panorama 2010, aug 16 2010

Human Resource Development Centre Rourkela Steel Plant Rourkela

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Panorama 2010

Contents Of Panorama

Sl. No. Department Sl. No. Department 1. RSP – A Resume 41. Instrumentation 2. Ore Bedding & Blending Plant 42. Repair Shop (Electrical) 3. Coke Ovens 43. Air Conditioning 4. Coal Chemicals Department 44. Heavy Maintenance (Electrical) 5. Sintering Plant‐I 45. Production, Planning & Control 6. Sintering Plant‐II 46. Traffic and Raw Materials 7. Blast Furnace 47. Scrap & Salvage 8. Slag Granulation Plant 48. Civil Engineering (Services) 9. Steel Melting Shop‐I 49. Structural Inspection 10. Steel Melting Shop‐II 50. Contract Cell (Works) 11. Refractory Engineering (Services) 51. Water Management 12. Lime Dolomite Brick Plant 52. Energy Management 13. Calcining Plant‐II 53. Safety Engineering 14. Tonnage Oxygen Plant‐I 54. Environmental Engineering 15. Tonnage Oxygen Plant‐II 55. Fire Services 16. Hot Strip Mill 56. Industrial Engineering 17. Plate Mill 57. Research & Control Laboratory 18. ERWPP 58. Total Quality Management 19. Spiral Welded Pipe Plant 59. AMR‐Project Monitoring & Spl. Cell 20. Pipe Coating Plant 60. Projects 21. Special Plate Plant 61. Computer & Info. Technology 22. Cold Rolling Mill 62. Materials Management 23. Silicon Steel Mill 63. Finance & Accounts 24. Roll Shop 64. Personnel 25. Maintenance Function 65. Human Resource Dev. Centre 26. Maintenance System and Services 66. Central Power Training Institute 27. Shops‐ Plg & Coordination Services 67. Law 28. Shops‐Foundries 68. Town Engineering 29. Shops‐Mechanical Shop 69. Town Services 30. Shops‐Repair Shop (Mechanical) 70. Sports 31. Shops‐Structural & Fabrication Shop 71. Corporate Social Responsibility 32. Repair & Construction (Mech) 72. Public Relations 33. Crane Maintenance 73. Protocol & Hospitality Services 34. Field Machinery (Maintenance) 74. Vigilance 35. Transport 75. Internal Audit 36. Design 76. Medical & Health Services 37. Captive Power Plant‐I 77. Central Industrial Security Force 38. Power Distribution 39. Electronics & Electrical Services 40. Communication Engineering

Department

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Rourkela Steel Plant

ROURKELA STEEL PLANT: A RESUME

Rourkela Steel Plant (RSP) is the first of the three integrated steel plants set up by Government of India in 1959. The first Steel Industry set up under Hindustan Steel limited on 19th January 1954 which paved way for laying up of infrastructure for rapid industrialization of the country. The plant was set up in collaboration with leading steel makers of Federal Republic of Germany. In the initial phase, 1.0 MT units were commissioned between December’ 1958 and early part of 1962. Hot Metal production in RSP started with lighting up of first Blast Furnace ‘Parvati’ on 3rd February’ 1959 by his Excellency President of India, Dr Rajendra Prasad. To meet the additional demand of flat products in the country, the capacity of the plant was expanded from 1.0 MT to 1.8 MT between the year 1965 and 1969. Besides, expansion of the capacity of the existing units, new units like Electric Sheet Mill (for Dynamo and Transformer Grade Steel) and Galvanising lines (for corrugated and plain galvanized sheets) were added. Subsequently, a number of units were added to enhance the product quality, production, productivity and to fulfill market needs. These units included Blast Furnaces, Spiral Welded Pipe Plant, Silicon Steel Mill, Captive Power Plant-II, Mechanical Shop, Structural & Fabrication Shop, Heavy Loco Repair Shop, Slag Granulation Plant and Coke Ovens Battery No. 5. In the year 1988, a new era was started with modernisation in RSP. This was necessary in order to overcome technological obsolescence and to continue to remain competitive in the market place. The modernization of the Plant was completed in two phases from 1994 to 1999. With this, the production capacity of the Steel Plant increased to 2 million tons of Hot Metal and 1.9 Million tons of Crude Steel. Phase-I was completed in the year 1994 which emphasised on improving the quality of raw materials consisting of a new Oxygen Plant, upgradation schemes for Blast Furnaces, Dolomite Brick Plant, Cast House Slag Granulation Plant at Blast Furnace # 4, Raw Material Handling System, Coal Handling Plant in Coke Ovens and Power Generation and Distribution System. Phase-II consisted of a new Sinter Plant, Basic Oxygen Furnace and Slab Casting shop in Steel Melting Shop-II, except for Hot Strip Mill. Except Hot Strip Mill, which was completed in the year 1999, all other units were completed in the year 1997. Rourkela Steel Plant has carved a name for itself as a unique producer of special purpose steels in the flat steel segment. Plates, Hot Rolled Coils, Cold Rolled Sheets and Coils, ERW Pipes, Spiral Weld Pipes and Silicon Steel Sheets and Coils are the products in RSP’s repertoire. RSP has many firsts to its credit. It was the first plant in India to incorporate LD technology of steel making. It is also the first steel plant in SAIL and the only one presently, where 100% of the slabs rolled are produced through the cost effective and quality centered continuous casting route.

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Panorama 2010 RSP is the only plant in SAIL to produce silicon steels for the power sector, high quality pipes for the oil and gas sector and tin plates for the packaging industry. Another uniqueness of RSP is that it does not produce semis. The use of its Plates in ship building & high pressure vessels, Silicon Steel in the electrical machine manufacturing industries, corrugated galvanized sheets for roofing including industrial roofing, pipes in the oil & gas sectors, tinplates in packaging industry and Special Plates in the defence of the nation is well known. Expansion of Rourkela Steel Plant: As a part of SAIL Corporate Plan-2012 to enhance the Hot Metal production capacity of RSP from 2 MTPA to 4.5 MTPA, Crude steel production to 4.2 MTPA and Saleable Steel production to 3.9 MTPA by the year 2012, Expansion projects were approved by SAIL Board on 21st May, 2007 and work is in progress. Project consultancy job for Iron & Steel zone has been awarded to M/s MECON with a role of integrating the entire Expansion and that of Rolling Mill zone to M/s M N Dastur & Co., CET/SAIL is the consultant for CO Battery No.6 & Auxiliaries & M/s RITES for the RAIL Infrastructure Project. The rated capacity of the plant after the expansion will be as follows:

S. No. Details Present Capacity Rated Capacity after expansion

1 Hot Metal 2.0 MTPA 4.5 MTPA 2 Crude Steel 1.9 MTPA 4.2 MTPA 3 Saleable Steel 1.671 MTPA 3.9 MTPA

Major Facilities in Expansion:

Sl. No. Facilities 1 Augmentation and Modification in OBBP 2 New 7 mtr Tall Battery # 6 (1 X 67 Ovens) 3 New Sinter Plant –III (1 X 360 M2) 4 New Blast Furnace # 5 (4060 M3) 5 Oxygen Plant – 2 X 700 TPD on BOO Basis 6 SMS-II – 3rd Basic Oxygen Furnace (150 T), RH-OB, 3rd Ladle Heating

Furnace & Caster 7 New Lime & Dolomite Plant ( 2 X 350 TPD) 8 New 4.3 mtr Wide Plate Mill 9 Auxiliary Packages, Utilities, Logistics for the whole Plant

Special features of Rourkela Steel Plant:

a) It is the first Plant in Asia to adopt LD process of steel making. b) It is the only Plant producing large diameter ERW/SW Pipes conforming to most

rigid standards of API. c) It is the first steel Plant in India to adopt external desulphurisation of hot metal by

calcium carbide injection process. d) It is the only Plant in SAIL producing Cold Rolled Non Oriented (CRNO) Steel

sheets for use in the electrical industries with installed capacity of 73,500 Ton/year.

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e) Rourkela is the first in vacuum degassing metallurgy. This system has been adopted primarily for production of silicon steel for the cold rolled non-oriented sheets. The system consists of vacuum arc refining and vacuum oxygen refining units and a degassing facility.

f) It is the first integrated Steel Plant of SAIL which adopted the cost effective and quality centered continuous casting route to process 100% of steel produced.

g) All the major production departments and some service departments certified to ISO 9001:2008 QMS.

h) Silicon Steel Mill, Environmental Engineering Department and Sinter Plant – II, HSM, PM, SPP, ERWPP, SWPP & Township certified to ISO 14001:2004 EMS.

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Panorama 2010

PROCESS FLOW OF ROURKELA STEEL PLANT

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Raw Materials

The fully mechanized captive mines under Raw Material Division (RMD), a unit of SAIL meet the bulk requirements of Iron ore, Limestone, Dolomite, Manganese, Quartzite and coal as raw materials of RSP.

a) Iron Ore: Captive Mines at Barsua, Kalta, Meghathatuburu, Kiriburu

b) Limestone: BF Grade - Purnapani and Kuteshwar SMS Grade - Jaisalmer and Katni

c) Dolomite: BF Grade - Biramitrapur and Sonakhan SMS Grade - Bilha, Baraduar and Katni

d) Manganese : Purchased from Barajamda and Koira e) Ferro Manganese

and Silico Manganese:

Maharashtra Electrosmelt Limited (MEL)

f) Quartzite: Purchased from Local areas g) Coal: Prime Coking Coal (PCC) and Medium Coking Coal

(MCC) from Indian Sources Imported Coking Coal (ICC) – Hard and Soft from Australia, Canada, USA and China

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Panorama 2010 Main Plant Units

a) Coke Ovens: 3 Batteries of 70 ovens each and 2 Batteries of 80 ovens

each b) Blast Furnaces: 3 BFs of 1139 M3 useful volume and 1 BF of 1658 M3

useful volume c) Steel Melting Shop I: 2 mixers of 1100 Ton each, 2 LDs of 60/66 Tons/ blow and

1 single strand slab caster of 0.300 MT of slabs per year d) Steel Melting Shop II: 2 mixers of 1300 Ton each, 2 LDs of 150 Tons each and 2

single strand slab casters of 1.600 MT of slabs per year e) Sinter Plant I: 2 Sinter machines of 1.5 MT per year f) Sinter Plant II: 1 Sinter machine of 1.57 MT per year g) Hot Strip Mill: • 2 Pusher furnaces of 100 Ton per hour each

• 2 Walking beam furnaces of 225 Ton/hr each • 3 Stand Roughing Mill and 4 hi 6 stand Finishing Mill

with a capacity of 1.44 MT HR coils per year. h) Plate Mill: • 1 walking beam furnace of 100 Ton/hr

• 3.1 meter wide and 4 hi Reversing Mill of 2,99,000 Tons of plates per year.

i) Pipe Plants • ERW Pipe Plant of 75,000 Tons per year with high frequency welding (400 KHz)

• SW Pipe Plant of 55,000 Tons per year with double sub-merged arc welding.

j) Cold Rolling Mill • 2 Pickling lines • 1 Cold Reversing Mill • 1 Five Stand Tandem Mill • Hood Annealing, Continuous Annealing • 2 Skin Pass Mills • Sheet Shearing Line • Continuous Galvanising Line of 1,60,000 Tons per year • Continuous Electrolytic Tinning Line of 85,000 Tons

per year k) Silicon Steel Mill • 4 Hi Reversing Mill of 73,500 Tons per year of CRNO l) Captive Power Plant-I • 5 units to produce 125 MW of power

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Product Mix and Application of Products

Products Applications

HR Coils LPG cylinders, automobile, railway wagon chassis and all types of high strength needs.

Plates Pressure vessels, ship building and engineering structures, space programmes

Special Plates Different defense applications, building of tanks, bullet proof steel etc

Chequered Plates Flooring and staircases in the industrial sectors and railway platforms etc.

CR Sheets & Coils Steel furniture, white goods like refrigerators, washing machines, automobile bodies, railway coach paneling, drums, barrels, deep drawing and extra deep drawing etc.

Galvanised Sheets Roofing, paneling, industrial sheeting, air condition ducting and structural.

Electrolytic Tin Plates Containers for packaging of various products including edible oils, vegetables and confectionary items.

Silicon Steel Sheets & Coils Small generators, starters for high efficiency rotating equipment and relays etc

SW Pipes High-pressure transportation of crude oil, natural gas and slurry transportation, water supply, sewage disposals, grain silos, civil engineering pilings etc.

ERW Pipes High pressure transportation of oil and water, sewage disposal, tube wells etc.

Plates and Sheets

Coils Pipes

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Panorama 2010 Major Milestones in Rourkela Steel Plant

• 21 December 1953: Agreement signed with Krupp-

Demag for RSP. • 3 December 1958: COB # 1A commissioned. • 5 January 1959: COB # 1B commissioned. • 26 January 1959: CPP-I Boilers-1 & 2 commissioned.

• 27 January 1959: Converter-X commissioned in SMS-

I. • 18 June 1959: CPP-I Boiler-3 commissioned. • 7 August 1959: CPP-I Boiler-4 commissioned. • 27 December 1959: ASU-1 commissioned in Tonnage

Oxygen Plant-I. • 9 January 1960: Converter-Y commissioned in SMS-I.

• 12 January 1960: BF # 2 commissioned. • 31 January 1960: Converter-Z commissioned in SMS-

I. • 22 March 1960: COB # 2A commissioned. • 5 April 1960: COB # 2B commissioned. • 6 June 1960: ASU-2 commissioned in Tonnage

Oxygen Plant-I. • 24 June 1960: ASU-3 commissioned in Tonnage

Oxygen Plant-I. • 12 September 1960: Plate Mill commissioned. • 15 October 1960: ERW Pipe Plant commissioned. • 13 June 1961: Pickling Line-1 commissioned in Cold

Rolling Mill. • 28 December 1961: Hot Strip Mill commissioned. • 8 January 1962: BF # 3 commissioned. • 7 November 1962: COB # 3A commissioned. • 21 November 1962: COB # 3B commissioned. • 28 February 1965: Sinter Plant-I commissioned. • 17 August 1966: Converter-P commissioned in SMS-I.

• 25 August 1966: CPP-I Boiler-5 commissioned. • 1 October 1966: CPP-I Boiler-6 commissioned. • 30 December 1966: COB # 4A commissioned. • 3 July 1967: BF # 4 commissioned. • 4 October 1967: Pickling Line-2 commissioned in Cold Rolling Mill. • 20 November 1967: Converter-Q commissioned in SMS-I. • 30 November 1967: ASU-4 commissioned in Tonnage Oxygen Plant-I. • 17 February 1968: Tandem Mill commissioned in Cold Rolling Mill. • 15 July 1968: Galvanising Line-2 commissioned in CRM. • 27 July 1968: Galvanised Corrugated Line commissioned in CRM.

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• 31 October 1968: Electrolytic Tinning Line commissioned in CRM. • 6 February 1969: COB # 4B commissioned. • 25 September 1969: Galvanising Line-1 commissioned

in CRM. • 21 September 1974: COB # 5A commissioned. • 3 February 1976: 10 MT saleable steel production. • 17 June 1976: Spiral Weld Pipe Plant commissioned. • 1 November 1982: First CCTV network in Asia

inaugurated. • 27 December 1983: COB # 5B commissioned. • 24 October 1984: Silicon Steel Mill commissioned. • 12 April 1987: CPP-II Unit-1 commissioned. • 23 March 1988: CPP-II Unit-2 commissioned. • 20 September 1991: 2nd phase of modernisation

inaugurated. • 11 March 1993: Units 1 & 2 commissioned in Tonnage

Oxygen Plant-II. • 29 November 1993: Ore Bedding & Blending Plant

commissioned. • 5 August 1996: Continuous Casting Machine-1

commissioned. • 29 September 1996: Sinter Plant-II commissioned. • 7 November 1996: LD-B and Caster-I commissioned in

SMS-II. • 7 February 1997: LD-A and Caster-II commissioned in

SMS-II. • 15 May 2003: Visit of His Excellency Dr. A. P. J. Abdul

Kalam, the Hon’ble President of India to RSP • 04 January 2008: Foundation Stone laying of the

Modernisation and Expansion programme • 03 February 2009: RSP celebrates Golden Jubilee of its

Hot Metal production

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Panorama 2010

ORE BEDDING AND BLENDING PLANT (OBBP)

Ore Bedding and Blending Plant of RSP came up during its modernisation and commissioned in two stages. Phase-I was commissioned in 1994 with the facilities of unloading, screening of Iron Ore Lumps (IOL) and dispatch of raw materials to different units like Sinter Plant-I, Blast

Furnaces and Lime Dolomite Brick Plant (LDBP). Phase-II was commissioned in 1996 with the facilities to prepare and supply Base Mix to Sinter Plant- I & II and screened Lime Stone and Dolomite to Calcining Plant-II. Capacity of OBBP is 5.0 MT of raw material dispatch per annum. In OBBP raw material transportation takes by a series of belts. There are around 140 numbers of belts and total length of belts added

together is around 45 Kms. Raw Materials Handled: OBBP is a centralised unit for unloading and stacking of all major raw materials excluding coal.

Sl. Raw Materials Sources (i) Iron Ore Lumps (IOL) Barsua, Kalta, Kiriburu, Meghataburu, Bolani,

Chiria (Manoharpur) & Gua (ii) Iron Ore Fines (IOF) Barsua, Kalta, Kiriburu, Meghataburu, Bolani,

Gua & Manoharpur. (iii) BF grade Lime Stone Kuteswar, (iv) BF grade Dolomite Birmitrapur & Sonakhan (v) SMS grade Lime Stone Jaiselmar & Gulf Countries( Dubai& Oman) (vi) SMS grade Dolomite Belha, Bhavaduar (vii) Dolo Fines Birmitrapur & Sonakhan (viii) Mn. Ore Orissa Mining Corporation.

Other than the above raw materials coming from mines, OBBP also handles Coke breeze, LD slag fines, SMS sludge, Mill scale, Flue dust and other spillage materials generated inside the plant and process the same. Unloading: There are two Wagon Tipplers and two Track Hoppers for unloading of the raw materials which comes from the mines. Generally side opening type of wagons(BOBS) are unloaded in Track Hoppers. Track Hopper-1 is dedicated for IOL and Track Hopper-2 for IOF. Wagons viz. BOX, BOXN, BOXC, NBOY etc. are unloaded in Wagon Tipplers numbered as WT-4 & WT-5.

After unloading in Wagon Tipplers materials are conveyed to designated bed through a series of belts and with the help of Stacker.

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There are total 14 numbers of Beds for stacking of different materials.

Bed-1 &2 Unscreened Iron Ore Lump Bed-3 & 5. BF grade Lime Stone, BF grade Dolomite & Dolomite fines Bed-4 & 6 SMS grade Lime Stone & SMS grade Dolomite. Bed-7 SMS grade Lime Stone, Dolomite Fines & -30mm Lime Stone. Bed-8 & 9 Screened IOL. Bed-10, 11 & 12 Iron Ore Fines. Bed-13 & 14 Base Mix.

IOL Screening: IOL coming from mines contains undersize fraction of -10mm which can affect Blast Furnace operation. Therefore, this undersize fraction is screened out in IOL Screening Section and then stacked in Bed No. 8 & 9 from which screened ore is dispatched to Blast Furnaces. Base Mix Preparation: For better and consistent quality of sinter and also for increasing Sinter Plant productivity, Base Mix is the prime ingredient used in most modern Sinter Plants. Base Mix is a near homogenous mixture of Iron Ore Fines, Flux, Dolo fines, Crushed Coke breeze, LD slag fines, Mill Scale, Flue Dust etc. mixed at certain proportion. Major constituents of Base Mix, its percentage and size required are as follows:

Constituents of Base Mix Percentage Sized ore required

IOF 78 – 79 % 0 – 10 mm Crushed Flux 9- 11 % -3 mm – 90% Dolo Fines 1- 3 % -3 mm – 90% LD Slag Fines 3- 4 % -5 mm – 80% Crushed Coke breeze 5 – 5.5 % -3 mm – 85%

These materials are stored in designated bunkers in Proportioning Bin building and stacked in Bed as per the above setting from their respective Weigh Feeders. Flux Crushing: Flux Crushing is carried out in Rod Mills. Lime Stone and Dolomite lump conveyed to Rod Mill hoppers before crushing at ratio of 40:60 or 30:70 as per the requirement of Sinter Plant. These are crushed initially in primary crusher known as Swing Hammer Reversible Impactor (SHRI) to -25 mm and then finally crushed to -3 mm which is around 90%. This flux is used in Base Mix preparation & also supplied to SP- II for trimming addition.

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Panorama 2010 Coke Crushing: Breeze Coke generated in Coke Ovens and Blast Furnaces is loaded in BOBS wagons and dumped in Coke Track Hoppers from where it is conveyed and stored in Coke Storage bins. This coke breeze is screened and +12.5 mm known as Nut Coke is dispatched to Sinter Plant-II for addition along with sinter and transported to BF by belts. -12.5 mm fraction is crushed in two stage crushing in roll crushers to get -3 mm around 82-83%. Dispatch of Raw Materials: The complete raw material handling and preparation system is coordinated from OBBP main control room through PLC. Each designated destination or operation is called a path and comprises of a series of belt running through PLC. The various paths are mentioned below:

Path-1 Wagon Tippler-4 running Path-2 Track Hopper-1 running Path-3 Track Hopper-2 running Path-4 IOL screening circuit running Path-5 IOF bin discharging path running Path-14 Wagon Tippler-5 running Path-7 Lime Stone, Dolo to CP-II Path-8 Screened IOL etc. to BF high line bunkers Path-9 Lime Stone to SP-I Path-10 Base Mix to SP-I Path-29 IOF to PB building Path-30 Base Mix stacking Path-31 Base Mix dispatch to SP-II Path-32 Trimming addition supply to SP-II

Customers of OBBP:

Sl. No.

Department Materials Supplied

1. Blast Furnaces Screened IOL & Mn. ore 2. Sinter Plant – I Base Mix, BF Grade Lime Stone, Dolo Fines 3. Sinter Plant-II Base Mix, Crushed Flux, Coke breeze, Dolo Fines &

nut coke. 4. Calcining

Plant-II Screened SMS Grade Lime Stone & Dolomite

5. LDBP Screened SMS Grade Lime Stone

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Major Facilities and Equipment:

Sl.No Equipment Capacity 1. Wagon Tipplers - 2 Nos. 20 wagons tippling/hour 2. Car Pushers - 2 Nos. Placement of 58 wagons at a time 3. Track Hoppers - 2 Nos. 6000 Tonnes each hopper 4. Apron Feeders - 5 Nos.

(AF-1, 2, 4, 5, 6) 900 T/Hour

5. Plough Feeders - 2 Nos. 1200 T/Hour 6. Stackers - 4 Nos. 1200 T/Hour 7. Barrel Reclaimers - 3 Nos. 900 T/Hour 8. Bucket Reclaimers - 2 Nos. 600 T/Hour 9. Transfer Car - 1 No. Transfer of equipment. 10. Vibrating Screens - 10 Nos. Varying capacity from 35-450 TPH 11. Vibrating Feeders - 35 Nos. Varying capacity from 35-900 TPH 12. Rod Mill - 3 Nos. 55 TPH 13. Impactors - 3 Nos. 55 TPH 14. Roll Crushers - 6 Sets 35 TPH 15. Weigh Feeders - 15 Nos. 100 – 500 TPH 16. Belt Feeders - 5 Nos. 35 TPH 17. Belt Conveyors - 42 Km 600 –1200 TPH 18. Sampling System - 1 Lot. Collection of sample from JH-3, out station

samples & its preparation

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Panorama 2010

Flow of Materials in OBBP

Base MixSized Ore

Screening Building

-30 mm

Ω

P B Building

Lime Dolo Screening Building

P/R Track Hopper

Coke Breeze Track Hopper

Coke & Flux Crushing Building

LS

& D

olo

to C

PII

LS

to L

DB

P Nut Coke to SP-II

Iron Ore Fines

LD Slag

Size

d O

re to

BF

Bas

e M

ix to

SP-

I &

SP-I

I

Ω Ω

Raw Materials Stock Yard

& Screened Ore & Base-Mix Beds

Iron Ore

Incoming Raw Materials

Wagon Tippler Track Hopper

Auto Sampling Station

Ω

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COKE OVENS

In any integrated steel plant, Coke Ovens Department is the first production unit. Coke is required in Blast Furnace for reducing iron ore (Fe2O3) to molten iron, which is also termed as Hot Metal. The major advantages of using coke in Blast Furnace are: (a) It is strong & hard and can withstand the abrasive action inside the blast furnace and

remains in solid form till it reaches the tuyere zone. (b) Because of its strength, it can take the load of the burden above it. (c) It is porous which allows good contact between the carbon (present in coke) & oxygen in

air. (d) It is uniform in size for better distribution inside the furnace. (e) It is having a high heating value. The Coke: Coke is made from coal. Normally two varieties of coals are available in the earth's crust. (a) Non-coking coal (b) Coking coal India has vast reserve of Non-coking coal, which is generally used for power generation by Thermal Power Plants. Coking coal is scarce, and is used for metallurgical purpose only. When coking coal is heated in the absence of air, pyrolytic cracking of coal occurs with the evolution of number of volatile products like Ammonia, Tar, Benzol and Coke Oven gas. The solid carbonaceous residue is called coke which is hard dense & porous. The residue of non-coking coal does not agglomerate but remains in powder form. Coal Blending: Coking coal is sub-divided into two categories depending upon its coking characteristics.

(i) Prime Coking Coal (PCC) (ii) Medium Coking Coal (MCC)

The analysis, usually termed as the proximate analysis, for the above varieties of Indian coal is as given under:

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Panorama 2010

Proximate Analysis

Prime Coking Coals

Medium Coking Coals

Ash 16% - 26% 19% - 29% Volatile Matter 19% - 26% 20% - 30% Gross Moisture 6% - 8% 6% - 8% Fixed Carbon 48% - 65% 41% - 61%

In India, the availability of PCC coal is scarce and hence its usage is also restricted. Further due to inherent high ash content, the coke made from above coal also has high ash rendering it unsuitable for use in Blast Furnace. In order to lower the ash in Indian coals, it has to be suitably blended with low ash imported coking coals. Two varieties of coals are usually imported primarily from Australia, USA & New Zealand. They are: (a) Imported Coking Coal (Hard) [ICC (H)] (b) Imported Coking Coal (Soft) [ICC (S)] The proximate analysis of the above-mentioned coal is:

Proximate Analysis

Imported Coking Coals (Hard)

Imported Coking Coals (Soft)

Ash 8% - 11% 7% - 11% Volatile Matter 21% - 23% 26% - 35% Gross Moisture 6% - 8% 6% - 8% Fixed Carbon 64% - 71% 54% - 67%

In order to produce good coke, PCC, MCC, ICC (H), ICC (S) coking coal is blended together. The present blended coal analysis is as follows:

Proximate analysis Analysis of Blended Coal Ash 12.5 ± 0.5% Volatile Matter 23% - 24% Gross Moisture 6% - 8% Fixed Carbon 63% - 63%

However proximate analysis provides only prima-facie data. Suitability of coal for coking is ultimately based on more advanced analysis which is called petrographic test. Petrographic characteristics of the different coal are as follows.

Coal Vitrinite % Mean Max Reflectance

Fluidity Crucible swelling index

PCC 45 1.2 200 ddpm 3 MCC 42 .95 100 ddpm 1 SCC 55 .95 100 ddpm 1 IMP(H) 70 1.15 600 ddpm 7

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The analysis required for Blast Furnace:

Proximate analysis Analysis of Coke Ash 16 ± 0.7% Volatile Matter < 0.7% Gross Moisture 4.5% ± 0.5% Fixed Carbon > 80% Strength of Coke M40 > 80% M10 < 8.5% Coke Reactivity Index (CRI) < 20% Coke Strength after Reaction (CSR) > 62% Coke size (25 mm – 80 mm) > 95%

Coal Preparation: Coal as it comes from the mine ranges in size from large lumps to dust and is known as "Run of

Mine". This coal contains a lot of impurities which are to be removed before it can be used. "Run of Mine" coal is sent to washery for cleaning. After removal of gangue material the coal is sent to steel plants in box wagons. Imported coking coal is brought through sea route, and is unloaded in ports from where it is loaded in box wagons & dispatched to all steel plants.

At RSP, all coal wagons are unloaded in Tipplers, a device which can unload at the rate of 12 wagons per hour. There are two such tipplers for unloading of wagons. The unloaded coals are stacked in "Piles" in the coal yard. Hence coal piles of PCC, MCC, ICC (H) & ICC(S) are made in the yard. The coal yard has a capacity to store more than 60,000 Tons of coals in piles. Coal from the yard is reclaimed with the help of scrapper type reclaimer from the piles of stacked coals. These are then sent to Central crushing station through various conveyor belts. Here the coal is pulverized below 3.2 mm size. The pulverized coal is sent to blending bunkers. The four varieties of coal is then blended proportionately such that desired coal blend is achieved. The blended coal is then stored in coal towers.

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Panorama 2010 Partial Briquetting Coal Charging (PBCC) Plant: To improve the coke quality and its yield, part of the coal is transformed to briquettes and blended with the Charging Car Coal fed to the coal towers. The briquette plant comprises of Binder Tank, Mixing Kneaders and Briquette Press where crushed coal is mixed with tar & binder and pressed to form briquettes. This plant was commissioned in 1996. The Coking Process: The carbonization of coal is carried out at high temperature in long, narrow silica-brick chambers called ovens in which coal is coked by the combustion of fuel gas in flues built in the refractory brick walls which separate the ovens. The typical dimension of RSP ovens are:

Length 13.59 Meters Height 4.5 Meters Width (Pusher Side) 0.37 Meter Width (Coke Side) 0.43 Meter Volume 21.60 Cubic Meters

Numbers of ovens are placed side by side and together it is called a Battery. At RSP there are five batteries:

Battery # 1 70 Ovens Battery # 2 70 Ovens Battery # 3 70 Ovens Battery # 4 80 Ovens Battery # 5 80 Ovens

Total 370 Ovens The walls of the ovens are maintained at a temperature of >1000oC by burners which are located inside the walls. Here CO gas, BF gas or mixed gas are used as fuel for maintaining the wall temperature. The annular spaces between the walls are filled with coal taken from coal towers. The coal is

indirectly heated for a period 18 to 20 Hrs. All volatile matters present in coal escape. The residue coke is pushed out from the oven, quenched with water to prevent combustion of coke and dumped into a wharf. The empty oven is again refilled with coal & the process continues. The by-products of carbonization namely Ammonia, Benzol, Tar & Coke Oven gas generated during

the process are sent to Coal Chemicals Department for removing impurities. The gas after cleaning is used as fuel throughout the steel plant.

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The Wharf: The wharf is an inclined platform lined with cast iron plates having gates at one end. Under the gates, a conveyor belt conveys the material which falls over it. The quenched coke is dumped & spread uniformly on the wharf. This helps to drive off any extra moisture which the coke may carry along with it. Further any hot spot remaining after quenching is quenched here. The quenched coke is discharged from the wharf to the belt below, and taken to coke sorting station where the coke from the wharf is segregated as per its size.

Nomenclature Size End user Hard Coke 25 < X < 80 mm Blast Furnace Nut Coke 15 < X < 25 mm Blast Furnace Breeze Coke X < 15 mm Sinter Plant

Hard coke is sent to Blast Furnaces directly through conveyor belts. Other fractions are loaded in BOX/ BOBS wagons & dispatched to the end user. Coke < 80 mm size are crushed in double roll crusher & segregated as per above fractions.

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Panorama 2010

COAL CHEMICALS

Coal is a treasure chest of an innumerable number of chemicals. The source for all these chemicals is the volatile matter present in coal, which in our case is from 20-30% of the coal. When coal is carbonised in the coke ovens, about 320 Nm3/T of gas is generated which comes from the volatile matter of the coal. The gases escaping from the coke ovens contain tarry matter, moisture, vapours of a number of chemical compounds like ammonia, hydrogen sulphide, naphthalene, benzol etc. These are commonly known as by-products though they are very useful and valuable materials. These are rightly called as coal chemicals, which form the chief raw materials for the manufacture of dye stuffs, pharmaceuticals, flavours, perfumes, rubber chemicals, plastics and a thousand of other useful products that are now almost indispensable in our present day civilization. The Coal Chemicals Plant at Rourkela serves two purposes: (i) To recover the primary products like ammonia, crude tar to clean and cool the Coke Oven

gas, so that it can be conveniently used for heating purpose. (ii) To further process and refine the crude tar to yield a number of marketable products. On operational basis, the plant can be divided into two parts (i) Gas cooling and condensation section which includes low pressure cleaning (ii) Recovery of finished chemicals by further processing the primary products obtained in No.

