(G) 11 kV Sections

(H) 6.6 kV Sections

(I) NET (Neutral Earthing Transformer)

(J) Peterson Coil

-

1

-

3

-

-

-

-

11

40

30

24

39

2

8

3

3

2

2

1

-

1

-

1

8

5+2

52+10

42

8+12

30+12

2

4

4

4

-

3

-

-

-

-

-

-

4

17

5

-

8

4

-

2

-

-

2

-

-

2

-

-

5

16

4

4

2

2

2

2

-

-

2

-

-

-

-

-

3

18

6

4

3

-

-

-

MAJOR EQUIPMENTS AT A GLANCE

INDEX

Bhilai Steel Plant

- 347 -

shop, each one is capable of taking the total load of the shop. Thus, in case ofplanned shutdown or tripping of any one feeder, the other feeder takes the total load.

At MSDS-I, there are two 132 kV lines, L-1 and L-2, from BRSS (CSEB) connectedto two 132 kV Buses, Bus-2 and Bus-1 respectively. These buses are paralleledthrough a 132 kV Bus Coupler circuit breaker.

There are three 40.5 MVA, 132 kV/7.2 kV Transformers (1T, 2T & 3T) & one 80MVA, 132 kV/11 kV /11 kV transformer (5T) at MSDS-I. Normally transformer 1T &3T are connected to Bus-I and 2T & 5T are connected to Bus-II. 132 kV Tie lines TL-2 and TL-3 are connected to Bus-I and Bus-II respectively. There are two 132 kVfeeders F-1 and F-2 for MSDS-IV (SP-3) which are also connected to Bus-I and Bus-II respectively. It is possible to connect all the four transformers, both the lines, tielines and feeders to any one bus section in case of bus shutdown.

On the 6.9 KV side, there are eight sections. 1T feeds sections 1 & 2, 2T feeds3 & 4 and 3T feeds 5, 6, 7 & 8. Duplex reactors are installed between the transformersand 6.9 KV sections to reduce the fault level. Bus sections 2-3 and 4-6 are coupledthrough reactors, whereas sections 1-4 and 3-5 are directly coupled. Sec 7 & 8 arealso directly coupled and supply to it has been extended from Sec-5.

6.9 kV Sec-2, 6 & 5 are coupled to PP-I by means of two lie lines (6.9 KV), TL-1, TL-2 & TL-3 each of 10 MW capacity.

Two 11 kV sections at MSDS-1 are fed by 80 MVA 5T.

Power distribution to various shops at 6.6 kV & 11 kV is done through cablesmostly laid in under ground cable tunnels. In some case, cables are also laid underground and in trenches. The shops having loads of critical nature are fed from bothMSDS-I and PP-I. Other shops such as rolling mills, auxiliary shops and township arefed from MSDS-I only. The scheme of distribution is as follows:

Distribution of power to Shops

NO.OF 6.6KV FEEDERS SUB- STATION FEEDING SHOP

MSDS-I PP-I

1 2 3 4 5

5-1

Coke ovens & BPP Sinter Plant-1 Blast furnace (1 & 2) Pump House SMS-1 (Furnace 1 to 6) BF

1 1 1 2 1 1

(thro’ S/S 35)

1 1

(thro’ S/S 35) 1 2 1 1

(thro’ S/S 35)

INDEX

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GATEWAY

NO.OF 6.6KV FEEDERS SUB- STATION FEEDING SHOP

MSDS-I PP-I

5-2 6 7 8 9

10

11

12

13

14

16

17 18 19 35 37

38

40 41 42

TSS-1

CDI Oxygen Plant – I Blooming mill Billet Mill Merchant Mill Rail & Structural Mill Auxiliary Shops Gas Booster station Foundry & Pattern shops Blast Furnace (3,4 & 5) SMS-1 (Furnace 7 to 10) Wire Rod Mill Compressed Air Station Sintering Plant-1 B/Furnace SMS-I SMS-I & RMP-I MSDS-4 SP-3 Package – I SP-3 Package – II Township S/S-1

(thro’ S/S 5-1) 2 2 2 2 3 2 2 2 1 1 4 3 2 1 1 1 2 2 2 4

(thro’ S/S 5-1) 1 1 1

(Sec-1 can be fed from PP-1

also) 1 1

(thro’ S/S 5)

INDEX

Bhilai Steel Plant

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SUB-STATION FEEDING SHOP

NO.OF 11KV FEEDERS FROM

MSDS-I

33

7

40

41

RSM BBM Thyristor Supply MSDS-4 SP-3 Package – I

1

2

2

2

EQUIPMENTS AT MSDS-I

(A) Power transformers

1. 80 MVA TransformerVoltage Ratio - 132/11.5/11.5KV

Connection - Star/Delta/Delta

Tap Changer - On load, 15 taps

Cooling Type - ONAN, AF & OF

2. 40.5 MVA TransformersVoltage Ratio - 132KV/7.2KV

Connection - Star/Delta

Tap changer - On load, 9 Taps +/-8%

Cooling type - Oil cooled with forced ventilation

The cooling fans are controlled automatically for starting and stopping at presettemperatures.The tap position can be changed locally or from the control room.Remote indication of the tap position and the oil/winding temperature is provided inthe control room. There is a provision of alarm as well as tripping of the transformerin case of excessive temperature, low oil level etc.

(B) 132KV SF6 Circuit BreakersRated Capacity - 7910 MVA

Rated Current - 2000 Amps

Operating Pressure - 5.6 bar

Control supply Voltage - 220 VDC

Operating Mechanism - Electro-Hydraulic

(C) 132 kV IsolatorsCurrent Capacity - 1200 AmpsOperating Mechanism - Pneumatic/manual/MotorisedOperating Pressure - 17 kg/sq.cm

INDEX

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GATEWAY

The isolators are installed on both sides of 132KV breakers and are connected toboth 132KV sections. It is possible to connect the transformer or line to either sectionI, Section II. A number of interlocks are provided in the operation of the isolators. Itis not possible to open an isolator on load without switching off the ABCB/SF6 CB.Similarly it is not possible to close an isolator with the earthing blade in 'ON' position.

(D) 132 kV Current Transformers

Rated primary current - 400/600/800 or 1200Amps.

No.of windings - 3

C.T.Ratio - 400/5, 800/1, 1200/1 etc.

The CTs are used for metering and protection of the 132 system. These CTs areof outdoor type, oil filled, single phase.

(E) 132 kV Potential Transformers

Rated Voltage - 132 kV

Total Nos.installed - 24 Nos.

No.of secondary windings - 02

PT Ratio - 132 kV/100 V,132/100/3

The PTs are of oil filled/outdoor type and are used of metering, and protection of132 kV system.

(H) 132 kV Lightening Arrestors

Lightning arrestors are provided to protect the main power transformers and132KV sections against lightening surges. Under normal conditions the lightningarrestors works like a perfect insulator, but in case of high voltage surge there is abreakdown of the insulating gaps thus passing the surge to ground before it reachesthe protected equipment.

(I) Arc Suppression Coils (Peterson Coils)

There are three arc suppression coils (1DK, 2DK and 3DK) connected betweenthe auxiliary transformer (41T, 42T and 43T respectively) neutral and earth to neutralisethe earth fault current in the 6.9 KV system. These coils have 5 taps to adjust thecurrent from 54 Amps to 104 Amps.

(J) Accumulator Battery

Capacity - 400 Ampere Hours

Total No.of Cells - 130

Bus Voltage - 230 Volts

No.of cells on bus - 102

Type - Lead Acid Cells

INDEX

Bhilai Steel Plant

- 351 -

The battery is required for providing control supply for the operation of circuitbreakers, isolators, protection circuit and emergency lighting of MSDS-I building. Thebattery is continuously kept under charging by means of a trickle charger whereasfor boost charging of battery, one MG Set is provided. There is a provision of adjust-ing the number of end cells connected to the bus automatically in order to maintainconstant bus voltage.

PROTECTION SCHEMES AT MSDS-I

The following protections are provided for various equipments installed at MSDS-I.

a) 132KV Incoming Lines

a) Distance Protection

b) Directional over current protection

c) Directional Earth fault protection

b) 132 kV Sections

a) Bus bar Differential Protection

b) Reserve bus bar protection - Over current Protection on 6.6KV Tie lineswith Under voltage blocking on 132KV side

c) Earth fault signalling

c) 40.5 MVA Transformer

a) Differential Protection

b) Directional over current protection on 132KV side with minimum voltageblocking on 6.6kV side

c) Earth fault protection

d) Gas protection (Buchholtz Relay)

e) Low oil level and excess winding temperature signalling/tripping

d) 80MVA Transformer

a) Directional over current protection on 132KV side with minimum voltageblocking on 11kV side

b) Over current protection with definite time delay

c) Local Breaker Back-up Protection

d) Transformer Protection (Buchholtz, Oil & winding temperatures)

e) 132KV Tie Line-2 between MSDS-1 and PP-2

a) Pilot wire Differential Protection



d) Under and Over Frequency Protection

e) Local Breaker Back-up Protection

INDEX

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GATEWAY

f) 132KV Tie Line-3 between MSDS-1 and MSDS-2a) Pilot wire Differential Protection





g) 132KV feeders-1&2 to MSDS-4a) Pilot wire Differential Protection

b) Directional over current protection (IDMT)

c) Directional over current protection (DT)

d) Directional Earth fault protection (IDMT)

e) Negative phase sequence Protection

f) Local Breaker Back-up Protection

h) 6.9 kV Sectionsa) Differential Protection

b) Reserve over current protection

i) 6.9 kV Outgoing Feedersa) Over current protection (tripping with time-lag)

b) Zero sequence earth fault protection for signalling

j) 6.9 kV Tie Lines - 1 & 2 between MSDS-1 to PP-Ia) Longitudinal differential protection with instantaneous tripping of OCBs

at both ends.

b) Directional over current protection with time lag.

c) Zero sequence earth fault protection for signalling.

d) Under frequency tripping at both ends in case the system frequency fallsbelow 47.75 Hz

k) 6.9 kV Tie Line - 3 between MSDS-1 to PP-Ia) Pilot wire differential protection with instantaneous tripping of OCBs at

both ends

b) Directional over current protection with time lag.

c) Zero sequence earth fault protection for signalling

d) Under frequency and Over Frequency Protection

l) Auxiliary Transformersa) Over current protection

b) Earth fault protection

c) Gas protection-Tripping/signalling

d) Low oil level/high temperature alarm

INDEX

Bhilai Steel Plant

- 353 -

Transformer Repair Shop (TRS) and Oil supply facilities at MSDS-I

Facilities for Capital Repair/overhauling of all types of transformers are providedat the Transformer Repair Shop (TRS) of MSDS-1. An electric winch of 75T capacityis provided for lifting of the core and a telpher of 5T capacity for material handling.Centrifuge filter press and streamline filters are provided for purification of transformeroil. There are three tanks of 60 Cu.metre and 3 tanks of 30 Cu.metre capacities foroil storage.

MSDS-IV (SP-3)MSDS-IV is fed from MSDS-I through 2 Nos. 132KV feeders. There are two 132

kV bus-sections and two 50 MVA, 132 kV/11 kV transformers to cater powersupply to Sinter Plant-3. Two 16MVA transformers of ratio 11 kV/6.9 kV are alsoinstalled at MSDS-IV to supply 6.6 kV loads. Two HT substations and 8 LT substationsare installed at different locations for power distribution.

4 MT EXPANSION (MSDS-II, III & VI):In 4MT expansion three main step down substation (MSDS- II , III and MSDS -VI)

have been provided. The power is received at MSDS - II from Khedamara through a220KV double circuit line Each line is rated for 115 MVA.MSDS-III & MSDS-VI arefed from MSDS-II at 132KV by a double circuit line for plate mill & OP-II area.

There is a captive power plant (PP-II) in 4 MT area for the essential loads.(Capacity2x30 MW + 1X14MW,Voltage 11KV). There are two step up transformers of 50MVA capacity and 11KV/132KV rating for interconnecting PP-II with MSDS-I andMSDS-II at 132KV.

MAIN SCHEME AT MSDS-II :There are two different HT distribution voltages in the 4MT are : 11KV for all the

motors above 1000KW capacity and 6.6KV for motors between 200KW to 1000KWcapacity. All the distribution Transformers are 11KV/440Volts rating, except C.O.B.9where the transformer are 6.6KV/440V rating.

At MSDS-II there are two 220KV lines coming from MPEB connected to two132KV sections through 220/132KV auto-transformers. There are two 132KV feedersgoing to MSDS-III, two 132KV feeders going to MSDS-6(OP2) and two 132KV Tie-lines connected to PP-II and MSDS-I. For stepping down the voltage to 11KV and6.9KV, there are two transformers of capacity 80MVA each with two secondarywindings of rating 11KV and 6.9KV. The two 132KV sections are paralleled througha bus coupler.

There are two 11KV sections and four 6.9KV sections fed from the two 80MVAtransformers. Duplex reactors are provided between the transformers and 6.9KVSections to reduce the fault level. Transformer 1T feeds 11KV bus-1 and 6.9KVSection 1 & 4 transformer 2T Feeds 11KV bus II and 6.9KV bus 2 & 3. From MSDS-II power is supplied to various shops in 4 MT area at 11KV or 6.6KV as per requirement

INDEX

- 354 -

GATEWAY

by means of cables going through underground tunnels. The shops having criticalloads are fed from PP-II also. There is one 6.6KV feeder from MSDS-II to PP-II toextend supply auxiliaries of PP-2 as and when required.

Two transformers of 400 KVA capacity and 11KV/400V voltage ratings areprovided for the auxiliaries of MSDS-II and the transformer repair shop. There aretwo neutral earthing transformers on 11KV side and two on 6.6KV side for connectingthe arc suppression coils(Peterson coils) to neutralise the earth fault current.

Generally there are two feeders to each substation with sectionalising arrangementin the sections to have reliability of supply in the event of tripping of any thefeeders.

DISTRIBUTION OF POWER TO SHOPS (4MT) :

Depending upon the capacities of the HT motors and other loads in the shop,power is distributed at 11KV or 6.6KV from MSDS-II or PP-II.

The scheme of distribution of power supply is as follows:

S/S Feeding shop No.of feeders11KV 6.6 KV

MSDS-II PP-II MSDS-II PP-II

15 Blast furnace 7 2 2 2 2

20 C.O.Battery 9 2 1

21 Sintering Plant II 4 1

22 OHP 2 2

23 CAS 3 2 2

24 O.P-II P.H. 1 1

25 O.P.-II 1(ATC-2) 1(For ATC-1,3 & 4)

25 O.P.-II 1 1

26 Convertor shop 1 1 1 1

27 Concast 1 1

28 CCS Pump House 1 1 1 1

29 MWPH (From s/s 28) 1 1

30 OP-2 (From MSDS-VI)

31 Plate Mill area 1 6 1 4(From MSDS-III)

32 Plate mill area 2 1 1(From s/s-31)TSS-II Township s/s 3 1(From s/s-31) (thro' S/S-28)

INDEX

Bhilai Steel Plant

- 355 -

MAIN EQUIPMENTS IN MSDS-II :

1. POWER TRANSFORMERS :There are two auto transformers 160MVA, 220KV/132KV. There are two 80MVA

transformers with star/delta split secondary winding with transformation ratio132KV,11.5KV/6.9KV.Both the secondary windings have the same rating (40 MVAeach). The transformers are oil cooled type with ON/OB/OFB cooling. The MVA rat-ings corresponding to the different cooling type is as follows:

ON : 45 MVA OB : 63 MVA OFB : 80 MVA

The transformers are provided with on load tap changers at primary side to havevoltage regulation +/- 10%.

2. AIR BLAST CIRCUIT BREAKERS, 132KV ISOLATORS, AIR COMPRESSORS,CURRENT TRANSFORMERS, POTENTIAL TRANSFORMERS, LIGHTNINGARRESTORS, DUPLEX REACTORS, STORAGE BATTERIES & CHARGERS, etc:The following equipments are installed in MSDS-2,3 and 6 which are similar to

those installed at MSDS-1

PROTECTION OF EQUIPMENTS AT MSDS-II :

1. 132 KV Sectionsa) Bus differential protection

b) Local back up protection for breaker failures.

2. 220 KV Incoming Line from MPEBa) Directional over current and earth fault protection.

b) Directional distance protection.

3. 160MVA Auto Transformersa) Differential protection

b) Restricted earth fault protection with time delay

c) Over current protection on 220KV side with under voltage blocking onwith time delay

d) Pole discrepancy protection

e) Transformer Protection (Buchholtz, Oil & winding temperatures)

f) Over current protection on 132KV side with time delay

g) Earth fault protection with time delay on 132KV side

h) Reverse Power Protection.

4. 80 MVA Transformera) Three winding differential protection.

b) Over current protection (132KV side) with minimum voltage blocking

INDEX

- 356 -

GATEWAY

c) Over current protection with time lag (LV side)

d) Gas protection (Buchholtz)

e) Oil & winding temperature rise protection

f) Low oil level protection

5. 132KV Bus Coupler

a) Two stage over current protection with time lag.

b) Two stage earth fault protection with time lag.

6. Bypass Bus

a) Directional over current protection with time lag.

b) Directional Earth fault protection with time lag.

c) Single shot 3 phase auto reclosing.

7. 132KV Feeder to MSDS-III & VI

a) Overload protection.

b) Directional earth fault protection.

c) Negative sequence current protection.

d) Current cut off protection.

e) Single shot three phases auto reclosing.

8. 132KV Tie Line-1 between MSDS-2 and PP-2






9. 132KV Tie Line-3 between MSDS-1 and MSDS-2






10. Outgoing feeders to HT substations 11KV or 6.6KV

a) Over current protection with time lag.

b) Earth fault protection through core balance C.T.

c) High speed over current protection

INDEX

Bhilai Steel Plant

- 357 -

11. Feeders to Transformersa) Current cut off protection.

b) Over current protection with time delay.

c) Earth fault alarm through core balance C.T.

d) High speed over current protection when closing on fault.

e) Alarm/tripping for oil/winding temperature rise.

12. Feeders to Air Compressor Motora) Over current Protection with time lag.

b) Earth fault protection.

c) High speed over current protection when closing on fault.

13. HT BUS Sectionalising breakera) Over current protection with time lag.

b) High speed over current protection when closing on fault.

c) Auto Voltage change over.

TRANSFORMER REPAIR SHOP : MSDS-IIA transformer repair shop is provided at MSDS-II also for capital repair/overhauling

of all types of transformers in 4MT area. There is one electric winch with transfertrolley having capacity of 125 T (Main hook) and 10 T (Aux.hoist). One EOT crane ofcapacity 20T/ 5T is also provided in the repair shop for material handling. Additionalfacilities like oil storage, filteration, testing are also provided to carry out the repairwork. There is one drying chamber with heating, temperature monitoring arrangement.One additional drying chamber has been constructed adjacent to transformer repairshop.

The drying/heating of windings is facilitated through hot air circulation with thehelp of heaters provided in the air circulation path. With this facility, the windings ofhigher rating transformers can be dried. An electrically operated winch is provided forpulling the transformer on the rail track between the repair shop and the 132KV yard.

SALIENT FEATURES OF MSDS-IIIAt MSDS-III yard, there are three 80 MVA Transformers connected to two 132

KV sections fed from MSDS-II. These transformers have two secondary winding on11KV rating & equal capacity. Other details of the transformers are same as those ofMSDS-II Transformers. The secondary sides of these transformers are connected tosix nos.11KV bus sections at S/S- 31 for plate mill through bus ducts. At S/S-31 one11KV bus section is fed from PP-II directly for the critical loads of plate mill area.There are three nos. 6.3 MVA, 11KV/6.6KV transformers for 6.6KV loads.

SALIENT FEATURES OF MSDS-VIMSDS-VI has come up as a part of OP2 Expansion to cater the additional power

supply requirement mainly due to ATC 3,4 and OTC 7,8,9. Two 5MVA transformers

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are installed which feed to two 11KV sections and one 6.6 KV Section through6.3MVA transformer.

TOWNSHIP SWITCHING SUBSTATIONSTownship Switching Substation (TSS) - I

The township substation-I (TSS-I) is fed from MSDS-I and is located near thetransformer repair shop. The details of transformers installed at this substation are asfollows:

Total installed : 4 Nos.

Capacity : 3 Nos - 5 MVA, 1 No.-7.5 MVA

Voltage ratio : 6.9 KV/ 11KV (D/Y)

Number of taps : 5 (Off-Load)

Type of cooling : Oil-Natural

From the Township S/s-11KV under-ground cables are laid to the townshipdistribution substation-I for distribution to the township.

Township Switching Substation (TSS) - II

No. of transformers : 3 (7.5MVA), 1 (3.0 MVA)

Voltage Rating : 11KV/ 11KV (D/y)

Type of cooling : Oil-Natural

No.of taps. : 5 (Off load)

These Transformers are fed from MSDS-III (S/s-31) through underground cables.Supply from TSS-II to TDS-II (Township Distribution Substation -II) is through 2 Nos.overhead lines and 2 sets of underground cables. The 3 MVA Transformer is providedfor emergency supply to the main hospital from PP-II.

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ELECTRO-TECHNICAL LABORATORYBhilai Steel Plant has numerous types of electrical equipment operating at different

voltages. There are extra high tension equipment at main step down substationsfrom where power received from CSEB is distributed to different users in the plant.These equipment operate at different voltage levels that include high-tension motors,switchgear and low-tension equipment. The custodians of these equipments are theshops and departments concerned, who are responsible for their day-to-day operationaland maintenance activities. Electro-technical laboratory or ETL, which is a part of theCentral Electrical Organization, provides specialized technical support to differentproduction and services departments. ETL provides services like Scheduled testingof protection relays, assistance in resolving breakdowns, specialized guidance inelectrical matters, preparing technical specifications for electrical equipment andassociation with commissioning of new projects/equipment. Modifications andadditions for better performance of the equipment are also done by ETL. ETL alsoensures that shops adhere to the technological norms in the operation of the equipment.The important roles of ETL are enumerated below:

1. Periodic testing of protective devices of electrical equipment according to aformulated maintenance plan. Periodic measurement of parameters of differentelectrical equipment.

2. Assist the shops in quick liquidation of breakdowns with a view to reduceequipment downtime.

3. Analysis of breakdowns to prevent recurrence of faults.

4. Testing and commissioning of electrical equipment after capital repairs andmajor overhaul.

5. Investigation of chronic problems in electrical equipment and their rectification.

6. Association during commissioning of new projects and major modifications undermodernization projects.

7. Technical support to the different shops in preparation of specificationsfor technological upgradation and scrutiny of technical offers of different vendorsin association with theproject consultants.

8. Testing and repair of electronic cards of different equipment to reducedependency on outside vendors and cost reduction.

9. Preparation of training manuals and standard maintenance practices (SMPs)and conductionof training programs for shop personnel for better understandingof different equipment.

10. To scrutinize the spare part requirements of electrical equipment of differentshops for better inventory and cost control.

11. Advising the shops on different energy saving measures.

12. Evaluation of technology during the conception stage of a project; technologyaudit and technology planning so that the plant has a competitive edge.

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13. Testing, repair and calibration of different electrical instruments and meters.

14. Testing of samples sent by different procuring departments as per relevant standards.

15. Study of power system, and suggest measures for improvement.

16. Fault Location in underground HT Cables.

The electrical technology has gone through a paradigm change over the years.The technology of the yesteryears like the Mercury Arc Rectifiers, Amplifying, MagneticAmplifiers, MG sets and conventional relays are now being gradually replaced byThyristor Converters, Microprocessor based relays, Digital drives, VVVF drives, PLCsand Computer Controlled systems. ETL plays a major role in this transition and adoptionof new technology.

ETL has two offices covering all the areas of the plant. One office based at RCLbuilding looks after the 2.5 MT area of the plant and the other office, located in aseparate building by the side of the Welfare building no 26 for SMS2, looks after the4.0 MT Expansion area of the plant. Each section has five groups looking after differentareas. These are as follows:

Power Systems Group

Drives Group

High Voltage Group

Electronics Division

Instrument Repair and Testing Group

The Drives group of the 2.5 MT area is further divided in two sub groups. One grouplooks after the Low Tension (LT) drives of rolling mills of the 2.5 MT area, the othergroup looks after the LT drives in the Iron & Steel zone of the plant comprising CokeOvens, Sintering Plant 1&3, Blast Furnaces 1-6, Steel Melting Shop-1, Auxiliary Shopsand Mines. The Drives group of the 4.0 MT area looks after the LT drives of Ore HandlingPlant, Blast Furnace-7, Sintering Plant-2, Plate Mill and Steel Melting Shop-2.

Though ETL primarily works on equipment at site, it has well developed testlaboratories for all the above sections, having the latest testing equipment anddiagnostic tools. In addition to the requirements of the plant, ETL also caters to thespecialized needs of Rajhara and Nandini mines and the electrical installations of thetownship. The detailed working of each of the above groups is enumerated below:

Power Systems GroupThis group deals with EHT, HT and LT equipment at our main step down

substations, captive power plants (PBS and PP2) and LT substations. This groupcaters to the power system requirements at our captive mines also. The main functionsof this group are as follows:

a) Periodic testing of protections at all our EHT, HT and LT substations, captivepower plants and HT equipment like HT motors, turbo generators andtransformers. This is to ensure the reliable operation of protective devices sothat there is no equipment damage, and minimum disruption in power supply.

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b) Periodic checking of islanding schemes for our captive power plants, voltageregulators of turbo generators and static exciters of synchronous motors.

c) Attending breakdowns in the above areas for quick liquidation.

d) Fault level calculations & load flow study to establish protection settings, ensuringproper coordination and discrimination.

e) Interaction with outside agencies like CSEB regarding our present and futurepower supply needs and coordination for proper protective relay settings in thesupply feeders.

f) Study of power system disturbances and chronic tripping problems and suggestsuitable remedial measures.

g) Interaction with departments like BEDB and agencies like MECON and CET foradditions and modifications in the power systems area in the design andimplementation stages of the project.

ETL has a software for power system analysis that can do load-flow studies andfault studies. This helps in reducing spurious tripping, ensuring better protective relaycoordination and power system reliability.

Drives Group

This group deals with different electrical drives and their controls in differentdepartments of the plant. The group performs the following functions:

a) Periodic testing of protections of all the LT motors and DC motors in the plant.

b) Periodic checking of the operating parameters, protective devices andcharacteristics of thyristor converters of main drives of rolling mills, skip drivesof blast furnaces, UPS systems,inverters & VVVF drives, CVDC systems, Digitaldrive systems and regulation schemes for numerous DC and AC LT drives.

c) Attending breakdowns in the above areas for quick liquidation.

d) Testing and commissioning of electrical equipment after capital repairs.

e) Proactive measures like recording and documentation of parameters of differentLT drives and control systems and investigation on deviation of parameters.

f) Investigation of chronic problems in the drives area and their rectification.

g) Testing of DC machines and LT AC machines to ensure their healthiness.

h) Testing and repair of electronic modules, cards & regulators, and transducers.

i) Carrying out innovative modifications in the electrical schemes to achieve betterequipment utilization, energy savings and less equipment downtime.

j) Rendering technical support to shops in preparation of specifications, study andscrutiny of technical offers, interaction with departments like BEDB and agencieslike MECON and CET, and technical discussion with vendors for new projects.

k) Imparting training in the areas of VVVF Drives, Thyristor Converters and PLCs. Forthis purpose, presently, we have NELCO make Analog Thyristor converter Trainingkit, Siemens make Vector Control AC Drive and ABIL PLC (RS Logix) Test Bench.

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High Voltage Group

Bhilai Steel Plant has a very big network of HT cables inside the plant and township.This group meets the high voltage testing requirements of cables, HT equipment andhigh voltage safety appliances. The main functions of this group are as follows:

a) Scheduled high voltage testing of HT cables, motors, transformers, circuitbreakers, lightening arrestors, CTs and PTs and other HT equipment at differentsubstations and power plants.

b) Comprehensive testing of HT transformers and motors, after their overhaul andrepair, or as required during equipment breakdown.

c) Location of faults in HT underground cables.

d) Periodic HV testing of safety appliances like hand gloves, rubber mats and HVindicators. Periodic testing of transformer oil for breakdown voltage.

e) High voltage testing of samples like contactors, relays, insulating materials andother items sent by different procuring departments as per relevant standards.

High voltage section has advanced cable fault location equipment and high voltagetesting kits including 100kV AC test set, 100kV AC Oil BDV test set, 50kV DC testset, 40kV DC Portable test set, High Frequency Generator etc.

Electronics Division

This division was setup in 1997 for repair of complex digital and analog electroniccards and modules. This was done with a view to reduce the high outside repaircosts of these cards by the respective suppliers. The main functions of this group areas follows :

a) Repair and trouble shooting of electronic cards of different equipment. Faultsare located and rectified at all levels - equipment level, module level, card leveland component level. This group repairs multiple layered PCBs with SMDs.

b) Development of circuit diagrams of different cards whenever necessary, as inmost of the cases detailed circuit diagram is not available.

c) Maintaining an inventory of electronic components that are required for repairof electronic cards.

The electronics division has facilities like computer based In-Circuit IC Tester,soldering and desoldering stations, EPROM programmer and other diagnostic tools.Repair of electronic cards at ETL has resulted in substantial savings for the plant.Earlier, most of these cards were being sent back to the original equipment suppliersfor rectification.

Instrument Repair and Testing Group

This group deals with the repair, testing and calibration of electrical measuringinstruments used all over the plant. The main functions are given below:

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a) Periodic testing and calibration of electrical measuring instruments and metersinstalled all over the plant.

b) Scheduled testing of energy meters at all the substations and power plants toensure their accuracy.

c) Repair of electrical instruments like ammeters, voltmeters, power factor meters,meggers, multimeters (analog and digital), clamp meters, Wheatstone bridges,oscilloscopes and signal generators that are used by different shops.

d) Testing of metering circuits and transducers.

e) Association with CSEB authorities during the periodic testing of energy metersused in 132 kV and 220 kV systems, to ensure their accuracy.

This section maintains national laboratory calibrated instruments required fortesting and calibration of instruments and meters which includes a high accuracymultifunction calibrator, standard RS energy meter, 5½ digit Multimeters and standarddecade resistance boxes.

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ELECTRICAL REPAIR SHOP

Looking towards any integrated steel plant scenario, the importance of an ElectricalRepair Shop can be very well visualized. It is one of the major service shops whichcarries out repair of all electrical machines used inside the plant; there are around42000 electrical machines installed and running continuously years together, indifferent processes of production, in Bhilai Steel Plant. General maintenance likecleaning, greasing and physical inspection / checkup is done by concerned shopswhere the machines are used. All major repairs like winding repairs, mechanical repairs,modification in existing winding and periodic overhauling etc. are being attended byElectrical Repair Shop either at site or at ERS.

SCOPE OF WORK :Electrical Repair Shop carries out repairs of motors, generators, welding and

control transformers, load lifting magnets, brake & control coils of all types andcapacities. It also manufactures a large number of spare parts like contact materials,switches, components, busbar and various other electrical spare parts. Repair of loadlifting magnets, welding transformers, control transformers and rectifiers are carriedout in magnet and transformer repair shop (MTRS). MTRS also fabricates load liftingmagnets of all varieties using all in-house technology and resources including thedesign concept. Traction motors and roll table motors from various Rolling Mills areoverhauled in Motors Overhauling and Repair Section (MORS) adjacent to MTRS.

PRODUCTION TARGETS :E.R.S. on an average repairs 380 motors and generators, manufactures/reclaims

535 nos. coils, repairs 17nos. load lifting magnets, 28nos. welding & controltransformers per month. The monthly repair work in case of motors and generators isgiven below in tabular form :

Upto 10 Kw Machines >10 Kw Machines Total MachinesRewinding jobs 130- 140 Nos. 70- 80 Nos. 200- 220 Nos.

Medium repair jobs 70- 80 Nos. 90-100 Nos. 160-180 Nos.

Total 200- 220 Nos. 160-180 Nos. 360- 400 Nos.

Some repair work is off loaded to outside agencies strictly on need basis, suchas core staggering, shaft change etc. for which repair facilities are not available inERS. Such repairs are limited in number (5 - 10 machines per year) and applicable forbig size and critical machines only.

MAN POWER :ERS has a present manning of 234 non-executives and 13 executives of various

grades. The shop is headed by DGM ( E - ERS ).

METHODOLOGY AND PROCESS FLOW :Electrical machines are received from various shops within plant, township areas,

mines etc. alongwith its work order. The work order contains the machine specification,

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its defect, previous job no. and any specific requirement by the concerned department.Receipt & Issue section (R&I) of ERS allots a job No. to each and every machine afterproper verification of the machine and its accompanying work order. The number ispainted on motor body and on all dismantleable parts. Thereafter the machine istraced in ERS by that job number only. R&I section intimates to the concerned sectionsthrough internal job register for repair of these machines or components on day today basis.

To facilitate a systematic repair process the shop is divided into different sections.These are :

1. R & I section

2. Computer section

3. Assembly and dismantling section

4. Winding section

5. Varnishing section

6. Testing section

7. Machine section

8. Spare parts manufacturing section

9. Commutator repair section

10. Stores

11. Shop maintenance

12. Magnet & Transformer Repair Shop (MTRS)

13. Motor Overhauling and Repair Section (MORS)

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ASSEMBLY & DISMANTLING SECTION :

Machines after dismantling are subjected to preliminary check-up (Meggeringand visual inspection). Accordingly these components are sent to various sections onthe basis of the repair work involved. The healthy components are cleaned thoroughlyand varnished in varnishing section before being sent to testing section for preliminarytest. These components after testing, are sent to respective assembly sections. Thedefective components are sent to respective winding sections for repair / rewinding. The assembly sections takes those components of a machine for assembly whichare ready in all respects. Before assembly the components are thoroughly checked toensure whether all the repairs as mentioned in work order or as noticed by assemblygroup are carried out or not. In case there is some omission, it is sent to concernedsection for further repair. All the windings are meggered to ensure healthy IR valueand continuity in winding. All the mechanical parts like end covers, grease cups,bearings and their seatings are thoroughly cleaned before final assembly. The assemblygroup also conducts certain post assembly checked like freeness of rotor / armature,proper brush seating, tightness of rocker arms and their corresponding assembly incase D.C.Machine, meggering of components, tightness of body bolts etc. beforesending the jobs to testing section for final testing.

WINDING SECTION :

Winding sections take up jobs either for rewinding or partial repair. Beforerewinding the soundness of core laminations is ensured by "Flux Test". In case thereis some abnormal heating of at some patches as detected by "Flux Test" core repairis done to rectify it . Components are recommended for rewinding unless soundnessof core is ensured. The components rewound / partially repaired are subjected to aset of tests as per norms like high voltage test, current balance test, magnetic fieldtest, checking of all joints etc. for their soundness. These components, if passedthrough all these standard tests are preheated, varnished and cured in furnace for aperiod of 16 - 18 hours. Finally covering varnish is applied on these windings beforesending to respective assembly sections.

TESTING SECTION :

Testing section conducts the following tests on all repaired machines on no loadat ERS besides conducting a set of tests on all machine components in intermediatestages. These include :

AC SQUIRREL CAGE INDUCTION MOTOR :

Meggering, physical inspection, HV test, no load running test (for 30 minutes),inter turn insulation test (for 2 minutes)

AC SLIP RING MOTOR :

Meggering, physical inspection, HV test, ratio test no load running test (for 30minutes), inter turn insulation test (for 2 minutes), supply to rotor.

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D.C. MOTOR :

Meggering, physical inspection, no load running test (for 30 minutes), over speedrunning test (120% of rated speed for 3 minutes), load test (for 5 minutes).

All these machines during " No Load Test " should draw current as per prescribednorms and there should not be any abnormal heating, vibration, sound etc. so as tobe declared fit for despatch. D.C. machines in addition to these should run sparklessand speed fall should be within reasonable limits on load condition. Testing groupafter ascertaining all quality checks despatches these machines to R & I.

MAGNET & TRANSFORMER REPAIR SECTION (MTRS):MTRS repairs all load lifting magnets, control transformers, welding transformers,

rectifiers. It also fabricates load lifting magnets of all varieties. The design of thesemagnets is developed by planning & technical department ( P.T.D. ) with thedevelopment of drawing for shell, centre pole, coil and non magnetic plates. Themagnet shell is cast from high permeability steel. Centre pole is an integral part of theshell and the pole shoe is bolted to the shell. Shell and centre pole shoe have beencast in Foundry shop and machined to dimension in machine shop - I as per thedrawing developed by P.T.D.. These machine shells are tested by various ultrasoundtesting techniques and found acceptable. After insulating and curing the shell, coilsare assembled into the shell with suitable inter coil insulation. Heat resistant compoundis poured into the shell to make all the internals monolithic. These magnets afterfixing nonmagnetic plate and providing terminal boxes are delivered to shops aftertesting on no-load and load test at M.T.R.S.. These magnets are working satisfactorilyat various shops.

MOTOR OVERHAULING & REPAIR SECTION (MORS) :MORS does overhauling of traction motors and roll table motors received from

various rolling mills.

PERFORMANCE HIGHLIGHTS :- Machines waiting for repairs in ERS is 529 as on July'2002 as against 949 in

Oct.'1998, without any offloading support and additional manning.

- 10 to 15 nos. magnets are being fabricated annually since 1998 using all in-house resources. Purchase of new magnets are totally stopped resulting insubstantial saving.

- Recent achievement of ERS in form of successful repair of big size and critical machineswhich were previously repaired by BHEL and others include the following :

Repair of 3M1, 7100 Kw Armature of Plate Mill.

Repair of 3M1, 6300 Kw Armature of finishing stand of Plate Mill.

Repair of 4000 Kw Armature of roughing stand of Plate Mill.

Repair of 640 Kw Screw Down Armature of Plate Mill, 180 Kw ScrewDown Armature of Blooming & Billet Mill.

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Repair of 1300 Kw Armature and 1200 kw armature of Wire Rod Mill.

Repair of 150 Kw Armature of Left Manipulator of Rail & Structural Mill.

Modification of terminal board of 280 Kw D.C. Motor of casting craneof Continuous Casting Shop.

Repair of 1375 KW, 11 KV, H.T. Ventilation motor of Continuous Casting Shop.

Repair of 375 KW, 6.6 KV, H.T. Ventilation motor of Convertor Shop.

MAIN EQUIPMENTS INSTALLED AT ERS

1. Three E.O.T. Cranes 5 Ton, 15/3 Ton and 10 Ton ( Reclamation )

2. Four Cantilever cranes ( 1 ton each )

3. Two induction regulators

4. One H.T. & L.T. D.O.L.. starter

5. One load testing equipment ( Dynamometer - upto 50 kw.)

6. One load testing equipment ( Load generating system - 150 kw, 1000 r.p.m.)

7. Nine numbers coil winding machines

8. Six numbers lathes of various sizes

9. Five numbers furnaces

10. One bandaging machine

11. One balancing machine

12. One shaping machine

13. One stator coil forming machine

14. One coil cutting and pulling machine

15. Five telphers, 1 Ton each

16. Four drilling machines

17. Three grinding machines

18. One punching machine

MAIN EQUIPMENTS INSTALLED AT MTRS1. One 20 Ton E.O.T. crane

2. One coil making machine

3. One furnace

4. One grinding machine

MAIN EQUIPMENTS INSTALLED AT MORS1. One 20 Ton E.O.T. crane

2. One Hydraulic press

3. One bandaging machine

4. One lathe

5. One furnace

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TELECOMMUNICATION (OPR) DEPARTMENT

Communication is the most vital tool used by modern society. It has become themost indispensable tool in and day-to-day life. It helps and to keep in touch with alland everyone at any point of time, irrespective of location. In a large industry likeours, communication is the most essential tool to facilitate production activities. Inorder to streamline production activity and to enable the continuous coordination ofjobs a variety of communication equipments are deployed. The responsibility of thesedifferent communication equipments is entrusted with Telecommunication Dept. Thedifferent sections of this department take care of the regular maintenance and upkeepof these equipments. Enlisted below are the various types of communicationequipments presently installed and used in Bhilai Steel Plant.

A. Shop Floor Telecom Equipments1. Despatcher Communication System

Despatcher is a hotline communication system between a central control roomand field locations just by lifting the handset of respective telephone. 28 suchdespatcher sets are working in different shops catering to about 1300 subscribers.All major production shops such as BF, SMS-I, SMS-II, OHP, SPs, CO & CCD, RollingMills, WMD, PSD, EMD,etc. are provided with such systems.

2. Ex-Com System100 Line Ex-com system is installed in Plant Control at Sanyantra Bhavan, catering

to all strategic Production Control points in the shop. It is also given to the office &residence of senior executives of the plant. This system helps the ExecutiveDirector(ED) to hold a conference with all HODs everyday morning directly from hisresidence and at afternoon from his office.

3. Distributed Amplifier SystemThese are loud speaking system working in parallel mode having facility of speaking

one to all (page mode) and one to one(private mode). This system helps incommunication in the highly noisy areas where direct telephone connection is notfeasible. About 235 sets are installed in different shop floor areas in the plant.

4. Loud Speaker Intercom SystemThese are loud speaking Intercommunicating systems for Point-to-point selective

communication and most suitable for highly noisy area. This system is an enhancementof the above-mentioned DA system. Here the desired location can be selected toestablish a communication through a central control unit. 8 such systems havingabout 214 stations are installed in RSM, SP-3, CCS, Converter, Plate Mill, WRM,BBM and SBS.

5. Close Circuit Television(CCTV) SystemCCTV system comprises of Cameras and monitors are being used in Production process

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monitoring where close observations are required in shop floor. About 63 cameras and 61monitors are installed at RSM, WRM, SP-3, OHP, Plate Mill, Power Plant and BF.

6. Wireless Communication

The shop personnel use walkie-talkies and base units for communication duringmovement. 969 sets in 30 spot frequencies are being used at various departmentincluding Fire Services and CISF. These sets are also being used as communicationlink between ground staff to overhead cranes and for data communication as well.

7. Wireless in Local Loop(WLL)

700 WLL sets are used in various departments all over the plant. These sets arevery much useful when people are on move. These sets are supplied by BSNL onmonthly rental basis. Communication is established by dialing the four-digit code ofthe respective user. It is also possible to contact BSP landline by dialing the assignedaccess code(285-XXXX).

8. Hotline

This system is used in strategic points for instant communication between twopre-assigned locations. 154 subscribers are given this facility all over the plant.

9. Shop Announcement System

These are used for important announcements in the shop floor and propagationsof Safety slogans, etc. 7 such systems are installed at SMS-1, SBS, Converter, CCS,Plate Mill, Boria Gate and Main Gate.

10. Conference System

The system is being used at the conference hall of Senior executives to discussmatter round the table including presentations. It consists of chairman unit and delegateunits. 8 such systems are installed in the conference hall of MD, ED(W), ED(Projects),Ispat Bhavan Conference Hall, GM I/c(M&U), GM(E), GM(P,E&En) and GM(RSM).

11. Public Announcement System

These systems are provided as and when need arises for special functions likeSafety propagations, Quality circle, technical presentations, shop communicationforum, etc. by Telecom department.

B. Telephone Exchanges

BSP is having three exchanges and each caters to an area depending on itslocation. These three exchanges altogether have an installed capacity of 7200 landlinephones. Plant exchange is located at Telephone house nearby Ispat Bhavan. This ishaving a 3000 line exchange of Ericsson make and a 1200 line Tata make units.These exchanges serve the plant area exclusively. An ITI make exchange is installedat Sector-5 and is having 2000 subscribers capacity. This exchange caters to locationsfrom Sector-1 to Sector-10, Nehru Nagar, Maitri Nagar, etc. The third exchange isinstalled at main hospital. TATA Telecom supplied this 1000 line exchange. It servesSector-8, 9, HS and Hudco. An interconnectivity diagram of these exchanges isshown below for easy understanding.

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C. Cable & Line NetworkCable & line section refers to the field cable network of exchanges. The cables

are laid from exchange MDF to DPs in each area. All the three exchanges mentionedabove have its own cable network and having respective line group. This group alsodoes the day-to-day repair of field telephone complaints.

In plant area the field maintenance of Auto Telephones inside the plant are carriedout by this section. 35 Cabinets and more than 1100 Distribution points (DPs) areinstalled. The network of cables is about 200km in length. This cable network alsocaters to various other communication systems like Despatchers, Plant Control Ex-Com System, Hotlines, etc. 300 clocks working in 2.5 MT areas from central clockstation(situated at plant exchange) also uses the said network. The various dedicatedprocess control points (RTUs), 55 in nos. used by Energy Management Departments,Compressed Air Station, PLEM and T&D Department also uses the Telecom CableNetwork. The cable network also provides 100-lease line link for computer networkof INCOS, C&IT, CMMS and MMIS and maintain it. The said computer network linkis provided only in those areas where Fiber connectivity is not possible. In sector-5exchange area there are 12 cabinets and associated DPs. In hospital exchange areathere are 7 cabinets and its DPs. The township cable network is dedicated to autotelephones even though there are few other circuits working for data communication.

D. Customer Care ServicesThis is a round the clock telephone enquiry service. Dialing '00' one can access

the enquiry service and dialing 2244 we can access complaint service. This sectionmaintains a computerized telephone directory for providing the above services.

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E. Telephone Repair Shop

The telephone repair shop is responsible for overhauling and repairing all types oftelephone instruments like push button phones, cordless phones, plan-7, hands freetelephones, etc. This section also takes care of the field repair of plan-7 telephones.

F. Planning, Stores & Workshop

This section looks after the procurement, storage & distribution of spares andother required materials for the department. There is also a workshop, which providesfacilities for in-house fabrication work for telegraph channels, clamps, telephone poles,cabinets and distribution boxes etc.

G. Clock Station

This department also maintains a master clock station and 300 slave clocksinstalled at various locations throughout the plant, including all the gates of BSP.These slave clocks get impulse from the master clock and show same timing.

H. Mobile Phones

BSP has provided GSM mobile phones to its executives from E1 grade onwardsthrough Reliance Telecom. The nodal agency for this service is Telecom Department. Allthese GSM phones are in CUG mode and can talk to each other free of cost. BSP landlinenetwork can also be accessed from the mobile phones free of cost and vice versa.

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POWER AND BLOWING STATIONPower & Blowing Station is a vital installation of Bhilai Steel Plant. It serves the

following needs of the Plant.

1) Supplying Air Blast to Blast Furnaces at requisite parameters.

2) Meeting critical and emergency power requirements of the 2.5 MT. Units ofBhilai Steel Plant

3) Meeting the process steam needs of various shops for their safe/efficient operation.

4) Buffer consumer of available Blast furnace and Coke Oven gases to preventtheir wastage/high pressure in the gas line network.

POWER & BLOWING STATION HAS THE FOLLOWING MAIN SECTIONS :

Boiler House

There are five Boilers Russian make and one IJT Make Boiler. Each boiler has

steam production capacity of 150 T/Hr. at 450 0C & 44 ATM pressure. Each boiler isa multi-fuel fired boiler using Coal Dust, Blast Furnace gas, CO gas and PCM as fuel

separately or in combination. The Russian make boilers are water tube, radiant,refractory walled, natural circulation, single drum, bottom supported where as IJT

make boiler is having dual drum, direct coal firing system which has been suitablymodified to use Blast Furnace Gas and Coke Oven Gas at par with Russian Boilers.

Boiler No 1, 2, 5 & 6 are equipped with Electro Static Precipitator where as Boiler No3 & 4 have wet scrubber system for de-dusting of flue gases produced as a result of

fuel combustion in the Boiler Furnace. There is an Ash Handling Pump House for wetdisposal of bottom ash of boiler furnace hopper, scrubber and ESP to a distant place.

This pump house also handles Ash slurry from Blast Furnaces, SMS-1 and RMP-1.Steam produced in Boiler House is sent to Turbine Hall through two no. of Steam

Collectors as Boilers and Turbines are operated in Battery System for steam. Atpresent a project on Dry Fly Ash Collection System for ESPs is in progress. There are

five boiler type TKZ - 150 - 2 - Russian make and one new boiler of ISGEC JohnThompson Pvt. Ltd. The Russian make boiler are water tube, radiant, refractory walled,

natural circulation, single drum, bottom supported, vertical boilers intended forgenerating superheated steam of 150 T/Hr. at drum pressure of 44 ATM and

temperature of 450 0 C. The furnace chamber is formed by screen tubes on all sidesand top.

The ISGEC John Thompson boiler is having same specification (Boiler is British

make) except that it is having dual drum, direct firing system, an electrostaticprecipitator and rotary air preheater.

Originally all five Russian make Boiler were having wet ash collector system(scrubbers). Retrofitting of ESPs have been carried out in Boiler No.1,2 and 5.

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The principal data of boiler as follows :Boiler 1 to 5 Boiler - 6

Rated capacity - 150 T/Hr. 150 T / Hr.

Working pressure - 44 ATM at drum 44 ATM at drum

Feed water temperature - 150°C 150°C

Superheated steam temp. - 450°C 450°C

Working pressure at main steam valve - 39 ATM 39 ATM

Radiant surface of tubes - 601 m2 -

Total heating surface - 3326 m2 3679 m2

No of Safety valve installed - 4 Nos. 3 Nos.

The boiler uses coal dust, Blast furnace gas, Cock Oven gas, Pitch Creosote Mixture (aby product of cock oven Bhilai Steel Plant) as fuels separately or in combination.

The pulverized coal burners ( 6 nos.) are fed by primary air. These burners arelocated on side walls, six PCM burners are fixed concentric with coal dust burners.BF gas burners (6 nos.) are located below coal dust burners. Co gas burners (4 nos.)are fixed on front wall.

Coal dust preparation systemRaw coal from raw coal bunker of boiler is fed to ball mill through raw coal

feeder for crushing into powder form. Here a combination of cold air, warm air & Hotair is used to maintain outlet temperature of 650 C. The air is used as carrier of coaldust. The air-dust mixture is then passed through separator where bigger particles ofcoal are separated and fed back of Ball Mill for crushing again. The powder coal dustand air are then passed through cyclone where coal dust and air are separated. Thecoal dust gets accumulated in coal dust bunker and air is used to carry coal dust frombunker into boiler furnace for burning through mill fan. The capacity of Ball Mill (Tubemill type) is 16 T / Hr. The designed efficiency of the boiler is 85.18 % to 90.5 %depending upon the type of fuel used and their combination.

Drum : Drum is designed for two stage evaporation. It is divided into threecompartments with one central compartment having clear water and two sidecompartment known as salt compartments.

Feed water from economizer enters into clear compartment. Steam takes offfrom the clear compartment, passes through 2nd stage super heater coil (with respectto flue gasses passage) to attemperator where pure condensate is mixed to controlsteam temperature, steam further goes through 1st stage super-heater coil (w.r.t.flue gas flow) and then goes to steam collector through main steam valve.

Economizer : There is four stage economizer placed in the flue track where feedwater enters at 150°C and after heating by flue gas, goes to clean compartment ofthe drum. Re-circulation pipeline with valve exists between drum and economizer forfeeding the latter during starting and stopping of boilers.

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Air Preheater : The air preheater is of Tubular type and has two stage s placed in theflue gas passage after the economizer to get warm and hot air for Ball mill andsecondary air for combustion. The cold air is supplied by F.D. Fans(2nos/Boiler).

Scrubber : The dust laden gasses after preheating are passed through scrubber wherewater is sprinkled on the gases through nozzles and dust is removed. The dust freegases are then sucked by induced draft fans (2nos/Boiler) and are led to atmospherethrough chimney.

E S P : The electrostatic precipitator installed in boiler No. 1,2,5 & 6 efficientlyremoves the dust from gases to maintain environment norms.(150Mg/Nm3)

Ash handling system : This unit of Power & Blowing Station is most critical. Theslurry formed in the scrubbers ESPs, bottom ash from furnace is led to Ash handlingpumps through tunnel to pump it out by ash slurry pipeline to ash pond situated at 6Km from the slop. There are four strand of pumps having capacity of 300m3/hr. Eachstrand has two pumps in series.

Schematic diagram of working of Russian make boilers is given in Annexure 'A'.

Turbine Hall :There are three nos of Turbo-Generators (12 MW each) and 1no of 15 MW for

electric power generation and 9 no. of Turbo-Blowers ( 3 nos of 10 MW equivalent,4 nos. of 12 MW equivalent and 2 nos. of 16.369 MW equivalent) to supply air blastto 7nos blast furnaces installed. There are 10 nos. of High Pressure Feed waterpumps supplying feed water to Boilers. Also there are 6 nos. Deaerator installedwhere dissolved Oxygen and other gases in the Condensate and Chemically treatedwater are removed. Turbines of these turbo machines get steam from boiler housethrough steam collectors. Process steam to various customers is also sent throughthis section.

Turbine of Turbo Generators 1 & 2 is single cylinder, 15 stage, condensing,impulse reaction type with Curtis wheel. The rotor is directly coupled to generator bymeans of semi flexible coupling. The turbine has a normal speed of 3000 RPM andhas 4 pass outs of steam i.e bleeder, 2 regulable and 2 non regulable. The regulablebleeder supply steam at 8-13 atm at 246°C and 1.2 - 2.5 atm at 145°C for processsteam and for deaerator.

The non regulable bleeder supply steam to H.P. & L.P. heaters.

The turbine to Turbo blowers are of single cylinder, 12 stage, condensing typedirectly coupled with compressor by means of flexible geared coupling and providedwith 2 non regulable bleeders for regenerative system.

4 compressors of 1.0 M.T stage are single cylinder centrifugal type, with anintermediate air cooling system after 2nd stage.

4 compressors of 2.5 M.T stage are double cylinder centrifugal type, with intercooling system. The 4 M.T blower is of axial type single cylinder without inter cooling.

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The turbines are equipped with hydro-dynamic system & speed regulators, inthis system the impulse is proportional to the square of velocity of rotor. Presentlyproject work of retrofitting of 15 MW generator in place of TB-3 is in progress whichis likely to be commissioned in April 2006.

Turbo - Blowers 9 Nos.a. 3 of 2700 N.Cu.M/Min. (TBs 4,5,6) 3.6 atms. Abs. Pressure (10000kw eqv.)

b. 4 of 3000 N.Cu.M/Min (TBs 7,8,9,10) 3.6 atms. Abs. Pressure (12000kw eqv.)

c. 2 of 4200 N.Cu.M/Min (TBs 11, 12) 4.7 atms. Abs. Pressure (16369kw eqv.)

The characteristics of the turbines of blowers are :

Single cylinder impulse - reaction - one curtis wheel velocity compounded 8 impulsestage and 3 reaction stages - compounded, condensing tupe.

Use steam at 35 atms. And 4350 C.

Governing system with speed variation 2500 - 3250 r.p.m. ( for 9th / 10th Blowerspeed range is 3200 - 4500 r.p.m.) Protection from over speeding, lubrication failureand axial shift.

Emergency stop.

Regulation of Turbine (For USSR Turbine)

Hydro-Dynamic System impulse to the speed governor is given by changes inthe output of sensitive centrifugal pump rigidly mounted on to turbine shaft. Thespeed governor is of the diaphragm type actuated by the oil pressure developed bythe impulse pump. Oil pressure in the lubrication system is in between 0.4 to 1.0 Kg/sq.cm.

Speed changing device-hand operated or by remote control.

Axial shift relay trips the turbine in case axial movement exceeds safe limit.

Turbines are coupled to generator or blowers by geared teeth coupling.

Auxiliaries :

Condenser: Each turbine has one surface type of condenser with separate 2-passwater flow. This type of design permits cleaning of turbine condenser tubes ATurbo-Generator in halves in succession without stopping the turbine but workingwith reduced load.

Condensate pumps: There are 2 Nos. condensate pumps of 60 T capacities each toextract condensate from the condenser.

Oil tanks: Oil required for lubrication of bearing and regulation system is filled inthese tanks. The main oil pump is mounted on the shaft of the turbine and supplieslubrication oil & regulation oil through injectors. Oil cooler are installed to cool the oil.

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Oil pumps : There is main pump mounted on main shaft of turbine which supplies oilfor lubrication and regulation purposes. There is an emergency oil pump which startsautomatically when the oil pressure goes below predetermined pressure and suppliesoil for lubrication purposes. One Auxiliary oil pump is there during the starting &stopping to take over M.O.P. supply.

Ejector : As the condenser is a vacuum type so while starting the turbine it is necessaryto produce vacuum in the condenser and to maintain it when turbine is running. It isa two stage ejector.

Deaerators : Deaerators are the vessels where dissolved oxygen in the condensateand chemically treated water is removed as oxygen is corrosive. The deaerator are ofatmospheric type and works at a steam pressure of 1.7 atm abs. And watertemperature at about 1030C to 1050C. The deaerated water is then sent to boilereconomizers through feed pumps. There are 6 nos. deaerators in all.

Feed Water Pump : There are 10 nos Boiler feed water pumps. 3 pumps can pumps200T/Hr. & 7 pumps can pumps 100 T feed water to Boiler. Originally there pumpswere Russian made out of which 5 have been replaced with KSB pumps.

Main Control Room & Switch Gears.

Out of 270 MW maximum demand of Bhilai Steel Plant, Power & Blowing Station shares 51 MW with 4 generators having capacity of 12*3 MW +1*15 in operation. This plant is connected to CSEB grid through 3 Nos. Tie Lines. Apart from supplying its own auxiliaries it also feeds power supply to vital consumers such as Coke Ovens, Blast Furnaces 1 to 6, Sintering Plant – 1, SMS-1, Pump Houses, Oxygen Plant – 1, Compressed Air Station-2 and BESCL (Power Plant-2). The electrical wing of the shop looks after the operation and maintenance of all electrical equipments installed in Boilers, Turbine, WCTP, CHP and Repair Shop apart from maintaining own electrical installations like HT & LT Switch gears, transformers, Protections and other electrical related activity of the Shop. The Turbo Generator has Differential, Overload with minimum voltage blocking, Earth Fault in Stator and Double Earth Fault in Rotor Protections to safe guard the equipments .

. It feeds the following vital consumers apart from supplying its own auxiliaries.

1 Coke Ovens

2 Blast Furnaces 1 to 6

3 Compressed Air Station -2

4 Open Hearth Furnaces

5 Pump Houses

6 Oxygen Plant – 1

7 Sintering Plant-1

8 Power Plant-2

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Main features of electrical installation are described below

01 Generators :- 3 Nos. capacity – 12 MW each, 50 Hertz 6.9 KV, 3000 RPM, exciter – 75 KW with AVR (magnetic amplifier type) with field forcing.

02 TG-3 :- BHEL make –15 MW, 50 Hz – 16.9 kv, 1500 rpm, Brushes equator with DAVR 100 KW 620 ADC.

Protection : Differential, overload with minimum voltage blocking, earth fault in stator and double earth fault in rotor.

03 Reactors :- Concrete type – 15 Nos.

04 Main switch gears :- 6.9 KV, 1500 Amps, fault level 500 MVA with cross jet arc extinction type, double pole per phase Russian make oil circuit breakers.

05 Auxiliary switch gears :- 6.6 KV, 600 Amps, fault level 200 MVA with cross jet arc extinction type (oil circuit breakers -–69 Nos.) for B.6 – MOCBs are 1200 Amp fault level 250 MVA.

06 Air circuit breakers :- 400 V, motor operated.

560 KVA 6.6 / 0.4 KV Y/Y – 6 Nos 07 Auxiliary Transformers:-

630 KVA 6.6 / 0.4 KV Y/Y – 5 Nos

08 H.T. motor (6.6 KV) 49 Nos.

09 L.T. motors (400 V) 1600 Nos.

10 Station Battery – 600 AH 130 Cells

11 Lighting points – 6000

12 Tie line – 10 MW capacity and having protection of differential – Busbar and under frequency.

13 Auxiliary feeders – 3 Nos. with differential and over load protection.

14 Out going feeders – 11 over load protection.

15 Tie- line 3 one number – 15 MW capacity having protection of differential bas bar & u/f.

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Coal Handling Plant :

Power & Blowing Station receives Boiler Coal of D / E grade (UHV 4200 - 5200

Kcal /Kg) from Surakachar, Katkona and South Eastern collieries in railway wagonsand unloaded at PG hopper slot bunker having capacity of 300 T, by manual labour.

The coal unloaded at slot bunker of PG Hopper is conveyed to boiler bunkers througha series of single strand conveyors (6 nos) after crushing them by a hammer crusher

having a capacity of 120 T/Hr or a ring granulator of capacity 200 T / Hr. Thecrushed coal is first stored in the coal yard and then fed boiler bunkers as per

requirement. The capacity of coal storage yard at Power & Blowing Station is 22500Tones. The capacity of coal wagon unloading at PG hopper is 150 T/hr and feeding to

raw coal bunker is 90 T /hr Power & Blowing Station receives Boiler Coal of D / Egrade from Banki / Surakachar, Katkona and South Eastern collieries in railway wagons

and unloaded at slot bunker having capacity of 300 T, by manual labours. The biggersize coal and coal in defective wagons are unloaded on line 41 A to augment coal

unloading process to facilitate faster release railway wagons to avoid demurrage.

The coal received from mines has the following properties:

1) Useful heat Value - 4600 - 5600 K Cal / Kg

2) Ash content - 18 to 30 %

3) Volatile matter - 21 - 24 %

4) Moisture - 10 - 15 %

The capacity of coal storage yard at Power & Blowing Station is 22500 Tones.

The coal unloaded at slot bunker, is conveyed to boiler bunkers through a series ofsingle strand conveyors. The coal is crushed by a crusher having a capacity of 90T/Hr

and a ring generator of capacity 200T/Hr. there are 6 conveyors in all. The crushed coalis first stored in the coal yard and then fed boiler bunkers as per requirement.

SAFETY IN POWER PLANT-1

The safety in power plant-1 becomes one the of major issue for smooth operationof the plant, as it involves many processes / inputs / agencies. Because of this Power

& Blowing Station in Bhilai Steel Plant has been categorized as hazards factory in theplant.

In captive power plant safety revolves around mainly

1. Safety in the processes.

2. Safety of the personnel.

Safety of the person is more or less common as applied in any other parts /departments of the plant but safety involved in processes is entirely different because

of wide range of hazardous conditions required for the working of the plant.

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1. SAFETY IN THE PROCESSES.

The operation of captive power Plant requires water, coal, gas, air, oil etc asinput ingredient and steam, electricity, hot air blast, hot flue gases, hot dry fly ash asoutput products. Handling/processing of each ingredient poses potential safety hazardsin and around the plant.

Potential hazards involved with operation of the plant are classified on the basis of

A. Source/ equipment.

B. Medium.

C. Consequence.

A. On the basis of source / equipment it is sub divided as

Boiler- Furnace proper, coal dust preparation system , auxiliaries, ESP's etc.

Turbine/ Blowers - Turbine /blower proper, auxiliaries, air headers etc.

Generator / Motors - Generator proper, exciter, transformers, motors etc.

Coal Handling Plant - Yard, conveyor gallery, bulldozer etc.

Water Chemical Treatment Plant - Various chemicals.

Air compressors

B. On the basis of medium it is sub divided in to

a. Steam

b. Hot water- Feed water, condensate water, flushing water, cooling water.

c. Oil - fuel oil, lubricating oil and grease.

d. Gas - Blast Furnace Gas, Coke-oven gas, Converter gas.

e. Chemical

f. Electricity.

g. Hot fly ash

h. Hot air- Combustion air, air blast.

i. Hot flue gases

j. Coal- Lumps, fines

k. Compressed air

l. Sound

C. On the basis of consequence it is divided in to

m. Gas poisoning.

n. Explosion.

o. Fire.

p. Burn injury.

q. Electrocution

r. Diseases.

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Detailed potential hazards of Power & Blowing Station of Bhilai Steel Plant isgiven in Annexure A.

2. SAFETY OF THE PERSONALS

Each individual working in the plant is required to adhere to basic safety norms/rules while discharging his duties. Violation of these safety norms/rules causesaccident. Causes of the accidents can be explain as below :

DIRECT CAUSES

Unsafe act

Violation from the commonly accepted safe procedures of work is called unsafe act.

Examples

a. Operating without authority.

b. Failure to ensure.

c. Bypassing safety device.

d. Use of unsafe tools / tackles.

e. Unsafe loading and placing.

f. Taking unsafe procedure.

g. Working on moving machinery / equipment.

h. Non usage of PPE

Unsafe condition (Hazards)

Hazards are the condition with potential of causing injury to person or damage toequipment.

Example

a. Unguarded machines.

b. Defective machine.

c. Unsafe design / construction.

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GATEWAY

d. Improper illumination.

e. Poorhouse keeping.

f. Lack of proper tools.

g. Slippery floor.

INDIRECT CAUSES

These factors are contributing factors which give rise to direct cause.

Lack of knowledge and skill

i. Incorrect knowledge.

ii. Incomplete knowledge.

iii. Unskilled / low degree of skill.

iv. Misunderstanding job instructions.

Improper physiological / anatomical characteristics persons of

i. Poor eyesight.

ii. Hard of hearing.

ii. Overage.

iii. Sick.

iv. Allergic.

v. Intoxication.

Improper psychological characteristics persons who are

i. Arrogant.

ii. Lazy

iii. Fearful.

iv. Nervousness.

v. Egoistical.

vi. Absent minded.

vii. Over confident etc.

Some common conditions/ reasons for physical injuries related with the operationof captive power plant are as followed :

A. Injuries due to fall from height :

Although measures are taken to ensure safety at heights, in some cases, fencings/railings are not provided or during maintenance or otherwise the fencing are removed.This unfenced work places at heights may cause fall of persons. In some cases,open are allowed during maintenance work without its fencing. Also in some casesworkers do not use safety belt properly while working at heights or use temporaryladders, scaffolding, stairs. These also are potentially hazardous condition, whichmay lead to fall of workers.

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B Slip and fall at same level :

This is a leading factor causing a number of injuries, although minor in nature. Inthermal power stations, coal, oil etc. are used. Deposits of coal, dust / ash and itsmixing with moisture/ dew on the floors, ladders/ stairs makes them slippery. Inaddition to this seepage of oil near the oil storage tanks/ pipes, equipments/ gearboxesmay cause slipping of persons on slippery floors. In addition, a number of injurieshave been reported in various thermal power stations due to poor house-keeping orinattention of the employees. In some cases, workers have slipped due to obstructionsand raises structures.

C. Slackness / shortcut approach in maintenance :

As we know that maintenance is an integral part for the operation of the plant,injuries also occur due to deviation from Standard Maintenance Practice. Slackness/shortcut approach , psychological behaviors, absence of understanding between co -workers, in-adequate knowledge about jobs etc. are the prime reasons for accidents.

Gas Poisoning :

In captive power plants by-product gases Blast Furnace Gas, Coke-oven Gas,Converter Gas are used as a fuel in the Boilers. These gases contain some quantity ofCarbon Monoxide as shown in table 1. Carbon Monoxide combines easily with thehemoglobin of the blood, forming unstable compound called carboxy - hemoglobin. Theaffinity of Carbon Monoxide for the blood is 210 times more than the oxygen. So, evenif a small quantity present in the air hemoglobin in the blood will absorb Carbon Monoxidethan the oxygen. When this happen, the capacity of the hemoglobin carrying oxygen tothe tissues of the body is reduced. More and more breathing of CO displaces oxygen,causing the body to suffer form oxygen starvation thus resulting in asphyxia. Manytimes minor leakage in the gas circuit near tempers, valves, sector gate etc. makes thearea uncomfortable. Operators assuming these conditions not abnormal goes near theleaking point and suffer with gas poisoning. Some times during starting / stopping activitiesof the gas line result in heavy leakage due to failure of packing or mal-operation. Thisaffects masses severely working in the vicinity.

Water Chemical Treatment Plant -

Water chemical treatment Plant prepares make up feed water for boilers of Power& Blowing Station and Evaporative cooling system in Steel Melting Shop - 1. Rawwater from reservoirs at Maroda is required to be treated before it can be used inboilers. This plant has capacity of 325 T/hr of preparing soft water

A) Water chemical treatment Plant :-

Water chemical treatment Plant prepares make up feed water for boilers of Power& Blowing Station and Evaporative cooling system in steel melting shop - 1. Rawwater from reservoirs at Maroda is required to be treated before it can be used inboilers. This plant has capacity of 325 T/hr of preparing soft water

Sulphuric Acid, Sodium Hydroxide, Sodium chloride, Resin 225 (H) and 236, TriSodium phosphate, Sodium Nitrate, Hydrazine Hydrate and Morpholene are the bulkchemicals used in this plant.

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Schematic diagram of the working of this plant is given in Annexure

Planning Section -This section looks after the planning and procurement of spares of all the parts

of the shop, apart from maintaining small repair workshop.

SAFETY IN POWER & BLOWING STATION -Power & Blowing Station has been designated as a hazardous unit. In Boiler

Blast Furnace Gas, Coke Oven Gas and hot PCM are used as fuels, so much so theselines run around and inside the shop. Also High pressure and Low pressure Steam &Water Line network engulfs the entire shop. There are H.T and L.T electrical installationand cables in and around the shop. Because of various processes involved in thehandling of fuels, generation of steam, electricity and hot blast, many potential hazardssuch as High Noise Level, Heat Radiation, Coal dust, Fly Ash, Poisonous Gas leakagesetc. exist. So all new entrants are strongly advised to understand the safety hazardsbefore entering the shop.

POWER & BLOWING STATIONPOWER GENERATION CAPACITY - 51 MW

DETAILS OF EQUIPMENTS

EQUIPMENT COMMISSION DATE

H.P. BOILERS TUBRO GENERATORS TURBO BLOWERS TURBO BLOWERS TURBO BLOWERS

Boiler - 1 Boiler - 2 Boiler - 3 Boiler - 4 Boiler - 5 Boiler – 6 TG – 0 TG – 1 TG – 2 TG – 3 TB – 4 TB – 5 TB – 6 TB – 7 TB – 8 TB – 9 TB – 10 TB – 11 TB – 12

14-01-1959 15-02-1959 20-01-1960 07-01-1965 18-03-1966 August 1994 12-11-1964 04-06-1959 25-01-1959 29-09-2006 25-01-1959 17-12-1959 29-12-1959 24-11-1964 11-05-1966 14-02-1970 16-12-1970 14-09-1987 12-04-2000

NO.OF EXECUTIVE - 42NO. OF WORK FORCE - 353

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Turbine of Turbo Generator No-3 which will be commissioned during 29 sep.2006 consists of 1 impulse stage and 25 reaction stages.

There are two extractions for LP heater and HP heater.

The rotor is coupled to the generator through a gear box of double helical typehaving gear ratio of 4.2.

The turbine has normal speed of 6300 rpm and the gear box reduced it 1500rpm for generator.

SCHEMATIC DIAGRAM OF WATER CHEMICAL TREATMENT PLANT

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GATEWAY

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INSTALLED EQUIPMENTTO MEET THE OBJECTIVES

6 Nos. MULTIFUEL COMBINATION FIRED BOILERS

40 ATA.,450oC WITH INDIRECT COAL FIRING IN 5RUSSIAN BOILERS

4 Nos. TURBOGENERATORS

3 Nos. 12 MW RUSSIAN

1 No. 15 MW INDIAN (BHEL MAKE)

9 Nos. TURBOBLOWERS

PROCESS STEAM EQUIPMENT

2 Nos. REGULABLE BLEEDERS IN TG-1 AND TG-2

2 Nos. PRDUs VIZ. 40/8 ATA AND 40/18 ATA

POWER AND BLOWING STATION

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GATEWAY

BF GAS CONS (TH NM3/HR)


CO GAS CONS (TH NM3/HR)


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HEAT INPUT IN BOILERS (COAL VS OTHER)


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GATEWAY

ENVIRONMENT MANAGEMENT DEPARTMENT

Bhilai Steel Plant constituted Environment Management Department, in 1983,exclusively to meet the legal requirements, social demands and commitments madein the memorandum of settlements with NJCS w.r.t. Environment. It becamenecessary to notification of the Water Act 1974 and Air Act 1981.

Recognizing the need to effectively manage and protect this valuable environment,the Environmental Management Department (EnMD), is given the task to lead theimplementation of the Bhilai Steel Plant's Environmental Policy. Environmental Policyforms the framework for Strategy and a series of programmes aimed to ensure thatthe principles of environmental sustainability are adhered to. The four lead strategiesare minimization of pollution, energy conservation to combat climate change, solidwaste management and environmental education & training.

Environmental Policy

Bhilai Steel Plant (BSP), Steel Authority of India Limited, is an integrated steelplant with an annual production capacity of 4.0 million tonnes of steel and progressingtowards 7 MT, specializing in production of rails, heavy structurals, merchant products,wire rods and plates. Bhilai Steel Plant collective re-affirms its commitment to protectenvironment and shall strive to:

Introduce sound environmental management practices for minimizing pollutionand its impact on air, water and land, flora, fauna & human being.

Conduct operations in an environmentally responsible manner for complyingwith legislation and regulations related to its environmental aspects.

Conserve and optimally utilise raw materials, energy, water and other resources.

Minimize waste generation and promote its recovery, recycling and reuse.

Achieve continual improvement in environmental performance by setting andreviewing the objectives and targets periodically.

Enhance environmental awareness amongst employees and interested parties.

Communicate Environmental Policy to the person working for or on behalf ofthe organization and make it available to public on demand.

Date :01/03/07 (R. Ramaraju)

Place:Bhilai Managing Director

Bhilai Steel Plant

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Main functions of Environment Management Department

Compliance of provisions of various environmental legislations/regulations. (SeeAnnexure-I, the list of Environmental Legislation)

Statutory Monitoring of Air, Water & Noise Pollution in different areas of plantand township to comply the regulatory norms. (See Annexure-II.)

To advise for further need for improvement of pollution control systems indifferent departments.

Study of different kinds of solid wastes generated from plant and their recycling,selling & dumping status.

Environment Training to new comers in BSP service and employees, bothexecutives & non-executives.

To create Environment Protection awareness among BSP employees, citizensof this area & peripheral villages by organizing Environment related programme.

To co-ordinate afforestation efforts of BSP

Co-ordination with SAIL corporate Environmental Management Division, alldepts., other plants, occupational Health Center and statutory authorities likeChhattisgarh Environment Conservation Board (CECB), Central Pollution ControlBoard (CPCB), Ministry of Environment and Forests (MOEF) etc.

Implementation of Environment Management System, ISO : 14001

Developing and implementing Environment Management Plan

Co-ordination for waste management and resource conservation to minimizeimpact on environment

Preparation of Sustainability Report as per Global Report Initiatives guidelines.

Development of Clean Development Projects as per United Nation Convectionfor Climate Change.

Management of the Hazardous wastes and chemicals.

Conduct Life Cycle Assessment.

Environment MonitoringEnvironment Monitoring Laboratory:

Environment Monitoring Laboratory has been established inside the plant, nearPlate Mill. The laboratory is well equipped with the modern equipments to collect andanalyze Air & Water samples, from various sampling locations .In addition to this,noise & work zone area also monitored.

Air Quality Monitoring:

Stack Monitoring: Stack monitoring is carried out for the parameters mentioned inthe Annexure-II in the process stacks for statutory compliance and pollution controlpoint of view.

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GATEWAY

Ambient Air Quality: AAQ monitoring is carried out at 5 locations, three inside theworks area and two in township.

List of AAQ monitoring station is given below.

1. Water Works , Maroda

2. Works Office Building # 3

3. Rail & Structural Mill

4. CSEB Complex, Bhilai-3

5. Oxygen Plant-2

The monitored results from these stations for SPM, SO2 & NOx are communicated

to pollution control authorities.

Work-zone Air Quality Monitoring: Work zone air quality monitoring is carried out onregular basis for dust and gases at various locations in works area to assess qualityof work environment.

Water Quality Monitoring: Water quality monitoring is carried out for Plant Effluents (Outlets),Township (Domestic) Effluent, Water Receiving Bodies (River/Stream) and various wastewatertreatment systems for regulatory compliance and control of pollution.

Noise Monitoring: Noise level is monitored at source and in ambient air at specifiedlocations on regular basis.

Pollution Control/Prevention Measures:Air Pollution Control:

If prevention at source is not possible, emissions should be captured as close aspossible to the point at which they are generated. Hoods and enclosures are widelyused, incorporating carefully designed ductwork to prevent dust drop out, blockageor excessive and, once captured, the offgas is cleaned prior to discharge.

There are four main types of gas cleaning devices:

Fabric Filters, which have been adapted for use at high gas volumes andtemperatures, with variable dust size and dust loadings and user acid and alkalineconditions. Filters are used primarily to capture dust and fume and are routinelyintegrated into material handling systems, the blast furnace, BOF steel makingplant and rolling mills.

Electrostatic Precipitators (ESP), which apply an electrical charge to the particlesof dust causing them to attach to oppositely charged plates. Again, ESPs are usedprimarily to capture dust and fume and are routinely integrated into coke ovens (tarseparators), sinter and pellet plant, BOF and EAF steel making plant.

Venturi/Wet scrubber, which wash the offgas with a stream of water droplets.The pollutant laden water is collected, cleaned of solids and then recycled backto the scrubber. These system can be used to capture wider range of pollutants

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including dust, fume, acid gases, acid aerosols etc., and may be incorporatedinto lime production plant, coke ovens, sinter and pellet plant, BOF steel making,pickling and coating operations.

Dry cyclones, accelerate the offgas within a cyclone to remove particulate witha centrifugal action. Cyclones can only remove particulate and, because theyoperate at a lower efficiency than the other systems discussed above, particularlywhere fine material is present, they are not now widely applied.

Air pollution remains the most significant environmental issue for steel making,but the reduction or prevention of atmospheric emissions is closely linked to energyconservation and waste water management. For Example, by-product gases are avaluable fuel source, which form an integral part of a steelworks energy balance.However, cleaning systems are required to treat these gases before they can be usedand the resulting waste water may contain particulate matter and some heavy metals(in the case of blast furnace and BOF gas cleaning, for example) or organic pollutants,cyanide, ammonia and other species (in the case of coke oven gas cleaning). Inaddition, iron containing dusts and sludges will also be collected. Thus, by betterusage of by-product gases a steelworks can benefit from the flexibility of a captiveenergy resource and reducing purchased energy. The recycling of iron containingmaterials reducing resource consumption. Re-circulating system can be employedensuring that water is used effectively within the process and, with carefulmanagement of the necessary system bleeds, process water might be downgradedto less critical applications, thus minimizing the overall water demand of the steelworks.

Some of major pollution control measures taken at BSP are given below:Fugitive Emission Control:

Water Sprinklers and Dust Suppression Systems at Raw Material Handling Plant (OHP).

Water Sprinkler in Coal Yards of Coke Ovens.

On main charging in coke oven batteries

Door & door frame cleaning systems in coke oven batteries

Dust Extraction Systems (bag filters, scrubbers & cyclones) at material handling pointsof Blast Furnace, Coke Ovens, Sinter Plants, Steel Melting Shop, Power Plants

Electrostatic Precipitators at Sinter Plant-2 & 3.

Industrial Vacuum Cleaners

Flue Gas Cleaning systems (Stack Emission Control):

Wet scrubbers for Gas Cleaning Plants at Blast Furnace, Steel Melting Shop,Refractory Material Plant,

Multi-Cyclones for flue gas cleaning at Sinter Plant- I & 2,

Electrostatic Precipitators (ESPs) for flue gas cleaning at Power Plants and SinterPlant-III.

Ceramic Welding m/cs. for coke ovens.

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Water Pollution Control:

The iron and steel making processes require huge quantity of water and contributeto significant quantity of wastewater. Sources of waste water are direct and indirectcooling, gas cleaning, scale breaking, conveying, pickling, washing and rinsingoperations and rainfall runoff from raw material stock piles, roads, roofs etc.

Direct cooling involves the open spraying of water onto steel or equipment andis most commonly used for cooling hot steel leading to contamination with mill scaleand oil. Water used for indirect cooling is contained in a closed system and is far lessprone to contamination, however, some water must be removed from the circuit toprevent excessive hardness and build up of suspended solids. When direct and indirectcooling systems are used together, the water removed from the indirect circuit canbe used as make up water for the direct cooling system, although some intermediatecooling may be required. Similarly, although a wastewater treatment plant and pumpingsystem can render waste water reusable the use of poor quality water in criticalareas may cause product degradation and equipment deterioration. As such,wastewater may be best suited for quality insensitive applications such as thedampening of raw material stockpiles or road washing.

Wastewater treatment involves a combination of physical, chemical and biologicalprocesses. Each waste water stream normally undergoes an initial treatment close toits source, perhaps to remove gross solids and oil, before being sent to a secondarytreatment system.

There are several basic treatments, applied at most steelworks, that are capableof removing the great majority (by mass) of waterborne pollutants prior to dischargeand others, applied as necessary, to remove trace pollutants.

Removal of Solids:

Settling basins, which are a simple, low maintenance means of removing solidparticles from liquid by gravity. After a preliminary stage of chemical coagulation andprecipitation using alum or a polymeric flocculants (poly-electrolyte), the velocity ofthe wastewater stream is reduced as it passes into a large volume basin wheresettling occurs. Sufficient retention time and regular sludge removal are importantwhich determine the success of this method.

At Bhilai Steel Plant settling tanks and scale pits are used in the waste watertreatment facilities of Rolling Mills and Sinter Plant-2.

Clarifiers, which are more effective than settling basins for the removal ofsuspended solids, require less space and provide for centralized sludge collection.Conventional clarifiers consist of a circular or rectangular tank with either a mechanicalsludge collection device or a sloping funnel shaped bottom into which sludge collects.Chemical aids can be used to enhance solids removal, although chemical pretreatmentand sludge removal systems both require regular maintenance.

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Clarifiers (Radial Settling Tanks) are used in Effluent Treatment Plants providedfor gas cleaning system at Blast Furnaces, Steel Melting Shop I & II and RefractoryMaterial Plant-I

Filtration is a highly reliable method of wastewater treatment, capable of removingsuspended solids and unwanted odours and colour. The advantages of filtration are thelow solids concentration, which can be achieved, low investment and operating costs,modest land requirements and low levels of chemical discharge. Some pretreatmentmay be necessary if the solids level is greater than 100 mg/L. Several types of filter andfilter media are used, such as the pressure type or gravity types, operating with single,dual or mixed filter media. The most important variable in filter design is the width anddepth of the media, although particle density, size distribution and chemical compositionare also important in terms of media selection. The media selected depends on thefiltration rate and may consists of sand, diatomaceous earth, walnuts shells or, forconcentrations below 5 mg/L solids, anthracite. All filters require regular back washingto prevent accumulation of solids in the filter bed.

Filtration method is used at water treatment facilities of Power Plant, SMS-2 andPlate Mill.

Removal of oil:

Skimming, which can be used to remove floating oil and grease from the watersurface. Skimming efficiency depends on the density of the floated material and theretention time for phase separation, which varies from 1 to 15 minutes. Dispersed oremulsified oil cannot be removed by skimming. Skimming is often used as apretreatment to improve the performance of subsequent downstream treatments.

Oil skimming method is applied at waste water treatment facilities of Plate Milland CO&CCD units of Bhilai Steel Plant.

Filtration is an effective means of removing oil from water. Problems are onlyencountered when high oil concentrations contact the filter bed directly, althoughthis can be avoided if appropriate pre-treatment are applied. The filtration method isused for oil removal at waste water treatment facilities of Continuous Casting Shopand Plate Mill units of BSP.

Floatation, in which air bubbles attach to the oil particles which then rise to thesurface and can be skimmed off. The principal advantage of floatation oversedimentation is that very small particles can be removed more completely and in ashorter time. Various types of floatation are possible. For example, air may be injectedwhile the liquid is under pressure, the bubbles being released when the pressure isreduced (dissolved air floatation), aeration may take place at atmospheric pressure(air floatation) or the water may be saturated with air at atmospheric pressure and avacuum applied to release the bubbles (vacuum floatation). In all cases, chemicalsfor flocculation and coagulation are usually added before floatation.

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Dissolved floatation units are installed in the BOD Plant of Coal, Coke & ChemicalDepartment for removal of emulsified oil.

Removal of organics

Biological treatment is used to remove soluble organics and may be based on theactivated sludge system or other systems. The activated sludge process works bystabilizing wastewater using microorganisms in an aerobic environment, achieved bydiffused or mechanical aeration of the waste water in an aeration tank. There is aconstant bleed from the aeration tank to the settling tank which allows for theseparation of the biological mass from the wastewater, after which the waste wateris sufficiently clean for discharge. Some systems may also incorporate an anaerobicstage to enhance the removal of nitrogen from the system. Following separation, themajority of biological mass is returned to the aeration tank, but a small portion isremoved and disposed of or recycled to the coal beds. The system is generallyinsensitive to normal fluctuations in hydraulic and pollutant loading, although certainpollutants, for example ammonia at high concentrations and heavy metals, can beextremely toxic to microorganisms in the system. Temperature also influences themetabolic activity of the microbiological population, gas transfer rates and the settlingcharacteristics of the biological solids. The method incurs relatively low capital andoperating costs and is widely used in the industry for coke oven waste water treatment.

At Bhilai Steel Plant, biological treatment is used for organics (phenol, cyanide,ammonia etc.) removal from the phenolic effluents of Coke Ovens & By-products plant.

Noise Control:

Iron & Steel making processes in an integrated steel plant are potential sourcesof noise. These sources include turbo-generator, turbo-blowers, compressors,exhausters, steam & air leakages, rolling, forging, steam ejectors, pumps, extractionsystems and other heavy machines. Noise is typical of an environmental issue whereconcern for the working environment is also directly relevant to the generalenvironment. To reduce the impact of noise measures taken at BSP are given below:

Bellow type tuyers at all Blast Furnaces.

Snort Valve Silencers at Blast Furnaces

Sound proof Acoustic Cabins at Power Plants, Oxygen Plants, Pump Houses etc.

Blast by-pass silencers at Power Plant-I

Acoustic paneling at shipping office, R&SM

Suction and delivery silencer

Solid Waste Management:

Large quantities of solid wastes are generated in an integrated steel plant throughiron & steel making processes. Production of one tonne of crude steel, in an integratedsteel plant, as per International Iron and Steel Institute (Belgium), may require 5 Twater, 1.5 T iron ore, 0.61 T coking coal, and 0.59 T other materials and can contribute

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to 3 T wastewater, 0.455 T slag, 0.15 T other wastes (including dust/sludge, millscale, refractoriness etc.). Large quantities of waste and by-products pose variousenvironmental and other associated problems for steel-makers. The solid wastemanagement plays a vital role in the efforts directed at environment protection.Pollution control activities, like effluent treatment, dust recovery from emissions andraw material handling and processing, result in solid waste generation. Impropermanagement of solid waste may lead to in various environmental problems for example;I) air & water pollution as solid waste may get air borne, or may get washed away byrain water into water bodies, ii) may leach through soil and contaminate groundwater if improperly dumped, and iii) occupies large space and may make the land andsurroundings barren. Thus the best way to manage wastes is to recycle to the process,so that it becomes a part of the process or utilize the wastes in the form of marketableproducts.