(i). Geographically the plant is divided into 3 areas, viz: Site-A, Site-B and Site-C. In Site-A the gas from batteries 1, 2 and 3 is collected and cleaned and crude tar is removed. Site A and Site C each has a refrigeration plant. Similar procedure is carried out in Site-C, which handles the gas from battery IV and V. Site-C has low pressure cleaning units after which the gas goes to site-A for distribution. The H2SO4 manufacturing unit also is in Site-C. Site-B has all the storage facilities for the crude tar and it has got facilities for further processing and refining of these products into marketable chemicals. The main units in Site-B are:

i) Crude tar distillation plant ii) Naphthalene oil processing plant

The plant has a total capacity to treat 120,000 Nm3/hr of gas. Some of the special features of this plant are:

i) Vapour Absorption System for Refrigeration ii) Spray Saturator for removing ammonia iii) Continuous pipe still furnace for crude tar distillation iv) Double Conversion Double Absorption (DCDA) Sulphuric Acid Plant v) Direct distillation of road tars vi) Biological Oxidation and Dephenolisation unit for effluent treatment

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This vast Coal Chemicals complex offers a unique opportunity for the chemical engineers as it includes most of the unit operations and unit process of the chemical engineering field like fluid flow, heat flow, various types of heat exchangers transportation and metering of fluids, mixing, evaporation, centrifuges, crystallization, distillation (multi-component and vacuum) gas

absorption, extraction, drying, humidification etc. The gas generated during carbonization in the ovens rises through the ascension pipe into the goose neck at about 700-800oC. In the goose neck, the temperature is brought down to 80/90oC by spraying ammonical liquor solution. The gas along with the liquor and tarry matter flows in the horizontal trough called the hydraulic main or collecting main which is common for each sub-battery. From the collecting main the gas is drawn to the raw gas main leading to the by-products plant through the so-called suction or cross over main. The gas from

batteries 1, 2 and 3 is brought to Site-A in two streams where it is first cooled indirectly by recooled and refrigerated water in the primary cooler where tar, ammonia, water and naphthalene are condensed. The cooled gas is then passed through the electrostatic tar precipitators to remove final traces of tar and then it goes to the exhauster. The function of the exhauster is to suck the gas from the suction main and discharge it at a pressure of 500 to 1000 mm WG. The gas after the exhauster is sent to expansion units for removal of ammonia and making ammonium sulphate. Ammonium Sulphate is made by passing total CO gas produced in MT and expansion batteries through spray type saturator where dilute sulphuric acid is sprayed. After spray type saturator total gas is cooled in final gas cooler where recycled water is cooled by refrigerated water. Naphthalene is also removed in final gas cooler. The gas is then branched into three streams: (a) Gas Holder (b) Mixing Tank (c) Under firing Gas Line Similarly the gas from the expansion side batteries (No. 4 and 5) is brought to the Coal Chemicals plant of Site-C and is cooled indirectly in primary coolers using re-cooled as well as chilled water to remove tar condensate. The gas is sucked by exhausters. The gas is then passed through Electrostatic Tar Precipitators (ETPs) to remove the final traces of tar. The tar-free gas from Site-A and Site-C are mixed and passed through a tower where the gas comes in contact with two stages of sulphuric acid sprayer (1-2% in low acid sprayer, 4-5% in high acid sprayer). The ammonium sulphate thus produced is crystallised in vacuum crystallizer, centrifuged and bagged. The gas is then cooled in final cooler. The naphthalene content is also reduced in final gas cooler. The gas sent to gas mixing station, underfiring line and gasholder is having the following impurities:

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Panorama 2010

Impurities End Gas 1. Naphthalene max 0.12 gm/Nm3 2. H2S max 0.8 gm/Nm3 3. Ammonia 0.04 gm/Nm3 4. Tar Fog 0.06 gm/Nm3

The recovered tar is distilled to produce light oil, carbolic oil, naphthalene oil, wash oil, anthracene oil, road tars, coal tar fuels, soft pitch, hard pitch and special pitch for pitch bonded brick plant. Tar distillation plant (Capacity: 300 TPD of feed stock) is unique among SAIL plants, as it employs vacuum distillation technique. Naphthalene oil is redistilled in naphthalene plant. Hot pressed naphthalene is manufactured by cooling redistilled oil and hot pressing and cooled solid. There is a contact sulphuric acid plant, which produces 98% sulphuric acid using elemental sulphur as starting raw material. It employs Double Conversion Double Absorption (DDCA) process to reduce emission of SOx. The liquid effluent generated in Coal Chemicals Department is treated in Biological Oxidation and Dephenolisation (BOD) Unit. In BOD unit, effluent from all the three sides is collected and treated using pseudomonas and nitrosomonas bacteria. These bacteria degrade Phenol, Cyanide and Ammonia. The feed rate of effluent is 150 M3/hr.

The inlet and outlet composition of BOD Plant is mentioned below:

Inlet to BOD Plant Outlet of BOD Plant Ammonia 350 ppm 30 ppm Phenol 150 ppm 1 ppm Cyanide 100 ppm 0.2 ppm PH 8.5 6.5 - 7.5 Temperature - 35oC (Max)

Treated effluent is used as quenching medium in Coke Ovens Plant.

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SINTER PLANT - I

Sinter Making: Due to increased mechanisation in the mines, lot of fines are generated which can not be charged into the Blast Furnaces directly. In order to conserve these, otherwise waste material, they are compacted together and made into lumps by a process known as sintering. Sintering is defined as the agglomeration of the fine mineral particles into a compact lumpy mass by incipient fusion caused by the heat produced during the combustion of the solid fuel within the moving bed of loosely particles.

Advantages of Sinter: • Helps in the conservation of raw materials. • Enhances the productivity of Blast Furnace. • Decreases coke rate in BF. • Decreases the flux rate in BF. • Improves the permeability of BF. • Helps in the smooth running of the BF.

Technical Data: 1. Capacity of the Plant - 1.5 MT / Annum. 2. Sinter Machine - 2 Nos. (125 T/hr), 125 m2 working area, Mixed

gas fuel, Dwight Lloyd down draft continuous chain type machine

3. Sinter Breakers - 2 Nos. 4. Primary Mixing Drum - 1 No. 5. Pelletising drum - 2 Nos. 6. Hot Screen - 2 Nos.(separate +6 mm & -6 mm fractions) 7. Cold Screen - 2 Nos.(separate +25 mm,+15 mm-25 mm,-15 mm) 8. Process ESP - 2 Nos. 9. Dedusting ESP - 2 Nos. 10. Exhausters - 2 Nos. 11. Capacity of Sinter Storage

Bunker - 1200 T

Input material: The input materials and average consumption for one ton of sinter are:

1. Iron ore fines - 830 Kg 2. Lime stone fines - 80 Kg 3. Dolomite fines - 160 Kg 4. Coke Breeze - 69 Kg (Dry) 5. Return fines - 30% (max.) 6. Mill Scale - 10 Kg 7. LD Slag - 35 Kg

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Panorama 2010 Input in the form of Base Mix (a homogeneous mixture of Iron ore fines, Flux, Coke Breeze, Plant Returns) is supplied from OBBP. Process: The Sinter Plant-I has a rated capacity of 1.5 million tonnes of sinter per year based on 2- strand 3 shift running. There are two sinter machines of the Dwight-lloyd down draft type with 125 sq. meter working area. The raw materials as specified above are brought, stored, crushed and sent to proportionating bins. The different materials are drawn from these bins in a fixed ratio on to a common belt conveyor leading to the primary mixing drum. Here water and return fines are added. The raw mix is stored in two intermediate bins from where it is fed into the two pelletising drums. Here further water is added to facilitate balling which increases the permeability of the raw mix. This is carried to the charging hopper over the sinter machine 1 & 2. The material is fed over the sinter machine pallets and the height of the bed is maintained 400-450 mm depending upon quality of raw material used and sinter to be made. The sinter machine is provided with 21 wind boxes at the bottom to suck the air through the bed. As the bed travels through the Ignition Furnace, the top layer is ignited. This combustion zone proceeds downwards till the pallets reaches the discharge end. The temperature in the last wind box is maintained at around 250oC. The hot sinter coming out from the machine is broken by the sinter breaker and then screened. The -6 mm fraction is sent to the Return fines bin. The sinter is then cooled in the cooling strand by blowing air through it and finally it is sent to the double deck cold screen. Here it is separated into 3 fractions. The +25 mm is either stored in the sinter storage bunker (1200 T capacity) or is directly sent to the Blast furnaces. The -25 mm and +15 mm fraction is used as a bedding hearth layer on the sinter machine in order to:

1. Increase the permeability of the bed. 2. To protect the grate bars from the direct contact with the hot sinter.

-15 mm fraction is again screened with 6mm screen. +6 mm fraction is sent to the Blast furnace along with +25 mm fraction. -6 mm fraction is sent to return fines bin. Two space dedusting fans with Electro Static Precipitators are installed for dedusting from various transfer points. Two waste gas fans with Electro Static Precipitators are installed for creating suction in the sinter bed from bottom.

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Output: The output is sinter whose typical composition is:

Total Fe 54.0 % FeO 9.5±0.5 % SiO2 5.5±0.5 % Al2O3 3.0±0.2 % CaO 10.5 ± 0.5 % MgO 2.8 ± 0.2 % Basicity 1.8 - 2.0 %

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Panorama 2010

Material Flow in Sinter Plant – I

Sinter to Blast Furnace (+25,+6)

Bla

st F

urna

ce R

etur

ns

Ω

Primary Mixing Drum

Bas

e M

ix, L

ime

Ston

e &

D

olo

Fine

sfro

mO

BB

P

Cok

e B

reez

e fr

om C

oke

Ove

ns &

BFs

Water Return Fines Bunker

Pelletising Drum - I Pelletising Drum -II

Sinter Machine-I

Sinter Machine-II

Hot Screen-I

Hot Screen-II

Breaker-I Breaker-II

Cooler-I Cooler-II

Cold Screen

New Cold Screen

Hea

rth L

ayer

(-25

,+15

mm

)

+25 mm

-6 m

m

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SINTER PLANT-II

Commissioned on the 29th September 1996, Sinter Plant-II was a part of the modernisation programme of Rourkela Steel Plant. It along with Sinter Plant-I fulfils the Sinter requirement in the Blast Furnace burden to 70% from a level of around 50%. Higher Sinter proportion in Blast Furnace burden improves the Furnace productivity with substantial reduction in coke rates.

Major Equipments:

• 12 nos. of proportionating bunkers with electronic belt weigh feeders/ vibro feeders. • One 3.8 m diameter x 15.9 m long mixing and balling drum. • One 8-metre long ignition furnace with section one roof mounted multi slit burners and

balance three with wall-mounted burners. • One no sintering stand of 3 meters wide, 192 square meter sintering area. • One 1.2 m high, 195 square meter linear Sinter cooler with five cooler blowers. • One Hot Sinter Screen (-5 mm). • Cold Sinter screens (+50 mm, +25 mm, +15 mm, +5 mm) 4 Nos. • Waste gas fan with 5.72 MW synchronous motor. • Two Electro Static Precipitators: one for waste gas and another for plant dedusting. • Two Ingersoll-Rand centrifugal air compressors

Salient Features:

• Precise proportionating by using electronic weigh feeders & loss and weight system. • One combined mixing and balling drum of 400 tons / hour capacity. • Closed Circuit Cooling Water System. • Use of high bed thickness (550 mm) with high under grate suction of 1350 mmWC. • Elaborate pollution control measures with two electrostatic precipitators. • 10 nos. of sinter storage bunkers having a cumulative capacity of 5230 ton. • PLC controls for Plant operation, Distributed Control System (DCS) for process control. • Waste heat recovery system along with dust recovery facilities. • Pneumatic conveyors system for calcined lime transfer. • Dispatch of Sinter to Blast Furnaces by belt conveyors.

Design Data:

Production 1.57 MTA (Gross Sinter) Productivity 1.13 T/Sq.m/hr Annual working days 300 days / year Coke consumption 75 Kg/ton of skip sinters (dry) Gaseous energy consumption 32,000 kcal/T of gross sinter Sinter granulometry +50 mm 0% and -5 mm 3% (min) ISO tumbler index (+6.3 mm) 72% (min) Cooled sinter temp. < 100 oC Dust content in stack emission (Maximum) 100 mg/NM3

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Panorama 2010

Process: Sintering is the process of agglomeration of particle fines by incipient fusion, which bind them together into hard, porous, lumpy mass of material. Base mix, coke breeze and flux fines are received at Sinter Plant – II by a series of belt conveyors from OBBP and collected in bins. There are total twelve bins, four are for base mix, one for miscellaneous, two each for flux fines, coke breeze and Blast furnace return fines one for plant return fines. After proportionating, the material comes to mixing and balling drum for nodulising and moistening. Then with help of a series of belt conveyors, it (raw mix) is laid onto sinter machine pallets above a hearth layer. The top layer of material on pallet is ignited in ignition furnace with the help of mixed gas. As the sinter machine continuously moves on and exhaust blower (Waste Gas Fan) sucks air from the bottom of pallets, the combustion layer travels down. After the sinter process is completed, the sinter cake is crushed, cooled, screened for different sizes and the undersized (-5 mm) sent back for recycling. The sinter +15 mm to -25 mm size is used as hearth layer on sinter machine.

Achievements: Sinter plant – II has marched towards excellence consistently in many fields. The department has been ISO 9001 QMS and ISO 14001 EMS certified since 2001. It has achieved annual production of 1.98 MT against detailed project report (DPR) of 1.57 MT sinter, specific productivity 1.3 against 1.135 T/Sq.m/hr. With installation of multi slit burner specific gas consumption has been reduced to 23 MCal/Ton of Sinter against DPR of 32.

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Process Flow Chart of Sinter Plant - II

Lim

e

Wat

er

PR F

ines

Bas

eM

ixfr

omO

BB

P

Bla

st F

urna

ce R

etur

ns

Flux

from

OB

BP

Cok

e B

reez

e fr

om O

BB

P

Proportion Bin

Sinter mix preparation at Mixing & Balling Drum

Ignition & Sinter Making in Sinter

Machine

ESP Single Roll Crusher

STACK

- 50 mm

Sinter Cooling 50mm Screen

Hot Screen Double Roll Crusher

+50

mm

15mm Screen

25mm Screen

-25

mm

5mm Screen Sinter Storage Bunker

Blast Furnaces

- 5 mm

+5 m

m

+15 mm

+25 mm

-15

mm

Com

p. A

ir

- 5 mm

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Panorama 2010

BLAST FURNACE

Blast Furnace is a counter current heat & mass exchanger, in which the burden (solid raw materials like Iron ore, Sinter, Coke & additives / fluxes) is charged from top of the furnace & hot blast is sent through the bottom via tuyeres. The heats transferred through the ascending Hot Blast to the descending burden & oxygen from the burden to the gases. In the counter current process, the iron ore & reducing agents (Coke, Coal) are transformed to hot metal & slag, formed from the gangue of the iron ore, sinter & the ash of coke. The liquid hot metal & slag do no mix and remain separated from each other with the slag floating on top of the denser iron. The liquid iron & slag are separated in the cast house during casting. The other product from the blast furnace is dust laden, blast furnace gas, which is further cleaned in the gas cleaning plant and is used as a fuel all over the plant. These 4 Blast Furnaces in RSP were commissioned with the technical and financial assistance of M/s Fried Krupps Essen and M/s Demag. BF # 1 Commissioning on 27.01.1959 BF # 2 Commissioning on 12.01.1960 BF # 3 Commissioning on 08.01.1962

BF # 4 Commissioning on 03.07.1967 PCM Commissioning on 27.01.1959 SGP Commissioning on 23.09.1977

Capacity Modernization BF-IV Up-gradation MT Stage BF # 1, 2 & 3 1000 T/Day each 1200 T/Day in 1200 T/Day in

Exp. Stage BF # 4 1500 T/Day 1800 T/Day 97–98 2200 T/day 05-06. Total 1.8 MT/Yr. 2.0 MT/Yr.

Major modifications during/after modernization: • Sinter screening facilities in all 4 furnaces in 1995 - 96 • BF # 4 INBA commissioning on 28.01.1993 • BF # 1 INBA commissioning on 30.08.2005 • BF # 4 High Top Pressure in Sept’ 2005 • BF # 3 Tilting runner in May’ 2007

The main sections supporting the furnaces are: 1. High line Stock House & charging section. 2. Furnace proper and cast house 3. Hot Blast Stoves 4. Gas Cleaning plant 5. Cast House slag Granulation plant / External slag granulation plant 6. Pig Casting machine 7. Fleet of Hot metal ladles & slag pots.

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8. Ladle repair Shop, Slag dump and clay preparation unit. 9. Workshop.

The raw materials required for production of hot metal are Iron ore, Sinter, coke, LD Slag, Quartzite & Manganese ore (as per requirement of SMS). Apart from these solid raw materials, it also requires air and oxygen for burning of coke, water for cooling various parts & equipment of furnaces. Iron ore supplied from OBBP, Sinter from Sintering Plant (I & II), Coke from Coke Oven and LD Slag and scrap from SSD. The hot metal which is basic raw material for steel is supplied to steel melting shops I & II of RSP. In case SMS is unable to accept hot metal, the same is poured in Pig Casting Machine to solid iron called pigs.

HIGH

BELTWagon

THROUGH BF

GAS CLEANING

TO OTHER

PIG CASTING

SM

SM

INBA CH SGP

SLAG GRANUL-

ATION

SLAG

HM TAP HOT

FURNACE

COLD BLAST FROM

HOT

STOVE

IRON ORE SINTER

(SCREENED AT BF)

COKE (SCREENED AT

FLOW DIAGRAM OF BLAST FURNACE PROCESS

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Panorama 2010 Raw Material Sources for Blast Furnace Iron Ore : OBBP (Barsuan / Kalta / Meghataburu / Kiriburu / Gua /

Bolani / Chiria) Sinter : Sinter Plant – I & II Coke : Coke Ovens (Coals from Dugda, Bhojdih, Kargali,

Rajarappa & imported coal) Mn Ore : Purchased Quartzite : Purchased LD Slag : SMS through SSD Nut Coke : Coke Ovens through Sinter Pig Iron Chips : PCM through SSD

Material Balance for 1 Tonne of Iron

The Specifications of the above raw materials are given below:

Material Chemical Analysis (Norm) Specification Iron Ore Lump Fe : 63.5 % min

SiO2 : 2.0 % max Al2O3 : 2.0 % max

- 10 mm : 5 % max + 50 mm : 5 % max Size: 10 to 50 mm

SINTER 1.25 T ORE 0.45 T

+ ORE 0.45 T

LDS 0.005 T

COKE 0.570 T

GAS 3.615 T

DUST 0.006 T

HOT METAL 1.0 T

SLAG 0.400 T

BLAST FURNACE

AIR 2.42 T

INPUT OUTPUT

QTZ. 0.001 T

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Material Chemical Analysis (Norm) Specification Sinter Fe : 54.0 % min

FeO : 9.5 % + 0.5 SiO2 : 4 to 5 % Al2O3 : 2.5 % max CaO : 10.5 % + 0.5 % MgO : 3.0 % + 0.5 %

- 5 mm : 5 % max +40 : Nil Al2O3/SiO2 : 0.5 to 0.6 Size : 5 to 40 mm

Coke Ash : 16 – 18 % VM : 0.9 % Moisture : 4.0 – 5.0 % CRI : 20 – 22 % CSR : 62 % min

Size : 25 – 80 mm + 80 mm: 4% max. - 25 mm: 5% max. M-10 : 8.4 % max M-40 : 80 % min

Quartzite SiO2 : 99 % min Size : 20 – 40 mm Ld Slag CaO : 42 – 44 %

MgO : 8 – 9 % SiO2 : 12 – 14 %

Size : 20 – 40 mm

Mn Ore Mn : 30% + 1 % Fe : 24 % + 1 %

Size: 10 – 50 mm

High Line and Stock House Raw materials storage bins, conveyor belts for transporting raw materials to bins, equipments for screening, weighing & discharging material to skips are the major components of high line and stock house besides the open storage yard for storing Sinter to meet exigencies. The open storage yard is provided with a crane of 45 m span and 20 T capacities to load material into wagons and also to stock material after it is unloaded from wagons. There are total 65 bins for storage of various raw materials, 16 for each furnaces and one bin to store sinter return fines falling off from the head end of sinter belt. Out of 16 bins in each furnace 10 bins are having 246 m3 volume and called full bins. Four bins having 126 m3 volume are called ½ bins and 2 bins having 186 m3 volume are called 3/4 th bins. Full bins are normally meant for storing iron ore & sinter where as ¾ bins are meant for Qtz, LD slag or manganese ore. Each bin is provided with vibro-feeders to draw material from bins to conveyor belts which subsequently feed them to weigh hoppers and then to skips. But sinter after being drawn from the bins is screened through +5 mm mesh size vibrating screen to weigh hopper and – 5 mm size sinter is conveyed through sinter fines conveyor belts (SFC) to sinter fines bunkers and subsequently to both the sinter plants. There are two coke service bunkers in each furnace having 525 m3 capacity (300 T of coke) to store coke coming from coke oven. Each coke bunker is connected to a coke screen to screen out – 25 mm and discharge + 25 mm size coke to coke weigh hoppers. The + 25 mm size coke from weigh hoppers is then discharged to skips to be charged into furnaces. The – 25 mm size coke breeze is carried by fine breeze conveyor belt to fine breeze skip which unloads the breeze in fine breeze bunker. The coke fine breeze is then dumped from the bunkers to wagons for further transportation to sinter plants & OBBP.

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Panorama 2010 To charge the raw materials into the furnace there are two skip cars each of 8.5 m3 volume in MT furnaces and 10.5 m3 volume in BF-IV. The hauling capacity of each skip is 8.0. T at a speed of 1.8 m/sec for 1 MT furnaces & BF-IV 10 T at a speed of 3.2 m/sec and while one of the skip car remains in the skip pit to receive the raw material from the hoppers, the other one discharges the material at the furnaces top. The charging sequence, selection of charge material, switching of stock house equipment, weighing of raw materials their subsequent discharge to skip and movement of skip cars, all are controlled through a PLC system from charging side control room. Furnace Proper There are four Blast Furnaces with combined installed capacity of 1.8 MT of hot metal which was upgraded during the nineties to 2.0 MT of hot metal per annum. The Blast Furnace shop is currently passing through further modernization & technological up gradation to enhance production capacity to 4.5 MT per annum by 2012. Some of the technical information about the four furnaces are out listed below. The blast furnace is a vertical shaft type furnace where reduction & melting of descending charge material takes place due to the heat and ascending gases produced due to combustion of coke by hot air blown through the tuyeres. The furnaces are fully refractory lined, the bottom hearth to bosh with carbon blocks & there after with fire clay bricks whose % Al2O3 goes on decreasing from bosh to shaft. Major sections of the furnace proper are:

2.1) Top Charging Equipments 2.2) Cooling system 2.3) Hot Blast Stoves 2.4) Cast house & cast house Slag Granulation Plant

Furnace design parameters are given below:

MAIN UNITS UNIT FACILITIES AT MTP EXPN

Blast Furnace No. 3 1

Gas Cleaning Plant No. 7 HTP-SCRUBBER

Pig Casting Machine No. 1 1

Slag Granulation Plant 0.6 Mt/Yr.

Blast Furnaces

Production Capacity / Furnace Tpd. 1200 2200

Working Volume M3 995 1448

Useful Volume M3 1139 1658

Hearth Diameter M 7.4 9

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MAIN UNITS UNIT FACILITIES AT MTP EXPN

Bosh Line Diameter M 8.5 10

Stock Line Diameter M 6.2 6.9

Height of hearth M 3.80 3.60

Height of Bosh M 3.40 5.20

Height of Straight section M 2.40 2.00

Height of Shaft M 14.90 17.00

Height of throat M 2.20 2.00

Total Height M 26.50 31.85

Working Height M 21.00 21.20

Hearth area M3 42.99 63.59

Bosh Angle 89o 49’ 81o 10’

Stock Angle 85o 35’ 85o 10’

Tuyeres No 18 21

Tuyeres Size MM 130 X 600 140 X 600

Cinder notch No. 1 1

Iron notch No. 1 2

Cast House No. 1 1

Capacity of cast house crane T 15 T Each 30 T Reactions in the Blast Furnace Upper Stack Zone • Reduction of oxides

3 Fe2O3 + CO = 2 Fe2O3 + CO2 Fe3O4 + CO = 2 FeO + CO2 FeO + CO = Fe + CO2

• Decomposition of Hydrates CO + H2O = CO2 + H2

• Decomposition of Carbonates

Middle Stack Zone • Direct / Indirect reduction

FeO + CO = Fe + CO2 CO2 + C = 2 CO FeO + C = Fe + CO

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Panorama 2010 Lower Stack Zone • Calcination of lime • Reduction of reduced iron • Reduction of Silica / MnO2 • Formation / melting of slag

Combustion Zone • Burning & combustion of coke & complete reduction of iron oxide.

C + CO2 = CO2 + 94450 Cal (Direct Reduction) CO2 + C = 2CO – 41000 Cal (Solution loss reaction)

Race way • Coke & Hydrocarbons are oxidized • Large evolution of heat.

Top Charging Equipment There are two types of top charging equipments; one is the conventional bell type with movable throat armor (MTA) charging system in BF # 1 and the state of the art Bell Less Top (BLT) charging system in BF # 2, 3 & 4. In case of bell system (in BF – 1) the furnace top is provided with 2 bells, one small bell of bottom dial 2.35 m and under it the big bell having bottom dia 4.5 m. There is a distributor system which rotates the small bell through a pre set angle after 2 skips of material is discharged to receiving hopper, so that the material is dumped at a particular section of big bell when small bell opened. Whenever one bell opens invariably the other bell remains closed to prevent escape of furnace top gas. After the small bell is closed big bell opens by traveling downwards to dump material into the furnace. The injecting of falling material can be varied by varying the throat dia. by means of a set of variable armoured plates (called MTA) so that the desired burden distribution is achieved. The MTA is hydraulically operated & controlled through the PLC.

In case of BLT, these are no bells as the nomenclature states. The skips dump the materials to a receiving hopper, which is separated from the BLT by upper material gate and upper gas seal valve. After opening of upper material gate & upper seal valve, material is discharged into BLT material bin placed over the lower material gate & lower gas seal valve. Then the UMG (Upper Material Gate) & USV (Upper Seal Valve) are closed to seal the furnace from the atmosphere & the receiving hopper is ready to receive material from the skips.

To dump the material into the furnace, the lower seal valve opens and then the lower material gate is opened. The material is dumped through a rotating chute, which can dump material at any position of the furnace and can complete the dumping in variable number of rotation so that desired burden distribution is achieved. The whole BLT system is hydraulically operated & PLC controlled. Besides achieving perfect burden distribution, BLT ensures very good gas sealing at the furnace top so that furnace can be operated at a high top pressure.

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Cooling System In order to monitor, prevent damage and prolong the life of refractory lining inside the furnace, it is essential to have an elaborate cooling system in the furnace. In BF 1, 2 & 3 from bosh to 2/3 stack the lining is cooled by plate coolers, from bosh to hearth by spray coolers. The top stack is not provided with any cooling water. But the BF # 4 hearth bottom is provided with under hearth coolers, hearth to 2/3 stack is provided with close loop stave coolers and the tuyeres area with breast coolers. BF # 1 is provided with external spray system. The pure copper tuyeres and main coolers that are projected into the furnace through the lining are internally cooled by water. The temperature & steadiness of out let water of cooling members are regularly monitored. To control the top gas temperature in exigencies water spray system is provided at the furnace top.

Hot Blast Stoves & Associated System The function of Hot Blast Stoves is to pre heat the air blast before its admission into furnace through tuyeres. Each furnace is provided with 3 hot blast stoves which are tall cylindrical shell with dome shaped top. Each stove consists of two parts namely combustion chamber & checker brick work. The combustion chamber is lined with fire clay brick & checker bricks are Alumina bricks. BF gas is burnt in combustion chamber and the sensible heat of the flue gases heat up the checker bricks while passing through them from top towards bottom. The period of heating is called “On Gas” & normally a stove remains on gas for 1 hour 30 minutes at a stretch. After heating, cold blast, supplied from turbo blowers of CPP–I is passed through the checker works from bottom and the air got heated up by taking sensible heat from checkers. The period of blast heating is called “On Blast” condition of stove. The blast period is usually for 1 hour.

The hot blast stoves are provided with several attachments such as burners to burn the premixed air and BF gas in the combustion chamber. Different valves are provided for controlling the BF gas, combustion air, waste gas, cold blast and hot blast to or from the stoves. The hot blast from stoves passes through insulating refractory bricks lined pipes (hot blast main, bustle main & tuyeres stocks) and then injected through tuyeres into the furnaces. The entire operation & control of stoves & hot blast is made from a control room adjacent to stove. Stove design parameters are given below:

MAIN UNITS UNIT FACILITIES AT

MTP EXPN Stoves No. 3 3 Jacket Dia 8 8.5 Overall height Mtr. 37 38 Heating surface / stoves Mtr.2 34000 43000 Blast Temperature OC 950 1000

Blast Volume Nm3/hr 100,000 Nm3/hr.

140,000 Nm3/hr.

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Panorama 2010

FLOW DIAGRAM OF STOVE

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Cast House The Cast House is the most important section of Blast Furnace. The function of cast house is to tap the liquid metal & slag from the hearth of furnace on schedule, separate the metal & slag in troughs and flow them through runners to metal ladles and slag pots respectively. Production of Blast Furnace is greatly influenced by effective tapings which depend on a good cast house practice. Hydro pneumatic drill machines are used to drill the tap hole up to 2 m into the hearth to tap the metal & slag. Oxygen lancing through mild steel pipes is resorted to, if taping is not possible by drilling alone. The troughs & runners are made with special grade refractory mass to handle upto 40,000 T metal before repair. Few iron runners are also made with low cement castables to handle more then 1 lakh ton metal before repair. Hydraulic powered mud guns are used to close the tap hole after casting is over with anhydrous tap hole mass which get quickly hardened inside the tap hole. The main components of cast house is the tap hole, troughs, iron runners, slag runners, iron & slag spouts, mud gun and drill machine. Each cast house is provided with an EOT crane (15 T cap for BF – I, II & II and 30 T for BF – IV). BF 1, 2 & 3 have one tap hole where as BF – 4 has two tap holes with separate trough & runners for Iron & slag. More over BF – 4 cast house has two mud guns for 2 tap holes but one common drill machine. BF # 4 Cast house is provided with tilting runner & pusher car in iron side. BF # 3 is also provided with tilting runner in Iron side. Cast House Slag Granulation Plant. BF # 1 & 4 have Cast House Slag Granulation Plant (CHSGP) where the slag after being separated from iron in troughs, is diverted to the granulation plant. Major units of CHSGP are hot runner, old runner, Blowing box, Receiving hopper, Dewatering drum & disposal belts. As the Hot slag flows down from the Hot runner, several water jets from the blowing box, break the slag stream into droplets & carried them into a receiving hopper as a slurry. The slurry falls on wire nets and paddles of a rotating drum, wherein water passes through and goes to the hot water tank whereas the granulated slag is captured by the paddles, which move along with the drum rotation. When the paddles come over a belt running at the center of the drum, the granulated slag falls into the conveyor and is carried away to the disposal yard. The yield of granulated slag of CHSGP is around 90%. It has been designed by M/s Paul Wurth and can handle slag upto 6 to 10 T/ minute. Granulated slag is a major raw material for Portland slag cement. Therefore by granulating slag not only is the waste material used economically, it also avoids environmental problem that is associated with liquid slag dumping.

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Panorama 2010

FLOW DIAGRAM OF INBA - CHSGP

Gas Cleaning Plant (GCP) BF – I, II & III is connected to a common GCP where as BF – 4 has dedicated GCP. The BF gas leaving from top of BF – I, II & III is having about 20 – 25 gm / Nm3 dust. BF gas is subjected to successive cleaning in dust catcher (by changing the direction of the flow of the gas), gas washer (washing with water sprays) and Electrostatic precipitator (by ionizing the dust particle by applying high potential to electrodes), where by dust content is reduced to the extent of 4 to 6 mg/Nm3. Filter House The effluent dirt water coming from the water seals of the precipitators is collected in concrete channels leading to slurry pump sumps. From this sump, the slurry is pumped by a slurry pump of capacity 225 m3/hr. (1 R+ 2 S) into overhead steel channels for the dirty water. This slurry along with the slurry coming directly from gas washers goes to 3 nos. of Dorr Clarifier Basins. After clarification, the water goes to the hot water pump sumps at the pump house. The underflow water from of the clarifier basins is pumped to the Continuous Belt Press Filter (CBPF) for de-watering. After the extraction of the water, the filter cake generated by CBPF is removed by road transportation. The connections of the clarifier basins to the general sewage system permit a complete cleaning out of each clarifier basin. The sludge pumping station and the sludge filtration plant are provided to deal with 3,400 cbm per hour of dirt water.

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FURNACE

DUST CATCHER

WAGON

DOWN COMER

SCRUBBER

E.S.P

SLURRY PUMP

C.B.P.F

FILTER CAKE

WATER SEAL

HOT WATER SUMP COLD WATER SUMP

CO

OLI

NG

TO

WE

R

BF CLEANGAS MAIN

CLARIFIERS

Flow Diagram of Gas Cleaning Plant BF # 4 GCP and High Top Pressure Due to high top pressure dust content in top gas from BF – 4 is less compared to that in BF – 1, 2 & 3. Hence ESP is not envisaged in BF – 4 GCP. The top gas coming from dust catcher of BF – 4 is allowed to pass through cylindrical scrubber from top where in the gas is cooled & cleaned by means of several sprays. The semi clean gas is then allowed to pass through a ventury attached to bottom of the scrubber where in the rest of the dust is cleaned & washed away by the spray of water in the ventury. One annular gap element (AGE) regulates the flow of gas into out let pipe inside the ventury and creates a backward pressure in the furnace. As the annular gap decreases between the element & ventury, the top gas flow is throttled and furnace top pressure increases. The AGE is hydraulically operated & controlled by PLC to give preset top pressure. A mist eliminator attached to the scrubber reduces the moisture content in the clean gas before it joins the main clean gas line.

Pig Casting Machine (PCM) There are two machines. Each machine has two strands of chains fitted with small steel mould rotating on sprockets. Hot metal is poured into the lime coated moulds & cast as solid pigs. PCM is provided with 2 EOT cranes for pouring metal, 1 crane for cleaning and material handling and 1 magnet crane for loading / unloading pigs into wagons. PCM handles 80 T capacity hot metal ladles only. Ladle cleaning, repairing & heating is also done in PCM bay.

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Panorama 2010 Ladle Repair Shops There are two Ladle Repair Shops, where small and big ladles are repaired, cleaned and relined. These are used for transportation of Hot Metal. Clay Preparation Unit Tap hole clay, Mud gun clay and tar mass, which are needed for various jobs like tap hole making, mud gun filling, spout making and trough / runner making, are prepared in this unit by mixing ingredients like coke breeze, coal powder, fine clay, plastic clay, refractory grog, coal tar pitch, sulphite lye and water. Slag Granulation Plant For every ton Hot Metal produced in our Blast Furnaces, about 400 kg of slag is generated as an industrial waste. The Slag in granulated form is used as excellent raw material for manufacture of cement. The granulated slag when used in the manufacture of cement replaces the main ingredient clinker up to 50-60%. This results in significant cost reduction in cement industry and also results in marked conservation of lime stone, a basic raw material for both the industries. The project was commissioned on 31st March, 1977. Composition of Granulated Slag: The BF slag has a chemical composition as mentioned below and has about 8-10% moisture. The bulk density of the granulated slag is in the of the order of 0.8-1.2 Ton per cubic meter & size 0 to 3 mm.

CaO 30 - 32 % SiO2 32 – 34 % Al2O3 20 – 22 % MgO 10 – 11 % MnO 1 FeO 1% Max

S 0.5 to 0.6 Process The Rourkela Slag Granulated Plant follows the hydraulic chipping principle which can be classified in to the semi-dry process. The slag pots are placed in position and the solid crust is pierced by a conical dead weight of 2.5 tonnes with the help of EOT crane. Then the slag pots are electrically tilted over a receiving bath and from it falls in to hydro-chutes where simultaneously high pressure water is sprayed through a nozzle plate having 53 Nos. of holes of different size. The slag is instantaneously cooled and crushed to less then 3 mm size. The granules thus formed are thrown out in to the storage bay to a distance of 15 to 20 meters due to the high pressure (9 kg/cm2) water spray. From the storage bay the material is shifted by means of a 10 T – EOT crane with grab bucket arrangement to steel hoppers for truck loading.