Of the total solid wastes generated in an integrated steel plant, blast furnaceand steel making slags account for about more than 80% of the material followed byabout 10% oxide wastes from blast furnace, steel making and rolling mills and rest isother wastes.

The percent-wise solid waste generation and their utilization at Bhilai Steel Plantis shown in the following tables.

However, generation of solid waste depend upon the production and quality ofraw materials. About 600 kg of solid waste generated per tonne of steel produced.

BSP has adopted various waste minimization strategies including reduction at source,recovery and recycling. Solid waste recycling is considered as an excellent businessopportunity in addition to protection of environment. These measures have improvedsolid waste management. The solid waste utilization has increased to75% in the year2006-07. The ultimate target is to achieve 100% utilization of solid wastes.

Description % Generation Utilization BF (Iron making) Slag

70-74%

-BF Granulated slag is sold to Cement Manufacturers -Air cooled slag is sold to Slag Wool Manufacturers

Steel making) Slag (THF + LD) 14-15%

Dumped/Landfill, Recycled to SPs & BFs, Road making, Rail Ballast

Mill Scale 4 Recycling

Fly Ash 1.3

It can be utilized in cement making and brick making. Scheme for utilization is in progress

Others 11.5 -Recycled / Sold / Dumped

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Environmental Awareness:

As a part of environmental awareness measures the efforts initiated by Bhilai Steel

Plant for the maximization of the involvement of employees, citizens & students in thearea of environment protection and promotion of Eco friendly system are:

Workshops on "Pollution Control" in shops for executives & non-executives

Displaying slogans & messages in works area, township & villages forenvironmental awareness

50 nos. of Eco-clubs under the aegis of MOEF are actively operating in schools

of township to spread environmental awareness among students and throughthem in the neighbouring locality.

Life Cycle Assessment

Steel is a major constituent material in many mass-consumption manufacturedproducts. And like all materials, its production and use affect the environment in

many different ways. Assessing the overall environmental impact of products requiresan integrated approach that considers the product over its entire life cycle - Life

Cycle Assessment(LCA).

The Life Cycle Assessment (LCA) Study at Bhilai Steel Plant (BSP) was taken upunder the project entitled "Life Cycle Assessment of Steel Sector in India" initiated

by Ministry of Environment & Forests, Government of India. In this study, the followingthree steel plants of India are participating:

- Bhilai Steel Plant (BSP), Steel Authority of India Limited (SAIL), Bhilai.

- Tata Iron & Steel Company (TISCO), Jamshedpur

- Rastriya Ispat Nigam Limited (RINL), Vizag

With in the scope of this study, the system function is the production of a steel

product at the factory gate.

The functional unit, which enables the system performance to be quantified andthe associated in/outputs to be normalized, is one kilogram of steel product at the

factory gate.

Two products Rails & Plates are included in the study.

The study is a <cradle-to-gate> LCI Study. That it covers all of the productionsteps from raw materials <in earth> (i.e. cradle) to finished products ready to be

shipped from the steel works (i.e. the gate). It does not include the manufacture ofdown stream products, their use, end of life and scrap recovery schemes.

The study covers 'the blast furnace - basic oxygen furnace (BF-BOF) route".

Twenty three recommendations by the NML, on Improvement analysis based on

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LCA Study relevant to BSP, have been implemented. Bhilai Steel Plant is participating

in the latest LCA update 2006 being conducted by International Iron & Steel Institute,Brussels. BSP has also procured a LCA software GaBi 4 for conducting the life cycle

assessment of steel products.

Sustainability

The goal of sustainable development is to "meet the needs of the present withoutcompromising the ability of future generations to meet their own needs" as key

forces in society, organizations of all kinds have an important role to play in achievingthis goal. The GRI Reporting Framework is intended to serve as a generally accepted

framework for reporting on an organization's economic, environmental, and socialperformance. It is designed for use by organizations of any size, sector, or location.

It takes into account the practical considerations faced by a diverse range oforganizations - from small enterprises to those with extensive and geographically

dispersed operations. The GRI Reporting Framework contains general and sector-specific content that has been agreed by a wide range of stakeholders around the

world to be generally applicable for reporting an organization's sustainabilityperformance.

The Sustainability Reporting Guidelines (the Guidelines) consist of Principles for

defining report content and ensuring the quality of reported information. It also includesStandard Disclosures made up of Performance Indicators and other disclosure items,

as well as guidance on specific technical topics in reporting.

Bhilai Steel Plant has prepared its first sustainability report for the year 2001-02. Subsequently, For each financial year sustainability report is being prepared. This

year Bhilai Steel Plant has prepared its 4th Sustainability Report as per Global ReportingInitiatives (GRI) G3 latest guidelines, for 2005-06. BSP is the first public sector company

in India to have published this report and second steel plant in world to publishsustainability report as per GRI G3 guidelines.

CDM (Clean Development Mechanism)

Under Kyoto Protocol, the Clean Develop Mechanism (CDM) project enables

developing countries to participate in joint Green House Gases (GHGs) reductionprojects. Under this protocol, developed countries are required to reduce carbon

dioxide (CO2) emissions by 5.2% during 2008-12 compared to 1990 as the reference

year. Under the CDM, Bhilai Steel Plant has identified the following projects.

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These projects have potential to reduce 1 million tones of CO2 per year.

Implementation of CDM is being monitored by various levels of management andMinistry of Steel. Any new projects of BSP are evaluated by Design organizationsand Consultants for potential CDM applicability.

The potential revenues realized from CDM will be utilized in the development ofsustainable livelihood in the periphery, implementation of state of art pollution controltechnologies.

Projects implemented: Project under expansion

• Blast Furnace Gas Waste Heat utilization at boiler # 6 of Power Plant-1.

• Heat recovery at Sinter Plant-3. • Coal Dust Injection in Blast Furnaces

1,5 & 7 • Additional LD gas evacuation scheme

to increase LD gas recovery. • Modification in the furnace of RSM. • Microprocessor control system at

Furnace. • Upgradation of Blast Furnace # 7. • Recycling of LD slag in SMS-1 and

Blast Furnace. • Replacement of CFC-11 by Li-Br based

chilled water plant. • Independent exhaust system for slab

casters 2, 3 & 4. (other 2 slab casters had independent exhaust system).

• Resizing and improvement in design of impeller of GCP-4 in SMS-1.

• Thyristorisation of BF – 3 & 4 Skip Hoist Electrical supply for better operation efficiency and energy conservation.

• Commissioning of VVVF drive ID fan motor of SMS-2.

• Replacement of 175 Nos. Old ACs by energy efficient ACs.

• Dry fog dust suppression system replacing bag filter system at stock house of BF # 4.

• Coke Dry Quenching • Top Pressure Recovery Turbines • Thin slab caster • Installation of walking beam

furnaces one each at plate mill, wire rod mill, merchant mill and Rails & structural mill

• Upgradation of BF 6 • Installation of gas fired boilers • Replacement of old compressors

of OP-2 with energy efficient compressors

• Waste heat recovery in new sinter machine

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Ozone Depleting Substance : Phase Out

Under Montreal Protocol, as a part of phasing out ozone depleting substances,BSP has eliminated use of CFC-11 by replacing it Li- Br based chiller unit, way beforethe target date of 1.1.2010. Procurement of Carbon Tetra Chloride (CTC) has beenstopped and use of Trichloroethylene has been started. The project is beingimplemented under the UNDP aid. 50 % of Halon based fire extinguishers has beenreplaced by FM 200 based units. All industrial package air conditioners using CFC-12 will be replaced by year 2010 in phased manner using CFC free refrigerant.

Environmental Management System ISO: 14001.

Environment Management System (ISO-14001) is being implemented at BhilaiSteel Plant in phased manner. It has been implemented at 24 shops and implementationof ISO-14001 is in progress at 15 more shops.

ISO 14001 was issued on Sept 1, 1996, is being world wide recognized asenvironmental management standard. It has been revised on 2004 to make it morecompatible with other ISO standard such as 9001. It is a specification standard,which means that organizations, which conform to its requirements, can becomeregistered/certified to the standard. This standard is applicable to all type oforganizations. It can be applied to all parts or any single part of an organization and /or activities, products and services. Presently, ISO 14001 is the only standard in the14000 series that a company can be certified/ registered to.

ISO 14001 does not standardize performance requirements, it is usable in allcountries by all sizes of organization. It is worded in flexible terms that allow fortailoring to fit virtually any need. Since there is no specific performance requirementsin 14001, there is no start up performance test and no final performance goal imposedby the standard.

ISO-14001 is based on the Deming's model of Plan-Do-Check-Implement. Theelements of ISO 14001 are listed below:

Environmental Policy:

The environmental policy is the driver for implementing and improving theorganization's environmental management systems so that it can maintain andpotentially improve its environmental performance. The policy should therefore reflectthe commitment of top management to compliance with applicable laws and continualimprovement and provide the basis for setting of objective and targets.

Environmental Planning:

An organization has to identify significant environmental aspects that should beaddressed as a priority by the organization's environment management system. Alllegal and other requirements which the organization may subscribe need to beconsidered. The significant aspects which have a significant impact on the environmenthave to be addressed by fixing objectives and targets. The objectives need to be

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specific and targets measurable. The organization has to establish a managementprogramme for achieving its objectives.

Implementation and Monitoring:

The successful implementation of an environment management system calls forcommitment of all employees for organization. Hence, the responsibility forimplementation has to be a line function. Employees and contractors need to betrained on the impacts their work might have on the environment.

Documentation sufficient to describe the core elements of the environmentmanagement system, which may be integrated with other system should be available.

Checking and corrective action:

The organization has to monitor the key characteristics of its operations andactivities that can have a significant impact on the environment and establish recordsfor the same. A periodical audit would help determining whether the environmentalmanagement system conforms to planned arrangements and is being properlyimplemented and maintained.

Management Review:

The organization's top management shall, at intervals it determine, review theenvironment management system, to ensure its continuing suitability, adequacy andeffectiveness. This review shall address the possible need for changes to policy,objectives and other elements of the environment management system.

Benefits of implementing ISO 14001:

Position the organization in the market place as an environmental leader

Provides a framework for establishing an integrated approach to environmentalmanagement that is system dependent and not person dependent

Promotes the positive image in the community and with governmental agencies

Provides a systematic, repeatable process to achieve continual improvement ofthe organization's EMS, thereby promoting improvement of environmentalperformance.

Provides an internationally recognized standard for the organization to use todemonstrate to employees and interested parties its commitment to soundenvironmental management.

Environmental Milestones at a glance:

1. Establishment of Pollution Control Department -1983

2. Completion of expansion of 4.0 MT inclusive of pollution control systems-1988

3. Environmental Study by NEERI, Nagpur for assessing environmental status atBSP-1987-88

4. EIA study by EPCO, Bhopal, for 4 MT expansion environmental clearances-1988-89.

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5. Environment Management & Pollution Control Study by BHPE-Kinhill, JV,Australia - 1989-91

6. 28 Pollution Control Schemes implemented as per Action Plan- 1995

7. Installation of new units inclusive of state of art pollution control systems likeCOB-10, SP-III-1995/2001

8. Implementation of Environment Management System at Plate Mill in 1999.

9. Participation in the Life Cycle Assessment Study for Steel Sector in India underthe aegis of the Ministry of Environment and Forests, Govt. of India from SAIL,1997-98 to 2000-01.

10. First Sustainability Report as per Global Reporting Initiative Guidelines releasedin 2002, depicting the three core areas Viz Economic Responsibility,Environmental Responsibility and Social Responsibility of SustainableDevelopment.

11. Twenty four shops have been certified to Environmental Management SystemISO:14001 in 2005.

Glimpses of Environmental Achievements:1. Reduction of Particulate Emission Load from 4.22 Kg/tcs in 1993-94 to 0.89

Kg/tcs in 2006-07.

2. Lowest energy consumption rate amongst Indian steel plant, reduced from 8.14GCal/tcs in 1993-94 to 6.82 GCal/tcs in 2006-07.

3. Lowest Water consumption rate amongst Indian integrated steel plants, specificwater consumption has reduced from 33 m3/tcs in 1988-89 to3.19 m3/tcs in2006-07.

4. Solid Waste Utilization has increased to 75.0% in 2006-07 from 47% in 1993-94.

5. Increased in green belt cover, the estimated tree population has increased to 52lakhs (including mines).

6. National Environment Engineering Research Institute, Nagpur, carried out QualityAssurance studies and stack emission characterization study for Bhilai SteelPlant. Action plans for the betterment of Environmental Monitoring byEnvironmental Laboratory, as suggested by NEERI are under implementation.

7. EIA/EMP report has been prepared and submitted to Ministry of Environment &Forests for environmental clearance from 4.0 MT to 7.0 MT.

8. Sustainability Award: BSP has won the "Sustainability Prize" in independentunit Category for the year-2006 instituted by CII.

9. BSP has won the Golden Peacock eco-innovation Award for the year 2006instituted by Institution of Directors-New Delhi

10. Bhilai Steel Plant has been declared the Winner of Greentech Gold Award inMetal Sector for outstanding achievement in Environment Management for theyear 2006, sponsored by the Greentech Foundation, New Delhi.

11. BSP has won the Golden Peacock Environmental Excellence Award for the year2007 instituted by Institution of Directors-New Delhi.

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ANNEXURE-IList of Environmental Legislation

Table E-1 : Environmental Legislations and Evidence of Compliance

Legislation Evidences of Compliance

The Water ( Prevention and Control of Pollution) Act-1974 (Amended upto1988) & Rules 1975.

Measurement and analysis of effluent water, Operation & maintenance of ETP, Water Consent

The Water (Prevention and Control of Pollution) Cess Act-1977 (Amendment Act 2003) & Rules 1978

Payment to statutory authorities

The Air (Pollution Prevention and Control) Act-1981 (Amended in 1987) & Rules 1982

Stack emission monitoring Work area environment & Ambient air quality , Operation & maintenance of PC equipment, Air Consent

The Environmental (Protection) Act 1986 (Amended in 1991) & Rules-1986 (amended upto 2003).

Recycling / reuse of waste, Solid waste disposal ,Bio-medical waste, Phasing out of ODS, Fly ash utilization, Battery Management, Reduction of specific raw material consumption. Water consumption. Energy consumption

Environmental Clearances

The Hazardous waste (Management and Handling) Rules 1989 (Amended up to 2003)

Compliance as per HW rules 2003

Manufacture, Storage & Import of Hazardous Chemicals Rules 1989 and Amendment Rules 1994 & 2000

Safety Audits, MSDS, Disaster management plan & mock drills

The Public Liability Insurance Act, 1991(Amendment-1992) & Rules, 1992 (Amendment-1993)

Composite Insurance by SAIL

The Noise Pollution (Regulation and control) Rules-2000 (& Amendment Rules 2002)

Noise Monitoring & control of noise pollution

Compliance Reporting for above mentioned legislations

Submission of environment compliance report & Filing of returns & assessments

The Factory Act-1948 amended in 1989

License.

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Legislation Evidences of Compliance

Ozone Depleting Substances Rules 2000

Filing of returns

The Battery (Management & Handling ) Rules 2001

Filing of returns.

Notification of Flyash utilization; amendment upto 2003

Submission of annual report

Bio-medical wastes (Management & Handling) Rules 1998

Submission of annual report

ANNEUXRE-II

Environmental Norms:Air Quality Norms:Stack Emissions:

Ambient Air Quality Norms:

Shop / Unit Parameter Unit Norm Coke Ovens Particulate

Matters SO2 NOx

mg/Nm3

mg/Nm3

mg/Nm3

50 800 500

Blast Furnace, Sinter Plant, Rolling Mills, Refractory Material Plant, Power Plant etc.

Particulate Matters

mg/Nm3 150

Steel Melting Shop

Particulate Matters

mg/Nm3 150/400*

DCDA Sulphuric Acid Plant SO2 Acid Mist

Kg/T of H2SO4 mg/Nm3

4.0 50

*during oxygen lancing

Parameter Unit Norm (Industrial Area)

Suspended Particulate Matter (SPM) µg/m3 500 Oxides of Sulphur (SO2) µg/m3 120 Oxides of Nitrogen (NOx) µg/m3 120

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Effluent (Water) Quality Norm:

(Norms applicable for Integrated Iron & Steel Plant)

*per tonne of finished steel

Noise Standards:

I. Work-zone area: 90 dB(A) for 8 Hrs. exposure.

II. Ambient Noise

Category of Area Limits in dB(A) Day Time Limits in dB(A) Night Time Industrial Area 75 70

Commercial Area 65 55

Residential Area 55 45

Silence Zone 50 40

Day time: 6 am to 10 pm, Night time: 10 pm to 6 am.

Parameter Unit Norm Temperature °C 40 pH - 5.5 to 9.0 Suspended Solids mg/L 100 Chemical Oxygen Demand (COD) mg/L 250 Biochemical Oxygen Demand (BOD) 3 days, 27oC mg/L 30 Ammonical Nitrogen mg/L 50 Oil & Grease mg/L 10 Phenolic Compounds mg/L 1.0 Cyanide mg/L 0.2 Effluent Discharge (Quantitative) M3/tfs* 16

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COMPUTERISED MAINTENANCE MANAGEMENT SYSTEMThe result of Increasing mechanisation, more complex machines, organisation

structure, responsibilities and bubbling economy of India has changed the expectationsof Maintenance Engineer. Besides this more emphasis is being given on Safety andquality of output. As now a days when Maintenance people of BSP has alreadyadapted the new ways of thinking and acting and are looking for a new approach tomaintenance and there they seek a framework that combines the new Ideas into acoherent system, so that they can evaluate there data sensibly and use the resultsonly which will be of most value to them and there shop.

And there comes the CMMS system into picture. CMMS was formed in May'1987with the objective to develop a user-friendly system for addressing the daily activitiesof a maintenance Engineer, to generate powerful MIS for Maintenance applications,strengthen the planning activities, to improve equipment availability, reduce manualpaper-work. Apart from this CMMS has also developed and implemented CustomizedPackages as and when required by the users.

The third generation of maintenance management has been fulfilled by the CMMSdifferent systems. CMMS system has helped the user to determine the maintenancerequirement s of each item of the plant and equipment in the operating context.

CMMS started its journey with ND-500 Super-32 computer using SIBAS asdatabase and COBOL as the S/w language. CMMS smoothly crossed over the hurdleof Y2K and started switching over to Oracle database using D2K as the S/w package.Now as our databases are also shifting over to 10G, we are also enhancing the s/wcapabilities using Forms 10G and JSPs. All our systems are on 3-tier architecture.

The advantages of CMMS are manifold, with the information available throughCMMS different module.

CMMS ModulesMaintenance Module: This is a comprehensive maintenance. Solution for a shopwhich takes care of all kinds of Inspection, Repairs along with Breakdown and delayanalysis against each equipment. Eqpt wise History is also available for the same.

Engg. Shops Module is a complete on-line MIS for Engg. Shops namely, FG,FDY, SSS, RS, OG, M1, M2 and M3 and CPD, IED and Inspection dept. Engg shopsmanufacture spares for the plant units whenever required. The system takes care ofw/o requisition for the same at depts' end to w/o conversion, technology creation,production, Incentive Computation, Inspection and Despatch of the spares.

Electrical Repair Shop are the agency to maintain and repair Electrical machinesof the plan units. They have an on-line system for Job registration, planning, postingthe progress of repairs, testing, incentive and dispatch of the motor. Apart from this,the system also takes care of Magnets and trf repairs, coil manufacturing and windingdata system.

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CMMS has developed and implemented Shop-floor inventory system for monitoringof shop-floor custody stock and compute the stock position more accurately, as sincesome time back , a spare used to be declared as consumed as soon as it was drawn fromthe stores. The system can give item wise, section wise consumption analysis, generatedyearly forecast for coming year's budget preparation. The system has been integratedwith the Finance system for custody stock computation too. Apart from this CMMS hasfacilities for monitoring Lub, belt and brg consumption too.

Various central depts. Based systems have been developed and impl for addressingthe daily activities of central agencies like, EBSI, HME etc. Management reports aregenerated for the Central management from these systems.

Apart from our core activities, we have also developed and impl some veryuseful systems as and when demanded. We will cover some of them later in thispresentation.

Maintenance Module

As equipments are an important assets for an organisation enhance equipmentavailability.

This system is centered around equipment codification. The grouping ofequipments mostly done based on the convenience of the maintenance agency, likeit is based on the material flow for Mech where as it is based on Distribution flow forELE. Or based on functions.

Inspection planning section takes care of preparation of Inspection checklist, itsexecution and Inspection calendar. One has to create a set of Routine Inspection jobsalong with its time frequency.

The maintenance person can prepare the repair plan based on standard jobs, PMjobs master, timed jobs and defects observed thru inspection & CBMS techniques,allocate agency wise responsibilities and give agency wise execution. Some of theoutputs of the system are Repair plan, Agency wise plan and Time based jobs due. Itcan be made for a area or an equipment or the department as a whole.

Breakdown and delay recording system facilitates the user to record thebreakdown details, delay and downtime, possible causes of the same and its analysistoo. This data is available in the center for further analysis.

Capital Repairs System facilitates the user to prepare jobs schedule, agencywise plan and spare required. They can generate agency wise schedule and monitorthe progress of the CR by giving daily progress details and taking out CR progressreports.

The provision is available to record Equipment History separately too although itgets generated automatically from execution from the above systems also. Equipmentbehaviour and its performance can be monitored from this system.

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Condition Based monitoring system is a useful maintenance tool to assess thecondition of a running equipment using techniques like vibration analysis, thermography,oil contamination analysis, MCSA etc and take timely corrective action well before thecostly b/d occurs. We have state-of-the art gadgets and tools for the same alongwith thesupporting analytical s/w to come out with possible reasons of the behaviour.

We have now systems for central agencies like HME, EBSI, ETL, DNW, PTD,CHM too. HME generates annual schedule for maint. and repairs of heavy electricalmachines and post execution. EBSI which does the structural inspection has a systemfor posting defects observed against the inspection and the compliance accordingly.MSDS takes out Maint. Schedule from this application

To introduce the single window concept and to capture the maintenance dataright at the source i.e. the shift rooms, e-logbook has been introduced in various shitrooms of WRM, PM, SP-3, MSDS, HME, CO, BF, MM and CMMS. This featurefacilitates the user to post all the activities being done in the shift from a single entrypoint. Option is available for shift i/c to view the logbook and to give instructions too.The delay details are available to the central agency wise locbook.

Engg.Shops Module

Engg. Shops are responsible for manufacture of spares for plant units as andwhen required. They have a full-fledged on-line system right from Planning, productionto monitoring the shop's performance. The user can raise a requisition for a spare on-line specifying its material, size, drawing and nomenclature and send the same toCPD along with the drawings. This requisition is studied by CPD for its feasibility tobe manufactured at engg. Shops. And converts into a workorder if a decision ofmake is done, else it is sent back to the dept recommending for purchase.

The shop order is thus prepared containg the work order details, shop route andexpected delivery details and is sent to the respective shops for technology preparation.Blanking shops FG, FY , SSS, prepare the technology card for the same, if it is a newitem. CPD also has option to prepare the Monthly plan for these shops. When anitems appears in the plan, its further shift wise, ma/c planning is done at the blankingshops and prompt execution is given for the same.

The Inspection dept inspects the item and passes it in Class-I, i.e., passed withoutany defect or in class-II, passed with minor defects or it may reject it. Foundry shophas a system for recording heat wise cast system too. The ingot moulds and bottomstools produced there are dispatched on-line to SMS-I, which is available to theHMMS system of INCOS on-line.

Similarly Raw material accounting system is operation at FG and SS which recordsthe bill of material of all the items being produced there.

Semi-finished items thus produces in blanking shops are sent to Open Gantry forintermediate storage and for subsequent issues to Finishing shop i.e., Machine shops.

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GATEWAY

Machine shop gets the blank issued on-line from OG by generating a requisitionslip and prepares the route card which containg all opn wise, m/c wise operationdetails alongwith its setup and runtime on each m/c. Based on this route card theshift chargeman generated the jobcard for wach operation and once the job is over,updates the same and puts up from Inspection. Once the item passes the finalinspection, it is dispatched to the respective plan unit.

Based on inspection data various quality performance reports for each engg.Shops are taken out comparing the passed data wrt. Rejection.

Based on the time estimation done for each operation in each shop, Incentivereports are generated for put up to IED for claim.

ERS Module

ERS has the responsibility to repair and maintain electrical machine of the plant.This on-line system gives them a user-friendly facility to carry out their daily activities.Here one point is to be mentioned that all the motors os the plant categorized andgiven an ECN wrt its capacity, make, type, mounting etc. and each motor is given aunique shop ref. No. and painted on its body. One can track the repair and inst.History for a motor using this number throughout its life.

Like in Engg. Shops the user can raise a w/o req. for sending the motor for repair.The motor has to have its ECN and shop ref No. for the same. TP & IE is the agencyresponsible for preparing and monitoring the monthly plan for ERS. Once motor isreceived in ERS, after primary testing the job is registered mentioning the jobs to bedone.

Facility is given to record results of the repeated tests being done on the sameand progress of each component of the motor from the various sections. At eachdefined stage option is avl to send reports to IED for incentive to be claimed. On-lineTest certificate can be generated for any motor at the user end too.

Once the jobs is assembled, tested and made ready for dispatch, dispatch detailsare prompted at the user end to plan for collection.

Additional feature has been provided in this system to feed the results of rotorCage Bar repair and balancing data and integrate the findings from CBMS data andERS data and come to a conclusive solution. The system has also been extended forrepairs of magnets and transformer too, here all the types of magnets and transformersare codified into ECN.

ERS also prepares coils for the plant and issued then time-to-time to plant unitsas per demand. This on-line system provides at any time the details and preparationas well as its dispatch.

ERS has to continuously refer to Winding Data of the motors. This has beenmade on-line to provide the details whenever required during repairs.

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Misc. System

Shop-Floor Inventory System: This system has been designed to monitor the custodystock responsibility wise, store wise and item wise at the shop-floor. The system hasbeen integrated with SINGS(Store Indent generation system) of MMIS(Materialmanagement Information system). As soon as the item is drawn from the main store,the data gets populated in SIS(Store Inventory System) for further issues in the shop-floor. Regular entry of issues provides them actual stock of items. This system canhelp them monitor inventory and better planning, study consumption pattern, itemwise and store wise, custody stock comparison. This system has also been extendedto Finance to compute custody stock for a quarter/ fin. year. Here also the systemhas integration with MMIS here to compute the same. Input for stock verification isalso taken out from this system.

Contract Awarding and Monitoring System CAMS is a total on-line solution for awardingof rate contracts. The OA(Operating Authority) cans raise the proposal from their endand send it on-line to HOD(Head of Deptt.) and then to CA(Clearing Agency) forrecommendation. Once recommended, the respective nodal agency takes the approvalof IED (Industrial Engineering Department)and FIN(Finance) on-line and conducts PSCto select a suitable party. Once party is selected, the proposal is sent to CC(Contractcell) for award on-line as well as in hard copies. CAMS has been integrated with VMS(Voucher Management System)of C&IT for bill clearances.

Fire Engineering Module This module facilitates the Fire Engineering Department tocarry on their daily activities i.e., fire call slip generation, fire investigation, areainspection and re-inspection and their compliance. Khariyat report is a unique featureof this system in which data entry as well as the reports are taken out in HINDI.

BSP Page has been designed and developed as the company's intranet home pagewhich integrate all the IT applications running in the plant, besides it hosts manydepartments web pages, flashes latest happenings in the company, The valid usersare authenticated by their user name ( pno) and password along with the roles assignedto them to operate any database application. One has to sign-in only once to use anythe application present in CMMS page. Unified Plant view & production data fromINCOS are an important part of this page.

Shop Page Hosting CMMS web page hosts the depts' web pages of many units ofthe plants. FTP sites and authorization has been given to respective shop I/c forposting updates on their respective pages. Besides this, FTP sites have been providedto many other users like PTD, CHM for storing their important files and for regularbackup.

Utility System The Utility zone head is in need of daily report of their zone comprising ofOps and CAS and CWP. Here INCOS people extended a great help in providing us theaverage data from their CEMS systems, we compile it and with a small amount of dataentry from shops' end we bring out the daily reports for the zone. We get procurementdata of LOX, LIN etc from EDP's system in this application.

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On-Line Telephone Directory & Complaints For the first time , BSP telephone directorywas made on-line by our group, which is fully functional in Telecom dept 2244. Itgives you a powerful search of Telephone nos. on various parameters like name,designation, dept etc. Recently we have provided the dept with Docket mgmt systemwhich takes care of the daily telephone complaint, their compliance and they alsotake out analysts reports on type of failure, time taken to complete a call etc. Provisionfor giving requisition for updating is also available here.

Chetna On-Line CMMS group along with the group from HRIS dept have come out withthis unique application to create awareness about company and Industry and to createan environment of learning in the organisation with healthy competition spirit. The facilityis provided for collecting on line feedback from employees on issues of vital importance.They hold regular on-line quizzes on specific or general topics, questions relating to SteelEnvironment specifically. You can win attractive Prizes too!

Roll Monitoring System RTS has been provided with this application, objective ofwhich is to monitor performance of individual rolls & rolling mills with respect to rollconsumption and to maintain optimum inventory of roll blanks. It also helps them inbetter decision making regarding future rolling plan. Incentive calculation is alsocomputerized for them.

E E M S (Details) This system has been implemented in MSDS to Monitor the ElectricalEnergy Consumption dept wise and to provide MIS on the same to shop people by 9in the morning. This system eliminates complex manual Computation of specificenergy figures. Recently after implementation of PCMS - on our request to eliminateduplicate data entry INCOS has already provided us the data from the same, we haveincorporated the changes, the testing from shop's end is left.

B E D B Archiving Archive section of BEDB has been provided with this system formonitoring issue and receipt of their huge volume of microfilms. They have recordedcomplete microfilm data in the data base along with their images. Powerful searchhas been provided on the page to search for a microfilm and see its image.

H/w and S/w Complaints System Keeping in mind the growing strength of H/w as welland s/w applications, CMMS has developed and imp system to accept and comply the h/w and s/w complaints on-line from the users. The h/w vendors can take their respectivepending call report from the page itself from any of the BSP intranet pc.

OnLiFiT System As per the orders of MD on-line file tracking system has beenimplemented recently at all GMs and above offices successfully. This system canshow you any time the status of your file , replacing the existing manual diary/dispatch system at the same time.

Near Miss Reporting and Safety Audits As it is said that if we can take care of nearmiss cases we can avoid accidents to a great extent. So to monitor and analyse thenear miss cases this system has been provided to DSOs of the shops as well as toSafety dept for monitoring compliance and feed inspection reports.

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Drawings Enquiry for RED : Drawing at various stages have been scanned and madeavailable on-line on the page for subsequent viewing and usage, Like in RED thedrawings of refractory have been scanned and made avl on the page so that at thetime PI generation, the vendor can take the printout of the same from the purchasedepartment. Itself. Similarly the drawings have been integrated with work order systemin ESM.

Motor Search As already mentioned the motors have been classified wrt their specsand each motor has been given a unique shop ref no. you can search any motor bygiving any the parameters and see it repair history, you can also see the eqpt wisereplacement details.

Standards As standards are referred by the maint. Engineers quite frequently, BSPhas subscribed to BIS and ASTM standards and the same have been made avl. in theBSP intranet. Besides this Oil cont. standards , IPSS and BSP standards as well as listof pref. Makes is also avl on the page, recently we have recd request to put AWWAstandards on the net, but it was found that it is avl in hard copies, so the jobs is onto provide them on the page too!

Management Reports Based on the applications mentioned above various mgmt reportsare generated and are made available on the CMMS page for review.

E- DPR As DPR is an integral part of e-logbook, we have recently developed e- DPRsystem and implemented in few dept. As the system is quite complex, the developmentis still in full swing

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GATEWAY

CONDITION BASED MAINTENANCE SYSTEMS (CBMS)

The success of any industry depends on the continuous, safe and economicaloperation of its plant and machinery. This calls for a very systematic and predictivemaintenance approach to sense the generation of a defect well in advance in runningequipment so that timely preventive action is taken to avoid any surprise or unforeseenfailure of the equipment.

To achieve this, in addition to regular preventive maintenance practices, variousCondition Monitoring Techniques under Condition Based Maintenance Systems areused to monitor the health of the equipment and identify potential problems well inadvance and plan remedial measures, thereby avoiding catastrophic breakdowns.

In Bhilai Steel Plant Condition Based Maintenance group was formed in Nov '91.The objective of the group is implementation of Condition Monitoring in Bhilai SteelPlant. Benefits of Condition Based Maintenance in an integrated steel plant like BSPare numerous. Some of the advantages are given below:

Minimizing unscheduled downtime of equipment.

Enhancement in equipment life.

Decrease in maintenance cost by:

Avoiding serious secondary damages.

Extending the in-between repair periods.

Less spares consumption & inventory.

Increased availability & reliability of equipment

Decrease in repair time due to:

Fault diagnosis in advance

Less damage

At present around 1000 critical equipment are covered under CBM. Conditionmonitoring activities are performed by centralized CBMS group as well as decentralizedmonitoring groups under Shop Maintenance. A great deal of data about the conditionof the running equipment is collected on regular basis and its rate of change withtime is noted. Abnormal behavior or any deviation from normal working condition ofthe equipment is reflected in the change in pattern of various condition parameterslike vibration, shock, noise, current, voltage, temperature, wear debris, flow, pressure,etc. The data thus collected is trended and analyzed for assessing the nature andcause of the problem and remedial measures are planned accordingly thus preventingany unforeseen failure.

Various Condition Monitoring Techniques that are used at Bhilai Steel Plant are:1) VIBRATION MONITORING

Vibrations in a machine are normally generated due to various reasons like rubbing

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between metallic surfaces, defects in rolling element contacts, misalignment betweenshafts, out of balance, structural looseness etc. Vibrations once generated aretransmitted through the structure and medium to other components and sub-systems.When vibration reaches un-acceptable limits wear and tear process acceleratestriggering failure of the equipment.

2) SHOCK PULSE MONITORING

Shock pulse measurement is a special method assigned for condition monitoringof rolling element bearings. Shock pulses are random, transient low energy signals,almost undetectable with a normal vibration transducer. It detects even small changesin lubrication film thickness and the mechanical state of the bearing surfaces. Theinformation of bearing geometry, speed, type of lubricant used together with shockpulse data is used by the SPM technique to tell about the condition of the bearing andits life.

3) MOTOR CURRENT SIGNATURE ANALYSIS (MCSA)

MCSA is a non-intrusive diagnostic technique that is used for analyzing variouselectrical rotor defects. This technology has the ability to test electrical motors inworking condition and identify rotor bar defects and eccentricity problems.

Typical rotor problems include:

1. defective castings in die cast rotors,

2. rotor bar cracks,

3. high resistance joints due to poor brazing,

4. end ring fractures resulted due to high thermal and mechanical stresses and

5. rubbing between rotor and stator caused by large uneven static and dynamicair gap MCSA can be applied to diagnose such problems.

4) OIL CONTAMINANTION MONITORING

The main contributor to the functional failure of any oil system is the presence ofcontamination. It is generally observed that oil change in any system is required notbecause of the oil loosing its properties but due to the fact that oil is highlycontaminated, making the oil unserviceable. Contaminated oils cause acceleratedwear of the components, which contribute to oil leakages and development of heatin the system. This in turn accelerates the oxidation of the oil. Therefore the oilsused in systems should be free from contaminants for trouble free performance andlong life of the equipment. This in turn helps in extending the intervals between oilchanges, which cuts down the oil consumption.

5) WEAR DEBRIS ANALYSIS

Wear is the inevitable and anticipated consequence of surface contact betweeninteracting machine parts such as shafts, bearings, gears, bushing & similar otherrotating parts. Components wear through normal use, poor system or component

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GATEWAY

design, surface fatigue, rotating unbalanced component & temperature related factors,leading to wear particle generation.

Amongst the various techniques of Condition Based Maintenance, Wear DebrisAnalysis is a new approach to machine condition monitoring which is becoming verypopular in recent years. Lub oil reaches to all moving elements in equipment andthus is the best carrier of 'wear information' of the equipment. Testing the lub oilsample for wear particle concentration and analysis reveal considerable informationabout the condition of the lubricated surface in a machine.

6) INFRARED THERMOGRAPHY

Infrared (IR) radiation is electromagnetic radiation of wavelength longer thanthat of visible light, but shorter than that of microwave radiation. Infrared radiationcan be used to remotely determine the temperature of objects. Capturing and analyzingthe Infrared Radiation emitted by a body to identify the 'Hot Spots' is termed asInfrared Thermography.

Infrared Thermography is the latest Condition Monitoring technique that is adoptedin Bhilai Steel Plant. It is highly useful in predicting refractory wear-out in refractorylined vessels, pipes, ladles etc.; loose connections in electrical joints; deposits in gaspipe lines and bearing failures in mechanical equipment in addition to many otherapplications.

Various Condition Monitoring equipments available with CBMS are:

1. Vibration/ Shock pulse analyzer model A-2011 make SPM.

2. Machine condition analyzer model A-30, make SPM

3. Vibration analyzer / Data collector model FASTTRAK, make Entek IRD.

4. Motor Condition Analyzer for conducting MCSA - Model EMAX, Make PdMA,USA

5. Oil Contamination Monitoring -Particle Counter CM-20, Make Parker, UK

6. Wear Debris Analysis- Wear Debris Monitor, Model MIDAS, Make MTML, UK

7. Infra-red non-contact thermometer, make Raytek.

8. Infra-red Thermo vision Camera, Model ThermaCam E2, Make FLIR, Sweden

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INSTRUMENTATION & WEIGHMENT DEPARTMENTInstrumentation department came into existence along with the inception of the

integrated steel plant. Over a period of time, the department has grown in line with theplant. In the late 80s the Weigh Bridge and Scale Maintenance Department got mergedwith Instrumentation department and renamed as Instrumentation & WBSM Department.Now it is popularly known as 'Instrumentation & Weighment' department.

Instruments in the industry form the basic sense organs and provide informationabout the process, production, quality, and standard parameters. They also process theinformation into workable logics and deliver necessary outputs to meet the quality andquantity norms. They facilitate the process to operate at optimum to maximum efficiencyat reasonably low resource consumption within the design limitations.

An integrated steel plant is a conglomeration of various industrial units operatingin a programmed mode to meet the objective of production of steel to internationalstandards. Application of instruments and weighing systems are spread throughoutthe length and breadth of the plant. To cater to the needs of different units of theplant, the department is functionally divided into following areas :

- Central Instrumentation Laboratory (Pneumatic, Hydraulic, Flow and Electronics)

- Planning & Training

- Field Maintenance Wing

- Rolling Mills Zone (Soaking Pits, Compressed Air Station, Merchant Mill, WireRod Mill, Rail & Structural Mill and other nearby units)

- Power and Blowing Station (P&BS, RMP I, Pump Houses, etc..)

- Steel Melting Shop I

- Oxygen Plant I

- Auxiliary Shops

- Blast Furnaces

- Steel Melting Shop II (Converter Shop, CCS, Compressed Air Station, etc..)

- Plate Mill and Energy Center

- Coke Ovens & Coal Chemicals

- Sintering Plant II

- Refractory Material Plant II

- Oxygen Plant II

- Sintering Plant III

- Weigh Bridge and Scale Maintenance

These functional units are geographically located near the respective work areas.The department employs about 400 dedicated employees, working round the clockfor the upkeep of the instruments.

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GATEWAY

Major activities of the department are :

1. Maintenance and upkeep of various instruments in different areas (as above).

2. Evolving efficient control strategies for improvement in the product quality andprocess yield.

3. Developing suitable optimization techniques and implementation of thesetechniques on real time and continuous basis.

4. Emphasis on process efficiency and reduction in cost of production.

5. Developing methods of analysis of the process and retrofitting the suggestedactions there upon.

6. Providing innovative and cost effective solutions for various operational problems.

7. Coordination and active implementation of new projects.

8. Enriching the human skills by imparting technical and human values.

9. Coping up with the dynamic and challenging technological advancement.

10. Maintaining the ISO standards for testing and calibration of equipment.

For achieving the above, the department uses standard and proven sensors,master test equipment certified by National accredited Laboratories, latestmicroprocessor based controllers, Programmable Logic Controllers, Distributed DigitalControl Systems, Computerised Data Acquisition Systems and Analytical equipmentfor the analysis of various gases for process optimization and human safety. Indigenoustailor made developments in the field of combating obsolescence of technology andequipment, process modeling and advanced control systems have taken a front seatin refining the performance of the department.

Some of the significant achievements are :

- Cost control measures taken in the year 2000-2001 yielding about Rs. 1.248crores by means of effective utilisation of internal resources

- Reclamation of more than 10000 meters of special signal cables

- Moisture control of Sinter Mix in Sintering Plant

- RAFT control and automatic stove sequencing in Blast Furnaces

- Developing suitable sensor mounting methods in Rolling Mills and Blast Furnaces

- Innovative repair of cutting torches used in different units of the plant

- Provision of interfaces for obsolete/non-standard equipment and effectiveutilisation of the same.

- Reorganisation & upgradation of Instrumenation lab. with in-house resources

- Upgradation of various controlrooms of CO & CCD with in-house resources

- Upgradation of controlroom equipments of BBM & RSM with in-house resources

- Complete implementation of SIS system in Instrumentation main store

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In the current economic scenario, the key to survival is 'to be the fittest'. Fastobsolescence of technology is today's problem in this field. Keeping this in view, thedepartment sets its goal for achieving results, implementing efficient and cost effectivemeasures.

Function of various sections of the department is explained in brief as below :1. Central Instrumentation Laboratory , Field Maintenance Group, Planning & Training

Instrumentation Department has a centralised and well equipped laboratory locatedin R&C lab. building. There are sub sections in the laboratory such as Micro-processor& Digital Laboratory (MDL), Flow & Pressure Lab. (FPL), Pyrometry & Electronic Lab.(PEL) and Pneumatic and Hydraulics Lab. (PHL) for the purpose of calibration, repairing,servicing, overhauling, developing circuits and modifications of all types of instrumentsand equipment including thermocouples & RTDs used throughout the plant. In thePrecision Mechanic Lab. all types of precision and mechanical parts and items relatedto instrumentation are fabricated. The Gas Cutting Torches and Regulators of variousgas cylinders belonging to various shops/departments throughout the plant, townshipand mines are repaired, serviced and overhauled in the Oxygen Regulator Section.

All the test equipment (calibrators) are calibrated in the Instrumentation Laboratoryagainst measurement standards traceable to national/international standards to meetthe requirement of ISO:9001:2000, Quality Management System. These testequipment are used for calibrating the quality critical instruments/equipment of differentshops/departments.

Field Maintenance Group :

Unlike other steel plants of SAIL, Instrumentation & WBSM department of BSPhas a section called Field Maintenance, Modernization and Capital Repair Group (inshort called Field Maintenance Group) for carrying out various field maintenance,modernization & modification, and capital repair jobs including cable & conduit pipelaying and wiring jobs. This section plays vital role in achieving cost control by meansof doing modernization and modification jobs in-house.

Training :

The department is having an established training group looking into various aspectsof training. Being a specialised field, many in house programmes are designed andconducted throughout the year. These programmes are updated and upgradeddepending on the technological needs. New programmes are designed to meet theincreasing need of latest concepts of automation.

Planning:

Planning activities for all the instrumentation and weighment requirements ofthe plant is met centrally by this group. Analysis of various requirements of differentproduction units is done and procurement action is prioritised. Mechanisation ofplanning process is in the advanced stage for efficient inventory control. This is done

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with the internal resources of the department. Also the coordination of all ISO activitiesis done by this section for the department.