In the process of shifting the material from the storage bay, the water flows down to a re-circulation tank system of 450 m3 capacity. The water is allowed to settle here and the clean

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water is re-circulated through the pump house by the horizontal centrifugal pumps. The water loss is compensated by the make-up water which comes through the make-up water lines of 250 mm diameter. The usual water consumption is 2.5 m3 per ton granulated slag. The Granulation Plant is having the following sections:

i) Granulation Bay with one 3 Ton EOT crane, 6 numbers of Hydro-chutes and Control Tower.

ii) Storage Bay with 2 numbers of 10 Ton capacity EOT cranes provided with Grab Buckets (each 3 m3 capacity) and 2 numbers of steel hoppers.

iii) Water Circulation System including the pump house, re-circulation tank, 6 numbers centrifugal pumps of 300 m3 per hour capacity and 93 m head, and tunnel house system.

iv) Power Sub station with motor control circuits. v) Ventilation System.

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Panorama 2010

BLAST FURNACE

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SLAG GRANULATION PLANT The Slag Granulation Plant of Rourkela Steel Plant is located by the side of NH-23 and at a distance of 2 km from Tarapur Gate. It is in an area of 200 m X 400 m and has got a separate boundary wall. The Plant was constructed by M/s Engineering Projects (India) Ltd. and was commissioned on 31st March 1977 and has Capacity of 0.6 MT/year. The plant uses liquid Blast Furnace Slag and converts into granulated slag which is used as input raw material in cement plants for production of slag cement. The normally known Portland cement has almost same strength and setting properties required for constructions but production cost of slag cement is less than Portland cement. General lay out of the plant is shown in Fig. I. Input Raw Materials The input raw material for granulated slag is hot liquid Blast Furnace Slag at temperature around 1250 0 C. This liquid slag is brought from Blast Furnace loaded in slag pots. Input slag analysis is given bellow: CaO - 30-36% SiO2 - 30-35% Al2O3 - 18-26%

MgO - 10% Max. MnO - 2.5% Max. FeO - 1% Max. S - 0.5-1.0% CaO/ Si O2 = 0.96 Max

The granulated slag produced has got following properties: The bulk density is 1 - 1.2 ton/m3. Size of granulated slag is – 3 mm (approx.). Moisture content is 5 to 10%. Brief Description of Process Slag Granulation Plant consists of granulation bay with one open yard EOT crane of 3 T capacity and two storage bays each with one-10 T EOT cranes. Granulation bay is located at an elevation of 9 meter and storage bays is located at 0 .00 level. Six nos. of hydro- chutes are provided in the granulation bay to produce and discharge granulated slag in the storage bays. Hot liquid slag in slag pots from Blast Furnace comes to Slag Granulation Plant in slag pot cars driven by locomotive engine. The slag pots are placed on granulation hydro-chutes and connected to the power supply network through flexible cables from the power plugs located along the columns of the bay. Slag crust on the top is pierced by means of a conical weight of 1.5 T attached to the 3 T EOT crane situated over the pouring track. After crust is pierced, each slag pot is tilted by electrically driven motor with the help of ON/OFF push button switch is installed in Control Desk at control tower to discharge the liquid slag into the receiving bath. The water at 8 kg/cm2 flows through the nozzle box situated under the receiving bath which cools the liquid slag and thus fuses the liquid slag to granules of about 3 mm size known as granulated slag. The granulated slag produced in this process is thrown to a distance of 15 to

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Panorama 2010 20 meters away from the chute in the storage bays along with the pressurized water. Granulated slag in storage bay is dozed with the help of a dozer within the reach of the 2 nos. of EOT grab cranes. The grabbing capacity of each bucket of the cranes is 3 m3. The liquid slag residue, about 30% left over in the pot is removed at the de-sculling site of Scrap and Salvage Department. Electrical Power Supply System: Electrical power for SGP comes from MSDS-II. 6.6 kV power supply through feeder No.4 and feeder No.15 is stepped down to 415 V through 1.6 MVA transformers at sub-station. Thus, the power available at the incomer of the sub-station has 3-phase 415 V A.C. The Electrical power supply to all the drives and equipments ensured by 3 nos. motor control centers i.e. MCC-1, MCC-2, MCC-3 through dedicated feeders. Ventilation System: One centralized ventilation system has been installed on the floor of the sub-station building for ventilation of pump house, sub-station, tunnel and control tower. Fifty meters away from sub-station air intake house of size 1000 mm X 1600 mm is located and air is brought to the sub-station through an underground air duct. Air is cleaned in filter panels installed in the air intake chamber and cooled in the air washer and delivered by centrifugal fan at the rate of 40,000 m3/hr. The fan is driven by 15 kW motor. The flow of air has branched out in the following manners:

a) For Pump House : 15,000 m3/hr. b) For Sub-station : 13,000 m3/hr. c) For Water Pipe Line Tunnel : 9,000 m3/hr. d) For Control Tower : 3,000 m3/hr.

One booster fan of capacity 12,000 m3/hr driven by 3.7 kW motor has been installed at the entrance of tunnel house to deliver air to tunnel house and control tower. Water Recirculation System In Hydro Chute Method of granulating slag, the main consumable is water. In this process about 40% water is lost in the form of steam and rest 60% re-circulated as water, which contains some dissolved impurities. This water is recycled along with required amount of additional water collected from make up water line. The Water Recirculation System of the SGP mainly consists of:-

1) Recirculation Tanks 2) Pump House 3) Tunnel House.

RE-CIRCULATION TANKS Water, after use in granulation, flows from storage bay into 2 nos. recirculation tanks through a filtering media provided at the outside wall of the tanks. Water flows from the filter to the tanks through 11 nos. of pipes of diameter 200 mm. Each recirculation tank has got capacity of 110 m 3 located side by side. From the recirculation tank, water flows into 23 m long suction channel from which water is supplied to the suction pipes of 6 nos. of granulation pumps. The

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make-up water to the system is fed to the suction chamber through a 250 mm diameter pipeline in order to compensate the loss of 40% of water during the granulation process. PUMP HOUSE The pump house is situated at 7 metres below the sub-station building. The pump house is equipped with 6 nos. Centrifugal Pumps having capacity of 300 m3/hr each. Two dewatering pumps are installed to take out leakage water inside the pump house. The capacity of each Dewatering Pump is 10 m3/hr. The water from suction tank enters to the pump through suction valve and strainer. From each pump, water comes to the ring main through non-return valve and delivery valve. From the ring main water goes to nozzle box of hydro- chutes. The nozzle box has got a plate having 53 holes of different diameter from 8 to 16 mm in order to release the pressurised water to granulate the hot liquid slag. The pump house is connected to the ventilation system. A manually operated 2 T capacity monorail hoist is provided in side pump house for maintenance of equipments. TUNNEL HOUSE It is situated below the granulation bay. The major portion of recirculation water pipe line is situated inside the tunnel house. Six vertical pipe tapings of 300 mm diameter each have been taken from water ring main to nozzle box at granulatation bay for granulating liquid slag. The tunnel house is connected with ventilation system. A Centrifugal Fan and an exhaust fan in the tunnel house are used for of better ventilation. SHIPPING Material shipment is done by road only. Material from the storage bay is grabbed with the help of EOT Cranes of 10 T capacity and filled in the steel hoppers and discharged in the trucks for road dispatch. PROSPECTIVE CUSTOMERS: 1. M/s. Orissa Cement Ltd., Rajgangpur, Orissa. 2. M/s. Chariot Cement Ltd., Kalunga. Rourkela, Orissa.

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Panorama 2010

General Layout of Slag Granulation Plant

A B

GRAN

ULA

TIO

N

DISPATCH BAY

GA

RR

AG

E

AD

M. B

UILD

ING

CYCLE STAND

MAIN

CR -814 A

CR-810

FOR DISPATCH

RECIR- CULATION

LIQ

UID

SLA

G F

RO

M B

.F

PUMP HOUSE SUB-STATION

CONTROL

TOWER

MECHANICAL

WORK SHOP

CR-816

MAKE UP WATER LINE

WATER RING MAIN

WAY TO TARAPUR GATE

NH -23

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STEEL MAKING Steel is made by LD process. Hot metal from Blast Furnaces, Oxygen (from Tonnage Oxygen Plants) and Flux (from LDBP & CP-II) are the main input for steel making. Magnesia Carbon bricks from the captive Brick Plant are used for carrying out converter relining. In addition, purchased Magcarb bricks are also used for lining the converter. Hot Metal and Scrap are charged in requisite quantity in converter. Oxygen is blown from the top and flux is added in the converter in a continuous manner initially and subsequently as per the requirement to facilitate steel production.

During oxidation of hot metal, impurities in the hot metal like C, Mn, P, Si get oxidised and are separated by mixing them with flux (lime).The impurities thus generated are known as Slag and are taken out in Slag Pots and dumped in Slag yard.

Steel produced in the converter is tapped into a preheated ladle, placed on the self-propelled car below the converter (known as steel car). Ladle additives like Ferro Alloys and Aluminium are added before/ during pouring steel in the ladle to produce/adhere to the composition of required grades.

The ladle containing liquid steel is taken to Casting Shop via Argon Rinsing Station (ARS) /Ladle Heating Furnace (LHF). During treatment at ARS/LHF, Argon is purged through liquid steel from bottom, which causes the liquid steel to homogenize w.r.t chemistry as well as temperature. Corrective additions for achieving desired composition are also made at this stage. From ARS/LHF liquid steel is converted to slabs in continuous casting machines in SMS-I & II. The various units like Lime Dolomite Brick Plant (LDBP), Calcining Plant – II (CP-II), Tonnage Oxygen Plants (TOPs) and Steel Melting Shops (SMSs) are described in subsequent chapters.

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Panorama 2010

Crop end & Arisings (6.2 Kg/T)

Hot Metal = 1041 Kg/T

SCRAP 98 kg/T

Slag 175 Kg/T

Liquid Steel

INPUT

OUTPUT

For disposal

Ferro-Alloys (Fe-Mn, Fe-Si, Si-

Mn) & Al Special Alloys

(Fe-Nb, Fe-V, Fe-Cr, Fe-Ti)

Caster Steel slab

Tundish skull (19.7 Kg/T)

LIME 91 kg/T

DOLO 11 kg/T

STEEL MELTING SHOP-I

In early sixties SMS-I was commissioned with LD converters and later on a Secondary Steel Making unit and a Continuous Casting unit were added to it. Hot Metal from different Blast Furnaces is transferred to Hot Metal Mixers of SMS-I by locomotives. Using oxygen from TOPs and Lime & Dolomite from LDBP, hot metal is converted to steel. For smooth production of steel, SMS-I is provided with following facilities: Mixers: Two numbers of Hot Metal Mixers (1100 T Tons each) located at 7.5 mtrs from ground level stage situated at both ends of Converter Shop to act as buffer storage. Homogenisation of hot metal w.r.t. temperature and composition takes place in these Mixers. Temperature is maintained by mixed gas burners. LD converters There are total two eccentric type LD converters in SMS – I having 66 T capacities each. Converter is a vassal in which hot metal and scrap is charged and oxygen is blown from the top through water-cooled 3 holes expansion lance. Fluxes are added from overhead bunkers with the help of weighing hoppers and water-cooled chutes. Ferro alloys are added into tapping ladles from the working platform.

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Blowing Start blow with oxygen lance with height (working) as per the bath height measured. Before lancing lance should be free from any skull at the nozzle and also water leakage. Then the oxygen is blown. The agitation takes place which is indicated by luminous flame at converter mouth. If agitation does not take place within 2 minutes then lift the lance jerk the converter 2 to 3 time and again blow it. Start adding lime as per silicon contain and loss of ignition of lime. Add 50 % of total lime in three dozes within 4 to 6 minutes of blow start. Continue blowing up to 6 to 9 minutes. Stop blow, lift the lance and deslag by tilting converter from backside pull pit.

Keep oxygen lance within recommended height for the converter. Blowing or working height = depth indicator reading + bath height.

Blowing oxygen pressure varies from 8 to 10 kg/cm2 and flow rate 9000 to 10000 Nm3/hr. any deviation in blow pressure contact TOP-I, Instrumentation and Mech. Add remaining 50 % lime in dozes during the second half of blow. Observe the flame, when flame drops stop blowing. We can do straight blow without deslagging up to 6 to 9 minutes till flame drop with some lime addition. Tilt the converter from back side pull pit for organizing steel and slag sample and temperature. Take 1 to 3 slag sample per shift. FeO in slag should be 35 % max. If FeO is more then desired limit then following actions may be taken for next blow. Working height/ bath height adjustment of oxygen lance position Total blowing time and reason for long time if applicable Corrective actions are taken based on above and add coke during blowing if necessary. For low turn down temperature (<1580°C) add 200 kg to 500 kg FeMn or SiMn in the converter by charging box. Rock the converter once and keep vertical. Blow at referred height. For each minute of the blow the rise in temperature 12 ±2 °C approximately.

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Panorama 2010

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Ladle preparation bay (Pit side) Ladle preparation Ladle is steel shell, which is lined with refractory bricks. After the lining is complete, ladle is lifted from relining pit and placed under burner for minimum 2 hrs for drying. Preheated Ladle is then placed horizontally on the ladle stand and inner surface of sealing block and well block is cleaned using compressed air. Ladle should be dry and setting of bricks should be complete before fixing of porous plug. There are total 16 steel ladles in SMS – I. Secondary steel making For most applications, the surface quality, internal quality, microcleanliness and mechanical properties of steel produced by conventional route are entirely satisfactory. However quality requirements of special steels in terms of cleanliness, grain size control, narrow hardenability range etc have become quite stringent in recent times. These requirements and compulsions led to the development of a series of new individual requirements. There are two processes adopted in SSM. These are:

Vacuum Arc Refining (VAR) Vacuum Oxygen Refining (VOR)

Secondary steel making can be defined as the process of making steel suitable for special applications b final refining and compositional adjustments. In RSP these two processes are adopted which is mainly based on the vacuum. The basic principle behind this vacuum treatment is that “the amount of dissolved gases in steel increases with increase in the partial pressure of gases. The other advantages are the temperature requirement for the vacuum treatment decreases according to Sievert’s law. % Gas dissolved = K×√ (partial pressure of gas at ambient atmosphere) Benefits of secondary steel refining process

Improvement in the productivity of primary steel making furnaces such as BOF, EAF etc.

Better deoxidation practice. Decarburizing to attain very low levels of carbon. Degassing to attain very low level of hydrogen and nitrogen. Desulphurization to attain very low level of sulphur. Inclusion shape control. Better alloying practice:

Improved alloy recovery. Achieve chemistry in very close range.

Dephosphorisation. Homogeneity with respect to :

Temperature. Chemical analysis.

VAR/VOR process sequence 1. LD converter steel (1650°C) 2. Teeming ladle (66 T & 1600°C) 3. Transfer by EOT crane 4. Lowering into VOR/VAR tank.

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Panorama 2010 5. Connection of tank and ladle argon hoses. 6. Argon purging for a minute 7. Initial temperature measurement. 8. Placement of tank cover over the tank 9. Start argon purging at required/specified rate 10. Start steam ejector and attain required vacuum level 11. Start arching/ oxygen blowing 12. Continue degassing 13. Addition of

Al Fluxes (LIME, ETC.) Ferro alloys

14. Increase argon flow for thorough mixing 15. Discontinue evacuation 16. Measure temperature 17. Take sample for analysis

Degassing process Following chemical reactions occur during degassing and processing:

[ FeO] + [ C] = [ Fe ] + CO, 2CO+O2 = 2CO2 [MnO] + [Fe] = [FeO] + [Mn] 3 [CaO.P2O5] + 5 Fe = 2[P] + 5 [FeO] + 3[CaO] [S] + [ CaO ] +2/3 [Al] = CaS + 1/3 [Al2O3] 3 [FeO] + 2 [Al] = Al2O3 + 3 [Fe] 2 [FeO] + [Si] = Si O2 + 2 [Fe] SLAG:

CaO - Al2O3 - SiO2 (50-55%) (30-40%) (5-10%)

Continuous Casting Shop Ladle Heating Furnace The main function of ladle heating furnace in SMS-I is to dispatch the liquid steel at required temperature for casting and addition for final aimed chemistry. The specific objective of heat processing at LHF is as follows: o Homogenizing the steel bath with respect to

temperature and composition. o Improved alloy yield and compositional control

within narrow limits. o Desulphurization, deoxidation, inclusion shape

control, improved steel cleanliness, high isotropy of mechanical properties.

o Hydrogen and nitrogen removal o Attainment of prescribed casting temperature within narrow range.

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o Providing sufficient holding time during treatment and casting. o Acting as buffer between converter and casting unit. Argon Rinsing Station (ARS) The main function of ARS is to homogenize the liquid steel with respect to temperature and composition and removal of non-metallic inclusions by formation of slag. The process starts with placing the steel ladle on the ARS stand. Argon rinsing is started from the bottom. Process chart is referred for rinsing procedure, additional duration of purging and minimum temperature for lifting the ladle for casting. Continuous Casting Machine The Process Continuous casting is the process whereby molten metal is solidified into a "semi finished" billet, bloom, slabs or beam blank. Prior to the introduction of continuous casting in the 1950s, steel was poured into stationary moulds to form "ingots". Since then, "continuous casting" has evolved to achieve improved yield, quality, productivity and cost efficiency. Nowadays, continuous casting is the predominant way by which steel is produced in the world. Continuous casting is used to solidify most of the 750 million tons of steel, 20 million tons of aluminum, and many tons of other alloys produced in the world every year. In the continuous casting process, molten metal is poured from the ladle into the tundish and then through a submerged entry nozzle into a copper mould cavity. The mould is water-cooled so that enough heat is extracted to solidify a shell of sufficient thickness. The shell is withdrawn from the bottom of the mould at a "casting speed" that matches the inflow of metal, so that the process ideally operates at steady state. Below the mould, water is sprayed to further extract heat from the strand surface, and the strand eventually becomes fully solid when it reaches the ''metallurgical length''.

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Panorama 2010 Solidification begins in the mould, and continues through the different zones of cooling while the strand is continuously withdrawn at the casting speed. Finally, the solidified strand is straightened, cut, and then discharged for intermediate storage or hot charged for finished rolling. To start a cast, a steel dummy bar seals the bottom of the mould. This bar prevents liquid metal from flowing out of the mould and the solidifying shell until a fully solidified strand section is obtained. The liquid poured into the mould is partially' solidified in the mould, producing a strand with a solid outer shell and a liquid core. In this primary cooling area, once the steel shell has a sufficient thickness, the partially solidified strand will be withdrawn out of the mould along with the dummy bar at the casting speed. Liquid metal continues to pour into the mould to replenish the withdrawn metal at an equal rate. Upon exiting the mould, the strand enters a roller containment section and secondary cooling chamber in which the solidifying strand is sprayed with water, or a combination of water and air (referred to as "air-mist") to promote solidification. Once the strand is fully solidified and has passed through the straightener, the dummy bar is disconnected, removed and stored.

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Torch Cutting Machine (TCM) TCM is used to cut the slabs online to the required length. The cutting operation is done by oxy-acetylene gas flame. Slab Storage and Dispatch Yard Produced slabs are stacked for proper identification for dispatching to Hot Strip Mill (HSM) and Plate Mill (PM) for further processing.

BLAST FURNACE

MIXER MIXER

CONVERTER CONVERTER

SSM UNITS

VAR VOR

LHF ARS

PLATE MILL HOT STRIP MILL

CASTER

Flow Chart of SMS-I

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Panorama 2010

STEEL MELTING SHOP –II

Steel Melting Shop (SMS) - II consists of a Basic Oxygen Furnace (BOF) Shop Complex and a Continuous Slab Casting Shop (CCM-II) Complex. This Steel Melting Shop was added as a part of RSP’s modernisation package in late nineties. Hot metal, Oxygen and Fluxes, the main input materials for steel making are provided by Blast Furnaces (BFs), Tonnage Oxygen Plants (TOP-I&II), Calcining Plant (CP-II) and Lime Dolomite Brick Plant (LDBP) respectively. BOF Shop Complex: BOF Shop Complex can be essentially divided into 3 sections:

a) Mixer & Desulphurisation (DS) Unit b) Converters c) Slag Yard and Scrap Yard

Mixer and DS Unit: Two Hot Metal Mixers are being used for storing Hot Metal (HM) that is received from all the four Blast Furnaces and to essentially homogenise the HM w.r.t. temperature and composition and to provide uninterrupted supply of HM as and when required for the converters. The details of the mixers are:

Two Desulphurisation (DS) Units are provided for removing excess sulphur from the HM to the acceptable norms before the HM is charged into the converter. This is being carried out by injecting CaC2 /MgAl based compound as DS agent through top lance. Details are as follows:

- Heat weight - 150 to 165 tonnes - Working volume – 165 m3 - Metal depth - 1165 mm

Two nos. of slag raking machines are provided to remove the slag from the HM ladles before it is charged in the converter.

- Working member boom with a scrapper - Boom travel - 5000 mm - Turning angle - 20o (right or left) - Boom inclination angle - 10o upward or downward

Capacity : 1300 T Operating angle : 30o Full emptying angle : 45o Average hot metal temperature in mixer: 1250 to 1350oC.

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Converter Shop: The shop is located at 9.5 m from ground level. Two numbers of converters (150 T capacity each) of top oxygen blown type were installed in this shop. These converters receive HM and scrap with the help of cranes and other input materials like Ferro Alloys, Flux by mechanised (hopper with weighing facility) as well as manual process. The converters are concentric vessels manufactured from steel plates and lined with basic refractories to sustain desired temperature and corrosion during the refining process. Oxygen supplied by Tonnage Oxygen Plants is blown into it from the top through a water-cooled lance.

150 Ton LD CONVERTER

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Panorama 2010 Slag Yard & Scrap Yard: The slag produced by the above process is handled by Slag Yard using a remote controlled over head crane for safety purpose. The scrap yard stores and provides the combination of light, medium & heavy scrap as per the requirement of the shop. The crane used has magnets to do the loading and unloading. CCM-II Shop Complex: CCM-II Shop Complex houses

a) Ladle Preparation Bay b) Tundish Preparation Bay c) Ladle Heating Furnace (LHF) d) Argon Rinsing System (ARS) e) Casters f) Slab Yard

Ladle Preparation Bay: The ladles used for handling liquid steel are prepared in this bay. Tundish Preparation Bay: The bay is equipped to clean the used tundish and prepare this tundish for new sequence. LHF: One LHF is used for homogenising and final adjustment of temperature and chemical analysis of steel tapped from Converter before being sent to Casters for casting. LHF consist of:

- Ladle Car - Electrode heating mechanism - Water cooled roof with dust collector system - Alloying system - Wire feeding machine

ARS: One ARS is used for homogenising and final adjustment of temperature and chemical analysis of steel tapped from converters before being sent to casters for casting. ARS consists of: - Alloying system - Wire feeding machine Casters: There are 2 single strand slab casters and two turrets for handling the ladles and providing steel on continuous basis. They can rotate 360o and can lift two 240 T ladles and rotate. The slab caster has a water cooled copper mould, which gives the required dimensions of the slabs produced. The strand produced is further cooled by water

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sprayed through specially designed nozzles and simultaneously pulled out by drive rolls and straightened. The continuous long strand is at suitable lengths to form slabs and are cut by using transverse torch cutting machine, which moves along with the strand and cuts slabs using oxygen and acetylene.

Average heat size : 150 -165 tons No. of strand / machine : 1

Casting size : 220 mm thickness Width : 900 - 1550 mm Length : 6000 - 8000 mm

Slab Yards: All the slabs produced are stored in two slab yards. Slabs sent to Plate Mill are further cut to required length before being dispatched. Hot slabs are also being loaded in specially made flats to Hot Strip Mill. Two slab marking machines have been installed for marking slabs thereby reducing lead time. Other Facilities Available: There is a Pump House to cater to the exclusive needs of the SMS-II Shop. There is also a Compressor House for supplying the required compressed air that is required in the Shop. Mould Segment Repair Shop exists to repair mould, segment and other allied repair activities.

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Flow of Materials in SMS-II

LD Gas

Hot Metal (Blast Furnaces)

Mixer

LD Converters

Oxygen (TOP-II)

Nitrogen (TOP-II)

Ladle (Steel Car)

Aluminum

LHF /ARS

Flux

Turret Tundish Mould Segments TCM

Roller Table

Transfer Bed

Slab Storage TTCM

Slab Disposal

HSM & PM

Flux (CP-II)

Ferro Alloys

TCM: Torch Cutting Machine, TTCM: Transverse Torch Cutting Machine

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REFRACTORY ENGINEERING (SERVICES) Refractory Engineering (Services) department is responsible for maintaining the health of all furnaces/kilns situated through out the plant. The major functions of the department are:

Cold & Hot Repairs of furnaces. Capital & Mid. Campaign Repairs of all refractory lined structures. Relining of Blast Furnaces Hot Metal Ladles, LD Converters, Steel Ladles, Tundishes,

Hot Metal Mixers, Limeshaft Kilns, Reheating Furnaces, Acid Proof Kilns in Cold Rolling Mills & Silicon Steel Mills.

Carrying out technical modifications and improvements to increase the availability and life of refractory lined furnaces, etc.

Preparing quantitative & qualitative requirements of various kinds of Refractories, initiating for its procurement.

Follow up with Material Management to arrange supplies in time.

The total job of the department is carried out in four zones. They are as follows:

1. Blast Furnace Zone a) Blast Furnaces & Stoves b) Sinter Plants c) Power Plant.

2. SMS-I Zone a) LD Converters b) Steel Ladles c) Tundishes d) Hot Metal Mixer e) Lime Kiln of CP-I

3. SMS-II Zone a) LD Converters b) Steel ladles c) Tundishes d) Hot Metal Mixer e) Lime Kilns of CP-II

4. Rolling Mill Zone a) Foundries b) Reheating Furnaces of PM & HSM c) Cold Rolling Mills d) Silicon Steel Mills

1. Blast Furnace Zone: Under this zone two types of jobs are taken up.

i) Routine Repair/lining jobs ii) Capital Repair/lining jobs There are two types of Capital Repairs under taken in Blast Furnaces.

a. Top Repairs: This involves dismantling of top stack, lining (badly eroded) and then relining with new bricks. The total duration of this type of repair is normally 14-15 days.

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b. Complete Relining: This involves complete stripping of the furnace lining and relining with new Refractories. The total duration of this type of lining takes normally 70 days.

2. SMS-I&II Zones:

Under this zone two types of jobs are taken up. a) Routine Repair/Relining jobs, of steel ladles, Mixer ladles, Tundish, Hot Metal

ladle etc. b) Capital Repair and Major Lining Jobs.

Capital Repair Job – Hot Metal Mixers & Lime Kiln. Major lining jobs – Lining of LD Converters

This zone is most important and vital among all the zones. To improve the availability of LD Converter and Steel Teeming Ladles, numbers of steps have been taken from time to time.

3. Rolling Mill Zone:

Under this zone relining of Reheating Furnaces both of Plate Mill & Hot Strip Mill, Acid Proof Lining in Cold Rolling Mills (Pickling Line) & Silicon Steel Mills, are taken up both during routine repairs and Capital Repair periods.

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LIME DOLOMITE BRICK PLANT (LDBP)

Lime Plant: Lime Plant has a twin shaft kiln and a single shaft kiln to produce metallurgical lime for use in LD converters of SMS-I as flux. Twin shaft parallel flow regenerating kiln namely Kiln No.5 is of 150 T capacity per day and single shaft kiln namely Kiln No.8 is of 80 T capacity per day. Lime stone is supplied by Ore Bedding and Blending Plant. Feed size of Lime stone is 40mm to 80 mm and CaO content is 53% min. Lime stone is stored in the High Line bunkers of LDBP and charged in the Kiln by skip. Lime produced is stored in Kiln Bunkers and Classified Bunkers and supplied to SMS through Belt Conveyors. Mixed Gas is used as fuel for the calcination process and is supplied by the Energy Management Department. Lime stone is heated in the kiln by burning mixed gas.

CaCO3 CaO + CO2 Heat input for Kiln # 5 is 850 Kcal per kg of lime and for Kiln # 8 is 1000 Kcal per kg of lime. Brick Plant of LDBP: The Brick Plant of RSP produces Magnesia carbon bricks which are used as working lining of LD converters of SMS-I and SMS-II and are also used as working lining of ladles of CCM-I & CCM-II. Raw materials mainly used are sea water magnesia, graphite & pitch. Magnesia (25 mm size) is crushed & ground to generate various sized fractions which are stored in classified bunkers. Pitch used is obtained from Coal Chemicals Department of RSP. Graphite (0.7 mm size) is obtained from outside sources. Magnesia & Graphite are mixed uniformly with molten pitch at a temperature of around 200oC. Hot pressing of this mix is done in hydraulic press of 1600 T capacity to produce green (untempered) bricks. These green bricks are then tempered at a temperature of 300oC to achieve the desired quality of bricks. The tempered bricks after cooling are stacked, wrapped, stored and supplied as per requirement of Customers.

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CALCINING PLANT – II

Calcining Plant-II (CP-II) was commissioned during modernisation in order to meet growing demand of flux both in quality & quantity particularly of SMS-II & increased steel making capacity after modernisation. Four lime Kilns of capacity 250 Tons/day installed in between January 1997 and June 1998. 1st Kiln was commissioned on 12th January 1997. Lime Kilns (four numbers) are of double shaft, parallel flow and regenerative type. Three kilns are operated for Lime production and one for Calcined Dolo. Lime stone and Dolo Stone are stored separately & screened before charging to the kilns. Calcinations are done by using mixed gas as fuel. Though the installed capacity of each Kiln is 250 T/day, it is possible to operate the kilns up to 270 T/day. Parameters like Production rate, Specific heat consumption & the stone per skip are fed to the PLC. The other process variables are taken care by auto control system or manual adjustment. Dust Extraction systems are available in this plant but Gas cleaning facilities are to be renovated. A new dust cleaning system has been installed at screen house in Dec-2007. The final product Lime or Calcined dolo (named as per raw material used) are screened by a 10 mm screen to meet size requirement of SMS-II & finally delivered via conveyor belts. Under size products/arising are supplied to other internal customers. Bunkers are available for storage of materials at various stages of operation. Also Dolo chips, Nut coke, Iron ore are supplied to SMS-II through CP-II conveyors via Ground hopper. Raw Materials: Limestone & Dolo stone are received from OBBP through belt conveyors and are stored in four bunkers, each having a capacity of 500 T. Limestone and Dolo stone are screened & charged to Kilns by skip car. Equipment & facilities:

a) Lime Kilns 4 Nos capacity 250 T/Day b) Gas Boosters 10 Nos c) Blowers 28 Nos d) Hydraulic pumps 06 Nos e) Air compressors 03 Nos f) Dust Extraction and Gas cleaning Equipment

5 & 4 Nos. respectively

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Flow of Materials in Calcining Plant-II

Lime Fine Bunkers

SMS-I & II

Lime Stone & Dolo Stone from OBBP

Raw Material Storage Bunkers

30 mm Screen at Kiln Feed Bunker

Kiln #1, 2, 3 & 4

- 30 mm to OBBP

Flux Storage Bunkers

10 mm Screen

- 10 mm

SP-II and Outside Sale

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Tonnage Oxygen Plant – I (TOP-I) TOP-I was commissioned (1 MT Plant) in 1959-60 and expansion plant (1.8 MT) in 1966-67 for production of Gaseous Oxygen at 99.5% purity at the rate of 3300 Nm3/hr & gaseous Nitrogen containing less than 100 ppm of Oxygen at the rate of 6500 Nm3/hr. It comprises of 4 nos. of Air separation Units (3 X 100 TPD & 1 X 200 TPD). The basic principle involved is liquefying air by successive compression and cooling of compressed air (the input material) and finally segregating the components Oxygen and Nitrogen in Air Separation Units) through cryogenic distillation process. Oxygen and Nitrogen thus produced are stored in identified storage tanks from where they are supplied to the customers through header and pipelines. Salient features of TOP-I are: • Oxygen, Nitrogen and Acetylene cylinder filling station for plant use. • Medical Oxygen cylinder filling. • High capacity High Pressure Nitrogen compressor has been added for meeting the High

Pressure demand for slag-splashing and gas recovery in BOF.

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TONNAGE OXYGEN PLANT-II (TOP-II) To meet the growing demand of Oxygen, Nitrogen and Argon, with the coming up of SMS-II, TOP-II was added during modernization in 1993. TOP-II comprises of two units of 180 TPD capacity. Each unit at TOP-II has got a capacity to produce: Oxygen : 180 TPD (with provision of 6.2 % in liquid form) Nitrogen : 310 TPD (with 3.3 % in liquid form) Argon : 5 TPD (gas or liquid) TOP-II units can run in two modes of operation:

i) Gas mode operation : when demand is high ii) Mixed mode operation : when demand is low

Production rate of product gases in respective mode of operation is as follows;

Gas Mode Mixed Mode Purity

Oxygen (Nm3/Hr) 5400 4700 + 410 Litres/hr Liquid Oxygen

99.5 %

Nitrogen (Nm3/Hr) 10400 9000 + 525 Litres/Hr Liquid Nitrogen

99.999 %

Argon (Nm3/Hr) 120 120 99.995 % TOP-II has liquid storage tank for liquid oxygen, Liquid Nitrogen and Liquid Argon. In mixed mode operation, liquid products are transferred to the respective tanks. When the demand for product gases is more than production, liquid is drawn from the storage tank, is vapourised and supplied as gas to the product grid to meet the short-fall. Storage tanks are of following capacity; Liquid Oxygen Tank : 1000 M3 Liquid Nitrogen Tank : 1000 M3 Liquid Argon Tank : 20,000 Litres Salient features of TOP-II: - Energy efficient medium pressure process with

specific power of 0.850 KWHr/Nm3 of O2 in gas mode and 0.970 KWHr/Nm3 in mixed mode.