2. Rolling Mills Zone (Soaking Pits, Compressed air station, Merchant Mill, WireRod Mill, Rail & Structural Mill and other nearby units)

Rolling Mills Zone of Instrumentation includes Rail & Structural Mill, MerchantMill, Wire Rod Mill, Soaking Pits, Blooming & Billet Mill, Gas Booster and MixingStations, Compressed Air Station No. 2 and associated Water Pump Houses.

Soaking Pits & BBM :

There are 28 nos. of Soaking Pits in which ingots are heated before being rolledinto blooms or billets in the respective mills. The data acquisition system using FIX32software package is used to collect the data from differtent controllers and generatethe historical trend of the parameters. The important parameters which are controlledand monitored in all 28 nos. of soaking pits are :

- Pit temperature control

- Pit pressure control

- Combustion control

- Ingot temperature measurements at strategic points in rolling path

- Bearing and Winding temperature measurements of machines involved in rolling

Merchant Mill, Wire Rod Mill and R&SM :

The blooms/billets are preheated in the reheating furnaces of these mills beforebeing rolled into different products like angles, channels, TMT rods, plain rods, wires,rails and structurals. The merchant mill, Wire Rod Mill and R&SM have 3, 1 and 3reheating furnaces

respectively. Merchant mill reheating furnaces are equipped with a data acquisitionsystem. The important control parameters involved in the process of making finishedproducts are :

Furnace parameters

- Furnace Pressure Control

- Furnace Soaking Zone Temperature Control

- Furnace Heating Zone Temperature Control

- Mixed gas pr. Control

Rolling parameters

- Temperatures before and after rolling at different heavy duty stands

- Equalising temperature at cooling bed

- Cooling water flow and pressure measurements

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Machine Health Monitoring parameters

- Load end and free end bearing temperatures of machines

- Winding temperatures of machines

Gas Mixing and Gas booster Station :

The Coke Oven and Blast Furnace gases are mixed in proper ratio to get the gasof desired calorific value. This mixing is done at this station, subsequently the gas isboosted to higher pressure of 1800 mmWC and delivered to the distant mills likeR&SM, MM & WRM. The critical control parameters at this place are :

- BF gas flow measurement

- CO gas flow measurement

- CO enrichment flow

- Mixed gas pressure before and after booster

- BF and CO ratio control

Compressed Air Station 2 and LP Mill Pump Houses :

The air is compressed and dried in the compressed air station and is delivered tothe plant wide compressed air net work. The logic generation to control differentvalves is done through the controllers installed in different machines. There are sevenmachines running to generate the compressed air. The functions carried out by differentcontrollers are :

- Logic generation

- Throttle control

- Anti surge control

The health of the machines is monitored through the measurements of bearingand winding temperatures.

3. Power and Blowing Station (P&BS, RMP I, Pump Houses, 1, 2, 11, etc..)

The role of Instrumentation in Power & Blowing Station is :

1. To enable reliable monitoring of all the necessary measurements.

2. To maintain automatic controls of parameters like Boiler drum level, main steamtemperature, hotwell level, turbine speed etc.

3. To provide safety interlocks like protection against Ball Mill explosion through'after mill temperature interlock' in Boilers and axial shifts protection in Turbine.

4. Regular upkeep of instruments during capital repairs.

5. Strive towards betterment of the plant by improving the level and reliability ofinstrumentation.

Primarily the Instrumentation system in PBS comprises of stand alone indicators,recorders and controllers. In Boiler No. 6 MOD-300 Distributed Digital Control system

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of ABB make is installed. Potential free contact based alarm annunciation is used tobring the operators attention to the deviating parameters.

In the turbines the necessary axial shift protection system has been replaced invarious machines by the Bently Nevada Turbovisory system. In the Russian Blowers,hydraulic anti surge system is installed to prevent the surging of the machine. In TB-11 & TB-1, the protection is achieved through electronic antisurge control systemand surge detector. In TB-12, electronic speed governor through electro-hydraulicconverter is also provided to control the speed of the turbine.

The following measurements have very high importance in the normal operationof the plant :

1. Boiler Drum level

2. Boiler Drum pressure

3. Furnace draught

4. Axial shift

5. Lube oil pressure

6. Vacuum

7. Turbine speed

8. BF and CO gas flow

9. Steam flow

Major modifications in the Instrumentation system of PBS include :

1. Shifting of Boiler control from open panels to control rooms

2. Introduction of turbine speed measurement

3. Enhancement of axial shift protection with the introduction of Bently Nevadasystem

4. Conversion of potential free annunciation from 220 VDC based system

5. Revamping of control system of generators and larger blowers

6. Introduction of superheated steam temperature control

7. Introduction of remote operation of BF burners and secondary air dampers fromthe control room

4. Steel Melting Shop I

Instrumentation plays very important role not only for the production but also forquality of the product and safety of persons & equipment in steel making process inSteel Melting Shop-I.

The Instrumentation and Control System in SMS-I include measurement of variousparameters such as Temperature, Flow, Pressure, Level and Vibration of process andequipment.

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Steel making process is fast process in Twin Hearth Furnace and the processcan not wait for any delay in measurement of the parameters. The measurementsmust be accurate and reliable for quality process and also for Techno EconomicCalculation. For the purpose, all the instruments are checked and calibrated at regularintervals. Apart from regular calibration, the instruments and control system for veryimportant measurements such as Temperature of Liquid Steel, Water Level in ECSSeparator, Drum and Vibration of GCP Motor and bearing are jointly checked alongwith the users. The absence of the above important measurements will adverselyaffect the process in terms of Quality and Quantity. Instruments are Eyes and Ears ofSteel melting process.

The list of important instruments are given below :

1. Bath Temperature (Liquid Steel Temperature)

2. Oxygen Flow of Main Line

3. Liquid Fuel flow of Left & Right side

4. ECS Separator Drum Level

5. Draft Pressure of Chimney Gases in General Flue

6. Lance Position

7. Vibration of Fan Bearing (Drive & Non-drive end)

8. Temperature of Motor winding Fan Bearing and Motor Bearing

9. Roof Temperature of Mixers

10. Temperature of Hot Metal at Mixer

Alarming and Tripping system are provided in GCP's for Vibration and Temperaturemeasurements of Motor and fan bearings of GCP's.

5. Oxygen Plant I and Auxiliary Shop

Oxygen Plant I :

Oxygen Plant I supplies Oxygen mainly to SMS I and Auxiliary shops viz. MachineShop, Foundry, Steel Structural Shop etc. Oxygen Plant I consists of 3 blocks of5000 NM3/hr. capacity. Each block consists of the following units.

1. Pre-cooling Unit

2. Air Separation Unit

3. Air Turbo Compressor

4. Oxygen Turbo Compressor

Here Instrumentation plays a vital role in maintaining the different parametersrequired for process control and protection of the machines, such as, flow pressure,temperature, level etc.The important parameters are

1. Air flow to ASU

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2. Oxygen Flow

3. Air pressure before turbo expander

4. Bottom & Top Column levels

5. Air flow to turbo expander

6. Level in the supplementary condenser

7. Resistance of Oxygen & Nitrogen regenerator

8. Suction and by pass control

9. Water level in air water scrubber

10. Resistance of air water scrubber

Auxiliary Shops :

Instrumentation in Auxiliary shops mainly caters to the needs of different shopssuch as Machine shop, Foundry, Steel Structural Shop, Electrical Repair Shop, ForgeShop, etc. The measurements include Furnace temperature, pressure and controls,flow of fuel gases and oxygen, winding temperatures of machines under testing, etc.

6. Blast Furnaces

As Blast Furnace process has moved towards standardization with ISO 9 0 0 1, considerable efforts have been put into rationalization of the system of maintenanceand calibration of the various measurement and control instruments critical to theprocess.

Stoves constitute the heart of blast furnace process. For controlled and efficientheating of stoves, provision has been made for

1. Mix Gas Pressure control

2. Air/Gas ratio control

3. Dome Temperature control

4. Stove Model in BF5 for auto changeover of stoves.

In the furnace area, various controls and safety interlocks have been provided torun the process efficiently and smoothly.

1) Hot Blast Temperature control

2) Top Pressure Control

3) RAFT Control

4) O2 Flow Control

In Blast Furnace 6, Coal Dust Injection Plant has been commissioned which hasdrastically brought down the Coke Rate. This plant is highly automated and variouscontrols and safety interlocks have been provided through ALLEN-BRADLEY PLCsystem. Coal Dust Injection Plant is also started in Blast Furnaces 1,5 & 7 .

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Blast Furnaces 5,6 & 7 are equipped with Distributed Digital Control/PLC Systemfor monitoring and control of the process. In addition to the main units, auxiliary unitslike Gas Cleaning Plants and Slag Granulation Plants are equipped with variousinstruments for monitoring the process.

A few of the innovative jobs done in the area are as follows:

- Modification of Thermocouple Fixing Assembly for Hot Blast and Stove DomeTemperatures.

- Development of castable thermocouple .

- RAFT control in all the furnaces.

- Development of Stove Model for auto changeover of stoves.

- Development of New Differential Pressure/Top Gas Pressure Control scheme.

- Provision of Raw Gas Pressure Control with auto changeover for safe operationof GCP.

- Provision of controlled nitrogen flow to Bin/Gas Seal line.

- Intermediate furnace pressure measurement scheme developed and implementedin Blast Furnace.

- Interlocking provided to shutoff CO Gas line during stove changeover.

- Interlocking of stove Isolation from gas is provided with Combustion air flowand pressure.

7. Steel Melting Shop II (Converter Shop, CCS, Compressed Air Station, etc.)

In SMS-2 zone, Instrumentation plays a very important role in the following units:

1. Mixer Shop

2. Converter Shop

3. Argon Rinsing Unit (ARU)

4. Vacuum Arc Degassing Unit (VAD)

5. Ladle Furnace & R.H. degassing Unit (LF & RH)

6. Continuous Casting Shop (CCS)

7. CAS-3 and CWP-2

8. Gas Holder

In all these units the measurement of Hot metal/liquid steel temperature is themost vital measurement for the metallurgical process in SMS-2. Throw-awaythermocouples (B-type) are used for this. These thermocouples are fixed to a lanceassembly and dipped into the bath of hot metal/liquid steel to measure the emfdeveloped. Microprocessor / PC based secondary instruments process the measuredemf and display the accurate temperature. In addition lamps indicating "MeasurementReady", "Measurement going on" and "Measurement complete" signals are alsoprovided for operator convenience.

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In Converter Shop, the entire process is monitored and controlled through a DCS(Distributed Control System), TOSDIC 247-AS. Numerous process as well as safetyinterlocking are implemented through this and all the process parameters can bemonitored and controlled through the display Screens of all the three LD-Converters.Here in SMS-II the vibration measurement systems of ID Fans, Booster Fans and gasanalysers systems are the instrument of great importance.

In ARU, "Celox" probes are used for determining the temperature as well as thebath oxygen activity. Based on this the Aluminum required for killing of steel iscalculated and displayed in "Multilab Celox" a PC based instrument. The flow andpressure measurement of Argon gas used for stirring is also important parameter tomonitor.

Vacuum Arc Degassing Unit is very important in SMS-II for secondary steelmaking. Here the vacuum measurement is very important parameter to monitor andcontrol. A number of control loops and interlocking are incorporated for various processparameters. The PRDS (pressure reducing and de-superheating) and bottom stirringargon flow control are of great importance. The microprocessor based controllers,molten steel measurement indicator and Multilab - Celox instruments are installedhere.

Ladle furnace and RH-degasser units are recently added to SMS-II to increasesecondary steel making facility. Both these units are modern and having PLC basedcontrol systems.

In LF the liquid steel temperature, argon flow control for bottom stirring, furnace draftcontrol, cooling water flow/pressure and vibration measurements are important ones.

In RH - Degasser the measurement and control of all the parameters is donethrough Siemens PLC system. The vacuum measurement, closed and open coolingwater cycle monitoring instruments , PRDS instruments , Vessel heating and pre-heating burner instrumentation systems, Celox and Hydris measurement are theimportant measurments.

In CCS continuous casting machines all the control loops are implemented throughTOSDIC 211/215 single loop controllers. The water flow control systems of mouldcooling (4 zones) and secondary cooling (16 zones in slab caster and 20 zones inbloom casters) are mainly controlled in automatic mode. The mould differentialtemperature, casting speed and slab/bloom surface temperature measuring ininstruments are important ones. In slab casting machines 1 and 2 the air-mist coolingcontrol system is developed and introduced recently.

The compressed air and chilled water requirement of different units is met by theCAS-3 and chilled water plant situated closed to SMS-II area. Large number ofinstrumentation systems are installed in these units. The Header pressure and flowmeasurement, compressors, anti surge control , bearing /winding and processtemperature measurements are of great importance.

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In SMS-II area 40,000 M3 capacity LD gas-holder is also available. Its mainfunction is to store and export the LD-gas. If the gases coming out of converterprocess meet recovery conditions these gases can be recovered and stored in LDgas-holder. For holder operation several interlocking schemes are also implementedhere through conventional relay based logic. The gas analyzers, gas-holder volume,gas-holder pressure, export flow etc. are the parameter to monitor. Recently a CV(calorific value) analyser system is also commissioned in the LD gas export line tomonitor the CV of LD gas recovered.

8. Plate Mill and Energy Center :

Plate Mill and Energy Center section of Instrumentation department looks aftermaintenance of instrumentation and control system of reheating furnaces, normalizingfurnace, Gas mixing and booster station, Energy center, Acetylene plant, WCTP-3&4and various water pump houses.

The measurement of temperatures of various zones and control of gas and airflow for proper combustion are important for the proper heating of slabs in Reheatingfurnaces. Reheating furnaces of plate mill are equipped with Evaporative coolingsystem (ECS), where the skid cooling water is connected to a boiler drum and thegenerated steam is exported to 8 ata steam network of the plant.

Temperature of plates/slabs is measured in different stages of rolling with the helpof I .R . pyrometers. Special Quality Plates are processed through Spray cooling deviceand Normalizing furnace. Various mechanical properties of plates such as tensile strength,corrosion and abrasion resistance are enhanced through this process.

Another important area, Energy center, situated in the Sanyantra Bhavan isequipped with Computerised Energy Monitoring System (C.E.M.S.) and a back upsupport system for same of the critical parameters.

As many as 400 different signals from all over the plants related to energy suchas BF, CO, LD, liquid fuel, steam, compressed air, N

2, oxygen etc are monitored

continuously. The signals of flow, pressure, temperature, details of generation andconsumption are connected to different remote terminal units spread all over theplant as detailed below :

RTU Location Area Covered No, ofNo. Signals

1 Coke Ovens CO & CCD 43

2 PP-II RMP-2, PP-II 45

3 Plate Mill Plate Mill, Normalising, WCTP 18

4 SMS-I SMS-I, OP-I, PRMS Foundry Shop, 55Forge Shop, CWP

5 OP-II OP-II 25

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6 Rolling Mill GMS, BBM, RSM, MERM, WRM, CAS-II 31Booster

7 PBS PBS, RMP-I 75

8 E.C. BF, SMS-II, GMS(PM) 70

9 CAS-III CAS, C/S, CCS 25

All these parameters are monitored and data logging is done continuously in theEnergy Center. The system issues advises to all the users and supplier shops regardinggeneration and consumption of energy with the help of C.E.M.S. system.

9. Coke Oven And Coal Chemicals Department :

The role of Instrumentation is very vital in this CO & CCD area. The process ofCO & CCD is very complex and in addition it is highly fire prone area, so it is the needto make this complex process to a simple process and it should be free from fire. Thishas been achieved by incorporation of many instrumentation systems in differentunits of CO & CCD.

They are

COB # 10 - Tata Honeywell TDC-3000 System

COB # 9 - Fix 32based DAS System

COB # 3 & 4 - AB PLC based coking process management system

COB # 1,2, 7 & 8 - All Hydraulic controllers

BRP-II - Toshiba 211D based System

TDP - EC 321 controller based system

The measurements and controls of High Importance are as follows :

1 Hydraulic Mains Pressure Control In all the Batteries (all are hydraulic controllers)

2 Coke Oven gas suction control in Exhausters

In all the Exhausters

3 Crude Benzol Column Top Temperature control

In Benzol recovery

4 Benzol column Top Temperature control

In Benzol Rectification plant

5 Pitch Recovery Temperature and Tar flow in

Tar plant

6 Furnace Temperature In Sulphuric Acid plant

7 Turbine Back pressure control In Exhauster House

10. Sintering Plant-2

In Sintering Plant-2 the Instrumentation & Weighment plays a vital role in processoptimisation, quality & operator guidance. Following are the major parameters &control without which running this plant in better way is not possible;

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The important measurements are as follows:

1. Bunker level and weighing systems of mixing station

2. a. Moisture measurement & control after primary mixing

b. Water flow

3. Exhauster house

a. Primary vibrators & temp. of fan & motor

b. Lubricating oil pressure & temperature

c. Winding temperature of motor

4. Gas Mixing station

a. CO gas & BF gas pressure & flow

b. Mix gas pressure measurement & control

c. BF gas- CO gas differential pressure control

d. Ration control

All these control in GMS are from hydraulic regulator.

5. Machines

a. Sinter Charge Bunker level measurement

b. Moisture measurement & control of sinter charge at secondary mixing drum

c. Water flow at SMD

d. Mix gas flow & pressure measurement

e. Air pressure & flow measurement

f. Gas to air ratio control

g. Hearth temperature measurement & control

h. Exhauster outlet and collector vacuum

i. Vacuum and temperature measurement at 16 wind boxes across the lengthof machine

j. Machine & Sinter cooler speed measurement 8 control along with drumfeeder speed measurement

k. Wind box 1 to 4 damper control in each machine

6. ESP

a. Vibration and temperature measurement at ID Fan bearings

b. Suction and discharge pressure

c. Dust percentage in discharge section

7. Nut coke charging - Bunker level control

11. Refractory Material Plant II

Refractory Material Plant-2 has three main area of operation like Lime Kiln, RotaryKiln and TBDB shop. In these areas for achieving better process control & quality, theparameters measured are as follows:

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1. Lime Kiln

a. Lime temperature at 8 different section of shaft 1 & 2

b. Calcination temperature at 8 different sections of shaft 1 & 2

c. Channel & waste gas temperature in each shaft

d. LSHS oil temperature; pressure & flow measurement with oil flow counter

e. Shaft level measurement & control

f. Burning time count control system

2. TBDB Shop

a. 4 nos. of temperature measurement for tempering Kiln I & II

b. CO gas pressure measurement

3. Rotary Kiln

a. Furnace temperature measurement by radiation pyrometer

b. CO gas pressure & flow measurement & control

c. Air pressure measurement

12. Oxygen Plant II

Oxygen is one of the most critical inputs in the steel making process. Almost 3lakh NM3 of oxygen is supplied to SMS-2 daily for blowing. There are other customerslike Blast Furnace, SMS1, FSNL, Medical departments, cylinders for welding purpose,and liquid oxygen, nitrogen and argon are also sold commercially to outside customers.

Major units of Oxygen Plant 2 are as follows :

Air Separation Units :

Air Turbo Compressors

Oxygen Turbo Compressors

Liquid Oxygen Tank

Cylinder filling Station.

Pressure Reducing and Metering Station. Pump House Old and New.

Instrumentation Systems in Oxygen Plant 2 :

Oxygen Plant 2 is the place, where one finds very wide range of InstrumentationSystems ; like completely pneumatic systems (transmitters, secondary instruments )in the older units(ASU1,ASU2) to Distributed Control System (TDC3000 : withtransmitters communicating digitally to the main unit ) in the expansion units (ASU3); and electronic instruments for the remaining units. Other than the conventionalmeasurements of flow, temperature, pressure, level etc. there are measurements ofvibration, axial shift etc for machine protection. There are Oxygen analysers to measureright from the ppm level to the 100% level. Nitrogen analysers are used to measure

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the presence of N2 in the argon produced from the distillation column. CO

2 analysers

based on infrared absorption is used to measure the presence of CO2 in the air entering

the distillation column. Moisture analysers are used to detect the presence of moisturein the air entering the distillation column. Other than the conventional automaticcontrol schemes there is anti surge control scheme of ATC3 and ATC4; here thesurge line is dynamically determined based on flow, frequency, discharge pressure,rate of change of discharge pressure etc.

There are future plans to replace the pneumatic system of the older units with aPC based Supervisory control and data acquisition system.

13. Sintering Plant # 3

Sintering Plant-3 is a new addition in Sinter making consisting of 320 m2/1.262T/m2h ofSinter Machine with production capacity of 3.2mT/year=9696T/Day=404T/hour.

This plant is equipped with most modern Instrumentation and control systems."Role of Instrumentation Department is to monitor proper functioning of all theinstrument, control system, day to day maintenance, capital repair, proper calibrationof all the instrument etc."

Some of the important instrumentation/control systems at SP-3 are as below :Integrated Control System (ICS) :

Integrated Control System (ICS) is supplied by M/s. Seimens. Function of ICS isto monitor and control all the process parameter, electrical interlocking, instrumentationprocess control, man and machine interfacing with on line data processing, Real timetrends, historical trends and report generation. Special attention is paid for humansafety and avoidance ofequipment breakage.

Calorific Value Analyser (C.V. Analyser) :

It is necessary to get stable gas condition, not only gas pressure but also calorificvalue of mixed gas for ignition furnace. Pressure of CO and Blast Furnace gases fluctuatebetween 250mmwc to 800mmwc and 250mmwc to 1200mmwc respectively.

Gas pressure is controlled at the point of inlet and after pressure control valvethe ratio of BF and C.O. gases is controlled using Calorimeter.

Gas Analyzer :

For better process control, it is necessary to monitor exhaust gases composition.The Advanced Optima gas analyser system is used to analyze SO

2, CO, CO

2 and O

2

of main exhaust gases of main ESP Stock of SP-3 PKG-I.

Opacity Meter :

For any modern plant, it is essential to monitor dust concentration in exhaustgases. Two nos. NNG , Japan opacity meters are installed for continuous monitoringof dust concentration at main ESP and Room dedusting ESP for SP-3 PKG-I and Two nos.

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Durag, Germany Opacity meter are installed at room dedusting system of PKG-II area.

Moisture Measurement :To improve quality and productivity, it is necessary to get accurate moisture

content in raw mix.

1. Infrared moisture measurement system MM55 is used for on line moisturemeasurement and control of raw mix.

2. 3 Nos. Nucleonic Moisture Sensor LB350 are used to add correct coke in rawmix Coke moisture compensation is required to achieve this requirement. 3Nos. Nucleonic moisture sensors are installed in coke hopper.

Belt Weigh Feeds :The quality of sinter product is strongly related to accuracy of the proportioning

of raw mix. Twenty four nos. of Belt Weigh Feeders of J&N (Schuck) are installed tocontrol the accurate proportioning of Iron Ore, flux, mill scale, flue dust, lime dust,coke, inplant sinter return, BF return.

Belt Weigher :To monitor material flow and total material passed through important belts, 8

nos. Belt Weigher have been installed in PKG-I.

15. WeighmentWeighment section is playing the most important role in Instrumentation &

Weighment department under Electrical Organisation. It deals with maintenance, repairand calibration of different weighing and controlling equipment for monitoring variousprocesses as well as accounting purpose.

Weighing systems based on state of art technology enable availability of rightand true information at the right time and at the right place for right decision making.These systems are highly accurate, reliable and user friendly and play a vital role inreal time process management systems resulting in improved production, productivity,product quality and operational safety.

Main functional zone :1. 2.5 MT zone (CO, BFs, SMS I, Mills, RMP I)

2. 4.0 MT zone (SMS II, RMP II, SPII, PBS, Plate Mill, OHP)

3. Other units inside the plant (BF yard, RM yard, Cold pig yard, Work Station, PPyard, OHS, PM yard, Steel yard)

4. Outside plant (Disposal stores, PP yard etc.)

Weighing systems installed :1. Mechanical type : 235 nos.

2. Electronic type : 385 nos.

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Some important weighing systems are :

1. Receipt and despatch road weigh bridges

2. Receipt and dispatch rail weigh bridges

3. BF cast house charging system

4. Bell less top bin weighing system

5. Batching system

6. Hopper weighing system

7. VAD tank weighing system

8. Weigh line in-motion weighing system

9. CDI injection vessel weighing system

10. Weighing system of Coal Silo

11. Bulk material charging system

12. Weigh feeders

13. Belt converyor weighing system

14. Bagging scale

15. Platform scale

Some (interesting) figures of weighment :

- Approximately 15000 T/day finished products and scrap are being weighedand dispatched through our road weigh bridges.

- About 3000 T/day incoming materials are being weighed by our road weighbridges.

- About 25000 T/day material s are being weighed by our rail weigh bridges

- About 15000 T/day raw materials are being weighed by our in-motion weighbridges.

- Approximately 15000 T/day finished merchant products are being weighed byour platform scales at Merchant Mill.

- At Ammonium Sulphate Plant, approximately 2900 bags are being weighedand packed in 50 kg pack per day by our bagging scale.

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INCOS

1.0 Introduction:

INCOS, the Integrated Control Systems department, deals with the automationand computerization in our plant. Since its formation in 1986, the department hasbeen playing a key role in implementing automation and computerization schemes inour plant and maintaining them effectively. The department plays a pivotal role inassimilating and adopting newer technologies in the ever-growing field of processautomation.

In the production units that have been modernised recently and the upcomingfacilities under the expansion plans, automation and control systems form an integralpart of the processes. Any problem in the automation system may result in the totalstoppage of the particular process. Hence, ensuring trouble-free functioning ofautomation systems is very much essential for the smooth running of our plant.

2.0 The Role of INCOS:

Study and identification of key areas of the plant for introducing computerization.

Conceptualizing automation schemes in consultation with process personnel.

Conducting feasibility studies and obtaining management approval for viableschemes.

Implementation of automation & computerization projects with appropriate finetuning.

Training of users

Extending technical support in maintaining the systems.

System upgrade as per process needs.

Providing data communication infrastructure for the plant and ensure inter-connectivity of the various systems.

In order to carry out these functions in an effective manner, INCOS needs tocontinuously keep itself updated with the current trends in the field of informationtechnology and process automation.

3.0 Range of platforms:INCOS handles a wide variety of hardware and software platforms in various schemes.

Computer/ Networking Hardware:MicroVAX, Alpha, SUN and HP servers, PCs, ATM /Ethernet switches.

Process level hardware:PLCs (Programmable Logic Controllers) of Siemens, ABB, Allen Bradley (Rockwell

Automation), L&T, Schneider, GE Fanuc etc. and RTUs (Remote Terminal Units) ofECIL and Micromax.

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Operating Systems: VMS, Solaris, Digital-Unix, Windows, Sco-Unix and DOS

Programming Languages :C, C++, FORTRAN, Visual Basic, Visual C, Java, JSP, ASP

Databases:Oracle, Progress, MS-SQL

4.0 Location

The main office of the INCOS department is located in the Fourth floor of IspatBhavan. The automation lab here, houses the SUN servers and one of the ATM(Asynchronous Transfer Mode) switches of the Plant wide Fiber optics networkimplemented by INCOS.

There are 4 Software Development sub-centers located at Blast Furnace-6 WelfareBuilding, Energy Centre, RSM and Plate Mill Welfare building.

5.0 A brief introduction to some of the major automation & computerizationschemes :

5.1.0 Coke Oven & Coal Chemicals Area (CO&CCD):5.1.1 PLC Based Controls of Material Handling:

The coal unloading, storage, blending and transportation to the coal towersin Coal Preparation Plant are controlled through 5 nos. of KELTRONVERSAMAC PLCs. The remote Input/Output stations are spread fromunloading area to the coal towers.

Coke transport route from batteries 9 & 10 to Blast Furnaces is controlledthrough SiemensS5-315 PLC. The system extension has been undertakenfor the complete route.

5.1.2 PLC Based Controls of Reversing Winches:The reversing Winches of Battery Nos. 4, 9 &10 are equipped with PLC systems.

The winches have hydraulic drive in Battery 4 & 10 and electrical drive in Battery 9.Siemens S5-100U PLCs are used in Battery 4 & 9 and S5-115H in Battery-10 withprograms in STEP5 software of Siemens.

5.1.3 PLC based Controls of Battery Machines:These systems are installed in Coke Pusher, Door Extractor Machines and Charging

Cars of Battery No. 10. All the operations of various mechanisms in the machines arecontrolled through these systems. The Coke Pusher has an operating station in placeof control desk. The PLCs are Siemens S5-135U with programs in STEP5 software.

5.1.4 PLC Based Control / Monitoring of Processes:

In PBCC (Partial Briquetting Of Coal Charge) Plant, having Conveyors, MixingDrum, Briquetting Presses etc., the total process is controlled through L&T's U84PLC with programs under PROWORX software.

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5.1.5 Coking Process Management System in Battery No. 10:

This system provides computerized battery heating in advisory mode, processmonitoring, pushing scheduling, historical data storage, reports etc. and runsmathematical models for these functions.

The system gathers process data from the following subsystems:

- DDC (Distributed Digital Control) system, on serial communication / Ethernet.

- Allen-Bradley's SLC-5/03 (PLCs) in Battery machines, on VHF communication /Ethernet.

- Portable Data Logger (for Flue Temperature measurements), on serialcommunication.

The required gas / coke /coal analysis data is also fed into the system.

The system has Digital's Alpha 2000/300 as host computer on OSF/1 platformand PROGRESS RDBMS. The other software used are C, DEC GKS etc.

5.1.6 Integrated Combustion Control System in Battery No. 3:

The system provides computerized battery heating in advisory mode, processmonitoring, pushing scheduling, data storage, reports etc. and runs mathematical modelsfor these functions. Rockwell's Control Logix PLC is used for front-end and data storage.The application is implemented using Rockwell's RS View and 'C' platform.

Batteries 5 & 6, presently under rebuilding and will be commissioned with state-of-the-art automation systems.

5.2.0 Ore Handling Plant (OHP)5.2.1 PLC Based Controls of Material Handling:

The raw material transport facilities from OHP to various areas in the plant havePLC based controls for sequential operations of the stacking and reclaiming routes.There are two Allen Bradley (Rockwell) PLCs in redundant mode, PLC-5/60 in JH-4and PLC-5/80 in JH-10. The operator interface (HMI) is RS View and programmingenvironment is RS Logix5. The remote Input / Output stations are spread all over thearea. The PLCs and HMI stations interface on DH+ data highway extending fromCR1 in SP3, through JH-4, to JH-10. Besides, there small PLCs installed in Stackers/ Reclaimers.

5.3.0 Sinter Plant - 2 (SP-2)5.3.1 PLC Based Control / Monitoring of Sinter Machine 4:

Allen-Bradley's PLC-3/10, with program under TOPDOC software, is installedfor sequencing and alarm annunciation functions for the machine and its relatedequipments.

Siemens S5-100U PLC, with hand-held programming terminal, is installed forcontrols of Exhauster-4 and its accessories.

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5.3.2 PLC Based Control / Monitoring of Priority Routes:

The priority routes form part of transportation system of coke from CO Batteries9 & 10, Ore from OHP and Sinter from SP-2.

The system consists of L&T's QUANTUM PLC in hot-standby mode with programsunder MODSOFT software and HMIs under PROCESS WINDOW software.

5.3.3 Proportioning Section Automation:

The blending of the raw materials for sinter making and its transportation to thestorage bunkers at sinter machine level are carried-out in the proportioning section,using Allen-Bradley's PLC-2/30. The programs are under TOPDOC software and theHMI application under Visual Basic.

5.3.4 Sintering Process Monitoring System:

This system provides facility for monitoring the sintering process of all four machinesand the proportioning area. It has Ethernet link from the control room of machines 3&4to the Shift Manager's Room, through control rooms of machines 1&2 and proportioningsection. HMIs, with programs under 'C' are provided for each of the machine in respectivecontrol rooms, proportioning section and the Shift Manager's room.

For data acquisition from machines, RTUs (Remote Termination Units) have beeninstalled for each machine and the data from proportioning area is taken from thePLC system installed for proportioning control Necessary data is made available onPlant Wide Network (PWN) also, for monitoring by senior executives.

5.4.0 Sinter Plant - 3 (SP-3)5.4.1 Integrated Control System (ICS):

This system controls all the equipment in the sintering process starting from thestage of raw material blending under the proportioning bins to the final stage ofSinter transport to Blast Furnaces. The application includes material handling as wellas the process control including PID control loops.

The system consists of 6 nos. of Siemens S5-155H PLCs, in hot-standby mode,with remote Input / Output stations spread all over the area. 5 of these PLCs areinstalled in ICS room in machine building and the sixth in the control room of rawmaterial handling area. The sixth PLC is mainly for interfacing of this system with thesystem of raw material handling. The programs are under APT and STEP5 software -APT for the main programs and STEP5 for communication among these PLCs andwith other devices / systems. The HMI stations are under PCS5 software on UNIXoperating system. One of these HMI stations has additional function of providingdata to the Supervisory Computer system. All the PLCs and HMI stations communicatewith one another on dual SINEC-H1 data bus. The system also communicates onserial link with the following systems:

- PLC system of raw material handling

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- Control system of air compressors

- Control system of electro-static precipitators

- Temperature scanners of MND, Compressors, Sinter Cooler Fans & Room De-dusting Fans

5.4.2 PLC Based Controls for Raw Material Handling:

The raw material receipt from OHP and feeding to the proportioning bins arecontrolled by this system. The system consists of 2 nos. of Allen-Bradley PLC-5/60,in redundant mode with programs under RS-LOGIX software and HMI stations underRS-VIEW software. All of these communicate with one-another on DH+ data highway.The data highway extends to the counterpart of this system in OHP.

5.4.3 Other PLC Based Controls:

Exhausters

There are 2 nos. of Exhausters; each with its own PLC based control system.The PLCs are Mitsubishi (Japan) make, in hot-standby mode, and control theExhauster and its related equipments. The programming is under its own ladderdevelopment software.

Sinter Sampling / Sample-handling at Area Lab.

The on-line sampling and sample handling operations at the SP3 Area Lab arecontrolled through a Siemens S5-100U PLC under STEP5 programming software.It is an operator triggered batch process.

DC Drive of Mixing-cum-nodulising Drum (MND)

This PLC system is for controls of the DC Drive of MND, along with safetydevices. The PLC is Siemens S5-100U and programmed under STEP5 software.

5.4.4 Supervisory Computer System:

The main application on the supervisory computer system is the 'OperatorGuidance System'. In addition, it also provides historical data storage, trending andMIS.

The main computer is Digital's Alpha 4000 with Open VMS operating systemand ORACLE RDBMS. The application programs are developed using Developer-2000& 'C'. The system has terminals in Sinter Bhavan, CR1, Area Lab., OHP & CCR(Central Control Room). The communication from Sinter Bhavan to Computer Room(in Machine Building) is on Fibre-optic (FO) Ethernet.

The computer system is interfaced with the following systems, on serial link, fordata collection:

- ICS

- PC of XRF Analyzer in Area Lab.

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5.5.0 Blast Furnaces (BF)

5.5.1 Charging System (Stock-house & Furnace-top Equipment) :

The stock-house charging automation system controls the raw materials weighing& batching in desired quantities, as per the charging pattern, and discharge into theskips.

The furnace-top charging automation system includes skips control, charge receipton furnace-top and its discharge into the furnace, stock level measurement in thefurnace etc.

The HMI stations are provided, in Furnace Foreman's Control Rooms (FFCRs)and Charging Operator's Control Rooms (COCRs), for process monitoring, reportsand charging pattern editing & downloading (to PLCs) functions. The customizedapplications like Pattern editing & downloading and reports application etc. areimplemented on a variety of platforms, e.g. 'C' / VB with flat files, VB with SQLdatabase, .NET with ORACLE database, VB with ORACLE database etc.

The systems installed, furnace-wise, are listed below:

BF#1 has Schneider's Modicon-QUANTUM PLC in hot standby mode, withMODSOFT programming environment and IC2000 based HMI.

BF#2 has Rockwell's PLC-5/80 in redundant mode, with RS Logix5 programmingenvironment and RS View32 based HMI.

BF#3 has Rockwell's Control Logix PLC in hot standby mode, with RS Logix5000programming environment, for stock-house and, Siemens S7-400 PLC in hotstandby mode, with STEP7 programming environment, for furnace-top charging.WinCC based unified HMI is provided for complete charging system and MS-SQL for Database.

BF#4 has Rockwell's Control Logix PLC in hot standby mode, with RS Logix5000programming environment and RS View SE based HMI, on server-clientarchitecture, with Oracle Database.

BF#5 has two sets of Allen-Bradley's PLC-3/10 in redundant mode, one eachfor stock-houseand furnace-top charging. The programming environment isTOPDOC-3. A unified HMI based on RS View SE is provided for charging andstove systems.

BF#6 has two sets of Allen-Bradley's PLC-3/10 in redundant mode, one eachfor stock-houseand furnace-top charging. The programming environment isTOPDOC-3 and the HMIs are Control View based.

BF#7 has a Siemens S7-400 PLC in hot standby mode, with STEP7 programmingenvironment. Unified HMI for charging, stove and furnace-parameter-monitoringsystems is RS View SE based, on server-client architecture, with Oracle Database.

In most furnaces, the VVVF drives, Soft Starters etc., installed with the electricsof equipment, are interfaced to the respective PLC systems on Profibus.

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5.5.2 Stoves/Hot Blast System:

The stoves automation system controls the operations of various valves beingoperated to switch from ON-GAS to ISO-GAS to ON-BLAST to ISO-BLAST to ON-GAS states. The state change is initiated from Control Desk in manual mode or fromDDC/Computer System in auto mode.

The systems installed, furnace-wise are listed below :

In BF#5, Rockwell's Control Logix PLC in hot standby mode, with RS Logixprogramming environment and RS View SE based HMI.

In BF#6, the systems installed are Allen-Bradley's PLC-3/10, in redundant mode,with TOPDOC programming. The commands initiation is from Control Desk .

In BF#7, the system comprises Rockwell's Control Logix PLC in hot standbymode, with RS Logix5000 programming environment and RS View SE basedHMI system. The commands initiation is from Control Desk.

5.5.3 Coal Dust Injection (CDI) System :

The CDI plants are installed for BF#1, BF#5, BF#6 & BF#7. The complete processthat includes coal pulverisation, conveying and injection into the furnace, is PLCcontrolled. Different systems installed for are listed below:

For BF#1 & BF#5, the system comprises 3 sets of Rockwell's Control LogixPLC in hot standby mode, one for coal dust preparation plant (CDPP) and oneeach for injection in BF#1 & BF#5. The system also includes monitoring ofimportant parameters of BF#1. The programming environment is RS Logix5000and RS View SE based HMI, on server-client architecture, with Oracle Databaseand Crystal Reports.

For BF#6 the system comprises Allen-Bradley's PLC-5/40, in redundant mode,with IPDS programming environment and SCAN3000 based HMI, on server-client architecture.

For BF#7, the system comprises Rockwell's Control Logix PLC in hot standbymode, with RS Logix5000 programming environment and RS View SE basedHMI system, on server-client architecture, with Oracle Database and RSBizware.

5.5.4 Coal Tar Injection (CTI) System:

The CTI plants are installed for BF#2 & BF#3. The complete plant operation,from tar storage to injection, is PLC controlled. Two identical systems are installed,one for each furnace. The system consists of Rockwell's Control Logix PLC in hotstandby mode, with RS Logix5000 programming environment and RS View SE basedHMI system, on server-client architecture.

5.5.5 Closed Loop Cooling (CLC), Gas Cleaning Plant (GCP) Systems:The CLC and GCP automation systems are, presently, installed for BF#7 only.

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The CLC system is for cooling of the furnace shell, tuyeres, stoves etc. and hastwo sets of Rockwell's Control Logix PLC in hot standby mode, one each inPump-house No. 53 and FFCR. The programming environment is RS Logix5000and RS View SE based HMI.

The GCP is for cleaning of the gases produced and furnace-top pressure control.It has one set of Rockwell's Control Logix PLC in hot standby mode, withRS Logix5000 programming environment and RS View32 based HMI system.

5.5.6 Slag Granulation Plant (SGP) :The process in Slag Granulation Plants in BF#4&5 are PLC controlled.

The systems installed are listed below:

The SGP of BF#4 has Siemens S5-150U PLC with STEP5 programming. Thesystem will be shortly replaced with Siemens S7-400 PLC with STEP7programming and WinCC based HMI.

The SGP of BF#5 has Siemens S5-135U PLC with STEP5 programming.

Most of the systems have Ethernet interface between the PLCs and the HMI system.

5.6.0 2.5 MT Mills Zone:

5.6.1 Flying Shear Automation in BBM:

This involves synchronization of flying shear speed with Stand#10 speed foraccuracy in cut length and prediction of final billet length, selection of optimum cutlength for cut length optimization within a given range of allowances to improveyield. This is a PLC-based system with three modes of operation namely: Auto+Tailtracking, Auto and Semi-auto.

5.6.2 Ingot Buggy & Roll Table Automation:

Ingot buggy is the most critical equipment for feeding ingots to be rolled inblooming mill. The automation involves a PLC with thyristor convertor for generatorfield. The system helps in:

Reduction in average travel time

Smooth acceleration and deceleration

Improvement in life of equipment

Curtailing of idle running of roll tables resulting in energy conservation

5.6.3 Bloom Tracking System - Computerised Hot stamping M/c:

The system tracks complete bloom information from feeder zone to Hotsawzone. This information is automatically (on-line) transferred to the computerized Hotstamping M/c.

The system comprises of a network of PCs with Xenix server and DOS basedclients. The entire application is developed in 'C' programming language using client

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server concept.

The HSM is based on Siemens PLC 115 U for overall control and SX-1 systemfor synchronization and positioning of stamping head on Rail. Hydraulic controllersand servo drives are provided for actuating and driving various mechanism of themachine.

5.6.4 Long Rail Finishing and Long Rail Welding Automation

Long Rail Finishing and Long Rail Welding, the addition to existing 'Rail ProductionFacilities' have the state-of-the-art automation technology. The automation has beenimplemented in three layers for effective control.

Level-0 comprises a number of field sensors and Digital drives.

Level-1 PLCs provide the basic control for logistics and process equipments.The PLC system involves

PLC Central Processing UnitsRemote I/OsProfibus NetworksEthernet data Networks

Human Machine Interface(HMI) units, both types, client-server and stand-alone

Functions controlled through PLCs are:

Receiving Roll Table controlPre-camberingCooling-bedRail extraction from cooling bed and transportation to RRSMRolled Rail Straightening Machine (RRSM)

Transfer Bed movement and associated Roll tablesCleaning StationCompressorsLaser ControlUltrasonic Probe actuationsEddy current Probe ActuationsNDT Water system controlUT and ECT Hydraulic power systemUT and ECT electronic interface80m Rail Handling(telphers)4-D hydraulic PressesCarbide Saws

Before Welding cleaning stationWelding machinesWelding transfer bed and roll tablesGrinding station

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4-D Hydraulic press after welding260m Rail handling (telphers)Other auxiliary units supporting process and logistic operations such as hydraulicpower supplies.

Level -2 : 'Rail Tracking System', based upon redundant server and workstations,facilitates

Rail-Id generation for each long rail entering for long rail finishingAutomatic Tracking of rail, based on generated Rail-id till the dispatch.Distribution of Rail-id to process equipmentsExchange of process/test data with process equipment.Exchange of process/test data with Bloom Tracking System in rail rolling.

Server software is written in Visual C++ in Window2000 environment. Oraclehas been used for Database. Workstations are based on Visual Basic.

Data Network, comprising 6 nos. 24-port switches and fiber optic cables,facilitates process data communication among systems/sub-systems on Ethernet.

NDT System : Long Rail finishing has following Non-destructive testing(NDT) facilitiesfor each and every rail.

Ultra Sonic Testing - Volume Testing for non-metallic inclusions.Eddy Current testing - Surface testing for cracksLaser Straightness Measurement - Horizontal and VerticalRail Straightness checking.

The NDT consists of sophisticated electronic system and servers based on QNXReal Time OS for fast processing.

5.6.5 PLCs in other areas of RSM :

1 ABB MP240 RSM RRSM setting 2 ABB AC800M RSM RRSM Speed refrencing 3 ABB APC RSM RRSM Drive interlocks 4 ABB AC110 RSM Finishing stand control 5 L&T R84H RSM 2D Lub & Hyd control 6 Siemens S7 300 RSM Mill Monitoring 7 Siemens S5 115 RSM Comp HSM 8 Siemens S5 115 RSM Cooling Bed Control 9 Rockwell SLC RSM Thyristor logic 1D

10 Rockwell SLC RSM Thyristor logic 2D 11 Rockwell SLC RSM Thyristor logic 3D 12 Rockwell SLC RSM 26 M welding machine 13 Siemens S7 200 RSM ECT

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5.6.6 On-Line Rail Inspection System:

Ultra Sonic Flaw detection system is for on-line detection of volume defects inthe rails. Since large amount of data are to be processed in short span of time,parallel processing on transputer network is used.

Eddy current system is for on-line detection of surface defects in rails. Thesystem is based on VME system architecture.

5.6.7 Roll Turning Shop:

2 Nos. of CNC lathes ( 35 Ton and 30Ton) are working in Roll Turning shop. Controlsystem of the machines are based on Siemens 840 D and S7-300 PLC systems.

5.6.8 Mechant Mill :The major PLC systems functioning in MM are:

1 Siemens S5 135 Mill monitoring and interlocks WinCC HMI

2 Siemens S7 313-1DP Main Drive(1-12) process monitoring

3 Siemens S7 313-1DP Bifurgate entry auto control 4 Siemens S7 315-2DP Housing less stamd(9,10,12)

5.6.9 Wire Rod Mill :WRM - C & D Strand Automation:

The System comprises 6 Nos of Rolling Mill Computers (RMC) , 5 Nos.Processing Stations and 1 No. of Operator Interface. These RMCs are interconnectedover Ethernet. This Network uses MB 300 network software for realizing criticalinterlocking and data exchange among different areas on real time basis.

Major system functions are:Speed cascading

Auto cobble monitoring

Shear control

Reform tub Equipments control

Finishing area control

Technological Utility control.

Mill configuration

Status & Event monitoring/ logging

WRM - B Strand Automation:B-Strand automation is upgraded as part of B-strand modernization. The system

is based on ABB AC450 and AC800 PLC systems. The major functions of automationare the same as those for C&D strand automation. HMI, based on a client-serverarchitecture, consists of redundant Window 2000 servers and window-xp workstation.The other features are :

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- ABB Industrial IT is the basic system and environment for HMI.

- Domain Controller to enhance the security of the system and application.

- Usage Distributive programming language to provide ease of maintenance.

5.7.0 4 MT Zone:5.7.1 L D Automation System:

LD Automation system helps in monitoring and controlling parameters like Oxygenquantity, lance height, lime addition, Hot metal & scrap weights, hot metal temperatureetc. that influence the steel making process in the Basic Oxygen Furnaces.

The hardware consists of MicroVAX 3400 system at supervisory level, MP200Programmable Logic Controllers of ABB, TOSDIC 247 Distributed Digital ControlSystem, Automatic Crane Weighing System and DIGITEMP-E hot metal temperaturemeasurement system at the process level.

The system helps in improved hit rate, reduction in the specific consumption ofraw materials, accurate prediction of steel weight, tapping temperature etc resultingin improved productivity and leads to better shop management with an efficientManagement Information system.

5.7.2 Major PLC systems functioning in SMS-II :

1 ABB MP240 Conv Lance control for conv A

2 ABB MP240 Conv Lance control for conv B

3 ABB MP240 Conv Lance control for conv C

4 ABB CS32 Conv

5 Siemens S5 155 CCS RH maincontrol Siemens HMI

6 Siemens S5 155 CCS RH Aux

7 Siemens S7 317 CCS RH main burner

8 Siemens S5 95 CCS RH Ejector cleaning System

9 Siemens S5 155 CCS RH Pump House

10 Rockwell '5/80 CCS LF control(Hot Stand By CPUs) RS –View/LINX

11 Siemens S7 318 CCS VAD

5.7.3 Plate Mill :Hydraulic Automatic Gauge Control (HAGC) and PVR:

Plate Mill control in rolling area has been upgraded to cater to the HydraulicAutomatic Gauge Control (HAGC) and Plan View rolling(PVR). As Hydraulic controlwill provide fast and dynamic adjustment of roll gap during plate rolling passes, 2Nos. of HIPAC PLC system, with 2 CPU in each, capable to provide 1 ms scan timeresponse and necessary fast and precise acting PID control has been installed andworking. Apart from the HIPAC PLC system, 2 Nos. of S7-400 PLC system,one forrolling mill logistic equipments and hydraulic power generation are operational. TheHMI used is 'Wonderware' based on dual OPC server system.

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On-Line Ultra Sonic Testing Machine:The system is used for detecting internal defects in the plates. It consists of full

body scanner, edge scanner & 45 Degree scanner supplied by M/s Scanmaster. Thesoftware decides the internal soundness of plate on the basis of nature and numberof defects automatically.

Paint Marking Machine:The system paints Plate ID, Dimension, Specification & Destination on Plates in-line.

Plate Stamping Machine:There are two number of PLC based, Plate stamping machine. It punches Plate

number and Heat Number on Cold Plates on line. The marking data are fed by operator.

5.7.4 Order Processing and EXecution ( OPEX ) System:The OPEX system helps in tracking and processing of orders for 4 MT area right

from order placement to despatch. It also helps in on-line documentation includinggeneration of Test Certificates(TC) and Despatch Advices(DA). OPEX is a total in-house solution right from conceptualization to implementation. The system has beenimplemented over Plant Wide Network (PWN) in the 4.0 MT area.

The Database is built using Oracle 9i deployed on SUN 480R Server with SOLARISOperating System. Application Software has been developed using Oracle Forms,Reports & JSP. The application resides in the Oracle Application Servers at theMiddle Tier. The system is also deployed in the Client/Server mode for fallback.

The journey of Data begins with automatic capturing of order information fromSRM/CMO/MKTG and culminates in Despatch Advice (DA) and Test Certificates (TC)to Finance Dept. for Invoicing. In the Process, the system handles Order Processing,Production Planning, Execution & Monitoring, Despatches and Quality Management.Major clients of OPEX are: SRM, Marketing, PPC, SMS-II, PLATE MILL, RCL & TrafficDepartments.

OPEX is connected to other systems like OASIS, TRAMS, VAX, BTS, HMMS,UST System and HAGC of Plate Mill for further data processing.

The System is covered under ISO: 9001:2000 Quality Management System.

ISO:9001 QMS is to ensure error free working of the system through variousstandard operating procedures for system operations like backup, modifications &development, testing & validations, security handling and attending customercomplaints. This certification undergoes intra-plant, sister plant and finally LRQAaudit on regular basis since 1994.

5.8.0 Services Zone:5.8.1 Computerised Energy Management System (CEMS):

CEMS provides a centralized facility for round-the-clock, real-time monitoring ofthe generation and distribution of various energy forms. The energy forms include:

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by-product gases, oxygen, steam, nitrogen, and compressed air. Around 500 field-signals of flow, pressure, temperature and level measurements at various points inthe plant are connected to the system for monitoring.

CEMS consists of 10 Remote Terminal Units (RTU) installed at Coke Ovens,Power Plant-2, Plate Mill, SMS-1, OP-2, Rolling Mills, PBS, Energy Centre, CAS-3and SP-3 to acquire process data from the field on a continuous basis. These RTUsare connected to the Alpha and Sun server computers at Energy Centre. Operatorstations have been provided in Energy Centre, PBS, PP-2, OP-1, OP-2, SMS-1, PLEMand Compressed Air Dept for on-line monitoring facility.

The software has been implemented on Digital-unix and Solaris operating systemson the server side. Oracle RDBMS has been used for data storage. The applicationsoftware has been developed in C, C++ and Java languages.

The energy despatchers are presented with the entire energy scenario of theplant at any given moment in terms of mimics, trends, alarms and on-demand reports,thus enabling them to take corrective action. Prediction models also have been providedfor certain energy forms. Periodical reports and historical trend analyses provide aneffective Management Information System (MIS).

The system is being upgraded with ethernet-compatible RTUs and state-of-the-art servers.

5.8.2 Power Consumption Monitoring System (PCMS):

The system provides real-time monitoring of critical power parameters and thestatus of EHT lines, 11/6.6 KV feeders and Circuit Breakers. It monitors the status ofload flow of BSP with inputs from four incoming lines from CSEB and BSP's captivepower plants. PCMS consists of 5 RTUs at MSDS-1, MSDS-2, MSDS-3, PBS and PP-II, all linked to the Data Concentrators (DCs) and DataBase server (SUN) in MSDS-1.

The system obtains energy parameter inputs through RS-485 compatible tri-vector energy meters (ETVMs). The exact power consumption of all the productionshops can be obtained through PCMS. The connectivity between the load centers -MSDS-I, II & III and PP-I & II has been obtained through the optical fibre network

PCMS has been highly useful in Maximum Demand and Power Factor Control.On-line graphs indicate the instantaneous maximum demand from CSEB. If the demandexceeds the set limit an alarm is generated. This helps Shift Managers of PSD toinitiate necessary action to control the demand through load-shedding, load-schedulingand staggering of arc furnace loads. Thus BSP is able to effect financial savings withthe help of PCMS in maximum demand charges.

The major advantages of PCMS are :

Maximum Demand Control

Quick Remedial action in emergencies

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Effective analysis of breakdowns

Web-based MIS on Power distribution in BSP

On-line information of the entire Power System Network.

5.8.3 Traffic Management System (TRAMS) :

BSP uses Indian Railways' wagons to receive raw materials like iron ore, coal,Lime Stone etc. from external sources and also to dispatch saleable Products likePlates, Rails, Merchant products, wire rods etc. to various destinations across thecountry. All aspects regarding the movement of wagons is controlled by Transportand Diesel Department (T&D) of BSP. T&D also arranges for locomotives, internalwagons for production area like Blast Furnace, Open Hearth, SMS-II for movementsof semi finished products , hot metal and slag.

TRAMS is a computerised system implemented on a SUN E-450 server with 26nos. PCs at user end & 7 shipping terminals (dumb terminals) connected on ClientServer networking architecture using TCP/IP protocol. The software runs with ORACLEat the back end on Solaris Operating system.

The system helps T&D department:

Have better control on wagon movement with the help of data available on-line& computerised commercial activities.

Various on-screen queries are also available enabling right decisions at the right time.

Tminimize wagon detention and demurrage.

System also integrates 5 (five) different weigh-bridges with TRAMS using acommon GUI.

5.8.4 Computerised Receipt Note Preparation System (CRENS):

The raw materials are received in railway wagons every day but the RailwayReceipts (RR) arrive only subsequently. CRENS does the job of matching the wagonsreceived with what is mentioned in the RR. Reports are generated regarding theunlinked wagons and RRs for taking up with Railways for settlement. The systemhas been developed over an Ethernet LAN of PCs installed in the Raw MaterialsDepartment. The delays in preparation of Receipt notes have reduced considerablyafter the implementation of the system.

5.8.5 ATM based Plant Wide Fiber optic networking (PWN):

There are a number of heterogeneous computers used for various applications inthe plant. "ATM based Plant Wide Fiber Optic Cable Network" provides aninfrastructure to take care of the connectivity requirements of not only these systemsbut also the future communication needs.

This network forms a high-speed backbone connection using three ATM switcheslocated at strategic locations of the plant and single mode fiber cable, connectingfive nos. of Layer - III (Routers) switches to the ATM switches for providing connectivity

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to 44 nos. of layer-2 Ethernet switches in various locations of the plant. Major areasof the plant are now covered under one physical network with a large number ofcomputers connected to it. To have better connectivity and faster communicationamong a large numbers of computers, the network is logically subdivided into anumber of smaller logical and functional networks. These logical networks are calledVLAN (Virtual Local Area Network).

Some of the process control systems like: WRM automation network, BF6 datahighway, Bloom Tracking System, Soaking Pit LAN, SP-3 DAS, Power ConsumptionMonitoring System (PCMS), Energy Management system (CEMS) etc. are connectedto the network.

All the seven PPC control stations namely, Plant control, Heat Cell, BBM productioncontrol, CO production control, BF production control, SMS-1 production control andSMS-2 production control are on the network, sharing information online.

All employees are provided with e-mail accounts so that they can access theirInternet mails through the sail-bhilaisteel.com server established at Bhilai Steel Plant.Each user account has been provided with 10 MB mailbox space.

As the Plant wide network provides better accessibility to major servers /applications like: MMIS, CMMS, HRIS, Order Progressing, OPEX, TRAMS etc., thereach of the existing tasks has improved.

5.8.6 Heat Movement Monitoring System (HMMS):

Heat Movement Monitoring System is a Production Information application. Theprimary objective of HMMS is to keep track of steel heats made in SMS-1 fromprocessing to tapping and then tapping to finishing at various mills like BBM, MM,WRM and RSM. The application covers the entire quality process including: declaringthe finished grade, recording of all testing activities and test results.

The major activities of HMMS:

Data recording of all production related activities from SMS-I to Mills

Process Control and Testing Activities of RCL

Electronic Memo for supply of Heats for all shops.

Checking of Heat Quality and Tonnage at various Stages of production.

Yard Activities and Stock Inventory.

MIS Reports

Yard activities:

Identification and material balance of desired product

Provide information on

☯ Material receipt / Deliveries

☯ Current inventory

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☯ Item-wise stock

☯ Grade-wise stock

The following are some of the benefits of HMMS:

Effective online Monitoring of processing and finishing.

Automatic Heat Number Generation.

Heat History or Current Status of any heat

Ready Yard Status.

Reduction in Manual entries

Reduction in time duration of activities & calculation errors

Improvement in daily MIS reporting and weekly & monthly reporting.

Accurate material balance

Improvement in testing process.

Transfer of Data From Sample Analyzers (Spectrometer) of SMS-1&2

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CIVIL ENGINEERING DEPARTMENT (OPR)

The basic function of Civil Engineering Department (Opr) is repair and maintenanceof Plant Buildings, Roads, Sanitary installations and its modifications as per requirement.The following are Important functions of this department :

Repairs and maintenance of all types of buildings, equipment/machinefoundations, roofs of all buildings and structures of various units of Bhilai SteelPlant in works area including underground cable, tunnels, water tunnels andlubrication tunnels.

Carrying out all Civil Engineering jobs during Capital Repairs of various operational/Productions Units of Bhilai Steel Plant.Annual maintenance various buildings, canteens, structures etc. by way ofpainting of structures, sheets changing work, dust cleaning, white washing,colour washing, distempering, etc.Carrying out renovation and modification jobs as sanctioned by the Managementfrom time to time and as per requirement of various departments of the plant.Proper upkeep and maintenance of Plant perimeter wall/ patrolling track andPlant roads.Proper upkeep of all works office buildings and rest shelters and canteenslocated inside the plant perimeter walls.Proper upkeep and maintenance of all sanitary installations all over the plantincluding maintenance of drinking water supply lines inside the buildings.General cleanliness and upkeep of the plant.Maintenance of nurseries/ gardens, fountains, cactus house etc. and ensuringoverall greenery of the plant by Horticulture Unit.Arranging various functions in connection with VIP visits (State as well Centrallevel Ministers and other dignitaries).

Due to ageing of the civil assets inside the plant area, the work load of CED(Opr) has increased tremendously due to the last few years.

Functions mentioned on the overleaf are being performed by various zones of thedepartment as under :

(i) ZONE 1 : Rolling Mills of 2.5 MT area i.e. BBM, RSM, WRM, T&D Orgn, MachineShop III (MARS III), Slag Granulation Plant, Roll Turning & Repair Shop, etc.

(ii) ZONE 2: Auxiliary Shops & Steel Zone (2.5 MT stage) i.e. SMS I complex, Aux.Shops like Foundry Shop, Sand Processing Plant, Machine Shop I (MARS I),Forge & Steel Structura Shop, Elect. Repair Shop, Auto Repair Shop (PlantGarage/PVP) etc of inside the Plant Perimeter wall and Aux. Buildings outsidethe perimeter wall e.g. Telephone House, HRDC, Central Fire Station, CISFMain Gate wing, etc.

(iii) ZONE 3 : Blast Furnaces, SP I, RMP I, Ladle Repair Shop, Pig Casting Machine,and Power & Blowing Station I etc.

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(iv) ZONE 4 : Coal Chemicals Department and its Bye Products, Ammonium SulphatePlant, Benzol Recovery Plant etc.

(v) ZONE 5 : Plate Mill, Machine Shop-II (MARS-II) area.(vi) ZONE 6 : Continuous Casting, Converter Shop, OHC, Sanyantra Bhawan, and

Boria Storage Complex, Boria Gate etc.(vii) ZONE 7 : Power Plant II, SP III, Oxygen Plant II, and Ore Handling Plant, etc.(viii)SERVICES : This zone maintains the Plant Roads, daily sweeping of roads,

sanitary installation, cleaning of group toilets, shop floor toilets and toiletssituated inside the Building, Works Office Buildings including rest shelters, etc.This zone has been devided into three major groups viz

a. Road Services b. Security Services c. General Services

ROAD SERVICES - cater the needs of construction of new roads, repair & maintof roads about 80 KM length in 2.5MT and 4.0MT area of the plant.

SECUTIRY SERVICES - is meant for repair and maintenance of boundary wall,Patrolling track, including repair & maint of CISF & R/way Gates.

GENERAL SERVICES - i.e. Cleaning of about 50 WOBs, 135 Group toilets, 175Shop floor toilets and 220 toilets situated inside the Bldgs. (total 530 Nos.)

SERVICES-I is responsible for 2.5 MT area whereas

SERVICES-II is responsible for 4.0MT Expansion area of the plant.

(ix) BUILDING SERVICES & REPAIR SHOP : This workshop is mainly responsible tofulfill the wooden requirements of various operational/ production units likeRefractory Engineering Department. In addition, it undertakes repair of officefurniture, rolling, shutters, repair/ replacement of rain water gutters of variousdepartments, manufacturing, repair and maintenance of road side grills, windowgrills, etc.

(x) PLANNING : Planning of civil jobs for various departments, preparing & processingcontact proposals, execution and supervision of contracts after award ofcontracts for civil works.

(xi) TECHNICAL SECTION : Material planning and procurement of various civilconstruction and maintenance materials required for use in different Zones ofthe department for all the Works Departments inside the Plant Area.

(xii) HORTICULTURE : Maintaining nurseries, gardens, fountains, aquariums, lawns,etc. and developing greenery inside the plant area. Preparations in connectionwith VIP visits i.e. State as well as Central level VIPs, etc.

(xiii) CIVIL INSPECTION GROUP - Inspection of various civil structures inside theplant, preparation of list of such defects and present it to the concerned officialsfor its timely repairs.

(xiv) Various Training activities pertaining to Civil Engg. Deptt. (Opr)

(xv) Matters related to Departmental Safety (DSO)

The Main Office of this department is situated at Works Office Building # 2(ground floor), near Main Gate opposite Main Medical Post I and site offices arespread all over the plant at about 15 locations.

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BUILDING STRUCTURAL INSPECTION ANDSURVEY GROUP

Building Structural Inspection and Survey (B&SI) is a Central Group under TechnicalServices of Mechanical organization. It takes care of the following:

Periodic inspection of Building and Structures in units of Plant and Mines, touncover conditions leading to structural break down.Major structural items inspected are columns, under-crane girders, platforms,roof trusses, conveyor galleries bottom chords etc.Inspection of dust accumulation on the roofs, condition of painting of structuresin corrosive areasFollow-up of all major structural defects; their rectification taken up by repair agencies.Survey: Fulfils geodetic and engineering survey requirements of Shops &Maintenance Organization to restore the position of equipments, structures,furnaces, and pipelines etc., which get miss-aligned in course of working. Specialassignments are OH/EOT cranes tracks, casting machines pinch rollers, cokeoven batteries, sinter coolers etc.Painting of Steel Structures of structure houses of Plant, gas pipe lines ( diabelow 400mm & above 400mm) are also now entrusted to this section.

Functioning :

The yearly Inspection schedule for Building & Structural Inspection Section isprepared in consultation with the Shops. Frequency of inspections is fixeddepending on the condition of structures.Inspection of major structural members are conducted jointly by therepresentatives of B&SI group & Shop. Inspection of less important areas andtheir follow up is done by shop representatives.The defect lists are prepared and fed online through CMMS module for informationto the Shop and repair agencies. Structural defects are categorized dependingon the seriousness as Priority-I, Priority-II & General.A consolidated inspection report for major structural defects, after categorizingdefects under urgent and alarming category, is prepared in consultation withmaintenance Heads. A special budget is sanctioned to B&SI Section to supportthe Shops in liquidation of structural defects.Roof condition is checked for dust accumulation and for water leakage throughCGI sheets before monsoon in the month of April and defect list is communicatedto the respective Shops & repair agencies. Roof condition is again checked inthe month of Novemember.Painting of above steel structures are done in classified manner depending uponthe severity of corrosiveness i.e. nominal, moderate & severe. And norms forsurface preparation & painting IS/IPSS Standard are being followed.

STRUCTURAL INSPECTION ACTIVITIES

PREPARE ANNUAL STRCTURAL INSPECTION & ROOF DUST INSPECTIONSCHEDULE OF ALL THE SHOPS.

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INSPECT BUILDING STRCUTURES AS PER THE ANNUAL PLAN & ALSO ONDEMAND OF VARIUOS SHOPS.FEED ON LINE WITH CATEGORIZE OF STRUCTURAL DEFECTS.INTERACT WITH SHOP OFFICIALS FOR RECTIFICATION OF CRITICAL DEFECTS& FOLLOW UPS FOR EARLY LIQUIDATION.STRC.PRESENT SERIOUS STRUCTURAL DEFECT IN ED (W) WEEKLY CORDINATIONMEETING.PROCESS FOR SPECIAL BUDGET FOR ATTENDING CRITICAL DEFECTS THROEBSI AS A SUPPORT TO THE SHOP.INSPECT ROOF DUST BEFORE MONSOON AND FOLLOW-UP IT'S REMOVAL.INSPECT RAJHARA & NANDINI MINES STRUCTURES ON THEIR REQUIRMENTS.CONDUCT SPECIAL INSPECTION CAMPAIGN BEFORE CAPITAL REPAIR INMILLS, BF ETC.

NEW ACTIVITIES INTRODUCED

STEEL CHIMNEY REPAIR & ARC SPRAY AL COATING.

PIPE LINE SUPPORT REPAIR.

GALLARY BOTTOM CHORD, TRUSS, OVERHEAD WATER TANK PAINTING.

ELECTRONIC TOTAL STATION SURVEYING INSTRUMENT

Survey Activities:

The work orders for survey jobs during Capital Repair and major repairs are sentby the of Shop maintenance /Central maintenance Department. Routine surveyrequirement is taken up as per availability of group and criticality of the job.Survey of crane girders, crane track, wheel alignment is done for manufacturingof new crane/ revamping of crane.In Coke oven Batteries, alignment of anchor column, armor frame & level ofmachine track are checked. Heating & regulation of batteries are also monitoredby survey.Checking of chimneys for their verticality.During Capital Repair of Slab/Bloom caster, pinch roller alignment is done withthe help of survey This is an important activity of the section as accuracy ofalignment of pinch rollers have direct bearing on the quality of slab.For maintaining equipment in healthy condition, survey help is provided forleveling and proper alignment of equipment during Capital repairs and othermajor repairs.For erection of new equipment, reference lines are fixed and given by Surveysection as per coordinate of the shop

Scope:

STEEL Structures such as columns, column foundation, crane runway girders,brake platforms, roof trusses, roofing and other building steel structures, riveting,bolting, and welding joints are within the scope of this section. However gas mains,boilers, furnaces, batteries, bunkers, civil structures, RCC works etc. are not withinthe scope of this section.

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ENERGY MANAGEMENT DEPARTMENTEnergy Management Department (EMD) basically looks after the management of various

liquid and gaseous fuels in the plant. The department comprises the following sections:

1. B.F.GAS CLEANING PLANTS

2. ENERGY CENTRE

3. LIQUID FUEL STATIONS

4. GAS SAFETY SECTION

5. ENERGY SECTION

6. MAINTENANCE (Mechanical & Electrical).

B.F.GAS CLEANING PLANTS :

Each Blast Furnace has its own gas cleaning plant. The raw B.F. gas from BlastFurnaces carries a dust load of 25-40 gm/M3. More than 50% of the dust gets separatedout of the dry dust catcher. The raw B.F. gas contains about 10-15 gm/M3 of dust at theinlet of the scrubber. At the scrubber, gas travels from bottom to top and water spray tothe extent of 8001200 M3/hr is given through nozzles located at four levels. From thescrubber, the gas passes through a set of parallel ventury atomisers. Water spray isgiven at the ventury throat where again the dust is entrapped.

In the final phase of gas cleaning the gas passes through two parallel electrostaticprecipitators. The clean B.F. gas contains dust less than 10 mg/M3. In the gas cleaningplant the temperature of B.F.gas is brought down from about 180°C-250°C at theinlet to about 35 ± 5°C at the outlet.

A group of throttles called the throttle assembly (located in the semi-clean gascollector, before the electrostatic precipitators) helps in maintaining constant top gaspressure at the Blast Furnaces.

A 600 mm dia pipeline called the 'equalising main' carries the high pressure gasfrom scrubber top to inter bell space of Blast Furnaces. This helps in smooth operationof the bells/ upper seal & lower seal valves at the Blast Furnace.

The slime water goes to a set of radial settling tanks to settle down the dustfrom water. A set of cooling towers is used to bring down the temperature of circulatingwater to 30-35°C. In addition to the above regular equipment, B.F.No.7 gas cleaningplant has three Paulworth gas boosters which supply high pressure semi-clean B.F.gas to furnace top equipment for cooling the BLT gear box, in case of non-availabilityof Nitrogen.

2. ENERGY CENTRE :

Energy Centre is responsible for proper distribution of available fuel gases viz.B.F., C.O. and L.D. gas to all consumers. Since there are no gas holders for C.O. gasand B.F. gas, the network pressure is maintained by balancing the "Gas Make" and

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the consumption, continuously. During periods of surplus availability, the gases areburnt in high-pressure boilers. During shortages, restrictions are imposed on consumersas per priorities approved by management from time to time.

(a) Gas Mixing Stations:There are seven Gas Mixer Stations maintained by E.M.D. :

1. Rolling Mills

2. Sinter Plant-1

3. Sinter Plant-2

4. Sinter Plant-3

5 Plate Mill

6. Normalising Furnace

7. Coke Oven Batteries 9 & 10

A part from these, gas mixing is done for stove heating of B.F.Nos.-1, 2, 3, 5, 6& 7, as per requirement.

These are automatic mixing stations where B.F. gas and CO gas are mixed in adesired ratio based on principle of ratio controller (proportional mixing). Minoradjustments are carried out from time to time based on the calorific value of individualgases and the desired calorific value of mixed gas.

(b) Gas Booster Stations :

The reheating furnaces of Rail & Structure Mill, Merchant Mill and Wire Rod Millrequire high pressure gas suited to injection type burners installed at those furnaces.The mixed gas is boosted to a pressure of 1800 mmWC from 450 mmWC. There are6 boosters, and each has a capacity of 40000 M3/hr; they are fitted with 350 KWsquirrel cage type drive motors.

Similarly gas boosters are provided for Plate Mill and Normalising Furnaces toboost the gas pressure to 750-850 mmWC. The capacity of boosters are, 3 of 12000M3/hr & 3 of 40000 M3/hr each for Plate Mill, and 2 of 18000 M3/hr each forNormalising Furnace.

(c) L.D. Gas Holder :

A wet type of Gas Holder with working capacity of 40,000 Nm3 to sustain apressure of 350 mmWC is provided for recovery and storage of L.D. gas, of C.V.1700-2000 Kcal/M3, which is produced during steel making in Converter. The gas iscooled, cleaned and then collected in the Gas Holder. The yield of converter gas is85-90 Nm3/T of liquid steel. five boosters of 12000 M3/hr each are provided to drawthe gas from gas holder and pump to CO Gas Network. Before injection, the gas iscleaned by Three Electrostatic Precipitators.

The injection of L.D. gas in CO Gas network has duel advantage. Apart fromchecking the atmospheric pollution, L.D. gas meets and maintains the supply of CO

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gas to consumers, whenever yield from Coke Oven Batteries fluctuates.

3. LIQUID FUEL STATIONS:(a) For Pitch Creosote Mixture (PCM) :

There are two underground storage tanks of 500 KL capacity each, for storingpitch creosote mixture (Liquid Fuel produced at the by-products plant). Three electricpumps are provided for pumping liquid fuel to twin hearth furnaces and to boilers ofPower Plant-1 and Rotary kilns of Refractory material plant-1.

The liquid fuel is kept circulating in the network all the time. Surplus quantity ofliquid fuel comes back to the tanks by the return line. Steam heaters have beenprovided in the storage tanks, and in the unloading channels, electrified heat tracingin the pipe line network is also provided to keep the liquid fuel in hot flowing condition(with proper viscosity).

(b) For LSHS/FO :

Petroleum based Low Sulphur Heavy Stock (LSHS) Oil is used as for firing in RMP-II Lime Kilns. LSHS is procured from HPC/ IOC and is stored in the two 2000 KL Tanks.It is pumped continuously to RMP-II. LSHS is semi solid at room temperature. Heattracing system is incorporated from unloading upto the burners on the fuel system.

4. GAS SAFETY SECTION :

The objectives of Gas Safety Section are as follows :

i) Prevention of hazardous conditions leading to gas poisoning; fire and explosionsin gas lines, equipment and connected accessories.

ii) Updating maintenance method to avoid hazardous conditions in the gas networkand gas hazardous aggregates.

iii) To create awareness among all working people about the basic principles ofgas safety.

iv) Quick liquidation of hazardous conditions.

v) Scheduled and emergency monitoring of gas hazardous places in the plant for

presence of Carbon Monoxide in the atmosphere.

vi) Maintenance and repair of Oxygen Breathing Apparatus / Gas Mask.

vii) Standby duties and giving job clearances at the shop floor level.

5. ENERGY SECTION :

This comprises an expert group specializing in energy auditing and monitoringwork in the plants. Based on findings, the group suggests remedial measures toshops in order to bring down energy consumption.

An Energy Centre has been setup, in order to closely monitor and control allenergy parameters in the plant, in a central location.

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The group identifies areas for Energy Conservation and gets them implemented,and helps in bringing down energy rate to the target value.

6. MAINTENANCE (MECHANICAL & ELECTRICAL) :

This section looks after the maintenance of all mechanical and electrical equipmentprovided in the gas network, gas cleaning plants, gas mixing stations, gas boosterstation, gas safety station, liquid fuel station and L.D. gas holder.

In addition to above, repair and maintenance work on gas line and equipments iscarried out by this section alongwith gas safety expert group, as and when needed.

SOME USEFUL DATA :

Blast Furnace Gas :

(a) Composition :

Flammable Part CO - 22%

H2 - 3.1%

Non-flammable Part N2 - 54.9%

CO2 - 19.8%

O2 - 0.2%

(b) Calorific Value (CV) : 773 KCal/NM3

(c) Gas make per ton of skip coke : 3000 M3

(d) Limits of explosion :

% gas in air : Lower Limit -43Upper Limit - 74

(e) Properties : (i) Colourless

(ii) Odorless

(iii) Poisonous

(iv) Slightly heavier than air

(v) Burns with blue colour flame

Coke Oven Gas :(a) Composition :

Flammable Part H2 - 59.2%

CH4 - 24.4%

CO - 8.7%

CmHn - 2.1%

Non-flammable Part N2 - 2.1%

CO2 - 3.2%

O2 - 0.3%

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(c) Gas make per ton of dry charge : 300 to 315 NM3


% gas in air : Lower Limit -6

Upper Limit - 30


(ii) Having smell of H2S

(iii) Lighter than air

(iv) Highly explosive in nature

(v) Burns with yellow colour flames

Converter Gas :

(a) Composition :

Flammable Part CO - 55.2%CO2 - 19.2%H2 - 2.4%

Non-flammable Part N2 - 22.4%O2 - 0.8% (max.)


(c) Quantity of gas recovered/ton of steel : 70-80 NM3


% gas in air : Lower Limit -20Upper Limit - 70


(ii) Odorless

(iii) Deadly poisonous

(iv) Heavier than air

(v) Burns with blue colour flame

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PERSONNEL DEPARTMENTThe basic job of Personnel Department is to deal with human problems right

from the joining of the employee to his separation. It has come a long way sinceinception when the dependence on paper work and maintenance of files was theprime job of a Personnel functionary. The whole gamut of HR activities has undergonea sea change with online working and moving towards paperless office. The thrustarea has been improvement in employee services, which has seen a vast improvementas is evident from general satisfaction level of employees. The department boasts ofthree websites: Executive Cell, Rules and HRIS - glimpses of which are as follows: -

Web page of Executive Cell

Web page of Rules

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Web page of HRIS

Broadly departmental activities can be divided into two areas: -

(a) SHOP FLOOR PERSONNEL FUNCTIONS: All establishment functions of thedepartment like maintenance of personnel records of employees, promotions,appraisals, LTC/LLTC, HRA, LTE, Discipline Management, counseling etc. ThePersonnel offices are grouped into five zones within the Plant, viz. Iron, Steel,Mills, Maint & Services and Power & Quality Zones, with three to four personneloffices in each zone. At a higher level, the Shop Personnel are categorized intothree zones, viz Works, Non-works and Mines.

(b) CENTRAL FUNCTIONS: -(i) Manpower Planning & Recruitment - Planning for optimum manpower and

organization for BSP as a whole as well as all departments, Recruitment(both internal as well as external), Transfer of non-executives,Redeployment, Placement of office staff and placement of trainees.

(ii) Executive Establishment - Executive induction, placement and rotation,implementation of performance appraisal system, executive promotion,establishment functions of senior management cadre and personnelexecutives.

(iii) Human Resources Information System - Maintaining employee data, generatingvarious reports, development and communication of modules, total computerizationof personnel functions through comprehensive data validation.

(iv) Rules - Issue of personnel policy and procedure circular, issue ofclarifications on various rules/policies, processing incentive papers for Hindi

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qualification, Professional qualification and National award winners,production incentive scheme, Jawaharlal Nehru Awards, VoluntaryRetirement Scheme, Life Cover Scheme, formulation of motivation schemeslike scholarship schemes, reimbursement of professional membership feesetc.

(v) Industrial Relation & Contract Labour Cell - Sensing of IR environment forreporting to top management, crisis handling, handling works accidents,statutory returns for all factories, issue of gate pass, NDC in respect ofContract Labour, integrated contract labour management.

(vi) Canteen Cell - Supervision of all co-operative canteens (both statutoryand non-statutory) both within and outside the Works area. Administrativeof subsidies towards price rationalization in canteens.

(vii) Counselling Section - Counselling of employees with deviant behaviour.Alcoholic & Adolescent counselling, family dispute counseling etc.

(viii) Final Settlement Section - Processing of terminal benefit payment toseparating employees and operation of Employees Family Benefit Scheme.

(ix) Suggestion and Grievance Cell - Implementation of Suggestion Schemeand Stage-III grievances of employees. Grievances till stage 2 are dealt atthe shop level.

(x) Enquiry Cell - Conduct of departmental enquiry in disciplinary cases andsubmission of enquiry reports.

There is a full-fledged Mines Personnel department also which caters to theneeds of the Mines organization.

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HUMAN RESOURCES DEVELOPMENT DEPARTMENT

Bhilai Steel Plant is the winner of NationalGolden Peacock award for training for the year 2008

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One of the most important constituents of human resource development activitiesis "TRAINING". It is one of the vital tools to prepare the most valuable asset of anorganization i.e. human resource, to absorb new skills, face challenges arising out ofthe advent of new technologies and changing business scenario, to remove managerialobsolescence.

The effectiveness of training is linked to the question of how far training is ableto provide support to the achievement of the organizational objectives. Training seeksto bring about improvements in the skills, knowledge and attitudes of the people, sothat they are able to carry out their jobs effectively and confidently.

MODEL OF THE TRAINING PROCESS

A need for continuous effort to keep its human resources updated has led to theestablishment of a captive training center viz HRD Center (Bhilai Technical Institute)in the middle of 1959, alongwith the commissioning of first Coke Oven Battery, BlastFurnace, Steel Melting Shop, etc. The year 1961 saw the birth of BHILAIMANAGEMENT TRAINING CENTRE at the junction of Bhilai and Durg.

STRUCTURE OF HUMAN RESOURCE DEVELOPMENT DEPARTMENT & BROADAREAS OF TRAINING

The Human Resource Development Department structure of Bhilai Steel Plantconsists of three distinct entities - the Human Resources Development Centre (HRDC),the Bhilai Management Training Centre (BMTC), and a network of Plant TrainingCenters.

Annual Training Plan (ATP) for the department is prepared for ensuing financialyear and the implementation is reviewed periodically and at the close of the period.

The different areas of training can be grouped as under :

Training of new entrants.

Training in modernization / expansion areas.

Upgradation and enhancement of skill of employees.

Multi-skill Training and Retraining.

Special need based programmes : Safety, Environment Management,Occupational Health, ISO : 9001 QMS, ISO : 14001, OHSAS:18001, SA:8000,Performance Improvement Workshops (PIWs) etc.

Programme to enhance managerial skills and efficiency.

Training to sister unit personnel.

Learning from Each Other (LEO) Workshops.

Plant familiarization programme for CMO, CISF personnel.

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Training programmes for outside organizations and IAS, IRS, Indian RevenueService, Economic Service probationers / executives / employees.

Vacational training of Engineering and Management students.

Besides above, HR interventions are regularly carried out from time to timedepending upon the need felt.

HUMAN RESOURCE DEVELOPMENT CENTRE (HRDC)

The HRDC is the central training complex equipped with workshops andlaboratories, an air conditioned auditorium with seating capacity of about 250, alarge number of lecture rooms and examination halls. Audio - visual facilities includingOHPs, slide projectors, Video and 35mm film projection system, LCDs etc.

It maintains Central Library at HRDC containing large number of technical andnon-technical books alongwith all important periodicals and journals.

In the HRDC workshops, facilities exit for training in the following trades :

Fitting Welding / Gas - cutting

Automobile Electrician

Carpentry Machine / Tool operation

Electric Motor Winding Hi-Tech area

Materials Handling Vulcanizing

Training in these trades are imparted to new entrant categories, i.e. TradeApprentices, ACTs, TOTs, Sr TOTs etc. As per the requirement of various worksdepartments, regular employees are also trained in the above trades under SkillUpgradation and Preservation / Multi-skill Training Scheme.

LONG DURATION TRAINING FOR FRESH ENTRANTS

Fresh entrants like Management Trainees (Tech / Admn), Sr Technician-cum-Operative Trainees (Sr TOTs), Technician-cum-Operative Trainees (TOTs), Attendant-cum-Technician (ACTs) and Jr & Sr Staff Trainees are given institute based training,both theoretical and practical, of varying duration. "On-the-job training" is impartedon the shopfloor under the supervision of departmental Training Engineers andfacilitated by the training department. Trade Apprentices join training underApprenticeship Act.

TRAINING OF REGULAR EMPLOYEES

Regular employees both executives and non-executives of works and non-worksdepartments undergo courses like Team Building. Iron & Steel technology, Quality,Communication, Basic maintenance, Safety and Accident prevention, Unit Trainingof establish standard practices etc.

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Computer training to employees through courses like PC Fundamentals, MS Word,MS Excel, Hindi Computer, Windows Software Package, Auto CAD, ORACLE - 9i etcprovided by dedicated computer group or with the help of external faculty. In additionthrough mass movement of e-Abhiyaan training is provided in duty and beyond dutyhours for mass literacy in computer area.

Duration of these training programmes is need based, determined after consultationwith employees and their sponsoring departments.

IN-PLANT TRAINING CENTERS (IPTC)The In-plant Training Centers were established in all major shops with the objective

of bringing training to shop floor. Each such training center has facilities for deliveringtraining equipped with audio - visual aids like flip charts, OHPs and video projectionsystems.

In-plant training centers functioning at shop floor are in the charge of TrainingEngineer of the concerned department.

DEVELOPMENT TRAINING UNIT (DTU)This section is engaged in training and development of ministerial staff and also

conduct post selection course for E-0 employees joining executive cadre from non-executive cadre.

CIVIL DEFENCEPreparing the plant personnel to effectively deal with situations like man made

tragedies, natural calamity, emergency due to accidents etc through basic Civil Defencecourses which contains disaster management, first aid, causality transportation rescueetc.

FOREIGN TRAINING UNITThis unit processes cases of employees nominated for training abroad, and gives

training and guidance before their selection at corporate level. On final selection, theunit also arranges their deputation including passport.

Selection / Deputation under SAILCON is also coordinated by this unit.

OTHER FACILITIESHostels for various categories of trainees.

Facilities for sports, games and athletics for inculcating sportsman spirit in theyoung trainees. A play ground adjacent to Hostel - 3 for playing Football, Hockey,Cricket etc is maintained.

Venue for Professional Examinations : For the convenience of many of ouremployees and their wards,. HRDC serves as a venue for holding all Indiaprofessional examinations like AMIIM, ICWAI, IIIE, AIMA and NIPM etc.

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BHILAI MANAGEMENT DEVELOPMENT CENTRE (BMDC)

BMDC is situated by the side of Central Avenue, Sector-VII in Bhilai town 5 kmsaway from the plant.

Here the focus is on the development of managerial skills of executives at juniorand middle level. In addition, special programmes are also held for senior supervisorypersonnel. HR interventions from time to time also form an important part of theactivities of the center.

SOME OF THE REGULAR COURSES AT BMDC ARE

Management Development Programmes (MDP-I & MDP-II).

Enhancing Managerial Effectiveness (EME).

Action Leadership.

Micro Planning.

Instruction Techniques for Occasional Trainers.

Programmes on Personnel, Materials and Finance Management.

Communication & Presentations skills.

Creativity.

Counseling.

Safety Management for Sr Executives.

Stress Management.

Vigilance, Security and disciplinary proceeding.

Transactional analysis.

BMDC also has a library where Books and Magazines in managerial areas aremaintained.

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ORGANISATION & METHODS DEPARTMENTThe Organisation & Methods (O&M) is a management service department with

the role to evolve , maintain , follow up and review systems and proceduresaimed at work simplification , elimination of red -tapism , render specialisedassistance in the files of organisation analysis, offer office services, and to ensurebetter economy and cost control in the Plant.

Scope of Functions

The scope of O&M extends to the entire plant including Mines, Projects, MedicalServices and Township. Requirement of Govt. agencies such as CISF also fall in thescope of O&M Deptt.

Functions of O&M

The functions under the purview of O&M are enumerated below:

- Development and review of systems and procedures Facilitating Top Managementin faster decision-making.

- Assessment of manpower for Non-works area

- Review of delegation of powers

- Review of imprest accounts

- Registration of contractors

- Banning of business dealings with contractors/ suppliers/ vendors.