- Front end purification unit removing CO2 and H2O from process air before it enters Main exchanger

- Sophisticated automation with distributed control system for monitoring and control of the process

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Panorama 2010 - Wide flexibility of operation (80 % to 115 %) both in gas mode and mixed mode to take care

of fluctuating demand. - Argon production facility using hydrogen injection for complete removal of oxygen from

argon Brief process description: Air compressed to a pressure of 5.2 to 5.7 Kg/cm2 in a four stage centrifugal compressor. Compressed air is then cooled in air water tower, using chilled water from refrigeration unit to a temperature below 100C. Pre-cooled air is then sent to air purification unit, where in a twin bed absorber unit comprising alumina and molecular sieve, CO2 and moisture is removed from air. CO2 and moisture free air is then cooled to -1730C in the main exchanger using product gases from the distillation column. Air then enters the medium pressure column of double distillation column where it is liquefied. The liquefied air is then sent as reflux to the low pressure column where the process of separation of oxygen and nitrogen takes places through a process of cryogenic distillation. For separation of argon, a part of gas stream from low pressure column is processed in Argon purification unit to get pure argon. Product gas from the distillation column, after cooling air in the main exchanger, is compressed in the product compressor. Uses of Oxygen, Nitrogen and Argon in Steel Plant: Oxygen: - Reduction of hot metal to steel at SMS-I and SMS-II

Requirement per blow SMS-I : 3840 Nm3 at 16 Kg/cm2 (Min) Requirement per blow SMS-II: 8500 Nm3 at 16 Kg/cm2 (Min)

- Enrichment of hot blast in Blast furnace Requirement in BF-1 : 500 – 800 Nm3/Hr Requirement in BF-4 : 1500 – 2000 Nm3/Hr

- Oxy-acetylene flame for slab cutting in CCM-I and CCM-II Requirement 4 Nm3/TCS

- Oxygen lancing for scrap cutting in SMS-II Requirement in SMS-II services : 1500 Nm3/hr

- Miscellaneous welding cutting jobs in Rolling Mills repair shops Requirement: 1500 Nm3/hr

Nitrogen: - Low pressure nitrogen in Cold Rolling Mill and Silicon Steel Mill for maintaining

inert atmospheric in furnaces: Requirement is 9000 Nm3/Hr at 2500 mmWC

- Medium pressure nitrogen for desulphurisation unit in SMS-II and Instrument Nitrogen for SMS-II

Requirement is 800 Nm3/Hr at 16 Kg/cm2

- High pressure nitrogen for various seals and purges in GCP of SMS-I and SMS-II and gas recovery in SMS-II

Requirement in SMS-I GCP: 1500 Nm3/blow at 20 Kg/cm2 (Min)

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Requirement in SMS-II GCP + GRP: 2256 Nm3/blow at 20 Kg/cm2 (Min) - High pressure nitrogen for Slag Splashing of convertor in SMS-I and SMS-II

Requirement in SMS-I 600 Nm3/blow (Max) at 20 Kg/cm2 (Min) Requirement in SMS-II 1600 Nm3/blow (Max) at 20 Kg/cm2 (Min)

Argon: - LHF and ARS of CCM-I and CCM-II, Secondary Steel for making Steel

homogeneous. - CCM-I and CCM-II for providing inert atmosphere during casting - On line purging during tapping of Crude Steel in SMS-II

Requirement in SMS-I 72 Nm3/blow at 15 kg/cm2 (Min) Requirement in SMS-II 90 Nm3/blow at 15 kg/cm2 (Min)

PROCESS OF OXYGEN PRODUCTION:

Air

Filtration Cooling

Compression Purification Heat exchange incoming air with the cold of the outgoing product

Expansion Separation into oxygen, nitrogen and argon by distillation

Gas product

Product compression by liquid pump and/ or gas compression

Warm Equipment

Cold Equipment

C2+H2O

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HOT STRIP MILL Hot Strip Mill (HSM) is a 1700 mm semi continuous mill comprising 2 Walking Beam Furnaces of capacity 225 T/Hr., 3 Roughing Mills i.e. One 2-high Reversing Mill with powerful edgers (Ro/Vo), One 4 high Reversing Mill (R1) and One 4 high Continuous Mill (R2), Coil Box, Six Stand continuous 4 High Finishing Mill in tandem and 2 Hydraulic down Coilers. The Mill was originally commissioned in February, 1961 and was subsequently revamped in 1980 for computerization of Finishing Stands. During 1992-93 old Run Out Table (ROT) and Coilers were replaced by the state of art ROT and Hydraulic Coilers during 1995 to 1999. Ro/Vo, Coil Box, Quick Work Roll, Change Roll in Finishing Mill, High Pressure Descaler, Walking Beam Furnace were installed under modernisation programme for rolling heavier and longer slabs to coils. The HSM was originally designed and commissioned on turnkey basis by the M/s. DEMAG AG, West Germany. The main mechanical equipment were supplied by M/s. DEMAG, M/s. SACK, M/s. SCHLOEMANN and mill drives by M/s. SIEMENS and M/s. AEG (All firms of the then West Germany). It is designed to roll the slabs of thickness 150 – 220 mm to finished strip gauge of 1.8 to 12.5 mm in 725 – 1550 mm width. The annual production capacity of the mill is 1.44 Million Tons of slab weight. The HSM being an integrated unit of RSP supplies Hot Rolled Coils as input materials to its downstream customers such as Cold Rolling Mills, Silicon Steel Mill, and Pipe Plants and also to Dividing Line. It also caters to the requirements of external customers. Walking Beam Furnaces: Two Walking Beam Reheating Furnaces (5 & 6) of 225 T/Hr. capacities were commissioned during modernization of HSM. Each Furnace is having 6 zones (Preheating zone top & bottom, heating zone top & bottom and Soaking zone top & bottom). Preheating and heating zones are having dual firing system with mixed gas and furnace oil, where as Soaking zones are having only mixed gas firing. Slabs are put on charging side roller table from depiler with the help of depiler crane with tong / EOT crane with magnet. Each slab is weighed on Charging Roller Table Weigh Bridge. Spotting of slab is done with laser beam and after spotting, the slab is pushed inside the furnace with the help of pusher. Movement of slabs inside the furnace takes place by the movement of walking beams called movable skid pipes (4 nos.), which move in lift, forward, lower and reverse direction in one complete cycle. There are also 4 nos. of fixed skid pipes inside furnace on which the slabs rest while in stationary state. Tracking and heating of slabs to required temperature is done by computerized thermal model. Once the slab reaches the discharge end, it is detected in the discharge pulpit by the Gamma ray system provided at the discharge side. After slab detection and getting clearance from R1 cabin, slab is extracted from furnace by extractor and is placed on the discharge roller table and sent to Ro/Vo through primary descaler for rolling.

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REHEATING FURNACES TYPE- WALKING BEAM FURNACE: No. of Fce: TWO (FURNACE No. 5 & 6) FUEL: MIXED GAS & FURNACE OIL CAPACITY: 225 TONS / HOUR (SLAB Wt.) FURNACE DIMENSIONS: LENGTH: 50.8 Mtr. (EEFECTIVE LENGTH: 47.125 Mtr.) WIDTH: 11.1 Mtr. (INSIDE WIDTH: 9.6 Mtr.) SKID PIPES: MOVABLE - 4 Nos. & FIXED - 4 Nos. PRIMARY DESCALER: To remove the scale formed on the surface of slabs during its heating inside furnaces, water jet at high pressure of 145-160 Bar is applied on top and bottom surface of slabs. ROUGHING STAND (R0/V0): Roughing stand is reversing type 2 High Mill with full automation. It has twin drives with AC motors (with Cyclo-Converters) of 3000 kW each. Heated slabs are given 3 passes maximum and reduced to desired thickness and sent to R1. V0 is vertical edger for width control by squeezing slab width up to 100 mm. Slabs after rolling at R0/V0 are called Intermediate Transfer Bars. No. of PASS : 3 PASSES R#0 ROLL DIA. : 1005 – 1100 MM. BARREL LENGTH: 1800 MM R#0 DRAFT : 39 MM. (MAX.) IN EACH PASS V#0 SQUEEZING : 100 MM. (MAX.) R#0 MOTORS : 3000 kW X 2 A.C SYNCHRONOUS V#0 MOTORS : 1000 kW X 2 WITH CYCLO- CONVERTER ROLLING SPEED : 4 M/ Sec. Max.) ROLL SEPARATING FORCE: 20000 KN (Max) FOR R#0 : 4500 KN (Max) FOR V#0 ROUGHING STAND-I (R1): Roughing stand-I is reversing type 4 high mill with 2 work rolls and 2 back-up rolls. It has a twin drive with 2 DC motors of 3800 kW. Intermediate transfer bars coming from Ro are given 3 to 5 passes and reduced to desired thickness. There is provision for providing descaling sprays at R1 only on the forward passes. R1 is equipped with a pair of vertical edger rolls to control the width of slabs.

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REVERSING MILL : 4 HIGH WITH VERTICAL EDGERS No. of PASS : 3 – 7 PASSES R#1 MOTORS : 3800 kW X 2 (DC THYRISTOR CONVERTOR) R#1 WORK ROLL DIA. : 864 – 911 MM R#1 BACK UP DIA. : 1185 – 1311 MM. ROLL FORCE : 25000 KN (Max) SCREWDOWN DRIVE : 73 kW @ 485 RPM – DC OUTPUT THICKNESS : 32 TO 45 MM ROUGHING STAND-II (R2): Roughing stand-II is 4 high Continuous Mill with 2 work rolls and 2 back-up rolls. R2 has a single drive of 6250 kW DC motor. The thickness of the bar from R1 is reduced further at R2, which is operated from a control post in front of R2 mill stand. There is provision for providing descaling sprays before R2 stand. R2 is equipped with a pair of vertical edger rolls to control the lateral spread of the bar.

NON REVERSING MILL : 4 HIGH WITH VERTICAL EDGERS R#2 MOTOR : 6250 kW X 1 (DC THYRISTOR CONVERTOR.) R#2 WORK ROLL DIA. : 825 – 911 MM R#2 BACK UP DIA. : 1185 – 1311 MM. ROLL FORCE : 25000 KN (Max) ROLLING SPEED : 3.02 M/Sec (Max) SCREWDOWN DRIVE : 75KW@590/1600RPM–DC, GR-3.16:1

COIL BOX:

The Intermediate Transfer Bar after R2 travels through the Delay Table to Coil Box, where it is coiled in hot condition and subsequently uncoiled to feed tail end of transfer bar into the Finishing Mills. In general coils with finish gauge less than 5 mm are taken through coil box where as for finish gauge more than 5 mm are taken directly to Finishing Mills in Pass Through Mode (PTM). The head end of the transfer bar/ Coiled transfer bar is cropped at Crop Shear and after descaling at scale washer pinch roll, the transfer bar enters

the Finishing Mill for rolling to the required gauge. COIL BOX - Coiling and Uncoiling Device for Intermediate Transfer Bar TRANSFER BAR THICKNESS: 22 - 38 MM.

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MAJOR COMPONENTS: Entry Side Guides, Top Bending Rolls (2 Nos.), Bottom Bending Roll, Cradle Rolls # 1, Forming Roll, Adjustible Side Guides, Mandrel Peelar Main Arm, Cradle Rolls # 2, Pinch Roll ADVANTAGES OF COILBOX TECHNOLOGY: The coil box enables a remarkable improvement in rolling technology. Operations of a hot strip mill results in the following advantages

1. Uniform temperature of the transfer bar By winding the transfer bar to a compact coil the heat loss is only 0.06˚C/Sec. Furthermore, in the wound coil internal temperature compensation takes place whereby the skid marks are largely eliminated. This means the soaking zone of the slab heating furnaces can be shortened with a corresponding reduction in energy consumption.

2. Reduced power rating and lower energy consumption in the finishing train As rolling in the finishing train takes place exclusively at constant speed, less power rating is required than in conventional rolling with “speed-up”. Furthermore the possibility of being able to roll out smaller transfer bar thicknesses without temperature problems in the finishing train also contributes to reducing power

3. Shorter total length of hot strip mill The distance between the roughing and finishing train in a conventional mill is determined by the length of the transfer bar. A coil box can start to coil the transfer bar even when it is being rolled in the roughing mill. This means that the length of the roller table between roughing mill and coil box is determined by the length of rolling stock after the third to last pass. When rolling with a coil box and at a strip unit weight of 20 Kg/mm, the distance between the roughing and finishing train is reduced by 30-50 m, if the final roughing stand is a reversing stand. In case of non-reversing stand the distance can be reduced by 80 m.

4. Smaller number of finishing stands Due to possibility of rolling transfer bars with smaller thickness and at constant temperature, the number of finishing stands can be reduced for the same range of strip dimensions.

5. Optimum rolling time adjustment between roughing train and finishing train Due to straight forward conditions of the coiled transfer bar in coil box operations the transfer bar thickness can be selected such that the rolling time in the roughing and finishing train is nearly the same, which means an optimum production level.

6. Extended range of dimensions Due to the constant transfer bar temperature together with smaller transfer bar thickness the required deformation energy in the finishing train is lower. This means that the range of product dimensions can be correspondingly enlarged, that is greater strip width at the same strip thickness or thinner strip gauge at the same strip width.

7. Improved strip quality The surface of the transfer bar is not damaged by winding in the coil box. The constant transfer bar temperature and the consequent rolling in the finishing train at constant speed and at optimum temperature control, guarantees uniform metallurgical qualities

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Panorama 2010 over the whole strip length. Due to the bending of the transfer bar during coiling, there is an additional descaling effect.

8. Improved thickness control The constant temperature of the transfer bar over the total bar length means lesser demands on the gauge control in the finishing train and improved thickness uniformity and accuracy of thickness, improved strip shape and flatness.

FINISHING MILL: The bar enters 6 stands, 4 high continuous mills where reduction is given to the bar in each stand. In between the stands, loopers are provided to maintain constant tension. There are two R-30 process computers of Siemens make. One is speed computer, for regulating the speed of all mill stands, ROT, coiler wrapper rolls and mandrel. The other one is AGC computer for automatic gauge control to get uniform thickness of the strip. AGC hydraulic cylinders are provided in last four stands F3, F4, F5, F6. After rolling in finishing stands, the strip temperature is controlled on Run Out Table (ROT) by laminar cooling by water through cooling banks. There are 4 nos. of Cooling banks. There are 4 nos of cooling banks, each having SIX-STAND 4-HIGH TANDEM MILL: F/M #1 TO F/M#6. FEATURES:

MAIN DRIVE MOTOR :3700 KW X 1 IN EACH STAND (D.C.) MECHANICAL SCREW DOWN: IN ALL 6 STANDS HYDRAULIC SCREW DOWN : IN STAND # 3, 4 ,5 & 6 AUTOMATIC GAUGE CONTROL THROUGH S-7 PLC SPEED CONTROL THROUGH SPEED-MASTER PLC QUICK ROLL CHANGE SYSTEM IN ALL SIX STANDS ISOTOPE GAUGE FOR THICKNESS MEASUREMENT DISTANCE FROM CENTRE TO CENTRE OF ADJACENT STANDS – 5.5 Mtr.

LOOPER: INTERSTAND LOOPERS FOR MAINTAINING CONSTANT STRIP TENSION. LOOPER CONTROL THROUGH PLC. WORK ROLL CHANGE CYCLE: MAX. 2500 Ts. (60-100 Km) COILERS: The strip moves over ROT and gets coiled in one of the two hydraulic down coilers. There are two Hydraulic down Coilers each having three Wrapper Rolls. Coils are taken out from coiler and placed on Conveyor # 5. The hot coils are circumferentially strapped on the body by Automatic Strapping Machine and marked for identification. Necessary samples are cut from the coils for its testing. Coils are then transferred to coil yard where coils are allowed to cool to room temperature before they are sent for further processing in different units of RSP (i.e. CRM, SSM, ERWPP, SWPP & Dividing line of HSM) or to the external customers of HR Coils. The capacity of the Coiler is 17.5 Tons (max.) coil weight.

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HYDRAULIC DOWN COILER: 2 NOS. (COILER # 4 & 5) - Commissioned in 1994 MAJOR COMPONENTS: Side Guides, Hold Down Roll, Top Pinch Roll, Bottom Pinch Roll, Entry Table, Wrapper Rolls (3 Nos.), Mandrel with Outboard Bearing, Coil Car Upender PARTS OF COILER 1. Top & Bottom Pinch Roll 2. Three Numbers of Wrapper Rolls. 3. One Mandrel with Two Stages of Expansion. 4. Coil Car for Taking out The Coil 5. Centering Arm for Lifting Of Coils 6. Tilter for Tilting the Coil to the Conveyor 7. Mandrel Dia: 762 – 740 – 725 MM Hold Down Roll for Preventing Tail end Shifting SHIPPING AREA DISPATCH OF COILS TO EXTERNAL CUSTOMERS. SHIPPING AREA – 2 NOS. OF BAYS (EF & FG BAY) EF BAY – 2 NOS. OF RAILWAY TRACKS (EF MAIN TRACK & EF LOOP TRACK). FG BAY – 2 NOS. OF RAILWAY TRACK (FG BAY MAIN AND FG BAY LOOP). DIVIDING LINE: Hot Rolled Coils meant for converting into HR plates are uncoiled in Uncoiler, levelled in Leveller-I and then sheared at Dividing Shear to the required lengths as per requirement of the customer. After shearing, the plates are levelled once again in Leveler-II and piled in Pilers. HR Plates of sizes 3.6 mtrs. to 10 mtrs. in length and thickness of 5 mm to 10 mm are cut. There is also provision of plate inspection for both the sides each plate at Plate Turn over Device (PTOD) before Piler. PURPOSE: SHEARING OF HR COIL TO PRODUCE HR PLATE MAJOR EQUIPMENT UNCOILER, FLATTENER – I, SIDE TRIMMER, DIVIDING SHEAR, FLATTENER – II, PLATE TURN OVER DEVICE (PTOD), PILER – I & II

(SHIPPING AREA)

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Panorama 2010 HR PLATE DETAILS THICKNESS : 4.0 – 10 MM. WIDTH : 1000 – 1550 MM. LENGTH : 5 – 10 METERS

HOT STRIP MILL LAYOUT:

Crop Shear

Coil Yard

HR Sheets for Shipping

Dividing Line

Pusher Type Furnaces (2 x 225 T/Hr)

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Coi

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ippi

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R1

R2

Coilers

Run

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Tab

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Walking Beam Furnaces 5 & 6 (2 x 225 T/Hr)

MA

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MIL

LH

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Mill

Slab Yard

Through Scale Washer

Primary Descaler

Coil Box

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PLATE MILL

Plate mill of Rourkela Steel Plant was commissioned on 13th September 1960. This is first Plate Mill in the SAIL as well as in the country. This is 3.1 m, 4 high reversing mill. This mill is certified with ISO 9001 & 14001 certificates. Over the years plate mill has been achieving new heights. In financial year 07-08 mill has achieved 103% of ABP. The Techno economic factor is one of the best tools to make judgment about the performance of any unit in an integrated steel plant. For the sake evaluation data of some of the important parameters are given below: What are Plates? A hot or cold rolled flat products rolled from ingot or slab in rectangular cross section of thickness 5 mm and above with width 600 mm and above and supplied in straight length. In our plate mill we make plates from slabs which is mainly supplied to us from Continuous Casting Machine I (CCM I) and Continuous Casting machine II (CCM II). Our Input Slab and Finished Plates dimensions are as follows: Slabs Width : 800 – 1500 mm Thickness : 210 mm Length : 2200 – 2800 mm Finished Plates Width : 1500 – 2500 mm Thickness : 8 – 63 mm Length : 4500 – 13500 mm Our Plate Mill is comprised of following areas:

1. Slab Yard 9. Dividing Shear 2. Furnace Area 10. Side Piler I & II 3. Mill 11. Normalizing Furnace 4. Hot Crop Shear 12. Hot Leveler III 5. Hot Leveler I & II 13. Cooling Bed III & IV 6. Cooling Bed I & II 14. Piler III & IV 7. Inspection Bed & Marking and 15. Cold Leveler

Punching Section 16. Ultrasonic Testing Section 8. Circular Trimming Shear 17. Flame Cutting Machine

SLAB YARD Slab Yard is the entry point of Plate Mill. It is situated in AB bay. In our plate mill input slabs are received mainly from CCM I & CCM II. Apart from this input for special plates are also received from Bokaro Steel Plant and Durgapur Steel Plant. It has a capacity to store 900 slabs. For smoothly running of plate mill 600 slabs should always be present. The minimum weight of slab is 3.1 tons and maximum weight being 6.9 tons. There are total 5 cranes for handling of slabs. Slabs are kept in piles and 1 pile generally has 6 numbers of slabs.

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Panorama 2010

Furnace Area Furnace area can be divided into three sub groups as follows:

i) Charging Roller Table & Pusher ii) Walking Beam Furnace iii) Slab Extractor and Discharge Roller Table iv) Primary Descaling

i) Charging Roller Table & Pusher There are four roller tables through which slabs are transported to the furnace door. Pusher, which is above Roller Table No. 4, pushes the slab inside the furnace. There are total 33 numbers of solid rolls in all the four tables. Also all the four roller tables, pusher and charging & discharging doors are automated and controlled by PLC.

ii) Walking Beam Furnace Walking beam furnace is used for again heating of cold slab to the desired rolling temperature. Hearth of furnace has two rows and each row has one pair of fixed beam and one pair of movable beam. Slab that is pushed by pusher is initially rest on fixed beam. The movable beam transports slab in such a fashion that slab appears to be walking. Each row in the furnace can have 28 slabs. The furnace proper can be divided into three heating sections named as Pre Heating Zone, Heating Zone & Soaking Zone. Group of burners are referred as Zones. There are total 64 burners in different zones. a) Pre heating Zone: In this section preheating of slabs are done. The temperature in this

area ranges 1050 ± 30OC. This section is further sub divided into TOP & BOTTOM. TOP preheating area has 16 number of burners & is called Zone –I. Bottom preheating area has 2 number of burners & is called Zone –II.

b) Heating Section: In this section heating of slabs are done. Temp in this area is kept at re-crystallization temp of steel (which depends on % carbon in steel) i.e. 1300 ± 200C. This section is further sub divided into TOP & BOTTOM. Top heating area has 16 numbers of burners & is referred as Zone - III. Bottom heating area has 7 numbers of burners & it is referred as Zone – IV.

c) Soaking Section: In this area temperature is less than heating section but more than the preheating section, it is around 12800C.Here slabs are kept for soaking so that temperature at core & skin are almost equal (allowable temp. difference is 3000C).This section is further subdivided into TOP & BOTTOM. Top soaking area has 16 number of burners & is referred as Zone V whereas bottom soaking area has 7 numbers of burners & is referred as Zone VI. There is always temperature difference between top and bottom area. Top area is 1000C more than bottom.

iii) Slab Extractor & Discharge Roller Table : Its basic function it to remove slabs from furnace & keep it on discharge roller table it consist of the identical parts (left & right) each comprising of one frame (for vertical movement) & one transfer frame (for Backward/ forward) Horizontal. Movement of lift frame is regulated by hydraulic cylinder. Each transfer frame is fitted with one set of 2 arms & is actuated by one speed motor through rake & pinion. The two-transfer frames move together & are coupled mechanically.

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iv) Primary Descaling: In this unit the scales generated during reheating of slab inside walking beam furnace is removed by impinging jet of water. This unit is a box type. As the slab enters this unit an HMD (hot metal detector) senses it and water impact starts on slab at very high pressure of @ 100kg/cm2. Water is sprayed through nozzle.

Mill Plate mill is 3.1 m wide single stand, four-high reversing type mill designed to roll medium and heavy plates. The mechanical equipments are supplied by M/s. KRUPP whereas the drives are mostly supplied by M/s. AEG, both firms belongs to Germany. Mill is having two working rolls of 1000 mm x 3100 mm size and two back up rolls of 1500 mm x 3000 mm size. The only work of the mill is to give draft to the slab to convert it into desired plate. The number passes to be given depends on slab and final plate size. Draft to be given mainly depends on temperature of slab. In any case maximum draft given is 15 mm or 20% of the instant thickness of plate whichever is less. Hot Crop Shear This is the start of finishing line and is situated in the main mill line. The plates produced in the mill stand have weird front ends. This end is cut in suitable length in hot condition so as to facilitate smooth movement of plates in the cooling bed. Hot crop shear is a Guillotine type hot crop shear with movable inclined top blade. It consists of a depressing table and eight blades 4 on top and 4 at bottom. 1. Hot Plate Leveler I & II After hot shear the plate is passed through the hot plate leveller for making it flat. Plates from the mill are having wavy edges, or bent and slightly distorted shapes. Leveler consists of number of rolls arranged in checkered fashion. In principle straightening is achieved by successive bending of plates to and fro.

2. Cooling Bed I & II After leaving the levelers, plates are delivered to cooling bed where they are cooled and transported at the same time. Cooling is natural cooling. To avoid any difference in the mechanical properties between the top and the bottom surfaces of the plate, minimum possible area of the bottom portion of the plate is allowed to be in contact with metallic part

3. Inspection Bed and Marking & Punching Section After cooling bed I & II the plates are shifted to cooling bed III or generally known as Inspection Bed. Here the plates are inspected for various defects as well as removal of minor defects by grinding and sorting out. The plates after inspection bed is carried for marking the various information which give details about the plate like its destination, its quality etc which is carried out with Paint Marking Cum Punching Machine. It was commissioned and put on normal operation on 01-08-2008.

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Panorama 2010 Features:

1. Dot matrix paint marking head with electro-magnetic activated spray guns and activated punchers.

2. Trolley for the movement of marking head and punching heads. 3. Overhead structures/guides on which the above item moves. 4. Control panel with PLC for machine control and host communication. 5. Drive panel with driver electronics for the paint spray guns and punch marking heads. 6. Operation terminal –HMI- monitor and keyboard 7. Maintenance/Service panels with manual push buttons for maintenance

operation(mounted over machine) 8. Combined paint/pneumatic supply unit.

The punch head have one punch section with 4 punchers and the paint head have 8 paint sections. Marking Details:

• Position of Marking - Along the centre line of the plate • Direction of Marking - Lengthwise paint • Characters pattern - Standard 9 x 7 Dot Matrix (WxH) • Characters - Alphanumeric • Height of Characters - 40 mm • Number of Lines - 8 (Eight) • Number of Characters/Line - 20 Alphanumeric (Maximum)

Punching Details:

• Direction of Marking - Crosswise to Plate conveyance • Characters pattern - 9 x 7 Dot Matrix (WxH) • Characters - Alphanumeric • Height of Characters - 10.5 mm (Approx) • Number of Lines - 3 (Three) • Number of Characters/Line - 16 Alphanumeric (Maximum)

Benefits:

I. Improvement in Manpower Productivity: Earlier 6 operators/shift were engaged in manual marking and punching operation. Now only 2 operators/shift are operating the new marking & punching machine.

II. Operator gallery no 4 for inspection bed drive has been removed and dismantled which is now being operated by marking operators in the new cabin made for marking machine. Thereby reduction of manpower i.e. 1 operator/shift.

III. The total reduction of manpower is 5 per shift i.e. 15 nos and same have been re-deployed which was helped in introducing 7 days working in plate mill.

IV. Elimination of hazardous and tedious operation of manual spray paint marking and punching and improving the safety and moral of the operation.

V. Drastic improvement in customer satisfaction as well as marketability of the product. VI. Elimination of incidences of mix-ups in plates at the finishing/shipping stage, due to

illegible marking. VII. Elimination of incidences of wrong shearing of plates due to illegible marking

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Rourkela Steel Plant VIII. Faster loading and dispatching due to proper identification and

traceability of various grades and sizes of plates IX. Constant paint circulation and intermediate cleaning of spray nozzles by mixture of air

and water will prevent clogging of pipelines and nozzles. X. Better record keeping and retrieval of marking and punching records for references.

XI. Faster processing of plates in inspection beds thereby reducing the cooling bed delays. 4. Circular Trimming Shear Rotary trimming shears are normally used for slitting and edge cutting of the plates. The machine is designed for trimming the plates up to maximum thickness of 20 mm at tensile strength of 80 kg / mm2. It is designed for a width of trimmings 150 mm for plate of thickness up to 12 mm and trimming width of 100 mm for plates between 12 – 20 mm thicknesses.

Online UST Machine: The objective of the proposal is to install a new online UST machine to cater the growing demand of UST tested quality plates with high NCR. The capacity of new UST shall have 15,000 MT per month compared to present capacity of 7,000 TPM with latest art of state computer controlled machine.

I. Existing UST is OFF Line inspection system II. Manual operated trolley type single type probe testing machine

III. Occupies large floor space. NEED:

I. To cater to growing demands of UST plates. II. To match with normalized and ultrasonic tested plate demand of 10,000 TPM Approx.

III. Defect liquidation by paint marking. IV. Quick and easy liquidation of defects.

The proposed scheme is intended for non destructive ultrasonic inspection of plates online. Plate Parameters:

• Length - 2,500 mm to 27,000 mm • Width - 850 mm to 3,000 mm • Thickness - 5 mm to 80 mm • Scanning speed - 60 m/min • Plates will move on Roller Table for online scanning. • Paint marking on the top of plate to show defect locations. • Testing Zone - Full Body Testing

Benefits:

Improvement of market share for quality plates. Higher capacity production of UST plates without addition of manpower. Online facilities with high speed inspection, data acquisition, analysis, retrieval &

storage facilities. Net margin to go up. High internal rate of return and payback of project.

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Panorama 2010 To cater the demands of normalized plates with UST.

5. Dividing Shear The shear serves for dividing and cropping plates in the cold state. For dividing plates a gauge is arranged at the back of the shear making it possible to set precisely every plate length within the range of the gauge. 6. Side Piler I & II After cutting the trimmed plates to desired length at the crop end dividing shear they are kept in side piler I & II. On the side piler I plates up to a maximum length of 15000 mm can be transported. Longer plates up to a 20,000 mm go over side piler II. A dog type chain transfer serves for dragging the plates from the roller table to one half of the piler 7. Normalizing Furnace Normalizing furnace is used for gaining some specific physical metallurgical properties required in some plates. It is not carried out for all plates. Whenever it is required by customers we do normalizing on specific plates. There are 3 zones in the New Normalising Furnace named as Zone I, Zone II and Zone III. Each zone is 15 m in length. Zone I: Zone I is also known as Pre Heating Zone. The temperature in this zone is in-between 850 – 880 OC. There are all total 44 Burners in this Zone, 30 in top and 14 in bottom. Zone II: Zone II is known as Heating Zone. The temperature in this zone is 910 – 930OC. There are all total 48 burners, 32 in top and 16 in Bottom. Zone III: Zone III is called Soaking Zone. The temperature in this zone lies in between 910 – 930 OC. There are all total 44 burners in this zone, 30 in top and 14 in bottom. Mixed Gas mixed with air is used as fuel in the furnace and the maximum temperature in the furnace is 950OC. 8. Hot Leveler III After normalizing furnace plate is passed through this. The function of hot leveler III is same as that of hot leveler I & II. 9. Cooling Bed III & IV Normalized plates after going through hot leveler are taken to cooling bed III and IV for air-cooling. Here plates are made to move slowly so that they get enough time to cool. The transfer equipment of cooling bed III and IV may likewise operate in two groups. For this purpose, chain transfers of each rolling bed half has individual electric drive. 10. Piler III & IV All the plates of 8 to 20 mm up to a length of 5600 mm, after passing over the cooling beds are taken to the side piler III. Plates in the thickness range of 22 to 36 mm go to side piler IV. The plates of length more than 5600 mm but in the thickness range of 8 to 20 mm also deposited in the side piler IV.

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11. Cold leveller The cold plate leveler is so designed that the cold plates up to 38 mm can be safely leveled. It is located in AB bay along the B column near new normalizing furnace. This leveler is provided with reversing operation. 12. Ultrasonic Testing Section Ultrasonic test is carried out offline. This is not done for all plates but is carried out on special request from customers. This machine uses ultrasonic frequency rays for detecting defects inside the plates as well as on the surface of plates Flame Cutting Machine Flame cutting is done offline. This machine is used as a trimmer for plates of thickness more than 20 mm. This is located in AB bay between B-27 to B-30 along B column. Oxygen and acetylene gas is supplied by TOP-1. This machine is divided into two parts BED-1 and BED-2. Devices used: Two long cutting (used for side cutting one in each bed) and Three cross cutting machine (used for side trimming)

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Panorama 2010

PIPE PLANTS

Rourkela Steel Plant, a giant manufacturer of steel pipes, has two mills having combined production capacity of 1,30,000 T of steel pipes per annum. All these steel pipes are produced in two independent production lines viz.

1. Electric Resistance Welded Pipe Plant (ERWPP) having capacity of 75,000 T per annum.

2. Spiral Welded Pipe Plant (SWPP) having capacity of 55,000 T per annum Both the pipe plants are accredited with ISO 9001:2000 QMS, APIQ1 and ISO 140001:2004 EMS certified.

ERW PIPE PLANT HISTORY: Originally ERW Pipe plant was designed, supplied, erected and put into operation in October, 1960 by M/S Mannesmann MEER of West Germany. Subsequently with the requirement of API specification, in 1984, new normalizing unit (500 kW, 3 KHz) was introduce and roll profiles were changed to increase the product range from D/T ratio from 50:1 to 80:1. In 1991 the rotary welding transformer (Frequency 125 Hz) was replaced with HF welder - Thermatool make 400 KHz, 600 kW for better welding performance. In 1997 EDDY current m/c for detecting the welding cracks was replaced by OFF LINE AUTO UST m/c. However in July, 2005 it was completely modernized by M/S SALZGITTER INTERNATIONAL, GERMANY to produce API pipes up to grade API-5L-X70 with D/T ratio 100:1

PRDODUCT RANGE: DIAMETER (Outside Diameter): 8 5/8”, 10 ¾”, 12 ¾”, 14”, 16”, & 18” OD WALL THICKNESS: 3.2 to 12.7 mm GRADE: API 5L GR-A, GR-B and up to X-70 PSL 1 & 2 IS 3589 grade Fe 330, 410 & 450 INPUT MATERIAL: The orders from different customers are conveyed to the ERW pipe plant through PPC department. After the campaign size is decided PPC plan for the required steel and subsequently gets rolled at HSM. Specification of HR Coils:

Width – 693 to 1550 mm, Coil weight – 15 T max, Thickness - 3.2 to 12.7 mm, Coil ID - 760 mm, Coil OD – 1100 to 1800 mm max.

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SECTIONS OF ERWPP AS PER THE MATERIAL FLOW

All the processes are PLC controlled and all the entries, information’s are logged and shared at the computers through level-II automation system available at every work stations. All the drives are powered by AC motor with VVVF control. COIL YARD: The Input HR coils are received from HSM through internal wagons. After coils are received required samples are cut and send to Test house for confirmations of its grade.