- Formulation of rate contract system

- Scrutiny and recommendation of contract proposals for non-works

- Monitoring of petrol and diesel consumption

- Designing of forms, control and monitoring of printing of forms

- Allocation of office space

- Formulation of records retention schedule and its management

- Assessing /reviewing of requirement of welfare items such as dress, raincoats, gumboots

- Assessment of office facilities, stationery (including computer stationery andconsumables)

- Working out the feasibility for off loading different activities services.

- Assessment of items under non -plan capital budget (such as office equipment,communication facilities, cooling facilities and passenger vehicles).

- Requirement of CISF

- Examination of Investment Programming Unit (IPU) proposals.

- Constitution of committees such as pricing committees, screening committee,safety committees etc. with the approval of management.

- Participation in different tender/ OLFA committees/ finalisation of MOUs fordifferent committees.

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Detailed Description of Functions :

1. Systems & Procedures

System study and procedure analysis, work simplification of all jobs of alldepartments involving office/clerical routines

Review of existing systems /procedures, assisting in implementation , of revisedsystems/procedure, and further follow up.

2. Manpower Study / Job EvaluationAssessment / review of manpower requirement of all grades of non-executives.

3. Delegation of PowersPowers have been delegated to MD by Chairman SAIL, for running of units.

Based on the nature of the work, timely completion of jobs; procurement of materialsin case of nonavailability in stores; in exigency, meeting miscellaneous administrativeexpenditure etc. For further delegation of powers vested in MD, to different executives,MD's approval is sought after finance concurrence.

Office orders are issued time to time on DOP (Delegation of Powers) to differentexecutives along with the following instructions:

- These powers shall not be sub delegated to any officers under them.

- The exercise of power shall be subject to budget provision.

- Cases requiring approval of MD or having financial implications will have to berouted through ED/GM (F&A) by the respective HODs.

4. ImprestImprest is a small amount of cash sanctioned to a department, and to be kept in

hand throughout, to meet any expenditure in exigency. The amount of imprest andthe scope within which imprest can be spent varies from department to departmentand pertains to the need of the department.

- Allocation of imprest

- Review of imprest.

are done time to time based on the requirement of the organsiation.

5. Registration of Contractors

For any type of contractual work executed in BSP, the concerned party shouldbe registered with BSP. Registration is done based on the necessity of contractors inparticular disciplines , ensuring that contractor fulfills formalities such as possessionof PF code, availability of know how, equipment manpower, budget etc.

6. Rate Contract System

Rate Contract System for Civil/Mechanical/Electrical works is being reviewed afterthe expiry of validity of existing system. The following aspects are dealt in the review.

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- Constitution of committee

- Formulation of rate contract system with schedule of items and rates

- Empanelment of contractors

7. Scrutiny of Contract Proposals

O&M is a member of the screening committee constituted for examining contractproposals in compliance with PCP-2K. The proposals are scrutinized during themeetings, keeping in view the job, the availability of in-house resources such asmanpower, materials, etc., and the quantum/cost of the proposal.

8. Management Information & Administrative Cost control

Development, review and follow up management information system aiming atan integrated and comprehensive system for the whole plant.

- Development of management information system for strategic, tactical andoperational decision making, with respect to cost control measures.

- Installation of system, suggestions for curtailment of administrative expenditureand fixation of various norms.

9. Welfare Facilities

Provision of Uniform, Rain Coat & Gumboots.

Assessment of requirement of all deptts, based on existing norms, area / natureof work, designation of the employees etc.

10. Office Services

Assessment of requirement is done in the following areas:

1. Office lay out and space allocation (Ispat Bhawan & Old Administrative Building)

2. Office facilities like furniture, storage facility, air coolers, water coolers etc.

3. Office equipment such as Typewriters, Calculating Machines, Photocopiers,Computers & Printers.

4. Office Stationery Analysis.

- Review of stationery quota for all the departments of the plant (including Mines).

- Determination of stationery quota for new offices.

- Assessment of computer stationery requirement.

5. Record Management : Formulation of records retention schedule for varioudepartments.

11. Fuel consumption

Monitoring of Petrol / Diesel consumption in BSP, department-wise, on monthlybasis and suggesting measures for containing petro-fuel consumption in respectivedeptts.

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12. Forms analysis

Forms analysis and control of all forms originating in any department, to simplifyand standardize the forms, keeping in view the following parameters :

- Computerisation and ISO standard parameters.

- Fast changing technology

- Need of the information in changed business scenario.

13. Non-Plan Capital Budget

Assessment of the items under Non -Plan Capital Budget, office equipment,communication facilities, cooling facilities and furniture items etc. for the entire plant;monitoring procurement/release of the items to the concerned deptts.

14. Security

In consultation with CISF, study existing systems/procedures related to security,and suggest improvements for safeguard of materials and property; review systemsrelated to issue of passes for movement of man, materials and vehicles of BSP, Govt.and private organisations.

15. IPU Cases

As a member of IPU Committee, study of the proposals for investment of variousNon-works departments and offer suitable recommendations for undertaking/implementing the project.

16. Special Projects

As assigned by Managing Director and heads of departments from time to timebased on the needs of the organisation.

17. Off loading of Services/ Activities

Working out the feasibility for off-loading different services/ activities/ facilitiesw.r.t. cost effectiveness and submitting the reports to Management for approval/consideration for implementation.

18. Bathing of business dealings with contractors/ suppliers/ vendors

On the basis of reports of vigilance/ recommendations of the Baning committee.

19. Copy right/ Patenting

Convering the meetings and condinating the copy-right/ patenting proposals.

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STATISTICAL QUALITY CONTROL &OPERATIONS RESEARCH

The Statistical Quality Control & Operations Research department (SQC & OR) amanagement service department , is actively engaged in carrying out the followingfunctions :

1. Conducting SQC / SPC (Statistical Process Control ) & OR studies relating toimprovement in production, productivity, logistics, resource optimisation, wasteutilisation, patient care & health management etc.

2. Co-ordinating Quality Circle activities for Bhilai Steel Plant.

3. Conducting workshops on SQC & Quality Circles for executives and non-executives.

STATISTICAL QUALITY CONTROL (SQC)

SQC has three distinct areas within its fold : "Statistics, Quality, and Control" :

Statistics

The word "Statistics" is used with two fold meanings. In plural sense " Statistics"may be defined as facts, data etc. Thus we may say statistics of rolling of differentprofiles in the rolling mills is maintained by Production Planning and Control (PPC)department of Bhilai Steel Plant. In singular sense, the word "Statistics" is referred toas a body of methods or systematised techniques by which meaningful conclusionscan be drawn from a set of numerical data. It is in this sense that the word "Statistics"is used in "Statistical Quality Control".

QualityWhen we speak about quality, the following three things come in focus :

(i) Product - One which can give service to the customer.(ii) Customer - Who needs the product to satisfy his/ her requirement.(iii) Price - The money which the customer can pay for the product.

Therefore, the definition of quality, in its simplest form, is :

Fitness for use at the most economic price to meet the expectations of the customer.

Control

Control can be defined as

- Predicting an outcome with a certain degree of accuracy.

- Prevention of process variation to produce consistent quality.

Definition of SQC

SQC may be defined as : "the application of statistical principles and techniques,at all stages of manufacture, directed towards the economic manufacture of a productwhich has maximum utility and has a market".

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The method of SQC lays emphasis on control of the process (in contrast to theconventional method of Quality Control through inspection) and process parametersfor obtaining the desired product quality. The advantage of SQC over other tools ofQuality Control lies in the fact that application of the simple statistical techniques forachieving the desired quality, costs almost nothing or very little. Thus, SQC is one ofthe most effective tools for quality control and has profound influence upon theentire area of "Quality Control".

Thus the ambit of SQC is very large, from raw material selection to delivery offinished products. Therefore, the techniques which relate to process only have beensegregated and clubbed under one head called Statistical Process Control (SPC).

SQC Techniques

Some of the important SQC techniques are :

- Data Collection.

- Data Arrangement.

- Frequency Distribution.

- Histogram.

- Data Stratification.

- Check Sheet

- Regression and Correlation Analysis

- Sampling Inspection

- Control Charts

- Product Reliability Prediction etc.

"Control chart" is rightly called the "Heart of Statistical Process Control."

OPERATIONS RESEARCH (OR)

This discipline had its origin during World War-II. Though principally based onindustrial statistics, OR is a multi-disciplinary approach. At the time of World War-II,scientists from various disciplines were engaged in an intensified effort to use theirscientific knowledge in warfare. This type of activity has become known as "OperationsResearch". Since this initial breakthrough, the recognition of OR application has spreadbeyond the confines of military warfare. It has been applied as extensively in industrialoperations as it has been in the domain of natural sciences.

Operations Research, in the most general sense, can be characterised as theapplication of scientific methods, techniques and tools to solve problems involvingthe operations of a system so as to provide those in control of the system withoptimum solutions.

Thus OR, with the help of its techniques, fixes the strategies which will "optimise"the ultimate "objective" if the situation can be represented by a suitable mathematical

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model. In common parlance, OR is a collection of techniques which will answer whatshould be done either to maximise profit, yield etc, or to minimise cost, wastage etc,in a given set of conditions. The term "Operations Research" is thus a misnomer, it isneither "Pure Operations" nor "Pure Research". It is infact "Optimisation in the faceof constraints".

The major techniques of OR are :

- Linear, Non-Linear and Dynamic Programming

- Simulation

- Allocation

- Queueing Theory

- Inventory Control

- Network Analysis

- Replacement Models

- Decision Theory, etc.

Relationship between SQC and OR

Though both are principally based on statistical concepts and techniques, OR isa multi-disciplinary approach to management problems to arrive at "Optimum Solution".Contrary to SQC methods which examine and correct the basic behaviour of anyprocess/ system OR techniques provide the "best strategies" in a given set ofconditions. Thus SQC & OR are mutually complementary in nature.

QUALITY CIRCLE (QC)

Quality Circle (QC) is a small group of employees who are engaged in one placeof work. The group meets regularly to discuss specific problems from their work areaand suggests ways and means for improvement not; Their suggestions are consideredby the Management and all feasible suggestions are implemented by the groupmembers themselves. Therefore "Quality Circle" is basically a TEAMWORK. It is acollective effort, rather than an individualistic effort, to solve the problems at theworkplace.

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Focus & Objective of QC

The basic objective of QC is

- to harness the creative potential of the employees for problem solving,

&

- to achieve all - round excellence through involvement of people

Quality Circle thus symbolises TEAM SPIRIT & SYNERGY of the workforce.

Since there can't be any team without person, the central or focal point of QC is"MAN". In fact, it is another form of HRD (Human Resource Development).

QC Philosophy

The philosophy behind QC is that :

1. Every job is capable of being improved; improvement is a never ending process.

2. Every employee has the intrinsic potential ability to improve the job.

3. People do not resist change, they resist being externally changed. They arecapable of changing themselves.

4. Problems can be best identified and solved by those who actually do the job onday-in-day-out basis.

Group Size

The size of group varies from six to eight members, which may normally includenot more than one frontline executive at the level of Asst. Manager/ Jr. Manager. All

the members are those who are regularly associated with the particular work.

Problems to be tackled by QC

"QC" had its origin in Japan. Initially, when the movement took off in Japan, itwas dealing exclusively with problems relating to product quality. Later on, the Japanse

realised that it was such a powerful and potential tool that it could embrace allaspects of industrial working and could be applied to any field like Improvement in

Quality, Productivity, Safety, House Keeping, Environment and also for Work IntensityReduction, Energy Conservation, Inventory Saving, Import Substitution etc. In fact,

anything and everything which can be conceived under the gamut of industrialoperations can come within the purview of QC.

Thus QCs can tackle problems relating to :

- Methods / Procedures / System Improvement .

- Productivity / Quality Improvement.

- Safety and Housekeeping.

- Cost Reduction.

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- Work Intensity Reduction.

- Environment Improvement etc.

QC Methodology :

The steps involved in problem solving through QC are :i. Formation of Quality Circle.

ii. Selection of the Circle leader.

iii. Identification of problem.

iv. Collection of facts / data.

v. Analysis of data, and finding alternative solutions.

vi. Choice of the best solution based on the analysis.

vii. Trial of the chosen solution.

viii. Management presentation and approval.

ix. Implementation of acceptable solution.

x. Follow-up, monitoring and maintaining it.

QC Tools :

Some of the analytical tools found useful for problem solving through QC are :i. Flow Diagram.

ii. Brainstorming.

iii. Collection of relevant data.

iv. Data arrangement by frequency distribution/ Stratification/ Histogram etc.

v. Cause & Effect Diagram. (also known as Fish Bone Diagram or Ishikawa Diagram)

vi. Pareto Analysis.

vii. Scatter Diagram.

viii. Control Charts.

Benefits of QC

A. to the employees :

i. Important source of job satisfaction which may not be present in routine day to

day activities.

ii. Provides a sense of participation to the employees.

iii. Builds competence in employees to manage change and prepares them betterfor supervisory positions. Thus it helps in developing a sound human resources

pool in the organisation.

iv. Builds ability to work with others and inculcates team approach to problem solving.

v. Helps to improve work environment and methods.

B. to the organisation :

i. Development of complete coherent problem solving methodology.

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ii. Increased production/ productivity.

iii. Enhanced motivation of the workforce.

iv. Improved quality of the product.

v. Better employer - employee relationship.

BHILAI SCENARIO

Quality Circle (QC) activities in Bhilai Steel Plant were started in July 1988 withSQC&OR Department under General Manager (Management Services), functioning

as the central co-ordinating agency for QC activities for the entire organisation. QualityCircle in BSP was initially referred to as "Shop Improvement Group (SIG)". Later,

when the concept gained considerable acceptance and the movement gatheredmovement, 'SIG' was rechristoued amongst employees, as "Quality Circle" in 1992

to be in tune with the current trend.

Progress of QC over the years :

From a humble beginning of 52 QC projects in the year 1988-89 (the year of its inception)

the plant has come a long way to cross the milestone of 2000 QC projects per year.

Measures adopted to boost QC movement :

The following measures are taken to promote the QC activities in works and

non-works areas of BSP.

I. Training

An intensive round-the-year training drive was launched in February'92 to spreadthe movement and involve more employees in QC activities. Initially a series of 3-day

Workshops were conducted to expose middle level executives to QC concepts andtechniques. Later, it was modified, and presently 2-day Workshops titled "SQC

techniques and Quality Circle" are being organised by SQC & OR department, formiddle level executives, once a month at BTI.

Side by side, 1-day Workshops on "Quality Circle" are also being organised for

non-executives who would be the nucleus of the QCs in their respective areas. Theseworkshops are conducted in the training room of the shop, in order to cause least

disturbance to the production schedule.

II. Documentation of implemented projects

Systematic compilation and publication of all implemented QC projects is done

every year with a view to disseminate the information regarding improvement donein different areas so that the people can learn from the experience of others.

III. Annual Recognition Function

QC Recognition Function is organised every year in the concerned departmentsto felicitate the persons associated with the QC movement. Each and every employees

involved in the implementation of QC projects in a year is honoured with a certificate

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and a token gift. This serves as the single largest motivating force for the propagation

of QC activities in the plant.

IV. QC Manual

Quality Circle Manuals in Hindi and English have been published and are distributed

to the executives and non-executives participating in QC workshops to propagatethe concept of QC amongst larger cross section of employees.

V. Inplant Project Presentation Competition

QC Project Presentation Competition is held at Zonal Level and subsequently at

the Plant Level to create a culture of healthy competition amongst different QCs andto impart momentum to the QC movement. The successful teams from Zonal Level

Competition participate in the Plant Level Competition where they are ranked as pertheir performance by a panel of judges. Teams as per their ranks are prepared through

repeated rehearsals by SQC&OR Department, for participation in outside competitionsorganised by fora like Quality Circle Forum of India, Confederation of Indian Industry,

etc.

VI. In-house QC Trophies

a) MDs QC shield & Cup

In order to provide further to the QC movement in BSP, awards named "ManagingDirector's QC Shield" and "Managing Director's QC Cup" were instituted in 1993-94

for the BEST and SECOND BEST departments in respect of QC performance.

b) ED (Works)'s QC Cup

Another award was introduced from the year 1994-95 by Executive Director(Works). A department completing maximum number of QC Projects per 100 persons

is rewarded with ED (Works)'s QC Cup.

c) ED (P&A)'s QC Cup

Instituted in the year 2003-04, this is awarded to the department ensuringmaximum percentage of employer involvement in QC activities

VII. Awards & Accolades

The selected QC teams sponsard by BSP for participating in outside QC

competitions organised by national for a like Quality Circle Forum of India (QCFI) &confederation of Indian Industry (CII) have always a brought laurels to the plant. Out

of these again, teams in order of maint as per the performance at the national levelare sponsared for participating international conventiontion on QC. (ICQCC)

Following QC teams of BSP of participated in the (International Convention) inQC as per the details shown in given below :

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CONCLUSION

With continuous pertonage of the Management and enthusiastic participation ofout people in QC activities, it is hoped that QCs fluries in BSP SAIL and will play ameningful role in the quality of life of our employees.

# Name of the QC Team (Department

Year of participations in ICQCC Venue

1 SAHACHARYA (Blast Furnace)

2000 Singapore

2 SADHANA (Instrumentation) 2003 Tokyo, Japan

3 VIVEK (Instrumentation) 2003 Tokyo, Japan

4 AKSHAT (SMS-I) 2004 Bangkok, Thailand

5. NISHKARSH (SP-III) 2005 Seoul, South Korea

6. LAKSHYA (JLN&RC) 2005 Seoul, South Korea

7. CHARAIVETI (CO&CCD) 2006 Bali Indonesia

8. ABHINAV (SMS-II) 2006 Bali Indonesia

9. SNEHAN (Plate Mill 2006 Bali Indonesia

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PRINTING SERVICES DEPARTMENTHISTORY

For thousands of years men recorded their happenings and sent their messages

in the form of pictures called pictographs. Pictures were later simplified to signs andsymbols by Sumerians about 3500 BC in Mesopotamia. Egyptians also developed a

type of picture writing called hieroglyphics. The earlier Chinese script had more than50,000 symbols. Time went on. To make script easier, an alphabet was needed. The

first script that grew into alphabet was developed by Phoenicians in 1600 BC.

English is written in Roman alphabet having 26 letters, the Hawaiian languageuse only 12 letters where as the Greek use 24. Devanagari and many other Indian

scripts have been developed from Brahmi script much later.

Invention of paper toy Tsai Lun, a Chinese in the year AD 105 was revolutionaryas recording by aforesaid methods was not convenient it was felt that some way

must be found out to multiply the copies of the text.

DEVELOPMENT OF PRINTING

Johannes Gutenberg of Germany made hundreds of letter types of lead for eachalphabet. They were used to make words and sentences. These were assembled in a

tray and clamped into place. When a whole page was composed, it was inked andthen paper was pressed over it. This idea of printing by Gutenberg was known as

Letter Press Printing. The first book thus got printed was Bible. The modified versionof paper printing adopted now-a-days is Offset Printing in which the image on the

presensitised plates is transfered into rubber blanket and then to paper by impressioncylinder.

BIRTH OF BSP PRINTING PRESS

After setting up of first integrated Steel Plant at Bhilai in late fifties, management

found great difficulties for printing of forms, formats, office stationary etc. used forday to day official work of the plant. Due to non availability of printing press in the

vicinity of Bhilai, management was forced to get the jobs done either from Raipur orNagpur. To fulfill the internal stationary requirements of the plant, to save the printing

expenses and to avoid delay caused by outside printing agencies, management haddecided to start an in house printing press which came into existence in December

1958 with three latter press printing machines, one paper cutting machine and onewire stitching machine. Later it was expanded with some more machines.

Now the printing services are also extended to Bokaro & Rourkela Steel Plant.

Recently some of printing jobs pertaining to IISCO have also been taken up. Renderingbetter services in our core theme. With this aim, the department has been renamed

as Printing Services Department w.e.f. 17th August 2004.

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The current status of machine in our Press is as under :

SI No. Printings Allied Machinery Year of Procurement

1. Balvant Letter Press Machine 1980

2. Wire Stitching Machine 1981

3. Sulby Perfect Binding Machine 1988

4. Record Paper Cutting Machine 1989

5. Monotype Plate Exposing Machine 1990

6. Shiva Bi-Colour Printing Machine 1997

7. Proteck Plate Exposing Machine 2005

8. Max Single Colour Offset Printing Machine 2005

9. Autoprint Single Colour Mini Offset Machine 2006

10. Proteck Automatick Folding Machine 2007

11. Proteck Computerised Paper Cutting Machine 2007

12. Proteck Creasing Machine 2007

The various sizes / types of papers used in printing industry are given below :

PAPER SIZES (A SERIES )

A0 1149x841mm

A1 841x594 mm

A2 594x420 mm

A3 420 x 297mm

A4 297 x 210mm

A5 210 X 148mm

A6 148 X 105mm

A7 105 X 74 mm

A8 74 X 52 mm

A9 52 X 37 mm

A10 37 X 26 mm

PAPER SIZES (B SERIES)

BO 1414 X 1000mm

B1 1000 X 707 mm

B2 707 X 500 mm

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B3 500 X 353 mm

B4 353 X 250 mm

B5 250 X 176 mm

B6 176 X 125 mm

B7 125 X 88 mm

B8 88 X 62 mm

B9 62 X 44 mm

B10 44 X 31 mm

PAPER SIZES (C SERIES)

C4 324 x 229 mm

C5 229 x 162 mm

C6 162 x 114 mm

PAPER SIZES (IMPERIAL)

Foolscap 17 x 131/2 inches

Crown 20 x 15 inches

Demy 23 x 18 inches

Royal 26 x 20 inches

Elephant 28 x 23 inches

Imperial 30 x 22 inches

The entire requirement of forms, formats, journals, pamphlets, posters, brochures,

souvenirs, books etc. of BSP is met through in this in-house Printing Press. The leadtime for the purpose of indenting is six months. However, urgent and priority jobs are

having no time bar.

HIGHLIGHTS

Apart from the total requirement of BSP, the department has also started takingthe printing jobs of other SAIL units like BSL, BSO (Bhilai), Rourkela and IISCO in

recent past.

PROPOSED UPGRADATION

Installation of "Computer to Print" Printing Machine & continuous stationaryPrinting Machine.

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GATEWAY

THE PROCEDURE & PROCESS OF PRINTING

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TOWN SERVICES DEPARTMENTAn ISO 14001 certified Bhilai Township is maintained and managed by Town

Services Department. Town Services Department caters to housing, maintenance;education, environmental, hygiene and civic amenities need of the residents oftownship. Its main objective is to serve employees to live a pleasurable and peacefulfamily life. It is also contribute in development and maintenance of infrastructuralfacilities and assets for the welfare of the community.

Having an area of around 8.035 thousand acres, Bhilai township is divided into18 Sectors covering 35,954 residential units, 109 public buildings (including 41schools, 2 hospitals, 9 health centers, 14 clubs and community centers), 1804 licenseand 1231 lease shops, 6 parks and 3 stadia etc. Daily consumption of water in thetownship is around 16 MGD while electricity consumption of approximate load is 32MW per day (average) is also catered by Department.

The function of Town Services Department can broadly be classified into twomain divisions, namely Engineering and Services:

ENGINEERING FUNCTIONS (MAINTENANCE & SERVICES)

SERVICES FUNCTIONS

Civil Maintenance House Allotment, Records & NDC

Electrical Maintenance House Lease

Public Health Engg. (Sewerage System & Water Supply)

House Building Advance

Public Health Enforcement & Eviction

Horticulture HUDCO

Rent Collection & Shops Management

Land Management

Estate Court (As per provision of Public Premises (Eviction of Unauthorised Occupants’) Act’1971

Education

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ORGANISATION STRUCTURE :

Organisation structure of Town Services Department is as under :-

The Engineering wing deals mainly with maintenance of assets and servicesthrough well-defined operating system of preventive maintenance and curativemaintenance, under the control of DGM (Township). For improvising the system ofmaintenance, a value based contract system has been introduced. Various decisionlevels have been introduced depending on the value (amount involved) of themaintenance job of a house, which has helped in reducing the lead time of complaints'redressal for better maintenance of houses.

Civil and PHE sections of engineeringwing of the department are divided into twozones namely East and West. The sectionsoperate and control various contracts thatare operated for maintenance of residentialunits and Public Buildings of Township.Simultaneously, the sections also carry outvarious minor operational and maintenancejobs departmentally. PHE maintains 377 KMsof water supply mainlines and 434 KMs ofhouse connections through operating 120 Nos. of water supply valves. The storagecapacity of Under Ground Reservoir (U.G.R.) and Over Head Tanks (O.H.T.) is 96.05Lakh Gallons. There are 3 Nos. of water supply pump houses and 3 Nos. of boosterpump houses. Sewerage system of the Township is maintained through 07 Nos. ofpump houses and 352 KM of sewer mainlines. For treatment of sewage of Townshipthere are 5 oxidation ponds in the Township.

Electrical Section of Town Engineering wing deals mainly with electrical supplyto residential units of the Township and street lighting. TEED also take care of Air

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conditioning & ventilation system of Critical Area like Ispat Bhawan, JLNH&RC, BhilaiNiwas, other public buildings & Residence in scattered all over Bhilai Township.

The work of electrical section can be divided into the following:

High Tension .Section: The power from TSS-1 & MSDS-2 is being received at loadcentre named TDS-1 & TDS-2 through 11 KV lines to cater power in East & WestArea of Bhilai Township. The TDS-1 feeds power to Camp, Khursipara , Sector-1,2,3,4,5 & in some areas of Sec-6. The rest of the township i.e. Sec-6,7,8,9,10,MS, Ruabandha, Resali, JLNH&RC, Bhilai Niwas, BMTC etc gets power from TDS-2.TDS 2 is main controlling centre for all electrical supplies in the Township.

LT (East & West) : The LT Section maintains the power supply up to consumer endand ensures the maintenance of LT installations in the premises of customer. We arealso committed for our services in critical installation like JLNH &RC, Ispat Bhawan,Bhilai Niwas, various public buildings of township & schools. The total activities arecontrolled by Maintenance posts situated in Each Sector.

ACVR Section: The ACVR Section maintains the various Air Conditioning & VentilationSystems in Ispat Bhawan, JLNH&RC, Bhilai Niwas & Room Air conditioners in thetownship area. The whole activities of the section are organized by TEED Workshopsituated in Sec-10 with three maintenance post situated in Ispat Bhawan, BhilaiNiwas & JLNH&RC.

Energy & Meter Cell: The section is responsible for collection of meter readings, itsfeeding in computer. Meter reading of third party are being done on monthly basisthrough contract & quarterly for BSP employees.

A Township Help Center has been established where employees can lodge theircomplaints, over phone (Intercom no. 8499).

Public Health & Horticulture Sectionis responsible for hygienic environmentand beautification of Township. Mainfunction of Public Health Section issanitation and pest control along withveterinary services. It also maintains vitalstatistics related to population and isresponsible for issue of birth certificateand death certificate. Horticulture sectionof TSD is responsible for maintainingparks, gardens and monuments (likeKarmanya Vatika, Pioneer Monument)including Maitri Baag Zoo. The section is responsible for tree plantation andbeautification of Township. The functions of the section are carried out under theguidance of DGM (Public Health & Horticulture).

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GATEWAY

The Services wing is theinterface of department with theresidents of Township mainlyemployees and deals with a varietyof job. Estate wing of thedepartment deals with houseallotment to employees as well asnon-employees, maintenance ofrecords related to house andsanction of HRA & issue of NDCto separating employees,

management of land and shops, eviction and control of encroachment through enforcementby use of Public Premises (Eviction of Unauthorised Occupants) Act' 1971, rent &revenue collection, management of leased out houses and activities of Estate Court.

The 96 types of residential unitsof Township have been divided into10 categories. The Category ofhouses for non-executives is RAIL1to RAIL5 and Executives are PLATE1to PLATE5. House Allotment Sectionof the wing carries out two cycles ofallotment every month. Lowestcategory (RAIL1) of houses is beingallotted on daily basis on seniority.The section also issues NDC to

employees separating from the organisation. Land section of services wing isresponsible for allotment of land to non-BSP organisation as per the approved guidelinesof the corporate office. Shop section allots land temporarily for the commercialpurposes. It also deals with the matter related to change of allotteeship and changeof trade of shops of the Township.

Rent & revenue section of Estate Wing is centralised revenue collection centrefor the department and deals with the realisation of electricity, water & other billsfrom various non-BSP parties/organisation likeshopkeepers, educational and other institute,non-BSP residents of township and has done wellto realize approx. Rs. 10.5 Crore per year byvarious non-BSP organisation.

Bhilai is the education hub of Chhattisgarhand can be aptly called "SHIKSHADHANI" ofChhattisgarh. It is only because of thecontribution made by Education wing of TownServices Department. Education wing takes the

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burden-off from the employees by providing quality education to their children, andby ensuring children's all-round development. The section encourage students toparticipate in various competitions like calligraphy, debate, drawing, music, recitation& computer quiz etc. that are organised all over the year and 0.50 Lakh is spent tofelicitate students participating in these events. Also an amount of Rs. 4.50 Lakh isspent on felicitating meritorious students of BSP schools. Schools have rich libraryand state of the art laboratory. Education has some of the best and award winningteachers of the region.

Approximately 16 IITians and 5-6 doctors and hundred engineers every year areselected from BSP schools.

MAIN ACTIVITIES OF TOWN SERVICES DEPARTMENT

I. ESTATE

☯ Allotment of Houses to employees and non-employees

☯ Sanction of HRA

☯ Issue of NDC to separating employees

☯ Management of shops and hawker license

☯ Management of land

☯ Allotment of land and other public buildings

☯ Management of Leased houses and HUDCO houses

☯ Arranging House Building Advance to employees

☯ Identification and eviction of un-authorized occupants, and execution of decreesthrough Estate Court for eviction with the help of District and Police authorities

☯ Collection of rent and recovery of outstanding dues

☯ Maintenance of records, liaison with Bhilai Nagar Nigam, and State authorities.

II. EDUCATION

☯ Providing quality educational facilities to the children

☯ Organizing various co-curricular and extra-curricular activities in the schoolsand ensuring participation of students and teachers in prestigious programmes

☯ Oragnising entrance exam for class-I for BSP schools.

☯ Organising Workshops on physics, chemistry, maths, leadership etc.

☯ Encouraging sports participation by organising sports meets and felicitating thestudents

☯ Organising cultural programme (BAL RASHMI) and preparing students forparticipating in "RAJYOTSAVA"

☯ Organising "CUB BULBUL UTSAVA" and "SCOUT & GUIDE" rally

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III PUBLIC HEALTH

☯ Environmental control through collection and disposal of garbage and dead animals

☯ Pest control through anti-larval activities and fogging operations

☯ Epidemic control through disinfection of wells, distribution of chloride tablets etc.

☯ Food sanitation through maintenance of hygienic conditions and sanitation offood establishments

☯ Participation in organizing health camps in the near-by villages under CorporateSocial Responsibility.

IV HORTICULTURE

☯ Tree plantation in the township

☯ Upkeep and maintenance of Maitri Baag Garden including musical fountain, allparks and lawns in the township

☯ Maintenance of Zoo and Medicare of Zoo animals in Maitri Bagh.

V TOWN ENGINEERING

☯ Civil, Public Health Engineering (PHE) and Electrical maintenance of all residentialunits and public buildings in township (through a network of 16 civil maintenanceposts, 12 PHE maintenance posts and 19 Electrical maintenance posts)

☯ Capital repair and modification of various assets and installations, water supplysystem, sewerage lines, air-conditioning and ventilation systems in the Township.

☯ Repair and maintenance of all roads in the township

☯ Regulation of water supply, and monitoring quality of water

☯ Thorough cleaning and upkeep of sewer lines, conservancy lines and improvementin sewerage system

☯ Undertaking civil works in peripheral villages under Corporate Social Responsibility

☯ Maintenance of street lighting and beautification of squares and triangles' of Township

☯ Upkeep and maintenance of Guest Houses, community halls, stadia etc., forimportant events, VVIP visits and prestigious functions.

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INDUSTRIAL ENGINEERING DEPARTMENTThe subject of Industrial Engineering has grown, with the growth of industry

over the years, from a mere subject to a well recognised full fledged specialisedengineering course. The Industrial Engineering Department (IED) was setup at veryearly stages of coming up of Bhilai Steel Plant as a prime 'Management Service'department reporting to the Chief Executive of BSP. Presently it reports to GM (MS)under ED (P&A). It works towards promoting productivity, efficiency and economy inworking of the plant and helps the management in achieving optimal use of Men,Machines, Materials and Money. The role and responsibilities of IED are described infollowing paras:

MANPOWER PLANNING / ASSESSMENT, METHODS / SYSTEM STUDIES ANDORGANISATION STRUCTURE

To scientifically assess man power requirement

To design effective man-machine system using techniques like Method Study,Work Simplification, Man-Machine Charting and Ergonomics so as to providemeaningful jobs, multi-skill, minimise compartmentalisation of work and utilisethe full potential of every individual;

To design organisation structures best suited to meet the needs of the organisation,and to document roles and role boundaries for ensuring role clarity;

To standardise and document work practices, and assist in installing changedwork practices;

To chalk out short and long term manpower plans providing a smooth coursefor optimisation and restructuring of manpower, after analysing the impact ofvarious policy lternatives;

To train all new recruits and sizable fraction of existing employees in Techniquesof Industrial Engineering, Creative Problems Solving, Ergonomics, ValueEngineering, Computers etc., in consultation with Training Department.

INCENTIVE SCHEMESTo design, develop, modify, implement and monitor incentive schemes in all

production and service units of plant and mines (including non-works departments),with a view to achieve the organisational goals such as achievement in capacityutilisation, improvement in quality / techno economics, cost reduction, profitability,customer satisfaction etc. through a motivated work force;

To develop motivational package under Non-Financial Motivation scheme toachieve the pecific goals of Organisation such as "fulfilment of rail commitmentto Railways" etc, for concerned group of employees;

To estimate time for departmental work-order job;

To examine and sort out difficulties in operating of incentive schemes to generateand aintain employee motivation;

To assist the management in negotiating with the union for modification of theschemes.

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I.P.U. ( INVESTMENT PROGRAMMING UNIT)

To examine capital investment schemes of additions, modification, replacementsetc. for optimising capital investment decisions. The work involves critical examinationof the proposal for basic need, possible alternatives, available facilities utilisation,return on investment, pay back period, expected savings etc. and carry out postimplementation audit for effectiveness of the implemented schemes. In addition,proposals for welfare facilities, allotment of additional space for various requirementsetc. are also taken up.

The assignments can be classified broadly as :

1. Addition/Modification/Modernisations

2. Replacement of equipments

3. Welfare facilities/space requirements.

PERT/CPMTo use PERT/CPM technique for scheduling, co-ordinating and monitoring major

projects of repairs and construction activities of plant and mines so as to preventtime and cost overrun. The project include capital repairs of Blast Furnaces, SteelMelting Shops, Rolling Mills, construction of Coke Oven Batteries, capital overhaulingof major equipment like Turbo-Generator sets of Power & Blowing Station, SinteringMachines, Converters, Mixers, Rotary Kilns etc.

The work involves preparation of PERT Network, daily monitoring the progressof major repairs, delay analyses, preparation of MIS reports, introduction of PERTNetwork techniques in new areas of maintenance and repairs, standardisation ofactivity duration of past capital repairs.

SPECIAL STUDIES

To fix norms for various activities of company operations e.g. work output andtechno-economic parameters, consumption / production norms.

To undertake in-depth studies in different functional areas with a view toachieving various types of productivity gains in the field of product-mix, yield,rejections, cost reduction, mechanisation of work, balancing facilities, betterquality of work life, etc.

To identify bottlenecks in operation and maintenance activities and to suggestmeasures to overcome them economically.

PRODUCTON MONITORING / IMPROVEMENT STUDIES

To undertake production monitoring studies with a view to identify reasons fordelay and their quantum, and suggest remedial measures to achieve the desiredproduction / productivity.

To conduct production improvement studies in various fields like MethodImprovement, Cost Reduction, Waste Elimination, etc.

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CONTRACT MANAGEMENT

To scrutinize budget estimates for operational contract jobs of plant and mines,requirement of NMR / Casual labour, and finalise annual budget in consultationwith respective departments for optimum utilisation of resources.

To examine contract proposals related to house keeping , materials handling,maintenance / repair jobs and augmentation of production services etc. Thework includes scrutinising proposal for basic need, availability of in-housefacilities, volume of work involved, manpower / resources required so as tomaximise utilisation of available facilities and minimise off-loading.

To examine Mechanical Rate Contract jobs, and assist in fixing contractual party.

To estimate rates for machining spares done on rate contract basis.

To estimate rates for assisting tender negotiations for finalising rates of jobsdone on open tender basis.

INVENTORY CONTROL / MATERIAL ACCOUNTING STUDIES

To study status of inventories using ABC analysis to identify non-moving andslow moving inventories for recommending alternative use or disposal.

To establish norms for consumption of stored spares and consumables.

To develop and install inventory control system designed to optimise the overallinventory cost.

To conduct material accounting studies for the usage of material in process,lubricants, fuels, spares, etc. with reference to consumption, quality and losses.

FACILITIES FOR SHOP FLOOR / OFFICES

To plan progressive automation and computerisation both for the plant and forthe offices.

To render specialised assistance in office services (e.g. office facilities,equipment, management and office automation).

VALUE ENGINEERING

Value Engineering is the systematic application of techniques which identify thefunction of a product, process, equipment or service; establish a monetary value forthat function and provide the necessary function reliably, at lowest overall cost.

1. To organise Value Engineering appreciation programme and to impart training toemployees with the objective to enhance effectiveness in the area of Cost Control byresorting to Value improvement through the use of Value Engineering Techniques;

2. To conduct Value Engineering Workshop and develop Value Engineering teamsto solve live problems through multidisciplinary approach;

3. To identify potential areas and take up Value Engineering projects with theobjective to improve function and reduce cost.

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GATEWAY

BENCH MARKINGBenchmarking is used as a tool for measuring and improving the process, product

and services of an organization by compring existing prectices to the very best available. IED functions includes :

1. To conduct Benchmarking Awareness Programme and to impart training toemployees with the objective to identify the area for imprvement in process,product and services of various area of plant.

2. To identify and study the low performance area in the key shops of plant fortaking up the benchmarking project.

3. To coordinate the various activities and process of benchmarking forimplementation of project.

4. To arrange and coordinate with benchmarking partners and organize data exchange,analysis and implementation of process, products and services of the earmarked area.

5. To analyze the performance of the project taken up and improvement uponimplementation of best techniqe.

ERGONOMICSThe scientific study of man, machine and his working environment is being dealt

in ergonomics. Suitable work environment at workplace plays an important role toincrease body comfort and decrease fatigue. Objective of Ergonomics wing in IED isto design work system and man-machine system to enhance productivity by increasinghuman comfort.

Application of ergonomics in our plant :

Ergonomics awareness training program

Training program on Manual Material Handling

Training program on reduction of Musculo-Skeletal Disorder through stretchesand adopting right working posture

Application of ergonomics in office/computer work

Ergonomic survey of shops

Designing/Redesigning of control pulpits/cranes, layouts and amenities

To optimize work methods and practices, and layout modification through workdesign, Ergonomics etc.

CONSULTANCY SERVICES

To provide consultancy services to sister plants and to other organisations.

MISCELLENOUSTo develop, review and follow up management information system aimed at integratedand comprehensive system for strategic, tactical and operational decision making.

To assist as a team member in Bhilai Steel Plant Suggestion Scheme, QualityCircle, Internal Quality Audit, Lead Measurement, Conversion Factor, TenderNegotiation, Productivity Week Celebration, etc.

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MEDICAL & HEALTH SERVICESMedical & Health Services of Bhilai Steel Plant provides curative, preventive,

promotive and community health care facilities through its various satellite healthcenters and hospitals. The 860 bedded JLN Hospital & Research Centre is the biggestflagship of Medical & Health Services. It is a prestigious medical institution situatedin the heart of Chhattisgarh State and command centre for delivering health care.

The Hospital offers integrated comprehensive health care facilities i.e., Indoor,Outdoor, Trauma care, Intensive care & Investigative services on the following basis:

FREE to- Around 34000 employees & their dependents of Bhilai Steel Plant

- 10000 ex-employees

ON CREDIT to- Other public sector employees & their dependents

- Central & State Govt. Departments

- Banks & Other Private institutions under revolving deposits

- Medi-claim Patients

ON CASH PAYMENT to- Common population in & around Bhilai

The JLN Hospital is a prime referral centre to the neighboring areas with a radiusof 400 - 500 kms offering tertiary level patient care. The institution is having all thespecialties related to Medicine, Surgery & Paediatric and well supported by super-specialty services like Neurology, Neuro-Surgery, Gastro-Enterology, Cardiology,Cardiac Surgery, Paediatric Surgery, Burns & Plastic Surgery and Investigative serviceswith latest gadgets. The institution is reputed for its state of the art 22 bedded ICU/ICCU complex, 22 bedded Burn unit, 30 bedded Paediatric & Neonatal ICU, 40 beddedRadiotherapy unit and a National Occupational Health Service Centre (OHS). It isrecognized for DNB post graduate training by National Board of Examinations, NewDelhi in 11 disciplines

The average outpatient attendance is around 5000 / day and 130 patients areadmitted daily with total admissions around 47000 per year. Over 21000 surgeriesare performed annually in 6 well equipped Operation Theatres. The annual expenditureof Medical & Health Services is around Rs 45 Crores including salaries & wages ofstaff. The medical expenditure is Rs 9824 per employee per year

The institution is well supported by 60 bedded Bhilai Hospital & Oncology Unit atSector-1, Mines Hospitals at Rajahara Mines (100 kms), Nandini Mines (30kms) &Hirri Mines (140 kms), 10 satellite Health Centre in Bhilai Township and one NationalOHS Centre.

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GATEWAY

AN OVERVIEW OF VARIOUS FACILITIES

JLN Hospital & Research Center acts as the nucleus for providing and monitoring

all health care to Bhilai Steel Plant and nearby areas. The delivery system of healthcare is as follows:

Casualty & Trauma Care Services

Round the clock Medical, Accidental

& Surgical emergency services are offeredat JLN Hospital & Research Centre, Bhilai

Hospital, Sector-1 and inside the plant atMain Medical Post. Casualty at JLN Hospital

has 20 beds and is well equipped to handleany kind of disasters. Facility of direct transit

to ICU for serious patients and ambulanceon phone call are available.

Outpatient Services

At JLN Hospital & Research Centre, a spacious OPD block accommodates all

major specialties & super-specialties in its 8 wings located on two floors. Chest & TBand Psychiatry departments have their own separate blocks for outpatients, inpatients

and pharmacy services. OPD Timings are 8.00 AM - 1.00 PM & 4.00 - 6.30 PM. TheOPD services are available at health centre between 9.00 AM - 5.30 PM.

Indoor Services

Total bed strength JLN Hospital (860 beds) are divided among various specialties.

16 general wards with facility of side cabins and 2 wards with special individualcabins are located in the main building and 6 wards belonging to Chest & TB and

Psychiatry are located in their separate building (200 - 300 mts from main building).Besides general wards, Main ICU/ICCU complex, Neonatal & Paediatric ICUs, Burn

ward, Labour Room and Casualty Observation are also located in main building complex.Bhilai Hospital at Sector-1 (10Kms) has 60 beds including 40 beds of Oncology

Department. Mines hospital has total bed strength of 80 beds.

Investigative Services

These services function both for outdoor and indoor patients and run round theclock. During morning OPD hours, blood samples are collected at Central collection

centre located in the main OPD block.