ENTRY SECTION: Coil Saddles: Four Saddles are provided near uncoiler to ensure a steady supply of hot rolled coils to the uncoiler unit. Coil Car: 5.5 KW AC operated Coil Car mounted on rail transfers the coils one by one from the coil saddles to the uncoiling unit. Coil supporting cradles are provided on the coil car to support all the coils to be handled for different sizes. The lifting and lowering of the cradle is brought about by hydraulic mechanism. Dual Uncoiler: The primary function of the dual uncoiler is to receive the coil from the coil car and to feed it into the leveling unit. The uncoiler holds the coil during the opening process and controls the uncoiling of the strip. It receives the coil from coil car and feeds the strip to leveling unit by opening the coil front end by the peeler table and bending roll. Pinch roll and Leveller-I : Pinch roll is provided for receiving the leading end of the strip and feed it to the 5 roll leveler for flattening the whole length of the coil for subsequent forming in the ERW mill. Strip Centering Devices: There are five numbers of strip centering devices for aligning the strip along with the centerline of the mill CROP END SHEAR: The Crop End Shear which is hydraulically operated is being used for cutting the leading end of the coil. Provision is there for falling of end shear strap to a collection box via a chute.

SHEAR- END- WELDER: Function of Shear End Welder is to join the tail end of the coil with the leading end of the subsequent coil to make it a continuous strip. It is an automatic arc welding process with the principal of MAG (Metal active gas) welding, where Continuous wire electrode and shielding gas are fed through welding torch. The main parts of this unit are:

• The main carriage, carrying the hydraulic operated weld- clamp unit and the down cut shear.

• The base frame with mounted hydraulic cylinder for operating the carriage to & fro. • The welding rectifier sets • The twin wire welding torch • The wire feeding units (wire dia -1.2 mm) with motorized travel

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Panorama 2010 • The shielded gas units (CO2 gas)

LOOPER PIT: Purpose of the looper pit is to keep a certain reserve of strip, so that during stand till of the line for joining the strip- ends, strip can be pulled back by the main pinch roll 2 for cutting the crop end (Tail end of the coil). The loop height is sensed by a sensor and a constant height is maintained to prevent excess tension by regulating the speed of the pinch roll 2 & 3 located at the both ends of the pit. STRIP- EDGE MILLING MACHINE: The primary function of this unit is to give a smooth machine cut edge to the strip required for high quality weld and to maintain a constant strip width with minimum material loss. It is a very sophisticated equipment with high precision and successfully substituted the side trimmer as a better edge finishing equipment. Basically it consists of a four cutter heads with 54 inserts mounted on each head and each head can cut 6.25 mm maximum. The rotating cutters are driven by motor, the milling tools are carbide tips located at the circumference of the cutter. Each cutter units are equipped with width measuring device, clamping devices and surface copying device. The chips are collected below the milling unit and transported out by a chip conveyor. There is centralized lubrication unit to lubricate all the parts of the equipment. STRIP UST: UST for the strip has been provided to detect the lamination and other similar defects of the incoming strip. The system consists of ECHOGRAPH 1155 electronic equipped for 16 channels Transmitter/receiver unit. SEE ultrasonic-amplifier between probes and ultrasonic electronics, for long cable length to prevent disturbing noise by influence from other power stations. The system provides the data administration system (DAV) which administers testing and order parameters and is connected to the subordinate computers of the ultrasonic testing (USEL) via interfaces. The DAV additionally shows all the states of operation as well as disturbance and warning reports of ultrasonic testing electronics (USEL) and connected computer modules. There are 12 nos of probes which cover the strip body and 4 nos of probes at both the edges for testing. FORMING SECTION:

• STICKER STAND: After the strip UST strip enters in to the forming section. First unit of the forming section is STICKER stand. It is fitted with cylindrical rolls and serves as a pinch roll unit for feeding the strip further. Screws down arrangements are there for making top and bottom rolls up & down.

• PREFORMING SECTION: It transforms the flat strip into a shape which assists

the formation of the pipe in the subsequent breakdown stand. There are eight pairs of idle supporting rolls arranged in a V-shape. The angle of the first pair of rolls remains unchanged for different diameter pipes; however the final V- angle of the last pair of rolls, close to the breakdown stand can be adjusted. The adjustments of the rolls are motorized. When the strip edges are bent upwards by the supporting rolls, the center of the strip is kept down by 4 idle top rolls provided in a frame. The height of the frame is adjustable.

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• BREAK DOWN STAND: It is fitted with the top & bottom forming rolls and serves for proper bending of the strip entering the edge bending unit.

• EDGE BENDING UNIT: It is a top & bottom roll arrangement with all

adjustments facility where when the strip passes through this unit, the pre forming is being done at the edges for better forming at the weld point.

• UNIVERSAL CAGE FORMING: It serves for constant forming of the strip to a

slit tube between the edge forming unit and the first fin pass stand. It is basically consists of array of rolls, arranged in particular angle and mounted on beams. With the change of diameter the position of the rolls are changed by electrical drive. The different units of the Universal cage are as follows:

The outer cage rolls The inner forming rolls The lower supporting rolls The pinch roll unit

FIN PASS SECTION: There are three fin pass stands and one pipe guide unit to guide the strip from universal cage to the weld throat. It is the final stage of forming and helps to give final tubular shape before welding. There is a fin in the middle of the top roll which helps to prepare the edges and holds the strip edges firmly to avoid seam wandering and helps to form the required V angle at the weld point. Fin pass 1 is a two roll pass and Fin pass 2 & 3 are four roll pass design. Position of the roll can be adjusted by motors. WELDING STAND: The welding of pipes is carried out in a state of the art High Frequency Induction Welding Machine. It is induction type welding of 1000 kW capacity and 200 Hz frequency. The open pipe enters the welding stand where the strip edges are subjected to high frequency current of about 200 Hz by induction process. This generates required heat along the face of the strip edges for welding. The heated edges of the strip are then firmly pressed together by means of squeeze rolls, bottom roll and pair of pressure rolls to complete the welding process. The seam is thus formed from the strip without filler metal. HF welder has two major functional units:

• Control and rectifier unit(CRU) • Inverter, Matching and compensating unit (IMC)

The CRU unit is located at some distance behind the line, the IMC unit is located on a positioning table close to the line between the seam guide and weld squeeze roll unit. The two units are connected with a 10 meter long special DC cable. The CRU consists of input section, control section and rectifier section. The control section contains operating equipment and provides the interface with the external control equipment. The rectifier section has the main isolating switch and a full bridge diode rectifier that converts the main voltage to DC voltage. The IMC consists of the inverter module, a matching transformer and a capacitor bank supplying the necessary power for the induction coil.

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Panorama 2010 The positioning table is provided with the motorized drive for withdrawing the unit towards the back side of the mill for maintenance. Besides this the encircling coil can be adjusted with respect to the pipe. The welder can be operated in three modes like Manual, Power and Temperature and it has an integrated control in which the following data is being monitored.

• Welding speed • Welding temperature • Welding power

ID BEAD TRIMMER: Excess squeezed out internal bead is cut continuously as the welding proceeds by internal carbide tool. This equipment has rigid cantilever support and cantilever tool holding arm carries a tool holder at its extreme end. Tool holder has provision of internal tool fixing. The cantilever arm is operated hydraulically. The ferrite beads required for HF welding is mounted on its arm with all water cooling arrangement. OD BEAD TRIMMER: Excess squeezed out external bead is continuously cut external tool. Here movement of the cutting tool is actuated pneumatically.

WELD SEAM ANNEALER: The function of this unit is to normalize the weld zone of pipe for transforming the microstructure of the weld area to match the mechanical properties of the parent material. There are two units of solid state seam annealers with the output power of 600 kW each and the frequency of 2.5 KHz. With the induction heating the heat is is generated directly in the seam by means of the eddy current.

Each seam annealer has two major functional units: • Frequency converter (FC) • Annealer work station with output transformer and coil (AWS), positioned close to the

line and before the pull out stand. The unit ahs the facility of automatic seam tracking with quick lifting facility.

The temperature is recorded through optical pyrometers and has a facility to store the data. SIZING STAND: The very function of the sizing stand is to make the pipe to accurate dimension by giving reduction to 1% max. Sizing stand consists of pull out stand and sizing stand No.1,2,3. In between sizing stand No. 2 and No. 3, there is a turk head which helps to make the pipe straight. All these stands are four roll pass. The turk head can be adjusted up/down and left/right. It is fitted with the encoders for its position recording. FLYING CUT-OFF: In this machine pipe is cut to desired length in running condition. The main components of the fly cut off m/c are-

• The base frame • The cutting carriage • The disc cutter

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• The clamping devices • The carriage drive system • The cutter feeding hydraulics

Since there is a constant bottom line, the center line of the m/c is height adjustable by motorized lifting jacks. No of cutting knives mounted are 6. The carriage drive system consists of an AC-servo motor with built in encoder. The motor is flanged directly to planetary gears which are attached to the base frame. The carriage drive system gets information about the length and speed of the pipe emerging from an incremental encoder, coupled to a measuring wheel. When the desired length has passed the measuring wheel, the PLC submits the start signal and the carriage accelerates with the preset rate. The built in encoder of the driving motor submits the information about the carriage speed and the carriage position to the PLC the PLC compares the pipe speed, recorded by the measuring wheel encoder and the actual carriage speed. When both the speeds are synchronized, the cutting signal is provided for clamping and feeding of the cutter. After the cut has been performed the cutter knives are retracted to the initial position and clamp is open, the carriage drive gets the signal for reversing. STRAIGHTENING MACHINE: The function of this m/c is to straighten the pipe. There are 5 top rolls and 2 bottom rolls arranged in such a position that it gives the required bending moment to make the pipe straight. After the pipes are straightened, each pipe is numbered with a unique number for its traceability. BEVELING MACHINE: After the pipes are numbered, it is brought to the beveling m/c for end facing. The beveling angle is maintained 30-35 degree with the root face 0.8 to 1.2 mm to facilitate the pipe end to end welding at the field. It consists of-

• Pipe loading • Roller conveyor 1 & 2 • Cross transfer system • Long travel system 1 & 2 • Machining station 1& 2 • Delivery rack

The machine station mainly consists of main spindle head stock and the clamping device, mounted on a common base table. The clamping device is hydraulically actuated. The main spindle head stock contains the main spindle drive and the spindle feed drive. PIPE FLUSHING UNIT: Inside trimming burrs, beveling chips etc. are flushed with water at a high pressure of about 10 bars in this station for cleaning purpose.

HRD Centre Page: 93

Panorama 2010 HYDRO-TESTING PRESS: Here all the pipes are hydro tested after sealing both the ends from outside to the required pressure as per the specification. The maximum pressure it can test is 250 Kg/cm2. Hydro tester operates in sequential operation through a set of sensors and timers by PLC for the full testing cycle. Filling pump fills the required filling water at a preset pressure in the accumulator tank. Oil to water intensifier preset at the required water testing pressure operates in sequential operation till the set pressure is achieved and thereafter stops automatically. Thus testing is carried out in isolation system. Recorder is provided to record the test pressure and pressure holding time against the each pipe number. OFF LINE UST: The testing system has been designed fro the testing of welding seams, Heat affected zone (HAZ) and both the ends. Weld seam is tested for both Longitudinal & Transverse defects with 450 angle probes & a pilot line provided at 3 O’clock position on the pipe is tracked by a camera to ensure 12 O’ clock positioning of the weld seam. There is provision for doing static & dynamic calibrations as required by applicable Specifications thereby ensuring repeatability. The defect portion is again confirmed by Manual UST before final confirmation. The system provides the data administration system (DAV) which administers testing and other parameters and is connected to the subordinate computers of the ultrasonic testing (USEL) via interfaces. The DAV additionally shows all the states of operation as well as disturbances and warning reports of the ultrasound testing electronics (USEL) and connected computer modules. Coupling of the testing probes is done via guided beam of water. WORKS / FINAL INSPECTION: Here the pipes are visually inspected for dimensional accuracy and other surface defects. Finally accepted pipes are identified with running serial number and color band as per the specified colour code. Finally passed pipes are shifted to the pipe yard for dispatch. SHIPPING: The pipes are dispatched as per the movement plan in Trailer/Truck or wagon as per the requirement. Pipes are rust preventive varnish coated before dispatch if the customer desires.

HRD Centre Page: 94


Flow of Materials in ERW Pipe Plant

Sample Cutting Machine & Flattening Press

Sizing Stand 1,2,3

Fly Cut Off & Marking Machine

Cold Straightening

Machine

Pre-Inspection skid

Bevelling Machine

Flushing Machine

Hydro Tester 1 & 2

Off-Line UST

Works Inspection

Pipe Weighing & Final Inspection

Dispatch

Rotary Flame Cutting Machine

H R Coil

Through Coil Saddle Coil Car, Uncoiler Leveler and Edge Milling Machine

UST for Strip Testing

Sticker Stand Pre forming Breakdown Stand Edge Bending Unit

Universal Cage

Fin Pass Stand 1,2,3

Seam Guide Induction Welder & ID Bead Trimmer

OD Bead Trimmer & Scrap Winder

Seam Annealer & On-Line UST

Pull Out Stand

Cooling Jacket

HRD Centre Page: 95

Panorama 2010

SPIRAL WELDED PIPE PLANT

To meet the rising demand of handling bulk transportation of crude oil from shore to Refineries, a Spiral Welded Pipe Plant (SWPP) was added to Rourkela’s Mills in 1976. SW Pipe Plant has very modern and sophisticated production and testing equipment supplied by M/s Hoesch of West Germany. This mill comprises of fully automatic welding current, voltage controllers and weld gap control equipment, testing facilities like X-ray testing, and an Automatic Ultrasonic on line testing machine. The mill is authorised to produce API pipes. It has the capacity of producing pipes in the range of 16” to 64” (406.4 mm to 1625.6 mm) outer diameter with wall thickness of 5.6 to 14.2 mm. These pipes are available in API – 5 L, IS 3589, IS 5504 and also in works tested commercial quality (CQ) for application ranging from high pressure transportation of crude oil and natural gas, slurry transportation, water supply and sewerage disposal to civil engineering pilings. Coil Preparation Stand: In coil preparation stand the coil, after de-coiling the front end is cut to give a straight edge for welding to other coil. Pipe forming and Welding Machine: There are two numbers of pipe welding machines for pipe forming and welding. After coil preparation stand, coil is trimmed on both sides to have uniform width. The trimmed coil edges are bevelled and cleaned on both sides and then passed through drive roll and pre bending roll where the edges are bent slightly. The complete unit is on a base frame resting on rollers, which can be swivelled within 10 to 50 degrees angle, according to selected run-in angle, depending on the coil width and the pipe diameter. In the pipe-forming device the coil is formed to a pipe according to the principle of multi roller levelling. The coil edges running together with the pipe forming device are first welded inside and then outside by Submerged Arc Welding Process. A travelling Oxy-acetylene torch cuts off the pipes to required length, as per customer requirement. Pipes are tested in accordance with specifications of the standard / customer.

HRD Centre Page: 96


Cross Seam Welding Stand: This unit is used for cross seam welding of pipes to take care of the joining of the two coils. End Grinding: In this work station end grinding of machine gas cut pipes is done to make the ends smooth and free from gas cut burrs. Inside and outside surface of weld seams of pipes are ground, as marked, at inspection stand. X-ray Screen: This X-ray screen station is used to observe flow in weld seam, which is not visible and this helps in process control. Manual Repair Stand: Pipes identified at visual inspection and other stages of in-process inspection needing repairs, are repaired in this stand. The defects are removed by grinding. The body or weld seam are re-welded after removal of defects. Pipe End Cutting: On this device, testing rings and defective un-repaired pipe ends are cut off from the pipe. Hydro-static Pipe Tester: Here the pipes are subjected to hydro-testing as per grade, diameter and thickness of the pipe. End Bevelling Machine: At this station both ends of the pipes are bevelled to produce the machine end, which can be conveniently welded during laying of pipe lines. Final US Testing: A continuous Ultrasonic check is provided here after end bevelling of pipes. X-ray Unit: The first step of final inspection is x-ray photo control of weld seam at pipe ends. This is done at second X-ray station. Final Visual Works Inspection: The inspection station is provided with a rotating device. Each pipe is finally inspected visually to control the following:

a. Quality and dimensions of the bevelled ends. b. Surface defects including dents. c. Geometrical data such as roundness, straightness, off set of weld seam, height of

weld reinforcement, packing. d. Pipe dimension such as length, thickness and diameter.

HRD Centre Page: 97

Panorama 2010 Final Customers Inspection: The Inspector of the customer is provided with one rotating device and sufficient rack space. The Inspector carries out more or less the same inspection as is done in works inspection. If pipe orders do not require customer inspection, this inspection stand is by passed. Weighing of Pipes: Finally the pipe is passed through the electronic weighing station and leaves the building through the skid to a storing area from where the pipes are taken by EOT out door cranes for further storing and dispatch.

Laser Seam Tracking System 1.1 SWPP produces Spiral Weld Pipes from 16” dia to 64” dia. Hot rolled coils are formed in

to pipes in the forming cages of M 2.1 & M 2.2 m/cs. Automatic dc submerged arc welding is done at inside of the pipe first which is followed by outside welding. Outside welding is to be done exactly in the same inside weld joint. Laser Seam tracking system tracks inside weld seam & adjusts the outside weld head so that outside welding is done exactly on inside weld joint. The laser camera is mounted at the outside weld head such that laser light is focused sharply at 90 ° to the inside weld joint. The vision camera continuously detects the “V” joint & sends digital signal to the controller. The controller processes the signal & adjusts the outside weld head such that the welding torch continuously follows the inside weld joint.

1.2 Laser Camera head: Specification: A laser camera head is one of the main devices of Servo-robot’s 3D Laser vision system. The range sensing of Mini-i /60 3D laser camera is based on an active optical triangulation principle. Mini – i / 60 technology provides a high range sensing reliability & a very high lateral resolution. Characteristics of Mini- i/ 60 3D laser camera:

HRD Centre Page: 98


2.1 General introduction: EZ – TRACK / IT is an ultra fast image processing unit design to co - ordinate laser camera motion & 3D data acquisition . It also controls processes with the additional intelligence provided by 3D vision & adaptive feedback control. The EZ-TRACK / IT control unit contains the high speed SMART BOARD-V3 vision processor to process image analysis to keep the camera in the joint by moving the axes. The high resolution laser camera mini – i/60 coupled with the vision processor EZ-TRACK / IT, extracts the joint profile & the tracking point. It then sends the signal command to the axes to adjust the camera position over the part. An option is also available to allow the user to compute the gap, the mismatch and area of the joint as well as to adjust different parameters in real time including the travel speed & wire feed speed. 2.2 Features:

The operator of external laptop computer can programme different types of joints. The joints are then saved in the non-volatile memory of vision controller. After joints have been programmed laptop computer is no longer used. However the computer can be used during tracking process to display useful information such as profiles & status information.

2.3 Camera Cooling System: The camera head is cooled by closed loop chilled water. The chiller unit supplies chilled water at 24° C (adjustable) to the camera head continuously.

3.0 Operation:

The day to day operation of the EZ-TRACK/IT system can only be accomplished using teeth pendent. All necessary commands, either for controlling the tracking process or for

Camera Type Mini –i/60 Principle Active optical triangulation using structured laser

beam illumination. Detector Photo sensitive device Light source Build –in 50 MW visible laser diode. Stand off 56 . 6 mm Depth of filed 65 mm. Field of view : Close plane Far plane

24 mm. 35 mm.

Average depth resolution

0.08 mm

Sample points per profile

478 or 238

speed 30 / 60 profiles / sec. Data rate 14340 points per sec Dimensions 112 mm X 56 mm X 30 mm Weight 500 g.

HRD Centre Page: 99

Panorama 2010 selecting tracking parameters are accessible to the operator through the teeth pendent. Digital I/Os allow the PLC programme to perform exactly the same operation as the operator can do through the teeth pendent.

3.1 Manual Mode: When power is on, the EZ-TRACK/IT is in manual mode by default. The manual mode

allows the operator to manually jog the axis. This mode allows the operator to manually position the torch roughly in the joint at the beginning of the seam, prior to calibration of the system.

3.2 Calibration:

In automatic mode, the EZ-TRACK / IT tracks the joint, maintaining the torch at the same position relatively to the joint. The relative position between the joint & the torch might however be adjusted before welding in order to obtain the optimum welding conditions. This operation is called calibration.

3.3 Automatic Mode In automatic mode, the vision system guides the tool by comparing the current joint tracking point in its field of view with the reference point adjusted during calibration procedure & calculating a correction signal. During the automatic tracking mode, the operator can add offsets to the tool position by pressing the offset button & using the joystick simultaneously.

HRD Centre Page: 100


Flow of Material in SWPP

Coil Preparation

Stand

Forming

Cage

Inside & Outside Welding (Submerged

Arc Welding) Pipe Cutting

Unit

Visual Inspection

Station

Repair Welding

X-Ray Station

Grinding Station

Outside Welding

(Skelp Joint)

Hydro Testing

Bevelling Machine

Ultrasonic Testing

End Radiograph

Station

Works Inspection

Final Inspection

Electronic Weigh Bridge

Dispatch


Panorama 2010

PIPE COATING PLANT Rourkela Steel Plant (RSP), SAIL, has recently set up a 3LPE Pipe Coating Plant for applying coatings on external surface of the pipes. The products of the 3LPE Pipe Coating Plant shall be supplied to the oil and hydrocarbon sector and shall meet all the requirements as per the DIN 30670 Specification. The plant has been setup with Tech-know how from M/s Socotherm SpA, Italy. The Plant is in adherence with the Pollution Control Norms as per European Standards. Pipelines carrying hazardous materials especially oil and gas need protective coating both on the inside and outside of the pipelines to combat the corrosive nature of the harsh outer environment and the derivatives of the load to be transported. The three layer system uses a copolymer adhesive to provide excellent shear properties and an epoxy layer which provides corrosion resistance. Coatings are intended to form a continuous film of an electrical insulating material over the metallic surface to be protected. The function of such a coating is to isolate the metal from direct contact with the electrolyte, interposing a high electrical resistance so that electrochemical reactions cannot occur. CORROSION PREVENTION The principal methods for corrosion prevention on underground pipelines are coatings and cathodic protection. • Coatings are intended to form a continuous film of an electrical insulating material over

the metallic surface to be protected. The function of such a coating is to isolate the metal from direct contact with the electrolyte, interposing a high electrical resistance so that Electrochemical reactions cannot occur.

• Cathodic Protection (CP) is a technique to reduce the corrosion rate of a metal surface by making it the cathode of an electrochemical cell. This is realized by shifting the potential of the metal in the negative direction by use of an external power source. For CP to work, current must be discharged from an earth connection called a ground bed. In the process of discharging the current in a sacrificial system, the anodes in the ground bed are consumed by corrosion

Three Layer Three-layer polyethylene coatings were introduced about 1980 in Europe. They consist of:

• FBE primary coating • Polyolefin-adhesive (or tie) layer • Polyolefin topcoat



1. Layer 1: Immediately after abrasive blast cleaning the layer shall be formed by a film of liquid epoxy or resin of powder. The minimum dry thickness shall be between 20 and 60 microns checked in accordance with method 5 of ISO 2808 depending on the primer used. The thickness may be subject to agreement by the customer, and to conform to manufacturer’s recommendations. 2. Layer 2: A polymer intended to provide adhesion between first and third layers and be compatible with those layers shall form this layer. The minimum thickness shall be between 140 and 200 microns depending on the type of adhesive and the application. The thickness may be subject to agreement by the customer, and conform to manufacturers recommendations. 3. Layer 3: Polyethylene coating shall form this layer. The thickness shall be uniform and the minimum total thickness shall satisfy the requirements of DIN 30670 or as per the customer requirement. This layer gives the mechanical protection to the 1st layer and is also corrosion resistant to some extent. .


Panorama 2010

SPECIAL PLATE PLANT Special Plate Plant (SPP) is a valued unit of Rourkela Steel plant. SPP was set up in 1969 to cater the needs of country’s defense and research programs. It’s the only unit of its kind in the nation. SPP is pioneer in the field of special steel plates; with a diverse product profile that ranges from various grades of heat treated plates of high hardness and strength to dead annealed plates of high resilience and ductility. SPP products are used in various high end application e.g. T-90 tanks, MBT Arjun tanks, Ship-building, anti mines vehicle, atomic research etc. SPP takes pride in meeting the stringent Quality control norms of defense agencies (CQA (MET), OF CELL, DQAE(N)). Products:- Spade Heat Treated Plate, Spade Dead Annealed Plates, Jakal heat treated plates, jakal dead annealed plates, spade gas cut components, spade machined components, navy grade plates. Grades/Specification: Jackal: CQA(M)47, Spade: CQA(M)51 & CDA99, Navy Grade: DMR 249A & DMR 249B, SAILRATH, HARDOX, TARGET Customers: ORDINANCE FACTORY, MEDAK, HVF, AVADI, VF, JABALPUR, DMRL, HYDERABAD, IGCAR, KALPAKKAM, MIDHANI, HYDERABAD, CVRDE, AVADI CSL, COCHIN, GARDEN REACH SHIP BUILDERS, KOLKATA, TERMINAL BALLISTIC TEST LABORATORY, CHANDIGARH Alloy steels which are used for making armor plates are produced at ASP, Durgapur. Navy grade steel is produced at BSP, Bhilai & ASP, and Durgapur. Slabs are rolled at plate mill of RSP. Input material for SPP is plates rolled at plate mill of RSP. Following diagram illustrates material flow for armor plates. Plates received from plate-mill in rolled condition are strain hardened due to rolling. Grains are elongated in rolling direction. Machining/grinding of plates in rolled condition is difficult; hence soft annealing is done to improve grindeability. However for navy grade plates soft annealing and grinding is not required. Soft annealing cycle comprises of slow heating up to 7100C in 24 hours, soaking for a period of 16 hours followed by furnace cooling up to 1000C. It relieves stresses, reduces strain hardening and improves machinability. There are two furnaces used for soft annealing; namely S/A furnace and S/R furnace (both in BC bay).



MATERIAL FLOW

QC by RCL (RSP)

Operation

Top grinding is done to remove surface scale and minor defects from the plate, so that ultrasonic test can be carried out on the plate. Testing is done by Research and Control Lab staff. Ultrasonic testing is done to detect defects in metal. After testing, SPP index nos of the plates are stamped on the defect free plates and plates are sent for flame cutting. Size cut plates are then sent for primary inspection and bottom grinding. After bottom grinding thickness is measured and plates are sent for heat treatment/dead annealing. Heat Treatment Heat treatment is the most crucial operation among all. The objective of heat treatment is to impart desired mechanical properties (hardness, YS, UTS etc.) to metal by various meticulously chosen heating and cooling schedules. It consists of following operations.

STEEL MAKING AT ASP/BSP

CONCAST SLABS FROM ASP

ROLLING AT PLATE MILL, RSP

PLATE SOFT ANNEALING

TROLLY GRINDING OF TOP SURFACE

ULTRASONIC TESTING

FLAME CUTTING TO SIZE

BOTTOM SURFACE GRINDING & THICKNESS CHECK

HARDENING, OIL/WATER QUENCHING AND TEMPERING

BTP SAMPLE PTP SAMPLE TESTINGHARDNESS TESTING

FIRING AT PXE, BALASORE

SHOT BLASTING CAST CLEARANCE

DISPATCH STAMPINGPAINTINGSURFACE & THICKNESS

INSPECTION

SLAB ROLLING AT BSL FOR INGOT


Panorama 2010 Hardening comprises of heating the plates to desired temperature, soaking for some duration depending upon the thickness of plate and then rapid cooling (quenching) in oil/water. It transforms microstructure of steel to martensite. Tempering Steel in as hardened condition is highly brittle and requires further treatment before it can be used in various applications. A heat treatment cycle, called tempering is applied for improvement in ductility/toughness. Tempering comprises of heating to a fixed temperature (which depends on thickness) and for a fixed time. Heat treatment is done through two different routes in SPP. Heat Treatment Line in BC Bay It’s used for processing armor grade plates (Spade & Jakal). There are two different furnaces for hardening and tempering. Hardening Furnace:- Its capacity is 9 meters in length and 2 meters in width. This furnace uses mixed gas as fuel. There are two zones in the furnace; each zone has different control valves for air and fuel. Tempering Furnace:- Tempering furnace comprises of four zones; 1 and 2 are heating zones, and zone 3 and 4 are soaking zones. Total length of the furnace is 16 meters and width is 2 meters. Oil Quenching Unit:- Oil quenching unit lies near hardening furnace. Oil quenching unit has a capacity of 3.3 (rated 3.5) tons. Maximum size of plates that can be quenched is 2 meters X 6.5 meters. The unit comprises of oil tank, pumps to circulate oil, heat exchanger to cool oil, C hook, and quette etc. Apart from oil quenching unit a water quenching tank is also used for quenching thicker plates. Heat Treatment in Wesman Fce. (DE Bay) This furnace is used for processing navy grade plates. This is relatively modernized and versatile furnace and can be programmed for multiple heating cycles. The furnace can be used for annealing, hardening and tempering. A water quenching tank is used for quenching of navy grade plates. Testing and Quality Control All the plates, which have undergone heat treatment, have to meet quality parameters according to the specifications. Hardness test is carried out for every plate while other tests (charpy impact test, tensile test, fracture, lamination etc.) are done for few representative samples. As per the specifications given for armor plates, representative plates (BTP/PTP Plates) of every lot has to clear all the required tests. If any BTP/PTP plate finally fails in tests, entire lot represented by it may be rejected. Facilities for hardness testing and fracture test are within SPP, while charpy, tensile and microstructure tests are carried out at RCL test house.



Recent Developments SPP is undergoing modernization to keep pace with time. Renovation of DE bay furnace has enhanced total capacity of the plant. A new state of the art hardness testing machine has been installed. New generation CNC flame cutting machines and shot blasting machines will replace older machines, which will result in increased uptime for machines and less manpower requirement. Renovation of existing facilities is under process and some new projects are also under proposal. SPP has accentuated its ability to adapt with ever-changing demands from different quarters. Development of some new grades of steel like SAILRATH is under process. ISO and Environment Protection On environmental and safety front, trials for eco-friendly polymer quenching have been carried out and SPP is planning to switch over to polymer quenching instead of oil quenching. SPP has successfully undergone ISO 9001:2000 and ISO 140001:2000 certification. With new facilities in place, SPP is gearing up to further strengthen its niche in special steel market.


Panorama 2010

COLD ROLLING MILL Cold Rolling Mill is one of the complex units of RSP, producing bulk amounts of quality finished steel. Purpose of cold reduction is to achieve the following: (i) A reduction in the thickness of the final product. (ii) A designed surface finish. (iii) Desirable mechanical properties. (iv) Close dimensional tolerance. (v) Producing as per customer requirements. The input to Cold Rolling Mills is the Hot Rolled Coils (HR Coils).

Material Flow Diagram in Cold Rolling Mill, RSP

Legend: HR: Hot Rolled, PL: Pickling line, CR-1: Cold Reversing Mill-1,CAL:Continuous Annealing line, HAL: Hood Annealing line, SP: Skin Pass Mill, CPL: Coil Preparation line, ETL: Electrolytic Tinning Line, SSL: Sheet Shearing line, GP/GC: Galvanised plain/Galvanised Corrugated , ETP: Electrolytic Tin Plates, CR: Cold Rolled.

SP-1 SP-3

CPL

ETL SSL-2 & 3

ETP CR Sheets CR Coils

Galvanising Line

GP / GC Sheets

HAL CAL

HR Coils

PL-1 PL-2

Tandem Mill CR-1

Tin Mill Black Plate from BSL

CR Coils



Pickling Lines: The first unit of CRM after HSM is Pickling line. During the hot rolling process, a layer of scale (Iron oxides) is formed on the strip surface, which must be removed prior to further processing. This removal of scale is performed by physically breaking of scales by mechanical means & then chemically treating the surface of hot rolled strip with an acid. The process, called ‘Pickling’, removes the remaining scale by dissolving it in acid. In CRM, RSP HR Coils are treated chemically by hot dilute Sulphuric acid to remove the oxide scales, so that it can be further rolled to thinner gauge. There are two Pickling lines in CRM, RSP.

Pickling Line I Pickling Line II Capacity - 2,80,000 T/Yr. 4,68,000 T/Yr. Max. Strip width - 1560 mm. 1350 mm Thickness of Strip - 2-4 mm 1.6 to 4 mm Pickling Medium - Dilute H2SO4 Dilute H2SO4

The material flow in both the units is more or less same except for the above differences. The material flow in Pickling line No.-II is: Coils from HSM → Coil Conveyor → Coil ramp → uncoiler → Leveller → Crop shear → Welding machine (with bead planner) → Stitcher → Pinch Roll-1 → Wet looping Pit → Scale Pit → Deflector Roll (Delivery Set) → Side Trimmer → Oiling Machine → Lateral Strip Guide → Up Coiler → Binding Station → Coil ramp → Coil Receiving Device → Coil Conveyor → Weighing Machine → Coils to Tandem Mill → Coil Storage. In the acid tanks (numbered from the entry side) the Strip and the concentrated acid move in Counter direction. The Acid Concentration, Salt Concentration and temperature are shown below.

Tank No.

Acid Concentration

Salt Concentration

Temperature

1 16-18(%) 400 gm/liter 70oC 2 18-20(%) 350 gm/litre 75oC 3 20-22(%) 300 gm/litre 80oC 4 22-24(%) 250 gm/litre 85oC

The temperature is controlled by Steam heating. The spent liquor from Tank is sent to the Regeneration plant where the Ferrous Sulphate is separated by Crystallisation and Refrigeration Process and the acid is brought to original concentration by adding new makeup acid. Cold Rolling: The next operation is the cold reduction of the pickled coil. After pickling, the main cold rolling operation, i.e. cold reduction, is performed in cold reduction mill where pickled strip is fed between very hard rolls. This is done • Either in a single reversing stand, equipped with an uncoiler and a coiler, by making several passes in reversing directions; • Or In a continuous tandem mill where the strip is engaged in several stands simultaneously, enabling high-tension force to be applied. In CRM, Cold rolling is done in two mills:


Panorama 2010 a) Four-high reversing mill (CR-1) b) 5 stand tandem mill (TM)

Cold Reversing Mill-1 (CR-1) This is one, 4-Hi reversing mill which makes 2-5 passes to reduce thickness. It has a single stand with reels located on either side of the mill. Steel strip is passed back and forth till the required thickness is obtained. On the entry side of the mill, means are provided for the coil to be threaded through the mill to the tension reel on the delivery side. After the first pass, the tail end of the coil coming from the uncoiler is gripped by the second tension reel on the entry side of the mill. In each unit, the reel serving as the pay-off unit is operated as a generator, providing back tension to minimise the rolling friction and feeding of the coil into drive reel motor. In the last pass, the tail end of the coil is released from the unwinding tension reel. 5-Stand Tandem Mill (TM) The Five Stand 4 Hi Tandem Mill is one of the most vital units provided during the 1.8 MT Expansion Programme. In tandem rolling, the material to be rolled undergoes reduction in all the mills at a time. The Mills usually roll a wide variety of finished Coils with thickness varying from 0.15 to 1.60 mm. Each stand of tandem or reversing mills consists of a set of independently driven pair of rolls, which come in direct contact with the strip and create a converging gap for imparting deformation to the strip. These rolls are called work rolls. Comparatively larger diameter backup rolls support these work rolls. The maximum speed of the mill is 1830 m/min. in the fifth stand. The Mill rolls 3 types of finished Coils with following Specifications.