Administrative Services

Director's Office with Establishment & non establishment sections are located

on the first floor adjacent to main OPD block.

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Support Services

01 Personnel & Administration 02 Computer Centre

03 Dietetics & Kitchen 04 Pharmacy Services

05 Central Medical Store 06 CSSD

07 Laundry & Tailoring Unit 08 Multimedia Data Centre

09 Medical Accounts & Finance 10 Air-Conditioning Unit

11 Medical Records & Statistics 12 Hospital Security

13 Equipment Workshop 14 Medical Documentation

15 Hospital Maintenance Services 16 Bio-Medical Waste Treatment

17 Central Oxygen Supply & Vacuum unit 18 Autoclave for BMW

19 Horticulture Unit 20 Morgue

21 Library 22 Photography Section

OVERVIEW OF WORKLOAD Year 2006-07

OPD Attendance 12,03,000

JLN Hospital 6,86,000Bhilai Hospital 1,26,000

Mines Hospital 1,17,000

Health Centres 2,74,000

Casualty Attendance 1,17,500

Indoor Patient Admissions 47,500

Total Number of Surgeries 21,000

Number of Lab InvestigationsPathological Investigations 4,14,350Bio-Chemistry 5,12,600Micro-Biology 51,000CT Scan 7050US Investigations 13,000X-rays 49,000EEG / EMG 1,200

Work Force 150General Duty Doctors 38Other Executives 29Nursing Staff 362Paramedical & Others 803

CLINICAL DEPARTMENTS

SUREGERY & ALLIED SERVICES

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GATEWAY

AnaesthesiologyThe department runs 13 centrally air-conditioned operation theatres based as

separate complexes. Facilities exist for non-invasive and invasive cardiac monitoring.The main Operation Theatre complex houses the Emergency, Endoscopic Surgery,Gynaecology & Obstetrics, Neuro-Surgery, Dental, Plastic, ENT, Cardiac OTs andtwo General Surgery OTs. Burns Unit has an independent OT, attached to the ward.In another separate wing are located Orthopaedic (2 OTs), Eye and a Septic OT.Facilities for arterial blood gas analysis and specialized anaesthesia services for neuro-surgery are available.

General SurgeryWorks on 2 Units system and incorporates Thoracic Surgery, Urology, Paediatric

Surgery, Vascular and Minimal Access Surgery. A separate Endoscopic OperationTheatre exists to facilitate Endo-Urology and Laparoscopic Surgeries. Urology isundertaking Endo-Urological and TURP operations as specialized procedures apartfrom conventional work.

Burns & Plastic SurgeryBurns Unit of JLN Hospital and Research Centre runs a 22- bedded separate

Burns Ward with an attached Operation Theatre facility and 12 bedded plastic surgeryward. Around 500 patients are admitted yearly and 400-450 operations are beingperformed out of which about 200-250 burns, 150-200 are plastic surgery cases andaround 80-100 cases are of cosmetic surgery. Survival in Burns is at par withInternational level as high as 95%. Many cases of crush injuries of limbs are beingoperated regularly with good salvage rate.

Neuro-SurgeryNeuro Surgery has a 30 bedded specialty ward. Besides managing head injury

cases, specialized treatments done in the Unit include Acoustic Neuroma Surgery,Intra - medullary tumours of spinal cord, Vascular malformations of brain and anteriorapproach to cervical spine.

Cardiac-SurgeryCardiac Surgery Unit established in 1990, has a well equipped Operation Theatre

and an exclusive Intensive Care facility with all modern gadgets including Intra AeorticBaloon Pump. Congenital heart surgery, valve replacement and coronary artery bye-pass surgeries are being performed.

Obstertrics & GynaecologyObstetrics & Gynaecology department provides special facilities for high risk

pregnancy, cancer, infertility and monitoring with ultrasonography and cardiotopography.Diagnostic and therapeutic laparoscopy, tubal microsurgery, oncological surgery andGIFT are being performed. The department has 17 bedded labour room with all therequired facilities. RCH functions under Obstertrics & Gynaecology.

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ENT

It is a well established department having all modern investigative and surgicalfacilities. Specialised investigations being done are computerized audiometry andBERA. Facilities are available for evaluation of speech disorders. An Upgraded SpeechRehabilitation Centre functions on all working days. A fully equipped minor operationtheatre runs in ENT OPD premises to take care of minor surgical / emergencyprocedures. Various specialized surgical procedures done are :

Micro-ear surgery

Head and neck cancer surgery with reconstruction

Microlaryngeal surgery

Functional endoscopic sinus surgery

Facio-maxillary trauma surgeries

Orthopedics

The department is a specialised unit in trauma and emergency managementcapable of dealing all major and minor orthopaedic trauma problems. The departmentdeals with all types of orthopaedic problems that include replacement & spine surgery,therapeutic and diagnostic arthroscopy. The department has a well equipped Physio-Therapy Unit with following facilities available on all working days:

Computerised Microwave

Shortwave Diathermy

Laser Therapy

IFT

Ultrasonic Therapy

TENS

Contrast Bath

CPM

Infra Red Therapy

Ophthalmology

Ophthalmology offers a wide variety of outdoor, indoor & operative facilities onall week days. Specialised services include IOL implantation, glaucoma and squintsurgery. A Contact Lens Clinic also functions in the department. The department hasthe facility of Laser Photocoagulation and Fundus Flurocein Angiography. In January,2002, a "Free Community IOL Implantation Centre" has been started in Sector-IHospital with a target of about 500 cases per year.

Dental Surgery

The Department provides facilities for fixed crown and bridge work, RPD and fulldentures, root canal, cosmetic and maxillo-facial trauma surgery. Specialized equipmentavailable are OPG and cephalogram for orthodontic procedures and dental autoclave.

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GATEWAY

The deptt. caters to about 200 patients per day. Services are also extended to Sector-I hospital and Mines Hospital on designated days.

MEDICINE & ALLIED SERVICESGeneral Medicine

The department functions through two Unit system and has important sub-specialties like :

Cardiology Gastro-Enterology Neurology NephrologySub-specialities like Endocrinology (Obesity and Diabetes clinic) and Haematology

also function on fixed OPD days.

CardiologyCardiology Unit is equipped with Echocardiography and Color Doppler facility,

Transoesophageal Echocardiography, Holter monitor and TMT. The annual OPDattendance is around 9000 patients.

Procedures done in cardiologyECG

Computerised Holter Monitoring

Doppler Echocardiography

Temporary pacing

TMT

Trans- Oesophageal Echo-cardiography

Permanent pacemaker implantations

Gastro-Enterology

This unit provides and performs varieties of diagnostic and therapeutic Endoscopicprocedures. Approximately 20000 patients visit the OPD services per year.

Procedures done in Gastro-Enterology unit

Diagnostic & therapeutic sigmoidoscopy, UGI endoscopy & colonoscopy

Diagnostic & therapeutic ERCP

Neurology

The Deptt. provide both adult and paediatric neurology services with the supportof EEG and EMG machines in Electrophysiology Lab. Approximately 17,000 patientsattend the Neurology OPD every year in outdoor with Paediatric Neurology casesnumbering around 750 per year seen in Paediatric Neurology Special Clinic on everysaturday.

Investigations done in Neurology department

Edrophonium testing for myasthenia gravis

EMG test

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NCV test

Evoked potential study

EEG test

Botulinum toxin administration

NephrologyProvides haemodialysis facility (4 machines) in two shifts for 6 days in a week,

peritoneal dialysis, exchange transfusion and kidney biopsies.

PsychiatryVarious specialized facilities being offered are Child Guidance Clinic, De-addiction

Clinic, Cognitive Therapy, Behaviour Therapy, Modified ECT and Counseling for Sexualdisorders. Also operates a well-equipped psychology lab at OHS Centre inside theplant.

Chest & TBThe department is housed in a separate building with separate outpatient and

inpatient facilities for Chest & TB patients. Total of 4 wards, 45 beds for chest and30 beds for TB patients are available. Chest admissions are around 600 per year andTB cases 90 to 100 per year and around 37,000 patients are seen in OPD. Thedepartment is associated with the Revised National Tuberculosis Control Program(D.O.T.- Directly Observed Therapy) for control of tuberculosis.

DermatologyDermatology provides facilities for treatment of Skin, Sexually transmitted diseases

and leprosy. It also has equipments for PUVA therapy, Electric Cautery, Cryosurgeryand Dermato-Surgery. Around 62000 patients attend the OPD yearly. The departmentis associated with the National Leprosy Eradication Programme and AIDS awarenessprogramme.

Radiation & Medical OncologyRadiation & Medical Oncology Deptt. runs in a separate complex in Bhilai Hospital,

Sector -1. The Department is well equipped and has all modern facilities for dealingwith cancer cases like :

Radiotherapy (Cobalt Machine) - Treatment of Cancer with Radiation

Chemotherapy - Treatment of Cancer with anticancer Medicine

Treatment Planning System - Copmputerised TPS helps in planning adequate

dose for tumours while saving normal organs.

PEDIATRICS & ALLIED SERVICES

General Pediatrics

The services include General Pediatrics including immunization services andCommunity Pediatrics. The department has been awarded recognition as a "BabyFriendly Hospital" in the year 1995. The department has achieved its target ofsurpassing the National indices in relation to infant mortality rate.

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GATEWAY

The department actively participates in the organising

World Breast Feeding Week

Teenage day

ORS Week

Neonatal Unit

The 30 beds setup has been accredited by the National Neonatology Forum asLevel-II Special Care Neonatal Unit. A 10 bedded Upgraded Neonatal ICU wascommissioned on 2.10.2003. In addition to ventilation, phototherapy, exchangetransfusions, surfactant replacement therapy are done. Neonates with surgicalproblems are managed by Paediatric Surgeon. Monthly regular perinatal meetings areorganised. The unit has facilities like Sechrist millennium ventilators, Graphics monitor,HP Bedside cardiac monitor, Open Intensive Care Systems, Incubators & Infusionpumps, Single and double surface phototherapy units etc.

Hepatitis B vaccine is given free to all hospital born babies as SAIL policy.

Pediatric ICU

For managing cases in the pediatric age group, a 10 bedded fully equipped ICU isavailable. The unit caters to critically ill children suffering from various surgical &medical diseases. It supports various specialties like Paed. Surgery, Neuro-Surgery,Orthopedics, Nephrology, Cardiology & Neonatology (Out born Cases). The survivalrates are progressively improving. Ventilation, peritoneal dialysis, central lines,exchange transfusions are performed.

INVESTIGATIVE SERVICESRadio-Diagnosis

A very well equipped department, Radiology Section is doing a wide variety ofdiagnostic and therapeutic procedures. The procedure performed include therapeuticand diagnostic angiography, CT angiography, Ultrasound/ CT guided procedures, CTperfusion studies and Ultrasound Doppler Studies. The department is equipped withspiral CT Scan, Ultrasound & Peripheral Color Doppler, Portable X-rays and ImageIntensifier. MRI Scan and Digital X-ray facilities are being added shortly.

Pathology

Pathology Unit has four major sections namely Histopathology, Haematology,Cytology & Blood Transfusion Services. The Department ensures round the clockservices. The department has a modern Blood Bank that runs on a voluntary basisand provides 100% risk free and infection free blood to patients. The donated bloodis compulsarily screened for HIV, Hepatitis B & C, VDRL and Malaria infections. TheDepartment runs a centralised blood sample collection centre in OPD block on 1stfloor and has facilities like Automated Cell Counter for complete blood profile, Elisareaders, Electrophoresis system etc.

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Bio-ChemistryAll diseases have a biochemical basis and biochemical investigations contribute

towards diagnosis, prognosis, treatment and follow up monitoring while managingserious cases. With its dedicated team, the department is engaged in carrying outvarious routine & specialised life saving biochemical investigations on blood, urineand various other extra-vascular body fluids with strict Quality Assurance. On anaverage 1200 biochemical tests are done daily

MicrobiologyMicrobiology Unit deals with the investigations of Infectious diseases. The

department provides round the clock investigation facility and is managed by adedicated team of Microbiologist and Lab Technologists

Nuclear MedicineThe department is equipped with SPECT Gamma Camera with DOT Imager, 37

Digitrac, Orbiter, Cardiac Exercise Table. In addition Nobel Prize winning techniqueRIA (Radio Immuno Assay) is done with Gamma Counter for harmone estimation.Under Nuclear Thyroidology, special Thyroid Clinics are held weekly on Wednesdaysin OPD Room No. 5C with a number of thyroid beneficiaries.

Occupational Health ServicesOccupational Health Service Centre of Bhilai Steel Plant is recognised as a National

Model Centre and has OHSAS 18000 certification. The Occupational Health Servicesoffer multi-disciplinary work related health care facilities to all employees of the plantfrom recruitment to retirement & beyond. The OHS Centre is located inside the plantpremises & is dedicated to improve the quality of the work environment by studyingits impact on health of exposed employees through its regular Industrial hygieneSurveys. Recommendations in the form of engineering control measures are suggestedto improve the working environment. Many of the engineering control measures havebeen implemented in different departments making the workplace congenial and hazardfree. OHS Centre is fully equipped with all infrastructure facilities to provide totalhealth care through an integrated approach and is fully functional to achieve thecorporate objectives. The OHS center publishes Health education material and popularquarterly news letter 'Shubhchintak'.

The Centre has following facilities with dedicated & skilled man power :

• Occupational Medicine • Ophthalmology • Audiometry • Occupational Hygiene Computerised • Occupational Health Information System

• Work Physiology & Ergonomics • Occupational Psychology • Biochemistry and Toxicology • Radiology • Health Education • Emergency Medical Care

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GATEWAY

Work Place Monitoring :

Occupational hazards monitoring & control measures. Four deptt. are coveredevery month.

Specific problems on occupational hazard are attended in the shop floor

PPE (safety appliances) are issued on the recommendations by OHS Centrebased on hazard

surveys

Various health education programs like First Aid, AIDS awareness and workplace hazard & its prevention are organized regularly throughout the year.

COMMUNITY HEALTH SERVICES

Regular Camps are organized throughout the year in strategic places as a part ofCommunity Health Measures under Corporate Social Responsibility that includes

Free Intra-Occular Lens Implantation (IOL)

Free Rubella & Hepatitis vaccine in addition to Routine vaccinations

School Health Program

Health Camps in the adopted Model Steel Village Piperchhedi

Free Hepatitis 'B' Immunisation for all New born

National Health Programs

AIDS Awareness Program under NACO

National Pulse Polio Program

D.O.T.'s Program under Revised National Tuberculosis Control Program (RNTCP)

Blindness Control Program

Leprosy Eradication Program

Reproductive Child Health (RCH) Programs

'SHIHSU SANRAKSHAK MONTH' (Twice a year)

Under RCH Activities, Family Welfare Camps providing Laparoscopic tubectomyand Vasectomy & sterilisation operations, are organised routinely with provision forincentives. RCH activities also include supervision of immunization schedules andtreatment of minor ailments of children under 5-years of age by department ofPediatrics. This program is free of cost to all patients. World Breast Feeding week iscelebrated every year.

ACADEMIC ACTIVITIES

JLN Hospital & Research Centre is accredited by the National Board ofExamination, New Delhi for DNB Post Graduate Program in 11 disciplines with22 number of inductions every year. A total of 65 candidates have been awardedDNB degree till 2006. Various facilities include

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Regular departmental / Institutional level teaching

Regular internal assessment

High Speed Internet facility

A well stocked library with an annual budget of Rs 30 lakhs and facilities ofinternet and audio visual aids.

Training of Doctors, Nurses and Paramedical staff of State Govt. & other Institutions

CMEs and Guest lectures.

Publication in national and international journals ( Over 180 Publications)

Active and regular participation in various National Conferences by all specialities.

Organizing state/national level conferences.

Occupational health consultancy services to various industrial organisations.

New high-tech diagnostic medical equipments are installed in main hospital viz:

Most advance MRI machine worth Rs. 5.84 Crores.

Digital X - ray machine.

Colour Doppler in Radiology Department.

Operating microscope for Neuro - surgery.

Automatic red cell counter equipment in pathology deptt.

IRMA machine at nuclear medicine deptt.

Portable echocardiography machine for community health care services.

Occular Fundus Camera in eye deptt.

Variant haemoglobin machines at pathology deptt.

It is worth mentioning that online appointment for General Medicine Deptt.(Room No.-1) has been introduced in main Hospital.

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GATEWAY

MARKETING & STRATEGIC PLANNING DEPARTMENTMarketing & Strategic Planning department of BSP acts as an interface between

Plant & CMO for Co-ordinating marketing activities with CMO for sale of prime products. Apart from this , it also carries out direct sale of secondary products and by-products generated in plant . The activity frame work is given below in Fig-1

I) Prime Product Area: The various activities in prime product sale namely finalizingmonthly sales plan , order management, monitoring and review as well as the CSIreview and complaint handling are co-ordinated through M & SP department asdetailed below.

I.a. Making Sales Plan: Although annual sales plan is made in the beginning of the yearbased on the demand projection by MRG/CMO, month-wise sales plan is worked outbased on the actual demand indication from CMO. The plan is finalized in the salesco-ordination meeting jointly with CMO representatives from different regions. The plantakes into account the product-wise, profile-wise, quality-wise supply capability of plantand the most productive/profitable product mix in demand is finalized.

I.b.Order Management : It is one of the structured and core processes with logistics managedby Despatch co-ordination/Traffic department. IT is the key enabler of the process.

Customers' requirements are clearly understood, compiled and documented andcompared with Technical Delivery Conditions (TDC).

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Based on the TDC, the orders are classified as:

Standard orders: Standard orders are executed as per the laid out quality plan fromsteel making to dispatch.

Standard order with special conditions: The accepted special conditions are mentionedin the steel order and rolling programme so that they are communicated down theline and the customer requirements are taken care of.

Special /Customised orders: In case of special orders, a separate protocol is madewhich is the quality plan for that order from steel making to dispatch. All exportorders are treated as special orders. Protocol and TDC together ensure delivery ofcustomised products.

In case of flat products, each order is examined before its acceptance by across-functional team comprising of executives from Plate Mill, SMS-II, RCL, PPCand M&SP departments. Plate enquiry committee examines the feasibility ofacceptance of orders in terms of size, grade of steel, TDC and other requirements ofthe customers and confirms the delivery schedule. The process of "Order Processingand Delivery" of BSP products is given in Fig -2.

As regards long products, which are primarily standard products, campaign rollingis done for various profiles and qualities as per demand projection by CMO in thesales co-ordination meeting. Orders are provided by CMO as per the commitmentagainst which supply is made to the desired destinations.

Order Review Mechanism:

Review of status of availability of orders and planning for heat making is done ondaily basis. For plates, it is done by PPC (Programming) in consultation with PlateMill, SMS-2 & RCL. For long products, planning of heat making and review of dailyperformance is done by head of BBM in association with representatives from finishingmills, SMS-1, RCL and PPC.

Timely delivery in line with the customer's requirement/commitment is plannedin the daily despatch co-ordination meeting in which SRM is present from CMO for

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GATEWAY

deciding the destinations for rake dispatches. Review of plate order fulfillment (fromheat making stage to dispatch of material) on weekly basis is done by head of Platemill alongwith representatives from all concerned agencies. Quality related issuesand fulfillment of special steel orders/ committed deliveries are reviewed by ED(Works) on weekly basis. For plate orders which can not be serviced due to anyconstraint, revised delivery schedule is worked out and communicated to the customerthrough SRM.

I.c. Key Account Management :

BSP is continuously striving to improve customer sales and service relationshipthrough creativity and innovations. Categorising customers into National Key Accountsand Branch Key Accounts and making individual Key Account Manager accountablefor each Key Account customer is one of the major initiatives taken in this direction.The system has been further strengthened by identifying Plant Information Coordinator(PIC) and Plant Account Coordinator (PAC) from senior level executives of BSP. Thissystem provides the customer a single window support through KAM and a strongresponsive system at the plant to take care of his needs. Regular follow-up on salesand services is done by the Key Account Managers and feedback is sent to the plantto take corrective action, wherever required. If felt necessary, meeting of plantexperts are also arranged with customers to solve their problems. The RegionalManagers (RMs) of CMO posted in all 4 regions also keep a close watch on productand services provided to the customers of their respective region. They personallyinteract with the customers.

Plant leadership is in regular touch with RMs and EDs in CMO and appropriateactions are taken by Plant / CMO to enhance customer satisfaction by organizingcustomer meets in the different regions with all important/key customers forimprovement action at plant.

The various parameters on which customer satisfaction index(CSI) is receivedand monitoring and reviews are made at plant level on monthly basis includes

1) Quality of product- Physical & Chemical etc.

2) Delivery-Lead time, adherence to delivery schedule, information on order status.

3) Service- Performance of cross functional teams

In the CSI measurement process, the rating given by customer based on hisperception on the product and service received. The weightage given for differentparameters is decided by the customer himself depending on the importance of theparameter for him.

Here is an illustrative format showing the parameters and weightage identifiedby M/s BHEL Trichy, for BSP plates.

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Category Parameter Weightage

Thickness variation 10%

Width Variation 10%

Length Variation 10%

Edge Condition 10%

Quality

Chemistry 10%

Lead time 15%

Adherence to delivery schedule 15%

Delivery

Information on order status 10%

Service Performance of cross functional team 10%

Total 100%

The CSI is reviewed at plant level every month by PAC and PIC every monthalong with concerned shop personel and SRM and by GM (M&SP) on quarterly basis.Suitable corrective actions are formulated and implemented to enhance the customersatisfaction level .

A flowchart of CSI monitoring and review process is given in Fig-3.

SRM

Key Customer

SRM

Reviews

CSI Reports

Corrective Actions

PIC/PAC (BSP)

Key a/c Mgr

SRM

Check for Improvement

Fig-3

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I.d. Complaint Reddressal Mechanism: Apart from taking regular feedback from thecustomers on our products and service, there is also a well documented and structuredcustomer complaint handling procedure which is given below. The procedure fortaking corrective / preventive action is audited for checking its effectiveness regularlyby Internal Quality Auditors during scheduled Internal Quality Audits as well as bythe auditors from M/s LRQA, our certifying agency for ISO: 9001 QMS, duringsurveillance audits. The complaint data are systematically compiled, analysed and

reported ManagementReview meeting heldquarterly. This is aclosed loop systemwhere the customer isgiven the feedback onthe corrective actiontaken at plant to avoidrecurrence of theproblem.

In reaching out to customer, Central Marketing Organisation (CMO) is our partnerfor marketing of our products.

The network of CMO includes Branch Sales Offices, Warehouses and Customercontact offices. This network is supported by a strong network of SAIL dealers toensure Bhilai steel reaches even in the remotest areas of our country. Our Exportmarket is catered to by International trade Division

M & SP department facilitates in effective implementation of various strategiesadopted by BSP in enhancing customer satisfaction that are enlisted below.

Market segmentation Internal customer satisfaction

New product development Quality Improvement

Customisation. Customer service through IT

Maximising Value added products. Partnership with customers

Key Account Management

II a. Secondary Iron & Steel Products.At present, Plant carries out Sale of secondary iron & steel products primarily

through On line Forward auction (OLFA) through Metaljunction.com as per the corporateguidelines . The material is offered in different lot sizes in metalJunction's internet platform.The lots for which the prices are more than the reserve price, are cleared for sale and thehighest bidder amongst the participants where H1 price is above reserve price gets theoffer to buy the material in line with the guidelines. OLFA system ensures participationfrom wider customer base , competitive pricing as well transparency.

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II.b. Coal Chemicals,Fertilisers

Coal chemicals are produced from Coke oven gas by the fractional distillationprocess in the Coal chemical division. These products are required to be liquidated intime due to limitation in the storage as well as the explosive nature of the product.These material are sold both to local/outside customers. The various major productssold from CCD are detailed below.

Benzene Crude Coal Tar

Toluene Granulated Pitch

Xylene SM pitch

Solvent Oil Wash oil

Still Bottom Oil Hy Creosote Oil

Hy Benzol Light Creosote Oil

Anthracene oil Light OIl

HBO/DPO/DNO Sodium Phenolate

Ammonium sulphate

Presently both Fixed price and OLFA mode are being adopted for sale of theseproducts.

Dynamic pricing system is adopted for these products as per the market trend.The products are used in Chemical industry/Dye Industry/Aluminium industry etc.Ammonium sulphate is sold for agricultural sector to different states namelyChhattisgarh, Madhyapradesh, Andhrapardesh, Maharashtra, Bihar etc. The dispatchesare done both by Rail and Road.

II.c Blast Furnace Granulated Slag

Mostly sold through long term contracts (MOUs).

Other customers also buy through Fixed price sales mode.

II.d Misc / Non Ferrous Items

Misc/Non ferrous items viz used refractory brick bats, Cinder, Lime sludgeIndustrial gases etc. are sold through On Line Forward Auction (OLFA)/Fixedprice sale modes.

For secondary products/by-products, which has got a large no of local customerbase, interaction is held on regular/continuous basis for reddressal of marketingissues, if any, raised by the customers.

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FINANCE & ACCOUNTS DEPARTMENT

For any organisation, the Finance & Accounts function plays a key role in guidingthe organisation to meet its ultimate goals and objectives. While Finance functionembarks upon regulating the inflow and outflow of funds, the Accounts functionbasically supports the finance function by way of analyzing the transaction in a mostbefitting manner. Finance & Accounts function is like a mirror through which onecan peep into the health of an organisation.

Finance & Accounts Department of BSP has to execute several activities. TheDepartment has been divided into several sections based on organizational needs andfunctional expertise required by grouping activities of similar nature as a section.The objective of Department is always to meet the requirements of Line Departments,customers, suppliers, stakeholders and Government Departments while dischargingits own functions such as accounting, budgetary control, rendering advice on financialmatters and meeting the statutory requirements. To back up all above functions, theDepartment has a vast and dedicated team of professional accountants and experts.

The entire department is represented by the following sections -Cash & Bank

Central Accounts & Assets Accounts

Central Excise & Service Tax

Contract Concurrence

Contributory Provident Fund (CPF)

Cost Accounting & Energy Cell

Final Claim Cell (FCC)

Finance Co-ordination & Administration

Freight & Claims

Import Accounts

Incentive Cell

Management Accounting

Medical Accounts

Mines-Rajhara, Nandini, Hirri

Operation Accounts

Operation Budget

Project Finance & Accounts

Purchase Concurrence

Raw Material Accounts

Rent Cell

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Sales Accounting

Sales Invoicing and Central Freight

Sales Tax & Entry Tax

Stock Ledger (Stock valuation)

Stock Verification

Store Accounts

Store Bill Accounting

Store Bills

Township Accounts

Wages

Finance also discharges special functions such as taxation. A brief on variouskinds of indirect taxes is being discussed in the following lines.

Indirect Taxation at a glance

"In this world, nothing can be said to be certain except death and taxes."

(Benjamin Franklin)

(In a business environment, it is of utmost importance to know the taxation lawsas it affects the business directly. Acclimatization of indirect taxation would help inunderstanding external legal requirements and its importance in smooth operation ofthe business. Various indirect taxation laws being complied with by Bhilai Steel Plantare briefly discussed in the following lines.)

CENTRAL EXCISE

Central Excise is an indirect tax on the act of manufacture of goods and iscollected at the time of their removal from the factory for administrative convenience.The following conditions are to be satisfied for excisability of a goods :

Goods should have come into existence as a result of 'manufacture'. This meansa new, distinct and identifiable goods must emerge as a result of manufacture.

Goods must be movable. This means the goods should be able to come to the market.

Goods must be marketable. Any thing which is not marketable shall not attractexcise duty.

The goods must be specifically mentioned in the Central Excise Tariff Act so asto become excisable.

The entire law relating to Central Excise is covered under Central Excise Act andCentral Excise Tariff Act. While the Central Excise Act and Rules prescribe variousgoverning provisions, the Central Excise Tariff Act, which is divided into 96 chapters,prescribe the rate of tax. Entire tax administration is under the Ministry of Finance,Govt of India. Present rate of excise duty is generally 16% advalorem with Education

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Cess @2% and Secondary & Higher Education Cess of 1% on Excise Duty.Accordingly, the total duty would be 16.48% on the value of the manufacturedgoods.

Cenvat (Central Value Added Tax) credit is the credit of duty availed by thepurchasing manufacturer of the goods on the excise duty on inputs and capital goodspurchased by him to avoid the cascading effect of multiple taxation. Cenvat credit isallowed on the sole analogy that so long as output is taxable to excise, it should nothave burden of tax on inputs used in the manufacture of the same. In other words,both inputs and outputs should be not taxed to excise duty. The cenvat credit isallowed on the inputs and capital goods used in or in relation to the manufacture offinal products within the factory of production.

Excise duty is payable on the 5th of the following month except in the month ofMarch when the duty is payable on 31st of March itself. Excise Returns are submittedby 10th of the following month.

SERVICE TAX

Service sector has come to play a dominant role in the Indian Economy.Constrained by revenue pressure, the Union Government levied Service Tax in theyear 1994 and to begin with it was restricted to insurance, telephone and stockbroking services. The list saw steady expansion and by the year 2007, more than100 services have been made taxable. Salient feature of service tax law is outlinedbelow :

Like duty of excise, service tax paid on input services is also cenvatable.

Service Tax is administered by the Central Board of Excise & Customs throughits formations like Commissionerates, Divisions and Ranges.

Service Tax is applicable to the whole of India except the State of J&K.

Not all services are taxable. Only those services which are notified are liable toservice tax.

The tax is levied at a uniform rate of 12% on the value of taxable services.Besides,Education Cess @ 2% and Secondary and Higher Education Cess @1%on the service tax are also applicable. Accordingly, the total service tax payablewould be 12.36% of the value of taxable services.

No service tax is payable when service is provided free of charge or no amountis charged from customers.

The person providing the taxable service is required to pay the tax and collectthe same from service receivers.

Service tax is payable on 5th of the following month. However, Service Taxreturns are submitted half yearly.

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Some of the most commonly availed services on which service tax is payableare as under :

SN Description of the Service Effective From

1. Business Auxiliary Services 10.09.2004

2. Cargo Handling Services 16.08.2002

3. Commercial or Industrial Construction Services 10.09.2004

4. Consulting Engineer’s Services 07.07.1997

5. Erection, commissioning or Installation Services 01.07.2003

6. Maintenance or Repair Services 01.07.2003/16.06.2005

7. Transport of Goods by Road Services 01.01.2005

8. Cleaning Services 16.06.2005

9. Mining Services 01.06.2007

10. Renting of immovable property services 01.06.2007

VALUE ADDED TAX (VAT)

Value Added Tax (VAT) was first introduced in France and initially did not coverservices. The European Union, UK, China, Sri Lanka, Brazil and Canada are some ofthe countries who have introduced VAT. VAT as a system of commodity taxationexists in about 130 countries across the globe.

VAT as a tax model is expected to improve State finances, introduce fiscalreforms at the State level, bring down the prices of goods, improve sales taxadministration and reduce paper work in connection with sales tax. Salient featuresof VAT is discussed below -

Value Added Tax (VAT) is a general consumption tax assessed on the valueadded to goods.

It is a general tax that applies, in principle, to all commercial activities involvingthe production and distribution of goods.

It is a consumption tax because it is borne ultimately by the final consumer. Itis not a charge on companies.

It is charged as a percentage of price, which means that the actual tax burdenis visible at each stage in the production and distribution chain.

Input tax credit can be set off against the output tax by a registered dealer.VAT liability of a dealer is to be calculated by deducting input tax credit fromtax collected on sales.

Input tax credit on capital goods is available both for manufacturers and traders.However, tax credit on capital goods may be adjusted over 36 equal monthly

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instalments. Further, input tax credit on inputs like raw materials is available inone instalment.

Input tax credit is available based on the 'TAX INVOICE' issued by the VATdealers clearly showing the TIN of both supplier and purchaser.

There is a negative list of capital goods which is not eligible for credit.

CST purchases (tax paid on the purchases made from outside the State) do notqualify for input tax credit.

There exist a Tax Payer Identification Number (TIN) which is mandatory in allthe VATdocuments.

VAT liability will be self-assessed and there will not be any compulsoryassessment at the end of each year. However, correctness of self-assessmentwould be checked through a system of departmental audit.

All other existing State level taxes such as turnover tax, surcharge, additionalsurcharge and special additional tax would be abolished.

Entry tax existing in the State of CG shall continue as the same is levied in lieuof octroi. Further the said entry tax shall not be vatable.

VAT is payable on 10th of the following month. However, VAT payment forthe quarter end is payable on 30th the following month. VAT Returns aresubmitted quarterly.

CENTRAL SALES TAX (CST)

Central Sales Tax is the tax on sale of goods in course on inter state sale. Sale incourse of Inter state sale in simple words means sale of goods from one state toanother either directly or through transfer of document of title to the goods. TheCentral sales tax is governed by the provision of Central Sales Tax Act. Though it iscalled Central Sales Tax, it is payable in the state from which the movement of goodscommences and the tax collected under the Act is retained by the state in which it is collected.CST in each state is administered by the local sales tax authority of each state.

Under CST Act goods have been divided in two major parts 1) Declared goods(2) Other than declared goods. Declared goods are goods which are declared by theGovernment to be of special importance. An important provision of CST Act is usage

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of various Forms in which declaration is to be given by the seller/buyer. These formsare used for availing concessional/nil CST. For example "Form C" is given by aregistered dealer to his seller for availing concessional rate of tax @ 4% or nil whichever is lower provided the goods are mentioned in his registration certificate. Thesaid concessional rate of CST has been reduced to 3% in the Finance Act of 2007.In the absence of concessional forms, the full rate of tax as prevalent in VAT Actwould be applicable on the goods. The basic aim of giving concession to the dealer isto either provide conducive environment for the growth of particular industries in thestate or to avoid undue tax burden at the production/manufacturing stage or at thesales stage. As per the scheme of law, no credit is available on the CST paid oninter-state purchases of goods rendering CST purchases uneconomic and unviable.CST is paid on the 10th of the following month. However, CST payment for thequarter end is payable on 30th the following month. CST returns are submittedquarterly.

Govt of India is likely to phase out CST completely so as to augment Goods andServices Tax across the country.

ENTRY TAX

In the year 1976, Madhya Pradesh Sthaniya Kshetra Me Mal Ke Pravesh Par KarAdhiniyam (Entry Tax 1976) was enacted by the State Legislature to levy tax ongoods in lieu of octroi tax being collected by the local municipal bodies. The mainobjective of the Act was to make transportation of the goods trouble free by abolitionof octroi check gates. Immediately after the enactment of the aforesaid Act, Stateof MP issued a press note to the effect that entry tax on industrial raw materialwould be levied at the concessional rate of half percent. However, the said rate ofhalf percent has been increased manifold by the State Govt from time to time. Afterformation of State of Chhattisgarh, the said Entry Tax Act has been followed by theState of CG also.

The main features of Entry Tax Act in the State of CG is discussed below :

Incidence of taxation is on the entry of goods and not linked to sale or purchaseof goods. In other words, as soon as the goods are entered into a local area,the tax becomes leviable irrespective of the nature of transaction.

All kinds of goods (except few exempted goods) are subjected to entry taxwhereas in other States, entry tax is payable on few items only.

The maximum imposable rate of entry tax is 50% with effect from 05.06.2001. Priorto this, the maximum imposable rate was 10%. It is pertinent to note that suchmaximum imposable rate of 50% is the highest rate of entry tax in the entire country.

Since Entry Tax is payable by the dealer causing entry of the goods, it is a kindof direct cost which can not be passed on to the buyer of the ultimate goodsthrough price. Further, since entry tax paid on inputs and capital goods is notvatable, as no input tax rebate is available, it becomes a direct cost.

It is worth mentioning that a definite share of entry tax collected by the StateGovernment is paid back by the State Government to the local municipal bodieson the analogy that entry tax is leviable in lieu of octroi tax and the said octroi

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tax was otherwise leviable by the local municipal bodies. However, many ofthe local bodies have also imposed Terminal Tax on movement of goods beyondlocal areas. As such, the dealer has to bear tax both on entry and exit of thegoods rendering their products uncompetitive in the market. This has led to asituation like double taxation without matching benefit of tax concession onvalue additions.

Major raw material for BSP like iron ore, coking coal, limestone and ferro alloysare taxed @6% to 10% whereas in other States, these goods are taxed at nilrate/negligible rate.

BSP is liable to pay entry tax on its own mined ore from its captive mines.Entry tax is also payable on the goods imported from other countries.

In most of the States, there is no Entry Tax on minerals. In the neighboringstate of Orissa, the rate of Entry Tax on minerals is just 0.5% but in the Stateof CG the Entry Tax rates on minerals are highest.

Entry Tax is paid on the 10th of the following month. However, Entry Taxpayment for the quarter end is payable on 30th the following month. Entry Taxreturns are submitted quarterly.

TERMINAL TAX

As per Constitution of India, State Govt enjoys the power to levy taxes ongoods and passengers carried by road or on inland waterways. As per the provisionscontained in Municipality Act, Bhilai Municipal Corporation (BMC) has imposed TerminalTax wef 15.05.1999 for exit of goods affected outside the municipal limit of Bhilai.The salient features of the said tax is discussed below -

The rate of terminal tax is 0.10% on iron & steel, chemicals and all types ofmachinery. The terminal tax is calculated on final value of goods at the time ofremoval from the factory.

Payment alongwith returns is to be made by 10th of the following month to BMC.

Terminal Tax is payable only on goods despatched by ROAD. No terminal taxis payable for goods being despatched through RAILWAYS.

Terminal tax is not payable on goods meant for exportation outside the territoryof India.

Terminal Tax is a kind of indirect tax which is recoverable from the customers.

Terminal tax is imposed without providing any civic amenities in BSP Township.BSP spends huge amount on its township without getting any aid/facility fromBMC.

Only few municipal councils in the State of CG have imposed terminal tax.

"The art of taxation consists in so plucking the goose as to obtain the largestpossible amount of feathers with the least possible amount of hissing."

(Jean Baptiste Colbert)

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PROJECTS DEPARTMENT(KNOWN AS CONSTRUCTION DEPARTMENT ALSO)

1. Background

Steel Industry with its vital and forward linkage has a critical role to play in theplanned economic development of the country. Steel is one of the critical materialsrequired for sustaining the growth of countries economy.

While the steel industry has phases of conscious success in the past, it is presentlybeset with the problem of lower capacity utilization, high-energy consumption, lowerproductivity, high cost and Technological obsolescence. These problems are beingtackled through comprehensive planned corporate strategies for greater satisfactionto the customers & meeting the global demand of steel.

2. Importance of Projects

A Project in a steel plant involves number of activities right from Conceptualization,Planning, finalization of Consultant, Feasibility report, seeking approval, Tendering,Ordering, Execution & Commissioning of units to achieve the desired results.

During the execution of Projects various activities viz Enabling works (Siteleveling), Excavation, Concreting, Structural fabrication & its erection, TechnologicalStructural fabrication & its erection, Manufacturing & supply of equipment & itserection, Sheeting, Refractory lining etc are involved.

With market globalization and capacity expansion, present steel industry is passingthrough a phase stiff competition among large number of major players. Today inorder to remain in the competitive market, it has become essential for the manufacturersto produce steel of superior quality at competitive cost. This needs continualimprovement in Techno-economics involving maximizing capacity utilization, higherproduction, lower energy consumption besides adoption of latest Technologies toproduce customized and value added products. It is also very important that the up-gradation/modification/addition is executed in time to reap the benefit of theopportunities available in the market.

Thus the role of Project department is of extreme importance in effectivecoordinating and meticulously monitoring the various activities and ensure that theProject is completed in time.

3. Need of Projects

☯ INSTALLATION OF NEW UNITS

☯ MODIFCATION OF EXISTING UNITS

☯ SUBSTITUTION OF AGED UNITS (REPLACEMENT)

☯ INTRODUCTION OF AUTOMATION SYSTEMS.

☯ INTRODUCTION OF STATE OF THE ART TECHNOLOGY

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4. Advent of Bhilai Steel Plant

The Government of India, entered into an agreement with the Government ofUSSR on February 2, 1955, seeking technical & financial collorabation forestablishment of Bhilai Steel Plant. The 1.0 MT Expansion work was completedsuccessfully. The BSP journey for expansion is continued since then.

5. Non stop journey of Bhilai Steel Plant (1.0 MT to 7.0 MT Crude steel)

I. 1.0 MT Stage

The work of 1 MT was started in 1955-56 and completed progressively by1956-61 at a cost of

Rs. 202 Crs.

The following are the main features of 1 MT stage:

II. 2.5 MT Stage & 3.2 MT Stage

The work of 2.5 MT was started around 1964 & completed progressively by1967 at a cost of Rs. 150 Crs.

Unit Features

Coke Ovens 3 Batteries, 65 Ovens

Sinter Plant 2 Machines - 50 M2

Blast Furnace 3 B.F. -1033 M3

Steel Melting Shop 5 OHF (250 T)

Power Plant - I 2 Nos. 12 MW TG

Oxygen Plant – I 3 units

RMP - I 1 No. Dolomite Kiln & 2 Nos. Lime Kiln

Mills

Blooming Mill 1150 mm, 2 High Reversing

Billet Mill 700 / 500 mm

R&SM 950 / 800 mm

Merchant Mill 350 mm

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Note :- Coke Oven Batteries No. 7 & 8 and Sinter M/c No. 4 were added beyond2.5 MT Stage.

III. 4.0 MT Stage

The work of 4 MT was started some time in 1974-75 and completed progressivelyby 1988 at a cost of Rs. 2288 Crs.

The following are the main features of 4.0 MT stage:

Unit Features Coke Ovens 3 Batteries, 65 Ovens, 21.7 M3 Sinter Plant 1 Machine – 50 M2 Blast Furnace 3 B.F. – 1719 M3 Steel Melting Shop 5 OHF (500 T) Slag Processing Plant Crushing & Screening of Aggregates Power Plant - I 1 No. 12 MW TG Oxygen Plant - I 1 Unit RMP - I 1 No. Dolomite Kiln & 3 Nos. Lime Kiln Mills Blooming Mill 8 Groups of Soaking Pits R&SM Finishing groups – 3, 4, 5 & 6 Billet Mill 1000 mm Wire Rod Mill 250 mm

Unit Features Coke Ovens 1 Battery 67 Ovens, 7 Meter Tall (COB –9) Sinter Plant 4 Machines - 75 M2 Blast Furnace 2000 M3 with BLT (BF-7) Steel Melting Shop 4 Twin Hearth Furnaces (500 T)

3 Nos. 100 / 130 T Convertor Continuous Casting Shop 4 Nos. Single Strand Slab Caster

1 No. 4 Strand Bloom Caster Oxygen Plant II 3 Nos. Air Separation Units RMP II 1 No. Dolomite Kiln, 2 Nos. Lime Kiln & Brick shop Power Plant II 2 Nos. 30 MW TG & 1 No. 14 MW TG OHP & CRMBSY Mills Plate Mill 3600 MM – 4 High Reversing and 4 High Finishing

The following are the main features of 2.5 MT stage:

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IV. Other AMR Schemes & De-bottlenecking Schemes & Capital Schemes &Township

Number of AMR Schemes & De-bottlenecking schemes & Capital schemes, Pollutioncontrolschemes & work on Township were also executed from time to time.