Parameters Galvanised Sheets CR Sheets Tin Plates Rated Capacity 1,60,000T/yr 2,50.000 T/yr 85,000T/yr Max. Strip Width 1220 mm 1250 mm 1040 mm Min. Strip Width 560 mm 560 mm 560 mm Max. Strip thickness

1.6 mm 1.6 mm 0.30 mm

Min. Strip thickness

0.31 mm 0.31 mm 0.15 mm

Inner Coil diameter

510 mm 510 mm 450 mm

Outer Coil diameter

1600 mm 1600 mm 1600 mm

Max. Coil weight 15 tonnes 15 tonnes 15 tonnes Production rate 60 T/hr 60 T/hr 30 T/hr

Isotope Gauge after Stand 5 indicates the final thickness.



The material flow of Tandem Mill is: Coil from PL II → Coil Storage in Tandem Mill bay → Coil Conveyor → Coil ramp → Uncoiler box → 3 roller Pinch roll unit(Straightening machine) → Strip guide roller → Lateral Strip guide → Entry guides → 5 Stands → Delivery Guides → Tension Reel Coil Stripper → Belt Warper → Coil transfer Car → Coil Conveyor Annealing Process: Cold rolled strip as such is not suitable for drawing and deep drawing operations due to lack of ductility. The loss is caused by the work hardening effects of cold reduction. After the cold reduction process, the internal structure of the steel is as follows:

1. The grains in the steel have been elongated in the direction of rolling. 2. Longitudinal rolling stresses have been set up in the steel and any foreign matter

present in the core zone of the rimmed steel have been rolled out into the form of segregated bands.

3. The steel being very hard and brittle will fracture very easily in the direction of transverse to the rolling.

4. Myriads of stress points are found to be present in each grain. Now these CR coils are to be annealed to remove the stresses. The various purposes of annealing are listed below:

1. To improve the mechanical properties. 2. To increase ductility, particularly to restore the normal conditions of steel after cold

working. 3. To relieve the internal stresses. 4. To remove chemical non-uniformity. 5. To change the micro-structure of steel from the distorted structure of cold worked steel

to the equi-axed structure. Annealing is done in either of the following two lines:

1. Hood Annealing Line (HAL) 2. Continuous Annealing Line (CAL)

Hood Annealing: Hood annealing is still the most common and convenient method of annealing and a major portion of cold rolled coils are annealed in Hood Annealing furnaces in spite of development of continuous and open coil annealing. The main reason for its wide use is that wide range of annealing cycles can be adopted to suit to Customers’ requirements. Hood Annealing process can be divided into the following operations:

(a) Charging of annealing bases (b) Placing of inner cover (c) Purging (d) Placing of furnace (e) Lighting of furnace and heating of charge (f) Stopping of heating (g) Cooling and unloading


Panorama 2010

Heating Zone Cooling Zone In the annealing process, the temperature of annealing can be as high as 800oC. Different annealing cycles are followed for different grade & thickness. After annealing, the coils are given a further light tolling in a single or two strand mill, operated without strip lubrication. This operation is called as skin passing or temper rolling. Continuous Annealing: In Continuous Annealing Process Coils are annealed and the cooled in controlled atmosphere continuously. This is a much faster process compared to Hood annealing Process. Skin Passing: Skin passing is a cold reduction method and the steel surface or skin is hardened by cold working, keeping the steel core soft & ductile. In Cold Rolling Mills of RSP, one single stand 4-high mills and one twin stand 4-high mill have been installed.

Skin Pass Mills (SP-1 & SP-3): The softened or annealed Steel is then skin passed or Temper rolled with the aim of imparting a work hardened skin to the steel strip leaving its core soft in the annealed condition. Following are the main advantages of Skin Passing.

a. To impart different surface finishes to the strip required for painting, coating enamelling etc.

b. To give a flat surface to the strip. c. To impart the desired mechanical properties to the strip. d. To keep the strip free from stretcher strains and luder bands that may develop

during the forming operations. At RSP we have 2 Skin Pass Mills with the following Technical Data.



Parameters SP I SP III Rated Capacity 2,70,000T/yr 3,60,000 T/yr Type of Mill 1700 mm, Single Stand,

4 High Two Stand 4 High

Strip Width 630-1550 mm 560-1040 mm Strip thickness 0.35 to 1.3 mm 0.15 to 0.31 mm Speed 500 m/min 1200 m/min Work Roll Size 460 X 1700 mm 460 X 1200 1st Stand

530 X 1200 2nd Stand Purpose Temper Rolling of SG

Coil Temper Rolling of TP & Light SG Coils

The skin passed coils are the packed and dispatched to stock yards or Customers as CR coils. Sheet Shearing Line (SSL): Some Coils are sheared in to different lengths in Sheet Shearing lines (line 1 & 2) and sent to Customers as CR sheets. SSL consists of one uncoiler & a Harden Shear to cut sheets of different lengths. On line inspection is done manually. C.R. Sheets & Coils:

Specifications Sheets Coils Length 2500 mm

and 3600 mm

Width 1250 mm (maximum) 920-1270 mm Thickness 0.5 – 1.6 mm 0.35 – 1.6 mm

Applications: Used for making steel furniture, refrigerator bodies, automobile bodies, railway coach paneling, drums, barrels, deep drawing and extra deep drawing available as per Indian Standard specifications. Besides CR coils and sheets CRM, RSP also produces two different coated products namely Electrolytic Tin Plates (ETP) and Galvanised plain and corrugated sheets. The Ferrous Sulphate salts from regeneration plant are used for water treatment at Tarkera Water works. Also some quantity of these are sold to outside parties and find use in making paints and in pharmaceutical applications. Coating Units: RSP’s family of coated steel sheet products includes both hot-dipped and electrolytically-applied coatings. The protective coatings add superior corrosion resistance to the many


Panorama 2010 other desirable properties of steel. The various types of Coated Steel Sheet products gives the designer and manufacturer a choice of combinations to provide the amount of corrosion resistance required, strength, formability, paintability surface appearance and other properties and characteristics to closely match the steel sheet to the need, whatever the environment. In CRM, RSP we have facilities for both Tin and Zinc coatings. Electrolytic Tinning Line (ETL) Complex: Here the Coating of tin is done by employing the principles of electrolysis in a acidic medium. The advantages of ETL are (1) it is faster (2) economical (3) Tin consumption is less (iv) differential coating can be obtained. The continuous Electrolytic Tinning Line produces a shining tin coated surface in a variety of coating thickness. The tin plate shearing lines are equipped with sensitive pin hole detectors and an automatic off gauge detection system. Description of various processing units and the activities performed are given as follows: i) Coil Preparation Line (CPL) ii) Electrolytic Tinning Line (ETL) iii) Electrolytic Tin Plate Shearing Lines-1 & 2 (ETSLs) Coil Preparation Line: In this line RSP Cold rolled TP Coils, Tin Mill Black Plate (TMBP) Coils (from BSL) are prepared before they are fed to the Electrolytic Tinning Line. The line is fitted with an Off gauge detector. The portion of the coils showing off gauge is cut off in this unit. The line has provision to make bigger coils from smaller ones and a side trimming unit to trim to final width required by the customer. Anode Cast House: In Anode Cast House anodes are made from Tin Ingots. These ingots are used in Electro Plating Tanks of ETL. Tin Ingots are melted in the furnace heated with mixed gas. It has a temperature measuring instrument. The molten tin from furnace is tapped from tap hole in the mould. Electrolytic Tinning Line: The purpose of this unit is electrolytic cleaning, pickling and plating of TMBP Coils with tin, chemical treatment (passivation) & Electrostatic oiling. The unit consists of Entry Section, Processing Section & Delivery section. The Entry section has two Coilers, a Double cut Crop Shear, a Welding Machine, Briddle -I, Vertical Loopers & Briddle-II. The Processing section has Electrolytic Cleaning Unit, Alkali Rinse Unit, Electrolytic Pickling Unit with rinsing facility, Electroplating Unit, Hot air Drier, Melting Tower, Quenching Tank, Chemical Treatment unit, Rinsing Unit, Hot air drier & Electrostatic strip oiler.



The electrolyte used in Plating section consists of i) Stannous sulphate, ii) Phenol Sulphonic Acid and additive as Ethoxylated Alpha Naphthal Sulphonic Acid (ENSA). Delivery Section consists of Briddle III & two upcoilers with side resistor control. Electrolytic Tin Plate Shearing Line: This unit serves the purpose of shearing the coil to sheet as per requirement of the customer and classification of ETP. The unit consists of Un coiler, Flying Shear, Pin hole & Off gauge Detector, Classifier and Pilers. The specifications of Tinning Line are:

Rated Capacity 25 Tons/hour or 1,50,000 T/Yr Strip size Width of Strip Thickness of Strip

560 mm – 1040 mm 0.15 mm – 0.31mm

Maximum speed 370 m/min Coating weight 5.6 gm/m2

Application: Electrolytic Tin Plates are used in the manufacture of printed and plain containers for packaging of various food products including fruits, vegetables, edible oils and food. Plates are available in 5.6 gm/m2 coating weight and variety of tempers. Continuous Galvanising Line: Galvanising Lines of CRM of RSP were commissioned in July 1968. There are two Senzimer type Continuous Hot Dip Galvanising facilities with On-line Oxidation Furnace for removing oil, grease, On-Line Reduction Furnace for annealing in protective atmosphere, Jet Coating for better control on coating thickness, Chemical Treatment to prevent atmospheric corrosion and Shearing facilities. These lines can produce Galvanised plain, Galvanised Corrugated as well as galvanized coils. The material flow for Galvanising Lines is as follows: UUnnccooiilleerr →→ PPiinncchh RRoollll →→ DDoouubbllee ccuutt HHyyddrraauulliicc SShheeaarr →→ PPiinncchh RRoollll →→ LLoooopp CCaarr11 →→ PPiinncchh RRoollll

55 →→ OOxxiiddiizziinngg FFuurrnnaaccee →→ RReedduucciinngg FFuurrnnaaccee →→ PPiitt ttyyppee GGaallvvaanniissiinngg ppoott →→ AAiirr jjeett kknniiffee →→ DDeefflleeccttoorr RRoollll →→ CCoooolliinngg bbooxxeess →→ PPaassssiivvaattiioonn UUnniitt →→ LLoooopp ccaarr 22 →→ HHaallddeenn SShheeaarr →→ SShheeeett ppiilleerr →→ GGaallvvaanniisseedd PPllaaiinn ((GGPP)) →→ CCoorrrruuggaattiioonn LLiinnee TThheerree aarree 22 mmuullttii--rroolllleerr ccoorrrruuggaattiinngg mmaacchhiinneess wwhhiicchh pprroodduuccee ccoorrrruuggaatteedd sshheeeettss..


Panorama 2010 Technical Details:

Continuous Galvanising Line Two nos. Width of Sheet 610 mm – 1220 mm Thickness of Sheet 0.31 mm – 1.60 mm Capacity 1,60,000 T/Yr

(80,000 T for each line) Maximum speed 90 m/min

Application: Galvanizing Sheet is used extensively for roofing, paneling, industrial sheeting, air conditioning ducts and structural applications. Shipping Section: All Cold Rolled products like CR Coils/Sheets are packed, weighed and dispatched through Road or Rail Wagons. ETP & GP/GC packets are packed in the line itself. Weighment and loading is done in Shipping Section.



SILICON STEEL MILL Cold Rolled Non-Oriented (CRNO), the energy efficient steel, is an essential raw material, recognized the world over for manufacturing electrical equipments like generators, motors, relays, small transformers etc. Used primarily in special rotating & static electrical equipments, the CRNO steel is characterized by low watt loss (core loss) & high permeability. Rourkela Steel Plant, a unit of Steel Authority of India Limited (SAIL) took the lead & achieved the distinction of being the first in the country to start commercial production of CRNO. Equipped with the state of the art technology, Silicon Steel Mill with installed capacity to produce 73,500 tpa of CRNO was set up with technical collaboration of M/s A.K.STEELS (Formerly ARMCO), USA, a pioneer in the field of electrical steel. Silicon Steel Mill is ISO –9001 & ISO –14001 Unit. The CRNO stream has been awarded ISO - 9001, the International Quality Assurance System, certified by M/s RWTUV, Germany in September 1996. And ISO –14001 Environmental Management System, certified by M/s BIS, India in October 2000. Meeting international standards with respect to magnetic properties, insulation coating properties, insulation resistivity, dimensional tolerance & lamination factor is the credo at Silicon Steel Mill. Various facilities have been added with a view to keep pace with the latest technology. The notable features are external desulphurisation of hot metal, high purity steel making, vacuum degassing, continuous casting, highly accurate hot rolling mill & Cold Rolling Mill complex incorporating the most advanced technology for manufacturing CRNO steel strips. The unit has a modern Magnetic Testing Laboratory, which is one of its kinds in the country.


Panorama 2010

FLOW SHEET

TANDEM ANNEAL DECARB ANNEAL

SLITTER –I

CUT TO LENGTH

PACKING

DISPATCH

STEEL MELT SHOP –I

HOT STRIP MILL

BILD UP & SIDE TRIM LINE

ANNEAL & PICKLE

4 Hi COLD REVERSING MILL



MAIN UNITS: BUILD UP & SIDE TRIM LINE Supplier: STAMCO / BLUE-STAR, Electrics: BHEL, PLC: L&T U-84 This line is used for side trimming & head end / tail end dressing of input Hot rolled coils of Thickness 2.2 To 2.5 mm, Input width 1055 + 10 / -0 mm & Finish width 1025 / 975 / 925 mm Line Features:

1. Coil Wt. 15 Mt (max ) 2. Coil I.D. 510 & 710 mm, Width: 600 To 1150 mm 3. Electronic weigh bridge 4. Line speed 15 to 125 mpm. 5. Jog speed 15 mpm 6. Line tension 1.75 Kg / mm2

ANNEAL & PICKLE LINE: Supplier: Main equipments: AETNA STANDARD (USA), Furnace: ELEC. FURNACE CO., Electrics: BHEL, PLC: L&T U-84 This line is used for pickling of HR coils after BUST line. Width - 600 - 1150 mm Max. Coil wt. 15 Mt Total Line Length – 290 Mts. Line Features:

1. Hydrochloric acid pickling (HCL) 5 tanks for pickling. 2. Acid conc. 8 To 12 %. Salt conc. 12 % max. 3. Acid bath temp. 70 +/- 3oC 4. Annealing of M-36 / M-27 & higher grades. 5. Gas fired & electric heating zones 3 each. 6. Annealing temp. 950 +/- 10oC 7. Anti rust oil coating after pickling. 8. Taylor - Winfield shifting head seam welding m/c 9. Line speed 10-35 mpm ( Entry-90 / Process 60 / Exit 90 mpm )

10. Tension - Entry - 0.35 to 1.05 Kg/mm2 Furnace - 0.35 to 1.05 Kg/mm2 Pickling - 1.05 Kg/mm2

Exit - 2.5 Kg/ mm 2

11. Pickling Tanks - 5 (L - 25. 7 m, W - 2.13 m, Depth - 1.207 m) Capacity - 36,000 Lts each (1 to 3) 4A – 16800, 4B-19600 lts.

12. Cascade rinse unit 3 compartments.


Panorama 2010 ACID TREATMENT PLANT: This plant is used for neutralization of waste acid from Anneal & Pickle line. Cold reversing mill rolling emulsion, mill washing & other spill oil of mill is also treated here to remove waste oil. After neutralization of waste acid effluent is sent to lagoon. Designed to handle approx. 503 gallons/ min of influents.

Plant Features: 1. Acid storage tanks FRP - 5 nos.11,000 Gallon each 2. Equalisation Tank - 20,000 Gallons. 3. Aeration tanks 4. Clarifier, floculator 5. Oil skimmer/ reclamation system

COLD REVERSING MILL Supplier: MECON / WEAN UNITED, Electricals: BHEL, Input: HR coils after Pickling Coil I.D.: 510 mm, OD: 1750 mm, Width: 600 - 1150 mm

Mill Features: 1. Work roll 280 / 305 x 1270 mm

Back up roll 1105 / 1220 x 1270 mm. 2. Coil ID - 510 mm 3. Coil OD - 1750 mm 4. Width - 600 - 1150 mm 5. Morgoil Bearing Size - 6. Hyd. Automatic gauge control 7. Isotope thickness gauges.

Source –Amrecium 241 / Ionisation gas – Crepton/ zenon 8. ABB computer MP-200 /1 9. Siemens plc 155 H 10. Quick work roll changing rig. 11. Work roll bending both crown in & crown out. 25 Kg/cm2 each plunger. 12. Motorised wedge drive for pass line adjustment. 13. AGC Cylinders – 780 mm Dia. & 1175 mm sroke. 14 Back Up - Morgoil Bearings Work Roll - 4 row tapered roller bearings. 15. Hydraulic Systems: System A - +ve bending, Back Up balance, Back Up change rig. Press - 210 Kg/ CM2

System B - Auxilliaries 60 - 70 Kg/ CM2

System C - AGC, 240 Kg/ CM2

Morgoil - 5 Kg/ CM2

Morgoil hydrostatic - 700 Kg/cm2 Circulating Oil - 5 Kg/cm2 Drive gear boxes Roll Coolant System - 4500 Lts/Min 10 Kg/ CM2, 2 Tanks 60 M3 each

Skimmers, CUNO filters, Magnetic filter.



16. Mill modulus - 564 Mt / mm 17. Roll separating force - 2280 Mt (max) Electrics: P.O.R. - 300 kW, 1200 rpm CONT. E.T.R. - 1125 kW, 800 rpm MILL STAND - 2 X 1687 kW, 670 rpm D.T.R. - 1125 kW, 800 rpm REPAIR & SIDE TRIM LINE Supplier: Stamco / Blue Star Elec. BHEL PLC Yashikawa Line is used for head end cutting of Reversing Mill strip breakage coils, Removing off gauge portion & dressing of coils. Line Features:

1. Gauge 0.27 to 0.70 mm 2. Coil Wt. 15 Mt. (max )

Width 600 to 1100 mm 3. Line speed 15 mpm

TANDEM ANNEAL LINE Supplier: EPI / ELEC. FURNACE Co., Electrics. BHEL, PLC : Siemens 155 H This line is used for decarburising annealing of cold reduced coils. Annealed strip is coated with insulation coating. Line Features: 1. Scrubber unit. 2. Elec. F/C, Length 153 mts., Decarburising zones 1 to 9 temp. 840 +/- 10oC

Annealing zones 10 to 12 temp. 1065 oC max. 3. Protective atmosphere of synthesis gas 75 % H2 + 25 % N2.

4. Two roll insulation coating system C-3 Organic coating C-6 Semi- organic. 5. Drying F/C

Open fire F/C using mix gas. Temp. 300 to 600oC. Line speed – 8 to 40 mpm Input –0.30 to 0.70 mm I.D. 510 mm / O.D. 1650 mm

Line Ten Entry – 0.35 Kg/mm² Process – 0.25 to 0.55 Kg /mm², Exit 4.5 Kg /mm² DECARB ANNEALING: Supplier: EPI / ELEC. FURNACE CO. Elec. BHEL, PLC: Siemens S-5 (135 U)


Panorama 2010 This line is used for decarburizing annealing & C-3 (Organic) & C-5 Semi – Organic Insulation coating of cold reduced strip.

Width -600 - 1030 mm Gauge 0.27 - 0.70 mm Max. coil Wt. - 15 Mt Coil O.D. - 1700 mm (max)

Line Features : 1. Wean United Dual seam welder 2. Scrubbing unit 3. 2 Roll tensiometer 4. Elec. F/C

Length 153 mts., Decarburizing zones 1 to 8 temp. 840+/-20oC, Annealing zones 9 to 11 temp. 1020oC max, Protective atmosphere of synthesis gas. (75% H2 + 25 % N2) 1575 kW elec. heating / 1800 kW elec. soaking brick lined static cool & water jacket cool . Jet cool fans - 3 Nos. Capacity 626 NM3 / Each –12 5. Coating System: Two roll coater; Drying F/C - Flotation type Elec. Heating temp. 300 to

450oC. length 27 mts. 6. Line Speed : Entry - 15 to 75 mpm. Process - 25 to 60 mpm Exit - 15 to 75 mpm 7. Line tension: Entry 0.35 Kg/mm2

Loop storage 1.05 Kg/ mm2 Furnace - 0.35 to 1.05 Kg/mm2 Exit - 4.50 Kg/ mm2 Entry looper - 4.5 min. strip storage (270 Mts) Exit looper -2.0 min. strip storage (120 Mts)

SLITTER - I Supplier : STAMCO / BLUE-STAR

Elec. BHEL PLC : Siemens 155 H

This line is used for side trimming / slitting of annealed coils. All coils are inspected during processing.

Line Features: 1. Pull through line 2. Unwind / trimmer / rewind 3. Scrap baller



CUT TO LENGTH LINE Supplier: -BLUE STAR/ STAMCO Elec – BHEL PLC – Siemens 155 H Line Features: Coil Weight - 15 MT Coil OD - 1700 mm Coil ID - 432 to 510 mm Width - 600 to 1150 mm Line speed - 60 mpm Gauge - 0.27 to 0.70 mm

Exit Sheets Width- 580 to 1150 mm Length- 900 to 4000 mm Pack Ht.- 600 mm Pack Wt.- 15 MT MAGNETIC TESTING LAB.

For evaluation & grading of silicon steel. FACILITIES INSTALLED:

1 Magnetic test console 3200, Donart electronics, Epstein control 2700 Mag. multi tester 2500 A

2 Fischer Coating thickness gauge 3 Franklin resistivity tester. 4 Sample shear.

AMMONIA CRACKING UNIT Ammonia cracking unit is producing synthesis gas used as Protective atmosphere in Tandem annealing line & Decarb annealing line of SSM, Galvanising, Continuous Anneal & Hood Annealing line of CRM. CAPACITY: 900 NM3 / Hr, 3 furnaces of 300 NM3 / Hr. each, Synthesis gas: 75 % H2 + 25 % N2


Panorama 2010

ROLL SHOP Roll Shop caters to the requirement of Ready Roll Assemblies to all customer mills namely PM, HSM, CRM & SSM as per schedule. Accordingly, for smooth feeding of Roll chock assemblies to all these units three shops are located at three different locations known as Roll Shop-I, II & III. Other than turning & grinding of rolls, Roll Shop performs various other functions as detailed below:

• Procurement, issue & performance assessment of rolls. • Procurement, inspection & maintenance of roll neck bearings (Oil film bearings, 4-row

taper roller, 4 row cylindrical roller, ball & thrust bearings). • Inspection & maintenance of roll balancing cylinder assemblies (hydraulic testing & seal

replacement). • Inspection & maintenance of chocks (chock bore; wear plates, keeper plates, hydraulic

fittings etc.). • Lubrication of roll chock assemblies. • Maintenance of roll grinding & shear blade grinding machines. • Record keeping of rolls & bearings through computerized roll management system.

Roll Shop-I: The shop came into operation from 1961 and at present caters to the roll requirement of HSM & Plate Mill. It is situated in DE bay of Hot Strip Mill from column No. 37 to column No. 58. In 1996-97 the shop was extended up to column No. 64 to accommodate two new CNC roll grinding machines for fulfilling the additional requirement of Hot Strip Mill. The Shop consists of following machines: a) Lathe- for Turning of R0 and back up rolls of HSM b) WG1 & WG2- Grinding of back-up rolls of HSM & PM and also work rolls of PM. c) WG 3, 4, 5- Grinding of Work Rolls of HSM finishing & roughing stands, CTS Blades of PM,

Rubber Rolls and Pipe plant cutter blades. d) EM1 & EM2- Straight blade grinding of HSM & Plate Mill. e) CNC-I & CNC-II - Grinding of finishing Mill work rolls of HSM.

Roll Shop - II: The shop came into existence along with Tandem Mill & Skin Pass Mill-III of CRM in the year 1968. Following machines are available in Roll Shop-II: a) HG 1- Roll grinding machine for grinding back-up rolls of CRM & SSM. b) HG 2 & 3 - Roll grinding machine for grinding of work roll of CR-I, SP-I, SP-III and TM. c) WG 6, 7 & 8 - Roll grinding machine for grinding work rolls of Tandem Mill & SP-III. d) EM 5 & 6 - Grinding of straight blades of PL1, PL2, SSL & ETL of CRM complex. e) EM 7-Grinding of circular blades for Pl1, PL2, SSL & ETL lines and SSM.

Roll Shop - III: The Shop came into existence with commissioning of Silicon Steel Mill in the year 1984. Following machines are available in Roll Shop-III: a) HG-6 - Roll grinding machine for grinding of SSM work Rolls.

b) Guistina - Roll grinding machine for grinding of SSM work rolls & crop shear blades.



MAINTENANCE FUNCTION Maintenance management is a vital part of industrial management as this is directed towards optimum utilization of the machineries in an industry, which engulfs highest chunk of investment made in business. Rourkela Steel Plant has been rightly giving due importance to maintenance, which is evident from the sound maintenance system that exists in RSP since inception. The maintenance system of at RSP has been designed and implemented by Mr. K.H. Kohrn, a German expert, way back in early seventies. Though Kohrn’s system vouched for a centralized system of maintenance for various production units of the integrated steel plant, with pressing needs, RSP switched over to decentralized system in 1991. By this, maintenance management is now responsibility of Head of the different production units. This switch over, and also timely computerization of the maintenance information system, however has not jeopardized the core Kohrn’s system design. The decentralized system also enjoys many centralized services, which have been described in following paragraphs. CENTRALIZED SERVICES The centralized services can be categorized as Mechanical and Electrical, each one being headed by separate General Managers. The mechanical services are –

Sl Department Assigned function 1 Engineering Shops Manufacturing / repair of spares, reconditioning of

damaged assemblies, fabrication of structures etc. 2 Crane maintenance Inspection & Maintenance of all EOT cranes of the

plant. 3 Design & modification Preparation/preservation of drawing, redesign /

modification of equipments in the plant etc. 4 Maintenance systems and

services o Vibration monitoring of rotating equipment.

Thermography, oil analysis etc. o Maintenance and modification of CMMS.

Training to users. o Expert advice on lubrication, hydraulics,

bearings including control function on usage. o Operation, Maintenance of Compressors and

distribution of Compressed Air to departments o Allotment/control of Consumption and

procurement Budget. o Inspection of condition Structures and

reporting. o Monitoring of maintenance activity in different

departments. Suggestions as per requirement. 5 Repair and construction

(Mech) Centralized man power help for heavy/ specialized repair jobs.


Panorama 2010

Sl Department Assigned function 6 Civil Engg. services and

structural inspection Maintenance and modification of Civil work in the plant & Inspection of shop floor structures.

7 Central monitoring group Monitoring of maintenance activity in different departments. Suggestions as per requirement.

8 Field machinery maintenance

Maintenance & operation of field machinery equipments.

9 Transport Maintenance & operation of vehicles inside the plant.

Apart from the above maintenance services, utility service of Compressed Air is also under G.M.(Mechanical). The various Centralized Electrical Services comprise of –

Sl Department Assigned function 1 Repair shop (Electrical) Repair/reconditioning of electrical equipments. 2 Air conditioning Maintenance of air conditioning units of the plant

including room a/c 3 Electronics & Electrical

Technical Services. Maintenance of electronic systems in the plant.

4 Heavy Maintenance (Elect)

Man power help to various units of the plant for heavy electrical jobs.

Apart from the above Maintenance Services, power generation & distribution, steam generation and blower station is also under GM (Electrical). DEPARTMENTAL MAINTENANCE ORGANISATION In each production units, under the departmental Head, there is one head of Mechanical maintenance and one head of Electrical maintenance. In some important units, both mechanical and electrical maintenance are lead by one Maintenance Head. The maintenance activity of the department comprises of several functional groups:

Group Function Planning group Material planning, Job cataloguing, Job planning, B/D

& delay analysis etc. Inspection group Inspection of machineries by schedule and defect

recording. Repair maintenance group B/D maintenance / Shut down maintenance jobs. Preventive maintenance group

Lubrication, adjustments, cleaning etc.

Maintenance practices that are followed in shop floor are of both time based preventive maintenance and condition based maintenance. These two types of maintenance practice, and related information system is narrated in subsequent paragraphs. For systematic approach in planning and execution of maintenance jobs, the equipment of the plant is classified in a scientific manner. This is explained below.



EQUIPMENT CLASSIFICATION The plant, which comprised of many production units, is in fact, collection of many equipment. For correct identification and location address of each part of these equipments, a hierarchal classification is adopted. PLANT is divided into different PRODUCTION CENTERS (max.100) - PRODUCTION CENTERS are divided into many COST CENTERS (max. 100) - COST CENTERS are considered to be comprising of many GROUPS OF EQUIPMENT (max. 100) - Each GROUP OF EQUIP. is classified into many SUB-GROUPS OF EQUIP. (max. 10). The mechanical and electrical discipline then list different ASSEMBLIES under each SUB-GROUP separately (max. 100). Each ASSEMBLY is considered as comprising of many parts (max.1000), which is the lowest level in the classification tree. Each level is suitably numbered by which it is possible to assign numeric code to any equipment at any level. Equipment classification number codes are referred in planning and scheduling of jobs. It is particularly very essential in computerization of the planning system which will be discussed in subsequent lines. PREVENTIVE MAINTENANCE SYSTEM The preventive maintenance system that has been designed by Mr. Kohrn, is in vogue in all production units. This comprises of time based inspection, regular defect recording, shutdown planning and execution of planned jobs, breakdown monitoring and analysis etc. The total system is shown diagrammatically in Fig-1. Different formats with a specific code number (like PM1, PM2…mentioned in diagram) have been designed for recording/reporting of each activity. The total maintenance job requirement of different machines is first chalked out from PM recommendations from the supplier or from experienced personnel. They are categories as time based jobs and condition based jobs. Out of the time based jobs, on daily basis, inspection, lubrication, adjustments etc. jobs (PM 7) are carried out as per schedule in each department on regular basis. For other time based jobs like, periodic over hauls, checking and to take up defect based repair or replacement jobs, shutdowns are planned in advanced. In fact, shutdowns affecting production (PM 1) and not affecting production (PM 4) are separately planned on monthly basis before the start of the month and consent of the operation head is taken. Before the start of the actual shutdown, time based and condition based jobs are planned in a job list (PM 3). Actual execution detail of each job is recorded in job history format (PM 10). A compliance report is made for each department on plan fulfillment on monthly basis (PM 9). While in mill side shutdown planning is a feature for the whole mill (usually weekly), in the iron and steel side, separate shutdowns are taken for different equipment/systems at required frequencies in a staggered manner. Apart from regular inspection and shutdown jobs capital/ major repair is also carried out in all units of the plant based on the condition and life cycle of the equipment. For better spare part and capital item planning, a three year rolling plan ( PM 1a) is made, which is updated every year with a detail plan (PM 1b) for the current year. Capital repair plan is prepared after discussion and approval from Head of works. Just before execution, a PERT/ BAR chart


Panorama 2010 scheduling (PM 1c) is done with detail jobs to be taken up for each such Capital Repair of different units /equipment. Capital Repair is mostly an annual feature for each department. While, in the mill side CR is done usually for the whole mill, in the iron & steel side different equipment / systems are taken up for CR in a staggered manner during the year. Capital repair job compliance is also recorded in job history (PM 10) with details of maintenance jobs. Breakdowns are encountered in emergency basis, particularly when it affects production. Each breakdown is also recorded (W 1b) with its cause and prevention action for future analysis. It is noted that breakdown job execution is also recorded in job history with details. RSP also takes up statutory maintenance jobs under normal and capital shutdowns, particularly for Boilers and pressure vessels. These maintenances are monitored by the Factory inspector from the State Government. COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS) The maintenance system described above is fully computerized at present. The system is popularly known as CMMS. This was introduced way back in 1987-89, under a UNIDO/ Govt of India project. The system has been designed under the guidance of UNIDO experts, by RSP’s internal manpower only. The system consists of the following modules:

1. Equipment Classification: This module takes care of the computerization of the equipment classification as per the style described before. The whole database of equipment of the plant is at present is available in computer.

2. Preventive Maintenance & Repair Planning: This module is the heart of CMMS. It

comprises of the following sub module which are self explanatory. a. Job cataloguing b. Inspection Schedule and feedback c. Defect recording d. Shutdown planning and feedback. e. History monitoring f. Breakdown/delay recording and analysis g. Capital repair planning

3. Captive Engineering Shops Module: This module handles the following activities

which concerns with job planning for the machines in the captive engineering shop. They are-

a. Work order forecasting & planning. b. Process planning of jobs & route card generation. c. Rolling Master plan for different shops. d. Machines database maintenance. e. Shop scheduling. f. Feedback and MIS system.



4. Material Requirement Planning: This module in fact is a part of the bigger computerized system namely, Integrated Material Management System or IMMS. IMMS covers both material planning function of Maintenance wing and Purchase/Store

5. function of Materials management department. Most of the activities in IMMS are at

present, electronically done to reduce paper work and lead time. The activities of maintenance wing of different department that are computerized are –

a. Annual requirement planning and budget preparation b. Budgeting and budgetary control c. Indenting & recommendation on suppliers.

About 50 terminals have been provided in planning cells of different departments to carry out data feeding and data retrieval. The output reports are printed at users’ terminal as and when required. The computer reports are also titled as per Kohrn’s system to avoid confusion to users. CONDITION BASED MAINTENANCE SYSTEM (CBMS) Preventive maintenance jobs that are taken up, are not only limited to time based frequencies but based on condition also. While regular inspection, monitoring of parameters like pressure, temperature, current etc. detects many job requirements, RSP also has adopted modern methods of condition monitoring. This service is provided by the central agency MSS (CBMS) department. The activities include: Vibration monitoring: Data collector and analyzers (FAST TRACK and DATAPAC 1500 from Entek IRD) are used by CBMS to collect data from about 475 rotating machines around the plant on regular basis. The analysis report is sent to departments with recommendation on action to be taken up. For problem of unbalance, which causes vibration in particularly fans and impellers, CBMS also takes up In-situ balancing job. RSP is first to start and is pioneer in vibration analysis and In-situ balancing job in SAIL plants. This expertise can also be shared with other plants with suitable arrangement. Thermography: Condition monitoring of electrical cables, vessel & ladles walls, pipelines is done by thermal imaging method by use of a thermo-vision camera. At present, Power distribution and Energy Management department are adopting this method for condition monitoring of high tension lines and pipelines respectively. Oil Analysis: Samples of lubricating oils are collected by CBMS/LUHP department from critical machines like gear boxes etc. These samples are analyzed for concentration of ferrous particle in oil sample by DR Ferrography method. The analysis reports are made from their finding and communicated to department. The concentration of metallic particles shows the extent of wear in the equipment and that calls for timely action before a breakdown. Motor Monitoring: This activity monitors the condition of rotor bars in electrical motors. RSP initially started this project with RDCIS. At present it is being done on few important motors using the equipment available in CBMS department. Plan for large scale motor monitoring through out the plant is on the anvil.


Panorama 2010

MAINTENANCE JOB CATALOGUE

TIME BASED JOBS

PREVENTIVE MAINT. JOBS

LUBN.,O/H, SERVICEING JOBS

CONDITION BASED JOBS

CORRECTIVE MAINT. JOBS

INSPECTION JOBS

BREAKDOWN RECORDING

Daily W1b

ROOT CAUSE ANALYSIS & INDENTIFY

JOBS TO AVOID REOCCURENCE

CAPITAL REPAIR PLAN

PM1b 1 Yr.

PM1a 3 Yr.

PIE CHART

WEEKLY/ MONTHLY

SHUTDOWN PLAN

JOB EXECUTION & HISTORY RECORDING

HISTORY PM10

INSPN. SCHEDULE

EXECUTION PLAN PM3

PM1 / PM4

DEFECT BASED JOB LISTING

INSPN. & DEFECT

RECORDING PLAN

FULFILMENT

REPORT

PM9

EXECUTION PLAN

PM1c

PM8



MAINTENANCE SYSTEM & SERVICES (MSS) Maintenance Systems & Services Department (MSS) was formed in 2000 by merging following six departments: 1. Lubrication (Organization Planning) - LU(OP) 2. Hydraulics & Pneumatics (Organization Planning) - HP(OP) 3. Computerized Maintenance Management Systems - CMMS 4. Condition Based Maintenance Systems - CBMS 5. Maintenance Planning (Organization Planning) - MP(OP) 6. Investigation & Evaluation - IE(OP) Later on two more departments are added in 2008: 7. Consumption and Expenditure control (CEC) 8. Structural Inspection (SID) Accordingly all the functions of the old departments are being carried out by MSS department. The major areas with activities in each section are discussed below: Lubrication: • Provide assistance to the Materials Management Department in procurement of lubricants

with respect to technical specifications. • Monitor & review the quota of lubricants of various departments w.r.t. past consumption &

Task force recommendations. • Monitor the stock of lubricating & hydraulic oil by keeping liaison with oil godown of

Central Stores, Stock Control & Purchase to avoid stock out situations. • Collect oil samples of various lubrication systems of departments as per sampling schedule.

Samples are sent to R&C lab for testing and reports are communicated to respective departments for remedial action in time.

• Monitoring of wear trend in critical equipment through Ferrography by sending samples to RDCIS, Ranchi periodically.

• Coordinate projects by different external agencies like RDCIS on lubrication systems. Hydraulics & Pneumatics: • Trouble shooting in hydraulic systems of plant units and assisting departments in fixing the

problems in case of breakdowns. • Proper documentation of technical literature and drawings related to hydraulic system

installations. • Allotment of new stock nos. to standard hydraulic components. • Working on special problems of hydraulics & pneumatics including development &

modification. Bearings: • Providing technical guidance for substitution of bearings to different plant unit as per

requirement.


Panorama 2010 • Technical scrutiny of offers of FOB bearings indented by Stock Control. • Exercise check for the emergency procurement of bearings. • Follow-up with different plant units to include all the bearings in the on-line bearing

survey. Maintenance Planning & Performance MIS reports: • Preparation of Annual Capital Repairs Plan & its fulfillment report. • Preparation of Investigation of Breakdowns & Recommendations Report. • Preparation of Monthly Department-wise Equipment Availability and utilization Reports. • Preparation of monthly Maintenance parameter performance report. • Determination of Maintenance cost of major production units and its reporting Central Compressor Station: The compressed air requirement of various units of RSP is met either through individual compressor station or through Centralised Compressed Air Grid. The individual compressor stations of department are located in the respective departments & dedicated to meet their particular requirement which is operated and maintained by the department itself. The Centalised Air Grid which is operated by MSS department gets air from the two compressor stations located one at I&S zone (11 compressors of CPT & KG Khosla make) and other at RM Zone (3 compressors of BHEL & Russian make). Operation & maintenance of the compressors & its auxiliaries are the main activities of the unit for supply of compressed air with an optimum pressure and flow. The average generation/consumption of compressed air is approx. 45,000 m3/hr which is being fed to the grid round the clock. The hourly loss of RSP on account of compressed air failure is approx. rupees seventy five lakhs. In addition to above main activity other activities are as follows: (a) Maintenance & operation of Circulating Cooling Water system i.e. Pump, Cooling Tower,

Sumps, etc. for the healthy operation of Compressors. (b) Maintenance & inspection of about 18 KM of grid pipe lines with sizes varying between NB

200 to NB 600 through out the Plant starting from SSM to SMS-II. (c) The inspection of compressed air pipe lines i.e. main grid as well as user points in different

shops to arrest / control the leakages & misuse of compressed air. The generation cost of one M3 of compressed air is approx. Rs. 0.40.

Presently, 5 numbers of CPT make compressors are being replaced by 2 Nos. of Centrifugal Compressors of 15,000 m3/hr capacity (Atlas Copco make) under AMR scheme. It is being installed at Modernisation zone. The compressors are expected to be operational by Dec’09. The Customers of Central Compressor Station are SMS-II, CO, BF, CCD, MS-I, CPP-I, LDBP, Shops, TOP-I, RS(E), SPP, PM, HSM, CRM and SSM. Oil Re-refining Plant: The re-refining plant (ORRP) under MSS department was commissioned in Jan 1982. This oil re-refining technology was supplied by M/s Indian Institute of Petroleum in consultation with R&C Laboratory, RSP.



Oil is re-refined on the principle that the lubricating oil never wears out. Its life is indefinitely long and can be reused after necessary treatment. The old used oil contains mostly oxidation product of oil, sediment and water etc. Following steps are involved in Oil Re-refining plant for refining of used oils. (a) Used oil collection & storage (b) Dehydration to remove moisture (c) Alkaline clay mixing (d) Clay treatment to neutralize the acid content (e) Cooling to avoid oxidation of processed oil (f) Filtration to remove traces of sediment (g) Storage of base oil in storage tanks according to viscosity gradation. (h) Blending of oil by transporting (i) Testing of blended oil (j) Barreling : Blended hydraulic oil T-3, T-4 & T-5 is issued to various departments like CRM,

HSM, SSM, Pipe Plants, CO, LDBP, OBBP, FMM, SP-I, SP-II, RSM & Blast Furnaces etc. (k) Production Capacity:

- Collection of used lubricating & hydraulic oil is about 1200 barrels per annum. - Production of blended hydraulic oil is about 1020 barrels per annum.

Condition Based Maintenance System (CBMS): Rourkela Steel Plant has a healthy maintenance practice right from its inception in 1959. Condition Based Monitoring through vibration Analysis has been developed and is in use at RSP, since April 1993, as a key technique for implementation of Predictive Maintenance Program. The coverage has grown many folds from 45 to 475 nos. of critical equipment in the last 12 years. In addition, for the first time in SAIL plants, single/double plane in-situ balancing have increased from a mere 9 to 121 (PM) cases, resulting in substantial financial savings. Objective of CBMS:

- To carry out predictive maintenance programme (PMP) at global level of steel plant. - To take up in-situ balancing of rotating machines. - To undertake technical surveillance of high speed machines with respect to vibration

monitoring as a second line of defense. - To enhance equipment availability & reliability of critical production units through the

above activities. - To cut down costs by prolonging the life of the equipment.

CBMS Techniques adopted:

- Vibration monitoring / analysis & diagnostic studies - Oil contaminants analysis through Direct Reading (DR) Ferrography Technique - HT induction motor monitoring (RDCIS Project) - Thermo-graphic technique using thermo vision camera for hot spots in switch yards, HT

cable galleries and thyristor control panel.


Panorama 2010 Services Rendered:

- Regular monitoring of health status of 475 critical machines throughout the steel plant by vibration measurement-fault diagnosis recommendation for remedial measures.

- Presently CBMS is using E-monitor Odyssey window based software for Fast Fourier Transforms (FFT) analysis for all types of rotating machines.

- To attend emergency calls when the equipment condition is deteriorating fast. - To do in-situ balancing of rotating equipment in critical production units like SMS-I,

SMS-II, SP-II, CPP-I, HSM, PM, SSM etc. as and when required. - Improvement in availability and reliability of all types of rotating machines. - At present the reliability of rotating machines is about 96%

Output Control:

- Quantity: Daily PM reports, in-situation dynamic balancing reports, financial savings accrued through CBMS activities, MIS monthly reports & Technical surveillance and equipment health status reports (potential failure) etc.

- Quality: The fault diagnosis is nearly 99% correct and meets customer requirement and satisfaction.

- External Services: Mines, NSPCL etc. - Communication: Oral/ Telephonic communication, immediately after taking vibration

measurement and written communication within 24 hours. Computerised Maintenance Management Systems (CMMS): Computerised Maintenance Management System (CMMS) is a tool for carrying out maintenance activities of industrial equipment with the aid of computers. UNIDO/UNDP envisaged the development and introduction of a modern integrated CMMS first in Rourkela Steel Plant, as it had a well established manual maintenance system. Investment on the project was US $1.06 million and duration of development was from Mar'86 to Dec'89. RSP has extended this technical know-how by giving support in designing, development and implementation of CMMS activities to Sister Steel Plants (Bhilai, Bokaro, Durgapur, Alloy Steel Plants, IISCO) in phase II of the project. Other industries and organisations (NALCO, BALCO, ORIND, etc.) were also assisted. Need for CMMS: • Timely maintenance is essential to ensure equipment availability • In any industry, keeping a track of the large number of equipment, their spare parts and

the huge amount of maintenance jobs is humanly difficult, time consuming and cumbersome.

• Close co-ordination is essential amongst host of related maintenance activities. • Carrying out routine jobs is time consuming. • Information needs to be made readily available for facilitating decision support. Keeping the above in view CMMS was developed, which serves as a library for easy and quick retrieval of data, information, reference and analysis of equipment maintenance related activities.



Hardware & Software: In 1996 the CMMS application was re-developed (earlier it was in DSDL/LINC in Burrough’s A3K machine) in SUN computer system at C&IT department using ORACLE 7.0. Users in the Production & Services units have access to the SUN from their work place through terminals, connected through a network (using telephone cables or fiber optics). There are 45 CMMS user departments/ sections. Modules of CMMS: • Equipment Classification: Equipment coded for location wise identification up to part level. • Preventive Maintenance: • Job Definition: Creates & maintains Job catalogue of equipment. • Inspection (PM 7): Schedules and Records Inspection activities. • Defect (PM 8): Records defect details and plans liquidation. • Shutdown Planning: Plans shutdowns, plans jobs, Records feedback of jobs done (both

planned & unplanned) • Breakdown & Delay (W1b): Records breakdown details for analysis. • History (PM 10): Maintains history of jobs done and defects liquidated. • Capital Repair (C/R): Prepares C/R plan and fulfillment details. • Crane Status: Special MIS for over head cranes status • Engg. Shops planning and scheduling ; Process Planning, Forecasting, Master planning,

Rout card preparation, Shop scheduling, Feedback, Status monitoring • Material Requirement Planning: Prepares indents, budgets, tracks requirement. Benefits: • Better equipment availability due to reduction in breakdown and sustained health of

equipment. • Cost effective maintenance. • Reduction in lead time in procurement. • Maintaining history of equipment and procurement and retention of expert knowledge. • Scientific planning of jobs, decision support and reduction in routine job efforts. Consumption and Expenditure Control: This section has the following functions:

a. Projection of ‘Stores & Spares’ (Spares, Consumables, Rolls, Refractory and Internal consumption) and ‘Repair & Maintenance’ ( Repair contract and Job contract) revenue budget requirement for coming financial year based on discussion with each department, APP targets and market situation.

b. Distribution of approved budgets in above categories to each department/sections based on need and budget availability by feeding the same in IMMS.

c. Management of budget re-appropriation between departments/ sections/ months based on approval.

d. Management of allotment of ED(W) reserve fund in above budget heads to departments in case to case basis based on urgency.

e. Monitoring of consumption and procurement budget utilization and inventory.


Panorama 2010

f. Nodal agency and convener of Indent screening committee for scrutiny of spares indents. Member of screening committee for contracts.

Structural Inspection Structural Inspection Department undertakes visual inspection of Industrial building structures (both steel and RCC) from ground to roof level of all plant units of RSP regularly to have well maintained buildings/shops. The main functions are:

Regular inspection of all industrial structures, chimneys and stacks, structures in mines area, Mandira Dam and structures of NSPCL to assess quantum of defects arising due to any accident, environmental condition etc.

Preparation of technical reports citing defect list, remedial measures/suggestions in a book-let from and taking approval of competent authority for liquidation of damages/defects.

Distribution of approved reports to owners of the shops/department for liquidation of defects.

Stage-wise monitoring/rendering help during execution to liquidate defects, final inspection after rectification/liquidation.

A joint certificate with owner department is issued stating the satisfactory liquidation of the defects.



SHOPS- PLANNING & COORDINATION (SERVICES)

Shop-Planning & Coordination (Services) is a unit of Engineering Shops & is a staff function created in the year 1970 as a result of the re-organization of Engineering Services wherein the new concept of having an independent planning department was introduced. Objectives: • Identification & approval by the competent authority of High value make jobs, Automake

jobs & Castings (Ferrous & Non Ferrous) in consultation with internal Customers & Shops in the beginning of each financial year to be executed in Engineering Shops. This exercise is being done to maximize the utilization of Engineering Shops capacity in line with Purchase policy of SAIL.

• Finalization of Capital Repair jobs of different units of plant to be executed in consultation with Internal Customers & Engineering Shops.

• To receive requirements in the form of Indents / O5 for manufacturing/ repair of spare parts, reconditioning of assemblies / Sub-assemblies, Gear Boxes, Hydraulic equipments & Castings (Direct delivery or with machining) of different plant units; scrutinize the possibilities of timely execution and distribute the work on the basis of work load and capacity of different shops. Coordinate with different shops for execution of the jobs.

• Planning the details of the above mentioned types of jobs of different Plant units in shop complex including Foundries.

• To achieve the pre-requisite for an economical and timely repair of manufactured parts and spares.

• Co-ordinate the processing of Items for reconditioning through Reconditioning Route to be executed by outsourcing.

• Processing of Indents [Buy through PC (S)] for procurement through local SSI units. • Inspection of jobs executed in Engineering Shops, local SSI units against PC (S) orders

against Indents [Buy through PC (S)] & jobs at different plant units as per the requirements of different Internal Customers.

• Preparation of different MIS Reports for review at different levels. Different Sections of the Department: • Production Control • Process Planning • Inspection • Off-loading Cell Production Control: • Receive work order (05 form) from different plant units • Scrutiny of the work order (05) and Record • Prepare bi-monthly plan for different units of Engineering Shops • Prepare monthly plan for Foundry. • Raise work order for MAKE indents and plan for execution


Panorama 2010 • Finalization of Capital Repair jobs in consultation with different Customers & Engg. Shops • Follow-up of Capital Repair jobs for timely completion • Receive orders from sister plants & outside parties and plan for execution • Printing of Route card & Cost ticket for planned jobs • Creation of EDC (Engineering data control) in CMMS Database for future reference. • Preparation of various MIS reports for review & follow-up • Follow-up AUTOMAKE jobs in different Engineering Shops for its completion Process Planning: • Detail study of drawings in line with scope of work specified in Work Order (05). • Allocation of the above Work Order to Planner. • Process planning of jobs indicating details like place of execution, raw materials required,

weight of the job, sequence of operations indicating work center, sequence and process along with catalogue number, drawing number etc.

• Estimation of time as per approved Norms for each operation • Preparation of Cost Tickets as per the estimated time. Inspection: • Inspection of job on completion of different stages of operation • Inspection of job on completion in shop complex / local SSI units • Inspection of job at shop floor of different plant units as per requirement • Preparation of quality report acceptance of inspected jobs in shops. Off-loading Cell: • Placement of orders on local SSI units against indented quantities cleared for "BUY

through PCS" • Co-ordination with Engineering Shops & Indenting Customers for issue of raw material to

local SSI units against the PC (S) orders • Follow-up with local SSI units for delivery of jobs as per schedule • Processing of Bills for payment.



SHOPS-FOUNDRIES The primary activity of this department is to make castings of spares used in various units of the plant. Some of the products manufactured at foundry are as follows: a) Ferrous castings like door frame, flash plate, wharf plate, sinter breakers, grate bars,

hammer heads etc. b) Slag pots required by BF & SMS-II. c) Steel, cast iron and non-ferrous castings of other spares needed by the plant. d) Salvaging of copper coils from rejected electrical cables & fittings and converting them in to

ingots. e) Conversion of Al ingots into nuggets for SMS. f) Making of ternary alloys of zinc, aluminum and lead for use in galvanizing line of CRM. Foundry is equipped with the following facilities: (i) Material handling. (ii) Sand moulds & core preparation and drying facilities. (iii) Melting Units and Pouring accessories. (iv) Fettling and cleaning of castings. (v) Inspection. (vi) Heat treatment. (vii) Pattern Shop, drilling, planing, milling, grinding machines, circular and band saw etc. A brief description of the various units under Foundries: 1. Engineering Casting section: Moulds are prepared for cast iron castings like door frame, flash plate, wharf plate for Coke Ovens and steel castings for various units of the plant. For preparing moulds the EC section has continuous sand drying and mixing plant used for preparation of resin sand (Capacity: 5Ton/hr.). 2. Steel Foundry: The Steel Foundry has one Electric Arc Furnace of 5 Ton capacity for making steel and cast iron heats; one sand plant consisting of sand mixers and allied accessories for sand preparation; two numbers of drying ovens for drying the green sand moulds; fettling equipments like swing grinder and gas cutting facilities and one number of annealing furnace for heat treatment of castings. 3. Non-Ferrous Foundry: The Non-Ferrous Foundry is having the following equipment:

(a) Three nos. of bale-out pit furnaces each of a capacity of holding 300 kgs of brass / bronze melts and one hydraulically operated tilting furnace with a holding capacity of 500 kgs brass / bronze.

(b) One hand operated crane with SWL of 3 MT capacity. (c) One EOT crane with a SWL of 25 MT.


Panorama 2010 Non-Ferrous Foundry produces

Non-Ferrous castings of spares Aluminum and copper bars / ingots Aluminum nuggets Zn Al Pb ternary alloys

4. Heavy Steel Casting section: For manufacturing of heavy spares (i.e. spares in excess of 5 MT in weight), sand moulds are prepared at the Heavy Steel Casting section close to the SMS-I pit side. The molten metal for the purpose of casting is obtained from the Steel Melting Shop. Presently two numbers of steel slag pots for our sister steel plants are cast every month, on an average. Besides, heavy spares like PMD tyre for Sinter Plant, LD trunion rings, Intermediate pieces, Dump Boxes and Trays for SMS and Breast Roll Carrier for Plate Mill are some of the notable castings that have been made in this section. It may be noted that all heavy steel castings are manufactured as per the definite requirements of other units of the plant from time to time. 5. Pattern Shops: A well-equipped pattern shop with circular saw, band saw, surface planer, thickness planer and drilling machine for preparing pattern required for making different moulds exists at Foundry.



SHOPS- MECHANICAL SHOP Mechanical Shop is a manufacturing Shop engaged in manufacturing/ reconditioning of spares for units of plant on regular basis. Mechanical Shop is the most modern Shop of RSP. This Shop is equipped with CNC Machine Tools & Higher capacity Horizontal Borer Machine SKODA, CNC Vertical Boring Machine HOMMA, Fully automated CNC Plano Miller Machine and CNC Lathe Machine. Mechanical Shop is a machine shop consisting of more than 60 numbers of small & big machine tools. The entire complex is divided into three bays. “AB” Bay consists of Heavy Machine tools, “BC” Bay consists of Light Machine tools & the material yard Bay consisting forge rounds and Saw Cutting & Centring Machine. With the recent inclusion of Band saw machine in the material yard, Mechanical Shop is now equipped to cut forge round up to 650mm. Depending on the type of operations, different machines as listed below are used to carry out manufacture/ repair/ reconditioning of spares/ equipment in Mechanical Shop:

1. Lathe 14 Nos. (Max Size 1000 mm x12 m) One Fully Automated One meter CNC Lathe & one 5 Meter Long CNC Lathe M/c

2. Horizontal Boring Machine 4 Nos. (2 SKODA Machine 200 spindle) 3. Vertical Boring Machine 2 Nos.

One HOMMA Double Column Vertical Boring Machine Table Dia 6.5 meter

4. Milling Machine 6 Nos. (CNC Milling -2) 5. Slotting Machine 2 Nos. 6. Shaper 3 Nos. 7. Drilling Machine 3 Nos. 8. Planning Machine 2 Nos.

One Fully automated with sub unit changer & Automatic tool Changer CNC Plano Milling Machine

9. Gear Hobbing 1 No. 10. Bevel Gear Generator 1 No. 11. Grinding Machine 2 Nos. 12. Saw Cutting Machine 2 Nos.

Semi Automated Maximum up to 650 dia cutting Band Saw Machine

13. Centring Machine 1 No. 14. Hydraulic Press 1 No. 15. Cranes (50/15,15/5 &15/5 T) 3 Nos


Panorama 2010

SHOPS - REPAIR SHOP (MECHANICAL)

Repair Shop (Mechanical) [RS(M)] is one of the three captive mechanical repair shops of Rourkela Steel Plant engaged in manufacturing and repair of spares/equipment of different units of the plant. This shop is equipped with conventional and modern machines for metal cutting, heat treatment, testing of chains and slings and dynamic balancing. Besides these, RS (M) also has a general Fitting & Assembly section, a Gearbox section, a Hydraulic section, a Forging section and a Calibration Cell. Following are some of the important machine tools and heat treatment facility available at RS (M): A) Machine Tools: i) Lathes: Maxm. Job size 1350 mm dia. X 10 mtrs. ii) Horizontal Boring Machine :

Maxm. spindle dia. = 175 mm Maxm. Boring depth = 1500 mm Maxm. Boring dia. = 1400 mm

iii) Slotting Machine: Maxm. stroke of Ram = 500 mm Maximum swivel = 12 degrees.

iv) Hobbing Machine : Maximum dia. of gears cut with mandrel = 1900 mm, without mandrel = 3200 mm Maxm. Wt. of job = 40 Tons, Maximum Mod. of gear generation = 26 (Steel), Maximum Mod. of gear generation = 30 (Cast Iron)

v) Vertical Boring: Maxm. Wt.of job = 12 Tons, Maxm. Turning Dia.= 4000 mm. vi) Dynamic Balancing Machine: Maxm. dia.of job (bearing dia.)= 400 mm

Maxm. Length of job = 5030 mm, Maxm. dia of job over bed = 2500 mm

B) Heat Treatment: i) Hardening Furnace: Size 1500 X 650 X 400 mm, Maximum working Temperature =

10000C, Maximum weight of the job = 500 kg. ii) Tempering Furnace: Size 1500 X 650 X 550 mm, Maximum working Temperature =

6500C, Maximum weight of the job = 500kg. iii) Spin Hardening Machine : Minimum dia. for Heat Treatment = 160 mm, Maximum dia.

for Heat Treatment = 450 mm, Maximum width of job for Heat Treatment = 250 mm, Maximum weight of job for heat treatment = 800 Kg, Flat Burners size = 75, 100, 125, 150, 200 & 250

iv) Double Decker Furnace: Pre-heating chamber size 500 X 500 X 450, Maximum temperature = 9000C. Heating chamber size 500 X 400 X 350, Maximum temperature =13000C. C) Chain Testing Facility: i) Maximum Length of Chain/Rope that can be tested: 27 mm ii) Maximum Load for Testing: 120 Tons



D) Dynamic Balancing Machine: i) Maximum Diameter of the Rotor/Fan that can be dynamically balanced: 2500 mm ii) Maximum/Minimum Weight of the Rotor that can be dynamically balanced:

13 T/0.1 T iii) Maximum/Minimum Length of the Rotor/Fan: 5030 mm/250 mm iv) Maximum/Minimum Diameter of the Journal dia that can be accommodated on the

Pedestal: 400 mm/50 mm E) High Capacity Dynamic Balancing Machine: i) Maximum Diameter of the Rotor/Fan that can be dynamically balanced: 4000 mm iii) Maximum Weight of the Rotor that can be dynamically balanced: 56 T. iv) Maximum Length of the machine bed is 12 meters. v) Maximum/Minimum Diameter of the Journal dia that can be accommodated on the

Pedestal: 125 mm/500 mm F) Fitting & Assembly Section: i) Horizontal Press machines of capacity 300 Tons & 200 Tons. ii) Vertical press machine of capacity 200 tons.

Reconditioning/ repair of various mechanical equipments of different plant units including those of Raw Materials Division are carried out here.

G) Forging Section: i) Heavy forging shop: Pneumatic Power Hammers of capacity 1000 kgs and 500 kgs with

mixed gas fired furnace. ii) Light forging shop : Pneumatic Power Hammers of capacity 200

kgs and 150 kgs with coke fired furnace.

H) Hydraulic section: This section is equipped with a hydraulic test rig of REXROTH make. Varieties of cylinders and pumps are overhauled & tested in this section. I) Gear box section: This section is equipped with a vertical press machine and three nos of induction heaters to facilitate assembly of bearings with gearbox internals.


Panorama 2010

SHOPS (STRUCTURAL & FABRICATION ) Structural & Fabrication Shop is another captive shop in the Engineering Shop Complex engaged in repair and fabrication of various plant equipment of Roukema Steel Plant. This shop comprises of the following sections:

i) Welding Shop ii) Rolling Stock iii) Structural Shop

i) Welding Shop: This is basically a reconditioning unit where worn out steel plant equipment/ spares are built up by welding through conventional and modern welding machines like Metal Inert Gas (MIG)/ Metal Active Gas (MAG) & Submerged Arc Welding(SAW). A selected typical application jobs are also manufactured here. The details of these machines are as follows: 1) a) MIG/MAG Welding Machine:

Supply Voltage 415 V, 3 phase, 50 Hz. Welding Wire Size used 1.2 to 1.6 mm Gas used Carbon Dioxide for MAG, Argon for MIG Wire Speed 1.5 to 15 m/minute

b) MIG/MAG Column & Boom Welding Machine:

Supply Voltage 415 v +/- 10 % V, 3 phase, 50 Hz. Welding Wire Size used 1.2 mm to 1.8 mm Gas used Carbon Dioxide for MAG, Argon for MIG Capacity 4.5 to 5 T Drive 4-Rolled Job to be done Dia 150 to 1000 mm

c) MIG/MAG Portable Auto Bore welding Machine

Supply Voltage 230 v,1 phase, 50 Hz. Welding Wire Size used 1.2 mm Gas used Carbon Dioxide for MAG, Argon for MIG Drive 4-Rolled Bore welding size 25 mm to 300 mm



2) a) SAW Machine:

Supply Voltage 415 V, 3 phase, 50 Hz. Machine Type Constant Potential Type Transformer/ Rectifier Maximum Welding Current 1200 Amps DC @ 60 % Duty Cycle. 1000 Amps

DC @ 100% Duty Cycle Wire feed 0.1 to 4.5 m/min. Wire Size 2 to 5 mm

b) Twin Head SAW Machine:

Supply Voltage 415 V +/-10 %, 3 phase, 50 Hz. Machine Type Constant Potential Type Transformer/ Rectifier Wire feed 0.1 to 4.5 m/min. Wire Size 2.5 to 5 mm, 3 wired system capacity 10 T each unit of 5 T each

3. Air plasma cutting machine:

Supply Voltage 400 V +/-10 %, 3 phase, 50 Hz Power rating 10 KVA to 30 KVA Cutting material Stainless steel Plate cutting capacity 25 mm & more Straight cutting length 7 to 10 mm Out put pressure 6 to 9 Bar

Other Machines available for processing jobs are as follows: 4. Shearing Machine (Flywheel Type): Shearing capacity : 6 mm (max.), Shearing width - 2 meters. 5. 3-Roll Bending Machine: Bending Capacity :12 mm max. (50% width) Bending Width :4 meters. Manufacturing Jobs like Hot Sinter Screen, Zn Pot, Skid Pipes for reheating furnace & recuperators for HSM, Wobblers, Adaptors for Mills, BLT-chute-fabrication, Hood Annealing, Inner Cover Fabrication etc. are done in Welding Shop. 90% of plant’s repair welding jobs are also done. ii) Rolling Stocks: This section repairs and overhauls all types of cars like 140 T Hot Metal (HM) Car, 80 T HM Car, Slag Cars of Blast Furnaces and SMS-I and Acid Cars of CRM for transportation of hot metal, steel & slag inside the plant. New frames are also fabricated and assembled as and when


Panorama 2010 required as per the need of plant. Major and massive repair of completely damaged Slag Cars and 140 T HM Cars have been undertaken more than 5 times within one year. iii) Structural Shop: Repair and fabrication of all types of fabricated items of the plant like Hot Metal Ladles, Crane Girders, LD Converters, Zinc Pots, Hot Air Socket, INBA Dewatering drum etc. are taken up in this shop. Most of the monuments seen today inside the Plant and Steel Township are all fabricated in this shop for beautification of Steel Township. Following Machines are available for facilitating fabrication: 1) a) CNC Profile Cutting Machine:

Supply Voltage 450 V +/-10 %, 3 phase, 50 Hz +/- 5 % Effective cutting length, width & thickness 8 m/min Effective cutting width 2.5 m/min Effective cutting thickness 6 mm to 200 mm

b) Profile Cutting Machine: (Max. cutting thickness = 100 mm) 2) Hydraulic Press: (Capacity: 600 Tons) 3) a) Plate Bending Machine: (Capacity: Max. MS plate width 2500 mm) b) Heavy duty Hydraulic Plate Bending Machine: (Capacity: MS plate width 3100 mm & 80 mm thick) 4. Radial Drilling Machine: (Capacity: Max. drilling 50 mm)



REPAIR & CONSTRUCTION (MECHANICAL) Repair & Construction (Mechanical) [RC(M)] was established in the sixties in RSP, known by the name Heavy Maintenance and Construction and was later on christened Repairs & Construction (Mechanical) – RC (M). It takes part in the weekly shutdown programmes, capital repairs and breakdown restoration besides fabrication and erection of equipment or facilities depending on resources available throughout the plant. The services are rendered through a number of zones set up at different locations of the plant and each zone has developed expertise in the respective zonal jobs. All the zones have the flexibility to take up any job of other zones in the plant. The zones are:

Sl. No. Zone Responsibilities / Areas covered

1. BF BF , CO & CCD

2. SMS-I SMS-I, SMS-II, LDBP, TOP-I

3. SP-I SP-I, SP-II, OBBP, CP-II

4. Rolling Mills PM, HSM, Pipes Plants, SSM

5. CRM CRM Units like PL-I, PL-II, ETL etc.

6. Vulcanising 121.6 km belt conveyor, jointing (hot /cold), lagging and replacement.

7. Workshop Lifting tools & tackles repair like Chain Pulley Block, Hub-zug, Ratchet Lever Hoist etc.

8. Pump Section Repair and maintenance of Dewatering Pumps.

9. CRNO CRNO

10. OBBP OBBP Conveyor belt, Counter Weight lifting

11. Weigh Bridge and Pressure Vessels

Weigh Bridge ( 51 nos.) maintenance, Pressure Vessel (458 nos.) testing, certification and liaisoning with State Govt.

12. Stores & Planning Up-keep of materials & services for RC (M).

13. Special Zone Fabrication, Special Projects

14. Hydraulic Section Repair of Hydraulic Jacks and Pumps, Hydraulic Power Packs & Eldros.

RC(M) maintains flexibility among all the zones to increase productivity of workforce.


Panorama 2010

CRANE MAINTENANCE

EOT Cranes are the most vital material handling equipment in Steel Plant. Smooth and continuous operation of all the units depends to a large extent on safe and efficient operation of these equipments. From raw materials to finished products the materials are required to be handled minimum 16-17 times at every stage, be it hot metal, slabs, coils, plates or pipes the handling has to be safe and prompt. This handling is being done by EOT Cranes. The mechanical and structural maintenance of these equipments is being done by Crane Maintenance department. Total 212 EOT Cranes in different production units of the plant are being maintained by the department. The main functions of the department are: • Regular inspection of Cranes and making inspection reports based on which all repair

activities are planned and carried out. • Prompt attending of breakdowns on Cranes so that there is no production loss. • Coordinating Major and Capital repairs of Cranes through Crane Capital Repair Group or

outside agencies. • Procurement of spare parts required for Cranes. • Revamping of Cranes. This includes lowering of complete crane, repair, modifications and

re-erection. • Relocation of surplus Cranes after required modification in the drives. • Thorough inspection of Cranes by competent persons as required vide Factory Acts and

ensuring compliance to all statutory requirements of EOT Cranes. The department is broadly divided into 3 sections viz 1) Iron & Steel Zone 2) Rolling Mill Zone & 3) Modernization Zone. In Iron & Steel zone , the cranes of Blast Furnaces including PCM, SMS-I, Sintering Plant-I,CPP-I, Foundries, LDBP, Coke Ovens, CCD & SSD are being maintained. Similarly, Rolling Mill Zone maintains the cranes of Plate Mill, HSM, CRM, SSM, SPP, Pipe Plants, ESM & RS (E). In Modernization Zone, the cranes of SMS-II (i.e. BOF & CCM-II) & LRS-II are being maintained by the deptt. The main activities of the zones are: 1) Regular inspection, Preventive maintenance & House keeping of cranes based on shutdown

schedule. 2) Attending to breakdowns. 3) Arrange spares / assemblies through Crane Workshop or Shops and maintain records of the

assemblies, subassemblies & parts. 4) Load testing of Cranes as per schedule / after replacement of any major component or after

capital repair.