V. Schemes under execution at present

VI. Schemes to be executed

cx PROJECT Sanctioned Cost (Rs. Crs)

1 Re-building of Coke Oven Battery # 5 219.04

2 Installation of New Slab Caster, RH Degasser & Ladle Furnace In SMS – II

520.76

3 Installation of Hot Metal De-sulphurisation Unit at SMS-II 86.23

4 Instln. of Power Supply Facilities(MSDS-VI) for 2 x 1250 TPD New Oxygen Plant

62.00

5 Installation of MSDS-V & associated Transmission line for Evacuation of Power from BESCL’s Expansion Project

125.94

6 Implementation of ERP System at BSP 51.20

7

Replacement of Dn-3000 BF Gas Header from BF-1 to BF-6 13.48

8 Repl. of existing MG sets for Roughing & Finishing stand drive Motors at Plate Mill by digital Thyristor Convertors

48.31

9 Instln. of 700 TPD ASU-4 with Associated facilities at OP-II 212.44

Total 1339.4

SN PROJECT Estimate cost (Rs. Crs)

1 Installation of End Forging Plant for thick web rails 53.92

2 Replacement of 120 T/Hr Pusher Type Reheating Furnace with 140 T/Hr Walking Beam type Reheating Furnace at WRM

85.36

4 Electro Magnetic Stirrer in Bloom Cast SMS-II 27.85

5 Oxygen Evacuation facilities for new 2x1250 TPD Oxygen Plant 37.00

6 Implementation of Manufacturing Execution System 40.51

7 Modernization & expansion of BSP to 7.0 MT 11262.00

TOTAL 11682.4

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VII. 7.0 MT Stage (Modernization & Expansion)

To meet the Corporate Goal, the SAIL Board has approved the Modernization &Expansion of Bhilai Steel Plant on 3rd April'07 at a cost of 11262 Crs.

The Consultancy for various schemes is being provided by MECON & CET. TheMajor Schemes are as follows:

SN Description of schemes

1. Modernization of BF-6 : Package-I (BF proper & CH)

2. Modernization of BF-6 : Package-II (GCP)

3. Installation of 2nd Sinter M/c in SP-3

4. Installation of 4060 M3 BF Complex

5. BOF Shop Technological Package

6. Installation of Continuous Casting Plant Complex

7. Installation of Universal Beam Mill

8. Installation of Bar & Rod Mill

9. Installation of new Normalizing Furnace under Plate Mill Modernization & Augmentation

10. Augmentation of Plate Mill capacity: Instln. Of Cooling Beds, Pilers & Other Equipment (Package –III)

11. Reheating Furnace for UBM, B&RM & URM

12. Installation of Secondary Refining Unit for SMS-III

13. Augmentation of OHP Part-A

14. Installation of Universal Rail Mill

15. Installation of New Coal Handling Plant

16. Installation of Hot Metal De-sulphurisation Unit for SMS-III

17. Replacement of Combi-caster with Bloom cum Beam blank caster in SMS-II

18. Installation of Compressed Air Station No. 4

19. Installation of Turbo-blower Station

20. Modernization of BF-6: Package-III (TB-9 revamping)

21. Modernization of BF-6: Package-IV (INBA SGP)

22. Aug. of Plate Mill capacity: Installation of Plate Edge Marking M/c & Automatic Length Measuring System (Package –IV)

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23. Aug. of Plate Mill capacity: Installation of 40 T EOT Crane & 17 T Semi-portal Crane (Package –V)

24. Aug. of Plate Mill capacity: Installation of CNC Roll Grinding M/c (Package –VI)

25. Aug. of Plate Mill capacity: Supply & Installation of GUILLOTINE Shear (Package –VII)

26. Aug. of Plate Mill capacity: Civil & Strl. Works (Package –II)

27. Aug. of Plate Mill capacity: Installation of 140 TPH Walking Beam Type Furnace (Package-I)

28. Augmentation of MSDSs & Installation of MSDS-VII

29. Boilers at P&BS

30. New OHP Part-B & Base blending facility for SP-3

31. COB-11 : 7 m tall coke oven battery No. 11 with 67 ovens

32. COB-11 : Installation of BPP with H2S recovery unit

33. COB-11 : Coke dry quenching facilities with coke sorting plant

34. Civil and Strl works for BOF, CCP shop

35. Civil & Structural Universal Rail Mill

36. Civil & Structural works for BOF & CCS, Universal Beam Mill and Bar & Rod Mill

37. Installation of 2 X 1250 TPD Oxygen Plant on BOO basis

Anticipated Volume of Works during 7.0 MT

The estimated volume of works for the Project on an overall basis is furnished below:

Activities Volume of works Piling (Nos.) 2500

Concrete (M3) 534000 M3

Structures (T) 156000 T

Plant & Equipment (T) 155000 T

Refractory (T) 80000 T

Road Work

1 1 M Wide 3 KM

7 M Wide 8 KM

4 M Wide 5 KM

Laying & Linking of Railway Track 35 KM

Dismantling of Existing Railway Track 15 KM

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VIII. Project organization

1. Presently Project Deptt. is headed by ED (Projects). GM (PP&E & BEDB), GM(Proj.-Steel, OP & Utilities), GM(Proj.-Iron, Elect. & Mines), GM(Proj.-Mills, Coke& Safety) and DGM I/c (Commercial) are directly reporting to ED(Projects).

2. The zonal concept is functioning in the Project Deptt. and headed by senior DGMs.

3. Presently the workforce consists of 212 Executives and 170 Non-executives.

4. The site executing zones are as follows:

Steel Zone Oxygen Plant-2 Zone Gas Pipe line Zone TPL work shop PMC, Inspection, follow-up & Quality

Reporting to GM (Proj.-Steel, OP & Utilities)

Iron Zone Power Generation Zone Instrumentation & Automation, Testing Electrical enabling Zone Civil services Zone

Reporting to GM (Proj.-Iron, Elect. & Mines)

Coke Zone Mill Zone HRD & Safety Construction Equipment Zone

Reporting to GM (Proj.-Coke, Mills & Safety)

Project Contract Cell – Turnkey Project Contract Cell – Non-Turnkey

Reported to DGM I/c (Commercial)

IX. Functional details of Project Department

9.1 Project Contract Cell (Turnkey)

a. Receipt of sanction letter from PP& E (Scheme No. & Amount code, etc.)

b. Coordination with shop, consultant & finalization of TS/specifications.

c. Receipt of final TS from consultant.

d. Issue of tender enquiry.

e. Organizing bidders conference.

f. Coordination with consultant & parties for getting technical and commercialclarifications.

g. Recommendations for placement of ordering.

h. Award of contract.

i. Sorting out commercial issues with the parties.

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9.2 Project Contract Cell (Non-Turnkey)

a. Receipt of Stage-II from PP& E (Scheme No. & Amount code etc.).

b. Receipt of draft TS from consultant.

c. Coordination with shop, consultant & finalization of TS / specifications.

d. Receipt of final TS from consultant.

e. Receipt of proposal from zone for tendering.

f. Finalization of eligibility criteria (NIT) including publication matter.

g. Seeking approval of management for release of tender enquiry forpublication in open tender/limited tender.

h. Release of publication matter for publication in newspapers & on sailwebsite.

i. Issue of tender enquiry in case of limited tender.

j. Sale of tender document.

k. Extension if required for submission & opening of offers.

l. Opening of earnest money deposit / BG.

m. Opening of tender / techno-commercial offers.

n. Process for bid evaluation techno-commercial & commercial.

o. Recommendation for placement of ordering.

p. Award of contract.

q. Extension of time, clarification, settlement of rates of extra items & interimdeviations.

9.3 Site Execution zone

a. Detail study of contract, scope, terms & conditions.

b. Planning & execution for enabling works.

c. Providing utilities & services to the executing agency within the boundarylimits.

d. Interaction with the executing agency for opening site office, gate passesfor workers & receipt of various policies from the party.

e. Study of L-1 network submitted by the party.

f. Finalization of implementation plan based on contractual commitments.

g. Follow-up with the party for completion of design engineering, equipmentordering, manufacturing and erection.

h. Execution of civil work, dismantling if any and trench work.

i. Fabrication & erection of building structures.

j. Follow-up with the party for manufacturing & supply of equipment.

k. Erection of equipment (Mechanical, Electrical, Instrumentation & Automation).

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l. Erection of refractory, sheeting etc.

m. No-load testing & trial run of equipment.

n. Load trial run of equipment.

o. Defect elimination.

p. Issue of PAT.

q. Commissioning of equipment.

r. Establishing performance guarantee.

s. Closure of contract.

t. Feed back.

9.4 Project Monitoring, Inspection & Follow-up

a. Understanding detail of contract by getting contract copy.

b. Organizing kick-off of meeting.

c. Coordination with party / consultant for finalization of list of drawings anddocuments.

d. Follow-up with the party & consultant for completion of design engineeringas per contractual schedule.

e. Follow-up with the party for submission of master PERT Network &coordination with zone, shop & consultant for its approval.

f. Finalization of implementation plan for various activities w.r.t. Contractualschedule.

g. Preparation of Annual Implementation Plan for the contract.

h. Preparation of High lights for the year.

i. Preparation of Monthly Progress Reports of all ongoing schemes.

j. Preparation of Weekly Progress Reports.

k. Preparation of Daily Progress Reports.

l. Preparation of agenda for review meetings being taken by MD/ED/GM asand when required in consultant with execution zone, consultant & shop.

m. Preparation of MOM / record notes of all project review meeting.

n. Preparation of MIS report.

o. Visit to site for follow-up of site progress.

p. Coordination & submission of all audit report.

q. Budget certifications.

r. Follow-up with party for expediting supply of equipment.

s. Inspection of equipment as per QAP.

t. Coordination for budget allocation.

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X. Capital Expenditure

As on 31.03.07 around Rs. 6642 Crores Capital Investment has been made byBhilai Steel Plant. The Details are as follows :

Schemes Cost (In Crs.)

1.0 MT Expansion 201



Social Facilities & Town Ship 185

AMR, De-bottle necking/ New Capital schemes & On–going schemes

3823

MODERNIZATION & EXPANSION PLAN OF BHILAI (REGIONWISE)

ZONE MAIN PROJECTS

COCCD Deptt. : 7 Meter High-Coke Oven Battery #11

IRON : SP-III - Second Sinter Machine (320 M2)

4060 M3 capacity Blast Furnace # 8

Technical up gradation of B.F. # 6

STEEL : New SMS-III of 4MT Capacity

3x160T convertor

2x6 Strand Billet Caster

1x6 Strand Bloom cum Billet Caster

1x3 Strand Blank Caster

MILLS : New Bar & Rod Mill - 0.90 MT Capacity

New Universal Rail Mill - 1.2MT Capacity

New Universal Beam Mill - 1MT Capacity

For 1.42 MT production capacity augmentation

of Plate Mill

RAW MATERIAL HANDLING : New Coal Handling Plant

New Ore Handling Plant

SERVICE & AUXILLARY : Compressed air station

MSDS & Power Distribution

New 2x1250TPD Oxygen plant on the basis of BOD

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BHILAI ENGINEERING AND DESIGN BUREAU (BEDB)

Bhilai Engineering and Design Bureau (BEDB) came into existence in 1974. Aneed was felt by the management of Bhilai Steel Plant to set up an in-house design,engineering and project consultancy department that would have the technical expertiseand capability to handle regular addition, modification and replacement schemes thatare required to be implemented regularly in order to maintain the plant and equipmentin healthy and working order and also to enhance their efficiency and productioncapability from time to time, without having to get into the lengthy and tediousprocess of negotiating and awarding design and engineering contracts to outsideconsultancy agencies. Prior to setting up of BEDB, such jobs were handled by theerstwhile CEDB, which was later incorporated as a central public sector companynow well known as MECON Ltd.

BEDB helps the management of Bhilai Steel Plant by providing a wide range oftechnical, design and consultancy services, for and in connection with the following:

1) ADDITION, MODIFICATION AND REPLACEMENT (AMR) SCHEMES AND PROJECTS

Every year, various AMR schemes are identified and proposals are made for theirimplementation by the various departments in the plant, mines, township and peripheralareas. BEDB helps in examining the technical feasibility and economic viability ofsuch scheme proposals and transforms the initial proposals into suitably worked outscheme proposal documents backed up with necessary drawings and write upsincluding the cost estimates for aiding the management in investment decision making.Once a scheme gets the management approvals, BEDB provides detailed engineeringdrawings, schedule of materials, technical specifications for equipment and plantprocurement, etc. for actual implementation of the schemes.

2) TURNKEY AND NON-TURNKEY PROJECTS

Depending upon the nature and complexity of the scheme or project to beimplemented, BEDB also advises on the implementation strategy. Some schemes areimplemented by adopting non-turnkey contracts with detailed working drawingsdeveloped by BEDB while in some others turnkey contract strategy is adopted. In thelatter case, the detailed design and engineering responsibility vests with the contractingfirm. However, BEDB needs to scrutinize the contractor's drawings and documentsand accord approvals before any work is actually implemented.

BEDB provides services as varied as preparing Feasibility Reports (FR), preparationof tendering specifications and tender estimates, scrutiny of offers submitted by thevendors and contractors, drawing up of final technical recommendations of competentand suitable parties, scrutiny and signing of final contract agreement with the agreedparty, technical scrutiny and approval of drawings, datasheets, specifications submittedby the contractor during project execution stage for turnkey projects, preparation of

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basic and detailed engineering drawings, tender schedules, equipment orderingspecifications for non-turnkey projects, etc. BEDB continues to provide technicalinputs and design assistance till the completion and commissioning of such projects.

BEDB also assists the management in the post completion audits for the capitalsinvestments made and in the process of closure of contracts.

3) BREAKDOWNS AND EMERGENCY ASSIGNMENTS

Apart from the planned projects, BEDB also provides immediate technicalassistance and design and engineering support, whenever required, in case of suchemergency as in the event of breakdowns that may happen in various units of theplant and township from time to time.

4) CONSULTANCY AND ENGINEERING SERVICES TO SISTER UNITS

BEDBs engineering services are also sought by other sister units of SAIL, likeDurgapur Steel Plant, IISCO, Burnpur, MEL, Chandrapur, VISL, Bhadrawati, etc. forcertain cases. For example, BEDB had provided the design and engineering consultancyfor the installation of Twin Hearth Furnaces (THFs) in Durgapur Steel Plant and IISCO,Burnpur . BEDB has been helping MEL, Chandrapur, VISL, Bhadrawati for certaincapital repairs and modification jobs.

5) MISCELLANEOUS FUNCTIONS

BEDB is also involved in various other technical functions, such as:

Association with other consultants such as MECON and CET for site clearance /layout clearance, scrutiny and clearance of FRs and Tendering Specifications asprepared by them. Besides, BEDB is involved in providing assistance in negotiatingand fixing the scope of work and fees of other consultants.

1. Participation in various Tender Committees, Purchase Committees,Standardization and Technical Task Force committees and providing varioustechnical inputs in these committees for decision making.

2. Involvement in the Investment Programming Unit (IPU) of Bhilai Steel Plant.

3. Representation on committees for formulation of standards (IS/IPSS & companystandards) including examination of draft standards.

4. Participation in technical audit related to ISO certification as internal auditors.

5. Participation in site co-ordination meetings during capital repairs to sort out siteproblems.

6. Engineering assistance to R&D schemes worked out by RDCIS for implementation.

7. Participation in corporate plan discussions and major modernization plans of the plant.

8. On an average, the department deals with around 450-500 assignments in ayear. Out of these, around 100 assignments in a year are those for emergencyand breakdown engineering services.

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PROJECTS AND SCHEMES HANDLED BY BEDBThe following are some of the important projects and schemes, which got

implemented with the design, engineering and consultancy services provided by BEDB:

1. Partial briquetting of coal charge (PBCC)

2. Conversion of sulphuric acid plant to Double Contact Double Adsorption (DCDA) plant

3. Reconstruction of OH Furnaces no. 1, 2 and 3 into Twin Hearth Furnace no. 2,OHF 4, 5 & 6 into THF-3 and OHF 7, 8 & 9 into THF-4.

4. Conveyorisation of Blast Furnace no. 1 and 4 stock houses.

5. Modified ignition hood design for Sinter Machines of SP-2 including detailedengineering of its burners for improving the quality of sinter.

6. Modernization of strands C&D of Wire Rod Mill for quality and yield improvement.

7. Double rail track connection from OH station of SMS muck dump.

8. Installation of Township Distribution Station no. 2.

9. Screening of Iron Ore fines at Dalli.

10. Installation of 250 T stationary shear (removed from Merchant Mill) in place ofpendulum shear in Billet Mill.

11. Design and engineering for installation of twin hearth furnaces at DurgapurSteel Plant, Durgapur.

12. Technological upgradation schemes for BFs during their capital repairs.

13. Conveyorisation and mechanized transportation of Pearl Coke from SP-2 to BF-7.

14. Improved layout in cast house of BF-7 for application of castable lining.

15. Modification in JLN Hospital in Sector-9 with the addition of new ICC (IntensiveCardiac Centre) Unit.

16. Installation of BOD Plant for phenolic effluent treatment in COCCD.

17. Installation of Gas Cleaning Plants for THF-II and THF-III alongwith slurrytreatment plants.

18. Installation of combined gas cleaning plant and slurry treatment plant for OHF-7, 8 & 9.

19. Installation of semiautomatic water chemical treatment plant (WCTP-4) forsupplying soft water to CCS and Oxygen Plant-2.

20. Conversion of Chilled Water Plant no. 1 with the installation of vapour absorptionchiller machines in place of old steam ejector type chillers.

21. Installation of Primary Crushing Palnt in Rajhara Mines.

22. Conveyorisation of nut coke addition to sinter from SP-3.

23. Conveyorised transportation of sinter fines from BFs to SP-3.

24. Design and engineering for installation of THF (110T+110T) capacity at IISCO, Burnpur.

25. Limestone screening and washing facility at Nandini Mines.

26. Independent exhaust systems for slab caster no. 1 and bloom caster at SMS-ii.

27. Installation of vapor absorption type chilled water plant.

28. Radiotherapy unit at Sector-1 hospital

29. NB2 type housing in Ruabandha.

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30. Revamping of interiors of Bhilai Niwas.

31. Provision of 35 T CNC lathe machine in Roll Turning Shop.

32. Interconnection of CPP- II silos with CHP for ensuring continuous supply of coalblend to Batteries 1-8.

33. Augmentation of rail finishing facilities for rolling 6.5 lakh Tonnes rail in Rail &Structural Mill.

34. Capacity augmentation of Maroda Water Treatment Plant.

35. In-situ revamping of clear water cycle cooling tower of Coke Oven Battery-9.

36. Conveyorised loading of BF coke into wagons at mechanized coke stockyard no.2.

37. Introduction of bottom pouring technology for ingot casting at SMS-I.

38. Installation of 1500 line Digital Exchange at Sector-5 of township.

39. Construction of new Managing Director's Conference Hall.

40. Installation of additional Gravity Sand Filter

41. Concreting of Forest Avenue between Main Gate & Boria Gate.

42. Installation of PAULWURTH make hydraulic mudgun & drilling Machine at BF-3.

43. Installation of VVVF drive for crane control during revamping of crane no. 2A inWire Rod Mill.

44. Additional flare stack for converter gas for Converter Shop.

45. Independent exhaust system for slab casters

46. Replacement of MG set by thyristor for skip hoist drive BF III.

47. Installation of propane gas storage & distribution system for SMS-II.

48. Installation of water flow measurement for Township.

49. Extension of Pinch Roll repair shop at CCS.

50. Installation of CDI in BFs 1 & 5.

51. Coal Tar Injection into BFs 2 & 3.

52. Oxygen enrichment facility for Blast Furnace 1, 2 & 3.

53. Revamping of Door extractor track platform for COB nos. 9 & 10.

54. Rain water harvesting and waste water conservation scheme at BSP's RecyclingPumphouse at Forest Avenue.

55. Construction of additional Sedimentation Tank and Extension of Crane Bay atSettling Tanks at SP-2

56. Installation of additional overhead slurry launder from Converter Shop to ETP.

57. Device for Rotor Block Testing for Roughing Stand of Plate Mill.

58. Raising the height of Hitkasa Dam without desilting to enhance its capacity

59. Replacement of Stock House weighing system at BF#4.

60. Modification of water cycle of GCP-IV of SMS-I.

61. Provision of Electronic Belt Weigh Feeders (4 nos.) at SP-I.

62. Installation of 80 MVA Transformer and supporting infrastructure facility at MSDS-I.

63. Replacement of MG sets nos. 3&4 and 9&10 by thyristors in Wire Rod Mill.

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FUNCTIONAL STRUCTURE OF BEDB

Engineers belonging to various engineering disciplines such as architecture, civil,mechanical, electrical, telecom, mining and chemical work in BEDB in the variousfunctional sections such as the following:

1. Mines

2. Coke Ovens and Chemical Technology

3. Techno-economics & Estimation

4. Iron Technology

5. Steel Technology

6. Rolling Mill Technology

7. Architecture

8. Civil Engineering

9. Structural Engineering

10. General Layout and Transport

11. Mechanical Engineering & Material Handling

12. Air Conditioning and Works Environment

13. Water Supply and Sewerage

14. Electrical and Instrumentation

15. Telecommunication

16. Energy

Apart from the above functional sections of BEDB, the Central Archives of BhilaiSteel Plant comes under the administrative jurisdiction of BEDB.At present the BEDBoffice is located at the 4th Floor of Ispat Bhawan whereas the Central Archives islocated at the ground floor of Ispat Bhawan.

THE CENTRAL ARCHIVES

Continuous developmental activities for an integrated steel plant is possible onlyby the continuous planning and developmental efforts of a large number of technicaland non-technical people. A substantial part of this work involves various kinds ofdesign and engineering works for the plants, mines, townships and relatedinfrastructure involving large number of technocrats, engineers, technologists,specialists etc not only from the steel plant but also from external agencies such asengineering consultants, government departments, contracting companies, indigenousand foreign suppliers, etc.

This complex activity becomes practically impossible in the absence of availabilityof relevant data regarding the facilities which have been built up earlier and will posedifficulties to those involved in the design, planning and decision making if the requireddata cannot be obtained at the right time in the right manner.

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Thousands of engineering drawings and documents are involved in the makingof an integrated steel plant facility. Proper up keep of these, adopting the right kindof preservation technology combined with the most appropriate indexing and retrievalsystem, thus assumes a vital role in the management of a steel plant, especiallywhere continuous growth is an accepted business policy.

The Central Archives located at the ground floor of the main administrativebuilding of Bhilai Steel Plant serves this vital function of preservation of all technicaldrawings and documents involved in the making of the Bhilai Steel Plant right fromthe inception stage through the various stages of its growth and development overthe years, for the benefit of all those who are involved with its management anddevelopment in the years ahead.

The BSP management has set up the Central Archives in the early Sixties. Overthe years the volumes of archived technical material has increased many fold and theexpectations from the archives have also increased.

FUNCTIONS OF THE CENTRAL ARCHIVES

The Central Archives is primarily concerned with the collection, storage andpreservation of all kinds of engineering drawings and documents which are generatedby various agencies over the years for different purposes involved with theconstruction, growth and development of the steel plant and its associated facilities.Associated with this the Central Archives is required to provide proper means ofsearching, viewing and retrieval of the stored information for those who need it forvarious purposes such as planning and technical decision making.

Since Bhilai Steel Plant is a government owned business entity, the technicaldrawings and documents concerned with it are secured confidential material only forthe use of authorized people. Hence ensuring the security and confidentiality of thearchived material is another vital function of the Central Archives.

Design and engineering involving complex technological plant facilities of massivesize and area is an extremely difficult and time consuming task and the difficultylevel increases with those jobs involving additions, modifications, replacements, etc.Copies of drawings and documents of the existing facilities are required by engineersfor effecting such designs, detailing and decision-making in such cases in the rightmanner without lose of time. The Central Archives provides services to concernedengineers in getting copies of stored technical material whenever felt essential.

Preservation of drawing and documents for quick searching and copying makesit necessary for the Central Archives to adopt latest technologies to the extent feasible.In the electronic and digital era of computers and Internet, conversion of drawingsand documents from conventional forms to electronic formats with various levels ofsecurity features is essential for the BSP to sustain in the competitive market and theCentral Archives strives to provide assistance in this area also.

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FACILITIES OF CENTRAL ARCHIVES

The Central Archives has the following facilities as of now:

1. Air Conditioned Secured Drawing and Document Storage where 3.12 lakh paperdrawings, 1.93 lakh documents, 56000 di-azo drawing prints, 39000 originaltracings are stored besides micro-films and digitized images in portable digitalstorages such as Compact Discs and Floppies.

2. Ammonia Printing Facility for conventionally made drawings

3. Microfilming and Processing Facility

4. Microfilm digitization facility

5. Document scanning and digitization facility

6. Printing facility for digitized drawings and documents.

7. Computerized title and archive number search facilities

UPGRADATION AND IMPROVEMENT PLANS

The Central Archives is in the process of upgrading the facilities to meet thepresent and future challenges. These involve the following:

Complete digitization of drawings and documents with full-fledged search andview enabling under network environment.

Up gradation of preservation and storage facilities with improved fire safetyand security features.

Addition of modern computerized document and drawing conversion andreprographic systems and software with wide format compatibility and security.

Improvements in HR skills to undertake tasks in the modern technical archivingenvironment.

Improved facilities for better drawing and document hard and soft copy issue tocustomer departments ensuring document/drawing security and quality.

Enhancing facilities for the receipt, storage and indexing of drawings anddocuments of future schemes and projects.

Awareness creation among the users of Central Archives for overallimprovements in line with the plans and policies of the company.

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GATEWAY

MATERIAL MANAGEMENT DEPARTMENTMaterial Management Department is guided by SAIL's Purchase/Contract

Procedure-06, which has emanated from Chief Vigilance Commissioner's instructions.

The main tenets of public procurement process are economy, efficiency, fairnessand transparency. Keeping that in view the main objective of Purchase/ ContractProcedure -2006(PCP-06) is to ensure procurement of material/ services of desiredquality at desired time, in desired quantity and at the optimum cost maintainingtransparency.

To facilitate procurement of small items, a separate simplified procedure viz"Procedure for small value purchases" has been incorporated in PCP-06.

The annual procurement budget of BSP's Material Management Department isRs.1055 Cr. and the consumption budget is Rs. 1220 Cr. in producing 5MT of steel. Thetarget inventory is Rs. 450Cr. that is the equivalent to 4.43 months consumption.

The Material Management Department is divided into the following sections.

1. RATIONALIZATION GROUP

2. MATERIALS PLANNING DEPT

3. PURCHASE SECTION

4. INSPECTION

5. STORES

6. ANCILLARY DEVELOPMENT & VENDOR DEVELOPMENT.

Rationalization Group does the codification, rationalization & standardization ofitems & framing of ISO inspection procedure.

The main functions of MPD are budgetary control, processing of indents &managing availability of centrally controlled items indented by MPD.

The major categories of items being procured by purchase Section of MaterialManagement Department are the following.

1. RAW MATERIALS

2. REFRACTORIES

3. MECH ITEMS

4. ELECTRICAL ITEMS

5. ROLLS

6. BEARINGS

7. CONSUMABLES

8. AMR ITEMS

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Depending on the need many items are imported too. Some important items arethe following :

1. VARIOUS MECH SPARES

2. CASTING POWDERS FOR

3. SLAB CASTER & BLOOM CASTER

4. SEA WATER MAGNESITE

5. SNORKEL GUNNING MIX

6. FERRO NIOBIUM

7. FORGED ROLLS

8. BEARINGS -SUPER CRITICAL & CRITICAL CATEGORY

Material Management Department adopt the following modes of Tendering:

1. Limited

2. Open

3. Proprietary

4. Global

According to the situations Material Management Department adopts the followingmethods of procurement too:

- Single Tender

- Memorandum of Understanding

- Rate Contracts

- Inter Plant Transfer

- Central Procurement

One very effective method of obtaining the right price for purchase is reverseauction. It is a dynamic & transparent bidding process. This results into quick purchasedecisions, avoids negotiations and ensures objectivity and transparency.

Online submission of offers by BSP's authorized Vendors has been facilitatedthrough internet for reduction in offer submission time. It helps in minimumdocumentation and is known as E- procurement. It eliminates physical tender opening.

Inspection prevents defective items from entering into the production process.

1. Standard items of reputed make are not inspected at vendors' site.

2. Performance of repeatedly procured items from reputed manufacturers (preferredmake) is known & established. Hence, quality testing during fresh procurementnot done.

3. Performance is the ultimate test. Hence, performance linked items are not inspected.

4. Proprietary items are not inspected at vendors' premises as quality / testparameters are not known.

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Stores Section engages in following activities:

Collection of stores

Receipt & accounting of stores

Issue of stores to user dept.

Documentation

Identification of slow moving & non moving items

Inventory control

Stock control (automatic procurement)

DIFFERENT STORES IN BHILAI STEEL PLANT:

BORIA STORAGE COMPLEX

PLANT SPARES STORES

CENTRAL PLANT STORES

REFRACTORY STORES

DISPOSAL STORES

CENTRAL MEDICAL STORES

RAJHARA MINES STORES

NANDINI MINES STORES

HIRRI MINES STORES

STORES GROUP AT ISPAT BHAVAN

The area of Vendor Development is related with the following:

1. Registration of new vendors for BSP

2. Renewal of vendor registration.

3. Service jobs connected with vendor registration & renewal

Ancillary Development activities are very vital for any material managementdepartment. It works towards achieving vendor-managed inventory. It also strives toachieve industrial development of the region. Activities of ancillary development involveco-ordination with government, SISI, NSIC, Lead Bank, Industrial Association etc.

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C & IT DIVISION (FORMERLY EDP)Evolution

The Bhilai Steel Plant has a golden history. BSP has been a trend setter in manyfields and Information Technology figures prominently among them. BSP has beenthe pioneer in adopting the computer culture in steel industry within the country.

The seeds of computerization in Bhilai Steel Plant were sown way back in 1963with the formation of EDP department. The first computer unit in EDP was IBM 402,aptly called unit-recording machine. In 1967, first main frame computer IBM 1401was installed. It was handed over to BSP officially on 1st August 1967, which isregarded as the birthday of EDP. From IBM 402 EDP has traveled far ahead to reachtoday's height with latest IT tools and machines.

The graphical representation of progress of IT with time is shown below.

New Name:

People knew that EDP was the department where the plant saw the evolution ofcomputers and they fondly called it by different names ranging from the 'KomputerDepartment" to Computers to EDP and even IBM (owing to the early IBM machinesthat were there). But now an unanimous decision has been taken at the Corporatelevel regarding the name of the Computer Department in different units and this hasled to the new name - Computer and Information Technology (C&IT). Hence EDP hasbecome C&IT now.

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GATEWAY

Services Offered:

The C&IT department is presently organized into five distinct groups with clearlydefined responsibilities of operation.

Groups Areas Benefits Financial Management

Finance, VMS, Oprn. A/c, RMBA, EFBS, Cost Control, Assets, Braman. ORAMS, E-Payment etc.

Timely closing of accounts, online details of financial Transactions, Online CPF Loan, Faster & accurate payment to parties through e-payment, Advance processing of Employee Tours etc.

Sales and Order progressing

OASIS, CISF Manpower Deployment System, PRAHARI, VATACS etc.

online Invoice Preparation Vehicle monitoring, Daily Duty Chart for CISF etc

Employee and Estate Services

Payroll for regular & DPR employees, Estate Services, CPF & Allied Jobs, Time Offices, Leave Accounting, VRS Module, Final Settlement module etc.

Qtr allotment, Salary payment on time, e-TDS, HB Advances and other Loans & recoveries, CPF Ledger, Estate Third Party Billing, Incentives Calculation, VRS details etc

Personnel Administration and Hospital Management and Web Services

HRIS, HRD, HMS, Contract Mgmt, Contract Labour System, UDAN, DATES, PADAM, DBA Activities, Assignment Monitoring System, Web Services etc.

Personal details, LTC/LLTC details, Training Details, Patients & Pharmacy accounting, All details & monitoring of Contacts in non works areas, Registration & online attendance system, Various departmental home pages etc

Networking, Hardware and Procurement

H/w Maintenance, Planning & Procurement, Networking and Computer Operation.

Hardware Complaints & monitoring, Procurement of Computer Assets and consumables including stationeries, 24 x 7 computer operation and monitoring of servers, Various reports for Users and Top Management etc.

Besides the aforesaid working groups, two other important functional groupsalso fall within the perview of C & IT. They are MMIS and ERP-MES groups. MaterialsManagement Information Systems (MMIS) under C& IT caters to the need of MMdepartment and other related areas of the Plant. The applications of MMIS are:

Materials Management Information System (MMIS)

Material Indent Generation System (MIGS), Stores Issue Note Generation System (SINGS), e-Planning, e-Procurement, Budgeting, Purchase, e-tendering, Store Bill A/c, Stores, Medical purchase etc.

This has helped the MM department in streamlining and expediting Purchase activities. The Financial entries are also created based on MMIS Module.

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BSP being the forerunner in adopting new technologies has taken a step ahead inthe whole of SAIL fraternity by going for Enterprise Resource Planning (ERP) andManufacturing Execution System (MES) for its improving operational efficiencies.

Milestones:

The C & IT Department has a number of "firsts" in its illustrious track record inBSP. Innovations have been its forte. Some of the recent achievements where C&ITdivision can take legitimate pride include:

Online employee Information through KIOSK installed at ISPAT BHAWAN andLong Rail Complex.

Digitized Photo I-CARD for all the employees.

E-Payment of Salary and Third Party Payment.

Computerized CPF loan Management System for faster disbursement of Loan.

E-TDS and online reports to income tax office.

Online VRS details.

Various Web Pages of different department and their linkages to BSP main page.

Online attendance of contract labour & accurate payment.

Online monitoring of Pharmacy of JLNH & RC.

Despatch information to all the SAIL-CMO branches throughout the countryusing Web Technology.

Ever Onward

Marching onward and creating values to the organization have been the guidingspirit of the C & IT department. The latest feathers in its cap are the adoption of ERPand MES in the key operations of BSP.

Enterprise Resource Planning (ERP) is an integrated suit of application softwaremodules providing operational, managerial and strategic information for an enterpriseto improve productivity, quality and competitiveness. It is a fully integrated, multi-dimensional information system for all functions based on a business model forplanning, control and resource optimization of an organization using state of the artinformation technology.

BSP is now in the process of adopting and implementing ERP. With the signingof agreement for implementation of ERP with the consortium members of M/s SAP,M/s Siemens Information Systems Ltd and M/s HP, BSP has taken one step ahead inthe area of IT in the whole of SAIL fraternity.

The ERP Modules that would be covered under this Project named "ERP-MESUtkarsh" are:

Material Management,

Sales and Distribution,

Financial management and Costing,

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Production Planning,

Plant Maintenance and

Quality Management.

BSP would be first unit to have Uniform Codification Systems for all kinds ofmaterials, suppliers, vendors and other related objects and this UCS would commonacross the SAIL Family.

Manufacturing Execution system (MES) is yet another area where C&ITdepartment is playing a leading role. MES comes in between ERP and Shop Supervisorylevel of automation. While ERP processes are discrete, the MES provides continuousplanning and scheduling functions at the shop floor level. Presently MES iscontemplated for

Steel Melting Shop 2

Rail and Structural Mill

Plate Mill

Future

Matching with the past traditions, the C & IT department is all set to play a moreproactive role in BSP's onward march towards glory and prosperity. The C & ITcollective feels motivated, spirited and elated in having been able to identify itselfwith this glorious journey.

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CORPORATE SOCIAL RESPONSIBILITY

Bhilai Steel Plant has been discharging its organizational social responsibilitybeyond statutory requirements. The BSP leadership sincerely believes that our existenceas an organization depends upon long term sustainability and has always pursuedCSR as a part of organization's commitment towards the society. The BSP leadershipalso believes that society and industry are mutually interdependent and both can actto benefit each other mutually. This has successfully established BSP, as a "caringand sharing" brand. Instead of focusing on CSR activities as a strategic move toexpand business, the organizational leadership has taken a holistic view of the deepinterconnection between the society and the organization appreciating the symbioticrelationship between the two.

Bhilai Steel Plant has long realized that its operations have major impacts on thecommunities in the nearby areas. In 1963, the Community and Peripheral Developmentdepartment was started and this department started running Bal (Shishu) mandirs,Adult Education Centre, Mahila Vidyapeeths, in the camps and neighbouring villagesin order to take care of the employees, their dependants and other residents of thearea.

In 1978 itself, the area was increased to a radius of 8 km around the TownAdministration building encompassing 31 villages and then later in 1983, the radiusbecame 16 km with 136 villages.

Thus, it was in 1978 that Bhilai Steel Plant started sharing its prosperity withneighbouring villages through constructing additional rooms in village schools, makingroads, bridges, culverts, Panchayat Bhawans, Community Halls, Cultural stages,digging bore well, deepening villages tanks/ponds, making ghats in the ponds forsafe bathing and other such activities. Subsequently, activities involving communityhealth were taken-up.

The Community & Peripheral Deptt. with the help of the Medical Deptt. & PublicHealth Deptt. Conducts eye camps, general OPD camps, Ayurvedic camps. BSPeven holds veterinary camps for the benefit of the cattle of the region.

The villages programmes of general OPD camps, veterinary camps continue andfrom the past couple of years, cancer detection camps are also being held everyyear. Aids & Cancer prevention awareness programmes are also being held regularly.

Apart from these activities, in the seventies itself, seeing the declining trend ofthe rich, vast heritage of the local Folk Art, Bhilai Steel Plant decided to involve itselfin its preservation & promotion. Thus in Nov.1976 was held the 1st Chhattisgarh LokKala Mahotsav for 2 days in Bhilai with a budget of Rs. 2,000/-.

It was a grand success and appreciated highly by the artists as well as thepeople. Seeing the acclaim, it was made an annual affair continuing in an unbroken

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chain, the 31st such Mahotsav, was held in May 2007.

Over the years, more than 1000 groups/parties have participated in this annualevent, giving an opportunity to more than 10000 local artists to perform on thestage.

Some of these artists, such as Smt.Teejan Bai, Sushree Ritu Verma and LateShri Devdas Banjare have won international acclaim for their art and it is a matter ofpride for Bhilai Steel Plant that they have started their careers from this stage.

It may also be mentioned here that Smt.Teejan Bai has been conferred the PadmaBhushan and Doctorate for her skill in the folk art of Pandawani singing. Themanagement of Bhilai steel Plant has instituted 3 awards in the year 2001-2002 forthe best party, individual performer or organisation in the field of folk art. These 3awards were instituted in the name of three acclaimed veterans in this field whospent their entire lives promoting folk art, namely the Dau Mahasingh ChandrakarSamman. The "Dau Dular Singh Sao Madaraji Samman" & the "Dau RamchandDeshmukh Samman".

12 awards have been given so far and have been highly appreciated. In 2004-2005, the management has increased the award amount from Rs.5000/- to Rs.10,000/- each and in 2005-2006 it has been increased to Rs.15,000/- each.

In the year 2002-2003, management also started awarding employees of BhilaiSteel Plant who are contributing to the development of folk art. This amount has alsobeen increased to Rs.2000/- w.e.f. 2005-2006.

The recognition of meritorious performance through these awards and the prestigeof the annual event have contributed greatly towards quality of the Bhilai Steel PlantChhattisgarh Lok Kala Mahotsav as well as growth of art in the region.

Disaster Management is another area where the CSR of BSP is reflected in all itsdedication and largesse. A sum of Rs 1 crore was made available for the disastervictims of the Sunami which hit the eastern coast of our country.

Bhilai has always been aware of its responsibility towards the society around itand has strived to uplift the standard of living of people around Bhilai. TraditionallyBSP has been concentrating on issues like health, family welfare, drinking water,roads & bridges, education, waste management and spreading awareness on vitalissues. A dedicated group is there in the organization to look after various programmesand issues regarding peripheral development.

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POLICYBSP is committed to share the benefits accrued through its just and ethical

business for the socio-economic development of people and creating a sustainableenvironment …

Guiding Principles

Align business operations with social values …

Bring about a meaningful difference in people's lives

Identify and strengthen weak economic zones in peripheral areas

Empower people, especially women for self employment

Education, Health, Sanitation

Minimize environmental impact

Promotion of folk arts and culture of the region

Triple Bottom-line Approach

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The Initiatives - A Wide Coverage

Peripheral Development

Model Steel Villages

Mining and Tribal Areas

Medical and Health Care

Education

Sports and Culture

Physically handicapped

Women Empowerment

Promoting Self Employment

Employee Volunteering

Supporting NGOs

Peripheral Development

136 Villages in 16 km Periphery

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Mining and Tribal Areas

Stakeholder Engagement in Rowghat 5 BSP employees interact with and identifythe needs of the local population.

digging of 50 bore wells ( 2 bore wells each in25 villages)

two tribal girls identified & sponsored for 4 yearBSc (Nursing) course.

Welfare of Tribal Children

Unique social initiative started with 36children

20 students adopted per year

Total 95 children adopted till date

Complete education, lodging, boarding facilitiesprovided

Mentoring done by senior level executives forcareer planning and personal counselling.

Grameen Khel Mela

Mega sports event for the tribals ofRowghat area

1593 students from 31 schools / 136villages participated in 2006

300 outstanding performers providedintensive sports coaching

2 selected for athletics academy

Participation by 1500 students (including300 girls) in 2007

Bringing Progress in Tribal Area

Establishment of railway link betweenDalli-Rajhara and Rowghat

Rail link from Rowghat to Jagdalpur

Already contributed Rs. 53 Crores in firstphase.

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MEDICAL AND HEALTH CAREEye Camps / Cataract Surgery

Eye Camps every month

Identification of cataract patients

Free Intra Ocular Lens transplantation

and eye surgery with all associated

facilities

More than 2100 surgeries performed

Sickle Cell Screening Centre

Genetic disorder prevalent in Chhattisgarh

region

Screening for all 30,000 school children

planned in first phase.

Screening to continue in rural areas

Screening of more than 2000 children

completed.

Separate sickle cell centre established.

Bhilai Ispat Kalyan Chikitsalaya

Established for free treatment of the poor

and needy

Free OPD facilities ( More than 8100

patients benefited)

Routine blood/ urine tests

Eye refraction / medicines.

Free dental OPD

Future plans

X-ray and ultra sound facilities

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EDUCATIONBhilai Ispat Vikas Vidyalaya

A CBSE pattern English MediumPrimary school started on 9th July2007 with 180 students from BPLfamilies

Facilities extended to school children :free uniforms / shoes / books /stationery/midday meals/transport

Future plans -

Library,

Toy room,

Coaching for English language

Personality development

Chhattisgarh Swami Vivekananda Technical University

A Technical University set up by the Chhattisgarh Govt. with affiliation grantedto all Engg. Institutions as well as Polytechnics of the state

Total grant of Rs. 50 Crores including 250 acres land transfer by BSP.

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SPORTS & CULTURESports

After formation of Chhattisgarh state in November 2000, more than 100 national& state level tournaments organised

National Handball Academy in collaboration with SAI

Sail Athletics Academy

Sporting Stalwarts

Arjun awardees

Vikram awardees

Olympians

Test cricketer

Everest conqueror

Culture

Lok Kala Mahotsav

31 years of celebrations

5-day Mahotsavs every year (atBhilai & Mines locations)

Grameen Lokotsav

5 Grameen Lokotsavs every year atperipheral villages

250 artists performed in a Light andSound Show during inaugural function of150th anniversary of first freedommovement at New Delhi

WOMEN EMPOWERMENTMahila Samaj

`Masala Udyog' , 'Hand Gloves Centre'

`Tailoring training and stitching of uniforms'

`Embroidery classes' 'soap manufacturing unit'

`Stationery & chalk manufacturing'

'Samriddhi fuels' petrol pump'

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Documents

cartridged

missing throughoutthe

aist eelpl

horizontal

corporate

aseparatechargingoperators

energy management

ammonium sulphate