Maintaining statutory records as per requirement of Inspector of Factories & Boilers, Govt. of Orissa. Apart from the above 3 zones, the deptt is having 3 more groups:

1. Crane Capital Repair Group 2. Central Planning Section & 3. Crane Workshop.

The main functions of Crane Capital Repair Group are: 1) Co-ordination of Major repair, revamping & relocation of cranes throughout the plant. 2) Maintenance of Lifts through AMC, Minor & Major Repairs. Central Planning: The activities include: 1) Procurement of Spares & Assemblies, Consumables based on requirement from all zones. 2) Processing & finalization of Repair Job Contracts. 3) Monitoring of Data & Records. Crane Workshop: In Crane Workshop following activities are done: 1) Machining / Manufacturing of spares for cranes. 2) Dismantling, overhauling & assembling of crane parts.


Panorama 2010

FIELD MACHINERY (MAINTENANCE)

All Mobile Heavy equipments like Dozers, Payloaders, Hydraulic Cranes, Crawler Cranes, Forklifts, Debricking machines, side loaders, Excavators including Trucks, Mini trucks, and tractors in Rourkela Steel Plant are maintained by Field Machinery (Maintenance) Department. All These mobile equipments are utilized by various production / service deptts for their production, operation, maintenance, housekeeping & erection /repair activities. Area of utilization of equipments is wide spread in the whole Plant area. Due to this, FM (M) has different zones (Eight Nos.) to cater to these areas. Maintenance Activities Zonewise:

1. Modernisation Zone looks after Equipments of SMS-II, SP-II, CP-II, OBBP & Refractories.

2. RMD Zone Looks after T&RM (All Dozers). 3. SMS-I Zone looks after equipments of CO, BF, SMS-I, LDBP, Shops and Refractories. 4. SSD Zone looks after Equipments of Stores, Pipe Plants and All Crawler Cranes. 5. CRM Zone looks after all Forklifts of CRM, HSM and SSM. 6. Pool Zone looks after all Heavy Dumpers including Haulpak (35T) Dumpers, Tippers,

All Tyre mounted Hydraulic Cranes & Compressors. 7. Truck Pool looks after all TATA Trucks and Mini Trucks. 8. Base Workshops looks after all Tractors, Excavators, Tyre Dozers and Capital Repair.

Operational Activities:

1. SMS-I Zone: Operation of Payloaders and Dozers at SMS-I and Slag loading, attending breakdowns at CO, BF, SMS-I related to Dozers and Payloaders.

2. Control Room: Operation of Hydraulic Cranes including Grove 20 T and 55 T, Crawler Cranes, Haulpak Dumpers, Tippers, Tractors and Trailers, Diesel Distribution.

3. Truck Pool Operation: Operation of Trucks for operation, housekeeping, collections funeral trucks.

Service Contracts: Leyland Tippers, Swaraj Mazda Mini-Trucks, JCB Payloaders, TPS make Vacuum Loaders, Sewage cleaning machines, Road Sweeping Machines, Garbage Compactors are cover under Service Contracts. Some of the Activities of FM (M)

1. Removing of wastages from SMS-I , PCM and CCM-I 2. Removable & shifting of sludge from SMS-I, WWTP, BF Filter House and sludge ponds

of SMS-II to OBBP bed for its gainful utilization. 3. Removable of wastages and arising from Blast Furnaces 4. Removable and loading of slags from INBA 5. Deployment of Mobile cranes for erection/ shutdown purposes. 6. Deployment of Haulpak Dumpers for Housekeeping 7. Shifting of Structural , heavy jobs, transformers etc by Trailers



8. Shifting of pug from pug mill to all Blast Furnaces. 9. Maintenance of all Mobile heavy equipments of the Plant. 10. Procurement/ Reconditioning of heavy equipments. 11. Tyre puncher repairs of heavy tyre mounted vehicles. 12. Capital repair of mobile earth moving equipments 13. Dispensing of diesel to all crawler equipments at site. 14. Housekeeping of different production areas. 15. One time cleaning jobs as per requirement. 16. Monument installation 17. Township requirement of mobile equipments and maintenance of heavy mobile

equipments. 18. Organising Training for operators and technicians of heavy Mobile equipments. 19. Shifting of tundish in SMS-I & SSD scrap Yard. 20. Transportation of dead body for funeral purpose. 21. Maintenance of de-bricking machines and dumping cranes. 22. AMR schemes related to Heavy mobile equipments.

Mobile equipments in FM(M) Fleet:

SN TYPE OF VEHICLE MAKE FLEET SIZE 1 Haulpak Dumpers BEML 10 2 Tippers Ashok Leyland 24 3 Payloaders Tyre

HM2021,430z,456zx,4D HM, JCB , TATA, Marshall 26

4 Payloaders (Chain) CAT,Komatsu 4 Excavators L&T L&T,JCB, TATA-H 10 5 Dozers (Tyre) CATerpillar 1 6 Dozers (Chain) BEML(BD 65,85,155), CAT

(8DR) 8

7 Debricking M/c 300/400L/Promex/Weiger

TML Germany/Promex 6

8 Hyd. Crane 8/12 T Escorts 24 9 Crawler Crane TATA 320/655/955 8 10 Hyd. Crane 20T/55 T TIL Grove 2 11 Forklifts 1.5/3 T Godrej, Voltas 36 12 Forklifts 16/20 T Godrej 4 13 Side Loaders Fantuzzi, Baumann 4 14 Compressors ELGI 3 15 Road Rollers L&T Case, Jessop 5 16 Sewage Cleaning TPS 2 17 Vacuum Loaders TPS 3 18 Road Sweeping TPS 1 19 Garbage Compactor TPS 3 20 Lime Tankers TPS 4


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SN TYPE OF VEHICLE MAKE FLEET SIZE 21 Truck Mounted Crane TIL 2 22 Trucks TATA 55 23 Mini trucks TATA, Swaraj Majda,

Mahindra 35

24 Trailer Ashok Leyland 1 25 Tractors Mahindra 5 26 Diesel Dispensing TATA-Elgi 1

FM (M) is having 10 executives along with strong dedicated workforce of 280 technicians and Operators to cater to maintenance and operation activities of all mobile heavy equipments including capital repairs. Deployment of Hydraulic Cranes for capital / breakdown repair as per requirement, Unloading of hard coke from railways wagons, loading in internal wagons, housekeeping in SMS-I pit side, WWTP, Tandish Removal in CCM-I, maintenance of debricking machines during debricking of converters which are one of the most critical activities in Steel making Process. FM(M) is an ISO certified department.



TRANSPORT

Transport department was formed to provide Transport services, as required for men and materials. This department is a unit of Centralised Maintenance (Mechanical) department. This is an essential service department which operates round the clock throughout the year. The total transport service at present is reached to customers through two of its control rooms. The major units of the department are as follows;

A) Central Pool B) IGH Pool at IGH campus C) Repair & maintenance centre at Central Pool D) Registration Cell E) Record keeping cell F) Store & Fuel Dispensing Unit.

A) At present Transport department provides service with a fleet of 240 Nos. Light Motor

Vehicles. The department takes up repairs through departmental resources excepting for reconditioning of vehicles as a whole. It issues fuel to all 650 Nos. of Vehicles & Earth Moving Equipment of RSP, NSPCL, Raw Materials Division & Quality Assurance Estate (Metal).

B) Central Pool: - Central Pool located inside the plant premises to provide light motor

vehicles and buses to different user departments. It provides Transport facility to senior officials of RSP by deploying chauffeur driven cars. 1. Vehicles to the Plant control. 2. Vehicles to Flood Control during monsoon. 3. Providing vehicles to valued customers of Transport Department include

Central Govt. & State Govt. staff, different plant units, Township, Sports, Social welfare, Periphery development department, Dignitaries of SAIL, Various visitors & inspectors. Transport services for ceremonial and various occasions of State and National importance. Provides Ambulance Service to JNC OHS Centre at Plant premises round the clock throughout the year. Provides Ambulance services at Fertilizer Hospital round the clock through out the year.

C) IGH Pool at IGH Campus :-

1. Provides Ambulance services to patients of Steel Township round the clock through out the year.

2. Provides ambulance service to peripheral villages and Family Welfare section. D) Repair & Maintenance Centre at Central Pool :-

Repair centre undertakes the maintenance and repair of vehicles & is sub-divided into following sub centers to carry out different repair activities.

1. Servicing Section 2. Electrical repair section


Panorama 2010 3. Tyre section 4. Body & chassis repair section 5. Painting section 6. Engine section 7. Battery section 8. Planning & procurement section

E) Registration Cell:- Registration Cell looks after all statutory obligations of the whole plant vehicles i.e., Road Tax, Fitness, Insurance, Pollution control & Legal complications as arise for all vehicles and Earth moving equipments of RSP.

F) Record keeping cell (Fuel issue record):-

Fuel is issued to all the tyre-mounted vehicles of RSP, RMD, NSPCL, Quality Assurance Estate (Metal). New Log books are issued and old Log books are kept in record room.

G) Store & Fuel Dispensing Unit

Store section of Transport Department is meant for storing spare parts & consumables being used for different maintenance & operation activities and the fuel (Petrol & Diesel) dispensing unit, a sub-unit.

The total numbers of vehicles with Transport Department pertaining to plant are as follows: LIGHT VEHICLES :

> Jeep : 58 Nos. > 10 Seater Jeep : 14 Nos. > Ambassador Car : 13 Nos. > Maruti Car : 20 Nos. > Gypsy : 36 Nos. > Mini bus : 08 Nos. > Pick-up : 22 Nos. > Ambulance : 13 Nos. > Tempo Trax : 01 No. > TMB Bus : 03 Nos.



DESIGN Design Department is the think tank of the entire Steel Plant. Basically Design Dept. caters to the maintenance needs of the plant by way of providing modification schemes, spare part drawings, feasibility reports and technical specifications for small projects etc. to all the departments. For all types of Engineering Jobs to be taken up by Design Department, other departments raise 'O3' Engineering Work orders. These work orders are raised on line through SUN systems by the Planning groups of departments and are electronically cleared by HODs, General Managers, General Manager (Mechanical) and HOD of Designs so as to reach the sections concerned. The types of jobs include modifications, spare parts, re-tracings, replacement specifications, technical studies, standardisation etc. Engineering Drawings are prepared on drawing boards as well as using PCs. A CAD centre has been set up in the department for preparing drawings through PCs using the software Auto CAD. The CAD centre is equipped with 25 PCs, 1 Server, 2 A0 size Plotters & A3/A4 size printers for this purpose. For engineering calculations of structural and piping & Electrical designs special software viz. Auto Cad Mechanical, STAADPRO, ADL pipe and ETAP 6.0 are also available in the CAD centre. About 90% of the total drawings made are through CAD Centre. 3D modeling is done in some of the intricate design jobs for in-depth study. Presently Design Department is having an Archive with almost 5 lakhs drawings and documents. They are kept in centralised AC environment. The printing unit of Archive prepares prints for all customers of the plant. Till recent past these activities were done manually with ammonia printing method which was cumbersome and involved health hazard. To overcome the constraints of manual retrieval of documents, On-line availability of drawings through RSP LAN system was conceived. The Digitisation and CAD centre of Design Department boasts of state of the art technologies and new age machines like Printers and Scanners. There are two LASER printers (XEROX 510 WIDE FORMAT), each used for printing upto A0 size printouts. Similarly two OPTICAL scanners (XEROX 36” WIDE) are used for scanning drawings and documents of upto A0 size. The files are scanned, after which the images in .tiff format, which is editable, is the output. They are then modified or redrawn in some cases or blurry backgrounds are cleaned according to requirements. In-house developed interface software ensures the online archiving of drawings and documents in server which is having storage capacity of 1.2 TB. The server is getting upgraded with acquisition of latest server with SAN system having storage capacity of 8TB extendable up to 96 TB. User Departments can download the drawings and documents in .pdf format from the design online intranet through RSP LAN System. 3 Nos. 10 Kva UPS for stabilized power supply to Digitisation lab & CAD centre are also provided. A library is set up where technical reference hand books, text books etc are kept. The Archives store drawing-tracings, reference drawing prints, microfilms, manuals, technical brochures etc. and is equipped with Fire Detection and Alarm system and Fire Safe Almirahs.


Panorama 2010 The standardisation section is the custodian of RSNs (Rourkela Steel Norms) and takes up assignments of preparation of new standards, revision of existing standards, periodical review of the utility of work study standards etc. The section also coordinates with Inter Plant Steel Standards (IPSS) Secretariat for distribution of IPSS copies in the plant units and other related correspondences. RSN (ROURKELA STEEL NORMS) RSP follows a set of standards known as Rourkela Steel Norms. Initially when the plant was set up in collaboration with Germany, a separate standard was formed which followed the DIN (German) standards as all the major equipments were of German origin. These standards closely follow the IS (Indian Standards). Around 1547 Nos of Standards have been incorporated into 9 volumes, classified by their types. RSP is the only Steel plant distinct in the respect that it has its own set of standards. No other steel plant in India can boast of such a facility. They comprise of the following volumes:

1) Volume 1 General Fundamentals and Drawing Practices 2) Volume 1A Gears and Gear Boxes 3) Volume 2 Engineering Materials 4) Volume 3 Tools 5) Volume 4 Machine Elements and Mechanisms 6) Volume 5 Fasteners and misc. machine elements 7) Volume 6 Pipes, Flanges, Hoses and Accessories 8) Volume 7 Cranes and Lifting Tackles 9) Volume 7A Material Handling 10) Volume 8 Lubrication, Hydraulics and Pneumatics 11) Volume 9 Electrical

MAJOR FUNCTIONS There are basically six categories of jobs being carried out in Design Dept. in a nutshell. These are:-

a) Category 1 jobs: These include jobs involving design, modification of prior design of equipments, evolution of new designs for some equipment or job and design & engineering for new/ongoing projects. The output is in form of drawings and design calculations. This is generally the work of highest of magnitude being done in design department.

b) Category 2 jobs: This category deals with jobs involving technical studies, feasibility analysis i.e. whether an installation of a new equipment or expansion or modification of existing themes is feasible or not. If a new machinery is to be introduced, its pros and cons are weighed and behaviour predicted by analysis and detailed studies. It also involves trouble shooting in case of equipment failure, problem solving and providing remedial measures to ensure smooth flow of processes. The out put in this case is in form of detailed report.



c) Category 3 jobs: In this category, the jobs are in form of replacement drawings. Drawings are made indicating the outer dimension details, technical specification & location in the equipment so that a particular equipment / a part of the equipment can be de-proprietorised or import substitutions of an imported equipment is made at lesser cost.

d) Category 4 jobs: Category 4 jobs are popularly known as indigenisation jobs or reverse engineering. In other words the plant is self reliant in these types of jobs. When RSP was started, not all the drawings of equipments were supplied by OEM. So it was not possible to undertake manufacturing for each and every spares. Design Department has so far made almost 1 Lakh manufacturing drawings since its inception. These have played a vital role in stabilising the procurement and maintenance activities. Drawings are made generally by taking measurements from worn out or broken spares and subsequently converted into detailed manufacturing drawings.

e) Category 5 jobs: This category deals with rejuvenation of drawings. Some of the earlier drawings were in the form of RTF’s (reproducible tracing films), polyester films, tracing cloths, prints etc. Due to repeated use the tracings have become soiled and opaque thereby rendering them unusable. The disadvantage with prints is that copying to produce more prints was not possible. Therefore rejuvenation of drawings is done by either retracing on another tracing paper. In case this is not possible it is redrawn using AutoCAD software.

f) Category 6 jobs: This deals with jobs involving Standardisation. Standardisation means to create a specification of any part which is to be followed in a particular geographical area. It is done primarily to reduce variety. Having no Standards not only means unavailability of parts during crisis hours, it also means loss of man hours in manufacturing in house each and every part which can be easily availed from outside otherwise. Design Department follows three standards- RSN (Rourkela Steel Norms), IPSS (Inter Plant Steel Standards) and BIS (Bureau of Indian Standards).

Design Department extends quick and prompt support to all the production units during breakdowns by providing repair schemes and keeping close co-ordination with Shop complex, RS (E), RCM and allied agencies throughout the repair period.


Panorama 2010

CAPTIVE POWER PLANT-I

An integrated Steel Plant cannot depend on a single source of power for its requirement. Any power failure will result into huge loss running into Crores of Rupees. So as a rule, all the integrated Steel Plants should have its own Power generation plant apart from purchasing power from local utility services. The present average power requirement for our plant is 160 MW, which reaches to a peak level of 200 MW for a short time of 15 minutes. We are having a contract with GRIDCO to draw power from the Orissa grid system. Time and again, CPP-1 has proved to be the most reliable source of power in the steel plant. Captive Power Plant is having following main functions to perform:

• To supply cold blast to all four Blast Furnaces. • To supply process steam to the whole Plant. • To take care of critical loads of the Steel Plant. • To utilize the by product gases arising out of the process of Steel making.

Equipment Details:

• There are 6 nos. of High Pressure Boilers to generate High Pressure Steam at 59 kg/cm2

(gauge) & 485 deg.C for running of the Turbo-Blowers as well as the Turbo- Alternators. a. HP Boiler # 1 & 2 were originally gas fired boilers which were converted into

fluidized bed combustion (FBC) boilers by M/s. BHEL during 1990s. The capacity of each of these FBC boilers is to generate superheated steam of 95 T/hr. at 59 Kg/Cm2 and 4850C. M/s. BHEL have supplied their make ESPs to these HP Boilers. These HP Boilers use coal of size minus 6 mm as the only fuel.

b. HP Boiler # 3 & 4 are of Babcock Steinmuller make, radiant type water tube boilers having maximum continuous rating of 150 T/hr. and economic continuous rating of 125 T/hr. Fuel used in the boiler is Blast Furnace gas, Mixed gas or LSHS Furnace Oil.

c. Boiler # 5 & 6 are also of Babcock Steinmuller make, Radiant type, water tube boilers having maximum continuous rating of 150 T/hr. and economic continuous rating of 125 T/hr. The fuel used here is 100% pulverized Coal or 100 % BF gas or a combination of both. These boilers have been retro-fitted with M/s. Orient make ESPs.

• There are 5 nos. of Turbo Blowers out of which 4 nos. run continuously to cater to the requirement of the four Blast Furnaces. The function of the Turbo-Blower is to supply the Cold Blast required by the Blast Furnaces. Turbo Blower # 5 can be connected to any of the Blast Furnace. The combined Steam consumption in the running of 4 nos. of blowers is 105 T/hr., which is equivalent to approx. 21 MW of electrical power.

• There are 5 nos. of Turbo-Alternators (TA). TA #1 is presently not in service. The Turbines of TA # 2 & 3 originally of Siemens make have been replaced along with condenser



and pre-heaters during 1990 by M/s. BHEL make. Insulation of Generators for TA # 2, 3 & 4 have been up graded from Class “B” to Class “F” and their original conventional excitation system has been replaced with static excitation system during the period of 2003-2010. The turbine of TA # 4 was refurbished in February 2004. During refurbishing all the rows of rotor and stator blades of the turbine were changed. The turbine rotor was straightened; condenser tubes and pre-heater tubes were changed. • Both turbine and generator along with auxiliaries were completely changed for TA #6 with

a new BHEL make machine in 2004. State of the art ‘Brush less excitation system’ was installed. This TA is in successful operation since October 31, 2004.

• Medium Pressure Boilers: In order to supply process steam to the whole plant, two MP boilers were installed & commissioned in 1978 each having a capacity of producing 60 T/hr of supersaturated steam at 18 kg/cm2 & 350 deg. C. The feed water that is being used in Main Power Plant requires to be de-mineralised water whereas MP boilers do not require that level of purity. In November’ 2006 & 2007, BHEL make ESPs were installed in MP Boilers # 1 & 2 respectively.

Make : M/s. ISGEC John Thompson. Type : Water Tube Boilers. Firing System : Spreader Stoker. Fuel : Coal of size minus 25 mm. Maximum Continuous Rating : 60 T/hr. Pressure of Steam : 18 Kg/Cm2. Outlet Temperature : 350 ± 500C. Required CV of Coal : 5000 to 5500 K Cal/Kg. (UHV) Coal is supplied from Old Coal Handling Plant.

In 1998, third MP Boiler was installed to take care of increased process steam requirement of the plant. It is CFBC boiler (Circulating Fluidized Bed Combustion) of 60 T/hr. capacity.

Make : M/s. ISGEC John Thompson. Type : Water Tube Boilers. Firing System : Over Feed, CFBC. Fuel : Coal of minus 6 mm size. Maximum Continuous Rating : 60 T/hr. Outlet Temperature : 350 ± 500C.

The coal is supplied from New Coal Handling Plant.

• There are two nos. of Coal handling Plants, two nos. of DM water plants, 1 no. of Ash slurry pump house, 1 no. of Cooling water pump house and 18 nos. of Cooling towers, which together meet the requirement of Coal, Water and disposal of Ash from the boilers.


Panorama 2010

POWER DISTRIBUTION Introduction Responsibility of Power Distribution department is to ensure availability of interruption free quality power to all units of steel plant as well as Steel Township and Fertilizer Township. To meet this responsibility Power Distribution department operates and maintains a vast transmission and distribution network. In addition, illumination and power supply to major buildings like Administrative Building, ED(W) building, Plant Medical building etc., street lighting of majority of plant roads, boundary lighting are also catered by Power Distribution department. Electrical Maintenance of some service departments, which do not have an electrical section, is also looked after by Power Distribution. Average daily power consumption of RSP (including Steel Township) is 180 MW, with a peak demand of 230 MW. This power requirement is met from three sources viz. CPP-1, CPP-2 and utility grid. Average generation of CPP-1 is approximately 45 MW. CPP-2 is owned and operated by JV Company NTPC & SAIL known as NSPCL. It has an installed capacity of 2 x 60 MW and the average generation available from these units is approximately 110 MW. Balance requirement of approximately 35 MW is met through import from our utility grid. i.e. WESCO. Power Distribution System At CPP-2, power is generated at 11 kV and stepped up to 132 kV. There are two nos. main Step-down Stations namely MSDS-II and MSDS-III. Power from CPP-2 is received at MSDS-III through 2 nos. 132 kV feeders. Grid power from Tarkera Grid sub-station is received at 132 kV at MSDS-II through 2 nos. 132 kV feeders. Third grid feeder is connected between Tarkera Grid sub-station and MSDS-III. There are two nos. interconnecting tie feeders between MSDS-II and MSDS-III. At MSDS-II and MSDS-III, power is stepped down from 132 kV to 33 kV. At CPP-1, power is generated at 6.6 kV and stepped up to 33 kV. CPP-1, MSDS-II and MSDS-III are interconnected to form a 33 kV network. All the 33 kV sub-stations are fed from MSDS-II, MSDS-III or CPP-1. AT different 33 kV sub-stations, power is again stepped down to 6.6 kV and fed to no. of 6.6 kV sub-stations distributed through out the plant. HT motors are directly connected at 6.6 kV buses. For other loads power is again stepped down to 440 V level for direct consumption in different plant units. Large loads like Ladle Furnaces, Sinter Pant Exhausters and main rolling mill motors are directly fed at 33 kV through dedicated unit transformers. Infrastructure Power Distribution department operates and maintains a huge infrastructure of power transmission and distribution equipment for reliable power supply to all consumers. There are 2 nos. 132/33 kV outdoor switchyards interconnected through 40 circuit kilometers of 132 kV Overhead transmission lines. MSDS-II & MSDS-III are main step down sub-stations where power is stepped down from 132kV to 33kV .MSDS-II 132kV is having double bus with transfer bus scheme. Both the main bus as well as the transfer bus has ACSR ‘MOOSE” conductor. There are two nos. 33kV buses with 21/2” IPS Aluminium tube as conductor. There are three nos. 63 MVA 132/33 kV transformers with 11 kV tertiary winding. Primary of the transformers are solidly grounded



where as secondary are grounded through reactors. At MSDS-III, 132kV is having double bus scheme having two main buses of ACSR ‘MOOSE” conductor. There are two nos. 33 kV buses with 2” IPS Aluminium tube as conductor. There are three nos. 62.5 MVA 132/33 kV transformers with 11 kV tertiary winding. Both Primary and secondary of the transformers are solidly grounded. Originally MSDS-II had outdoor 1250 A, 25 kA MOCB circuit breakers. In 2004-05 all the old MOCBs of MSDS-II have been replaced with 2500 A, 40 kA SF6 circuit breakers. Circuit breakers of MSDS-III are 2500 A, 25 kA Outdoor MOCB. There are 7 nos. indoor 33 kV sub-stations. RM-1 & RM-2 sub-stations installed since inception have 33 kV double bus system whereas all other 33 kV sub-stations have single bus system. All circuit breakers of 33 kV are Vacuum breakers. There are 61 nos. 6.6 kV sub-stations. Sub-stations installed during inception of the plant have pneumatically operated circuit breakers with ‘Expansin’; a mixture of alcohol and distilled water as quenching medium. Sub-stations installed during last modernizations and later have spring-spring operating mechanism with Vacuum/ SF6 as quenching medium. In addition there are approx. 100 nos. LT sub-stations under power distributions department mostly having ACB. Power distribution inside plant area is through hundreds of kilometers of 33 & 6.6 kV grade cables. Majority of 33 kV cables, some 6.6 kV cables and control cables are laid inside 8 kM of underground cable tunnel connecting different locations of the plant. There are about 600 nos. of power and distribution transformers of various rating located at different sub-stations. There are power transformers, distributions transformers, converter transformers, furnace transformers and other special application transformers of various rating. The main EHV grade transformers (6 nos.) are installed out door. Majority of other transformers are installed indoors (transformer rooms). Small distribution transformer for lighting and power at remote locations are out door type. 33/6.6 kV power transformers supplied during inception of the plant are of water-cooled (OFW) design. There are two nos. special transformers for LHF-1 and LHF-2 (furnace transformers), which are also of OFW design. Other transformers are generally of ONAN design. There are approximately 6 kM of 11 kV over-head line for power distribution to remote locations. Power distribution department also, looks after 1100 street lights 40 nos. tower & High Mast lights and electrical maintenance of 14 major buildings. Organization Power Distribution department is administratively under GM (Elect.). The major activity of the department is divided in to two parts – Operation and maintenance. Operation group looks after the total power system monitoring, operation and control round clock. The operational activity is controlled from the main control room and is headed by one shift engineer in each shift. All shift Engineers report to the head of operation. The maintenance activities are divided among different zones viz.- Iron & Steel , Mills, Modernization, Switchyards , Cables &


Panorama 2010 Lighting; each headed by one area In-charge. Planning Section of the department looks after procurement, stores, administration, documentation, energy accounting etc. System operation RSP power system remains synchronized with CPP-1 & CPP-2 and utility grid. Monitoring and control of captive generation vis-à-vis the import of power from the grid is done on continuous basis. Moreover monitoring of system frequency, power factor, maximum demand, voltage and other parameters is also done from the main control room with help of SCADA system called SLCC. Revival of power after interruption and normal switching operations for shut down etc. are also part of the operation activity. Islanding Due to presence of Hot Rolling Mills and Ladle furnaces, the load pattern of RSP is highly fluctuating in nature. Hence during normal condition, RSP power system remains synchronized with the grid, even in the condition of zero average net exchange of power. Typical to any steel industry, there are some critical loads in the steel plant, where power interruption can cause costly damage to equipment as well as personnel. As the system has to remain synchronized with the grid, any disturbance initiated in the grid is likely to affect the plant power system including that of the critical loads. In order to safe guard the critical loads of RSP in the event of grid disturbance, an ‘Islanding’ scheme has been put in place to isolate the Captive Generating Units of RSP, along with their loads, from the grid. SCADA / SLCC The SCADA (supervisory control & data acquisition) of RSP power system consists of RTU (Remote Telemetry Units) located at different sub-stations. These RTUs collect digital data (status of CB, isolators, earth switches etc.) and analogue data (voltage, current, power etc.) of all feeders of that sub-station and send to the Server installed in the main control room. Communication between the RTU and the Server is through dedicated telephone cables. There are two Operator Control Stations in the control room where the complete information about the system is available to the Operator. The SCADA system also has facility for control of identified Circuit Breakers from the control room itself. Other functions of the system are Maximum Demand Control, Energy Calculation, Data logging, Trend Display and Report generation etc. Power Factor Improvement Since low import power factor attracts penalty and high power factor (>0.97) earns incentive, power factor improvement is a priority matter in RSP system. One no. of 25 MVar bank at MSDS-III and one no. of 10 MVar bank at RM-1 are connected to the system at 33 kV level. There are about 10 nos. of small capacitor banks averaging 1Mvar each, are connected to various 6.6 kV bus. In addition, there is one SVC (Static VAR Compensator) of 0-50 MVar capacity for dynamic compensation of reactive power through thyristor controlled Reactors.



Maintenance Practices Preventive Maintenance as well as Predictive Maintenance practice is followed in Power distribution department. For routine preventive maintenance, all major equipments are enlisted in the CMMS (Computerized Maintenance Management System). Maintenance of equipment is carried out every day based on the schedule, generated by the system. In addition, comprehensive inspection is carried out and defect report is generated. The defect report is included in the system for job scheduling. Advanced testing equipment and methods are used to carry out insulation diagnostic tests on all major equipments. These tests are used to assess insulation health of equipment and to predict likely failures. Based on the test results, remedial actions are taken to ensure no surprise failure of equipment. Condition based maintenance tools like Thermo- vision camera are also used to detect defects and likely failures. Energy Billing and payment for import power, Unit wise energy accounting, co-ordination with utility grid, dealing with authorities for fulfillment of statutory obligations etc, are other responsibilities of Power Distribution department Power Distribution department is an ISO certified department. All the documentations are meticulously maintained as per laid down practices. SOP and SMP are strictly followed in day-to-day work. Compliances are regularly reviewed internally and corrective actions taken. RSP has undertaken a massive modernization plan which aims at enhancement of capacity of the plant to 4.5 MTPA of crude steel. Estimated power requirement of RSP during 4.5 MT stage, shall be 315 MW average 430 MVA peak. A comprehensive plan has been prepared for augmentation of RSP power system to remove existing system constraints as well as addition of capacity to meet power requirements of 4.5 MT stage. Major facilities being added under modernization plan are

Installation of one 220 kV GIS (MSDS-IV) along with three no. of 160 MVA, 220/132 kV Transformers.

Addition of Three 62.5 MVA transformer at MSDS-III and one 63 MVA transformer at MSDS-II

New 132/33 kV S/s MSDS-V & MSDS-VI A 33 kV Double Bus GIS indoor switchboard for RM-1 ( HRM loads) New 33 kV (4 nos. ) and 6.6 kV (5nos.) sub-stations for power supply to all additional

loads Interplant cabling at 33 kV & 6.6 kV and new cable tunnels Provision of Emergency power to modernization area loads Plant SCADA & EMS


Panorama 2010

PRESENT RSP POWER SYSTEM



RSP SYSTEM – AFTER EXPANSION


Panorama 2010

ELECTRONICS & ELECTRICAL SERVICES

This department mainly consists of two sections i.e. Electronics Section & Electrical Services (Electro Technical Services) section. Electronics: The Electronics Section provides reinforcement to different Electrical Maintenance Units of the plant for maintenance of advanced electronic equipment and electronic weighing systems. These equipments are otherwise maintained by respective departmental electrical maintenance units. But Electronics Section of E&ES department provide service support if some intricate problem arises in the electric circuits, solving of which requires advanced diagnostic equipment and skills. The department scrutinizes technical specification of various electronic/electrical equipments and also involved in its commissioning. The activities are as follows: • Repair of various electronic equipment, PCB, modules for different production units/ plant

units. • Maintenance of all commercial weigh-bridges. • Service support to production units maintaining of drives, power electronics, UPS, PLC,

process weighing systems etc. • Operation and maintenance of in-motion weigh bridge at Reception Yard for weighment of

incoming raw materials. • Maintenance of analytical equipment: X-ray & Optical Emission Spectrometers, Carbon &

Sulphur determinator, Magnetic Test console at CCM-I, SMS-I & II, BF and SSM. • Maintenance of analytical equipment of R&C Lab and Environmental Lab. • Maintenance of CCTV system at HSM, Plate Mill & Plant gates. • Maintenance of Electronics/Analytical equipment of IGH. • In-house development of new PCBs/modules for electronic controls, PLC & weighing

system. • Centrally procurement of spare parts for specified PLCs of different plant units. • Training on PLC, weighing & Analytical equipment. Electrical Services: Electrical Service Section (Electro Technical Services) is considered to the brain behind protection and regulation philosophy being followed in the plant for AC and DC equipment. Its main function is testing of protection relays of all electric drives and power distribution networks. In addition to this they are called upon to carry out in depth study and analysis of intricate and long standing electrical problems of the steel plant and to put forward suggestions/improvements. They are also involved in commissioning of electrics of latest testing /diagnostic equipment being purchased by the plant. The ETS section maintains Fire Detection and Alarm systems of C&IT, Design, EMD building and Oil Godowns. They also provide service support to all protection units in maintaining the fire alarm system installed in their respective departments.



• Testing of HT/LT motors at sites.

• Testing of Transformer oil BDV (Dielectric strength) and DGA (Dissolved gas Analysis) as per requirement of Power distribution and all other production department.

• Testing of Current Transformer, Potential Transformer when ever required by Power

distribution and other production dept.

• Testing of High Tension breakers at sites.

• Insulation resistance, Polarization Index measurement of HT motors, transformer cables and HT Bus bar etc.

• Motor failure Analysis and necessary suggestions.

• Hi-pot testing of HT cables as per requirement of Power distribution and other

department.

• CT – Ratio/Scheme testing as per Power distributions requirement.

• Making of PCB as per requirement of all production departments of Rourkela steel plant.

• Testing of Electrical drives, motors, panels, bus bars and Electrical protection system of

NSPCL as well as all mines (RMD – Division of RSP).

• Calibration of megger and other electrical equipments as per ISO 9001– 2000/BIS norms.


Panorama 2010

COMMUNICATION ENGINEERING DEPARTMENT The Communication Engineering Department (CED) maintains the following communication equipment in the Plant and Township. Integrated Digital Exchanges for the Plant and Township: The Steel Plant has two Integrated Digital Exchanges for the Plant and Township. The present capacity of the Plant Exchange is 2800 lines and that of the Township is 2100 lines. The Plant Exchange caters to the needs of the Plant premises and Sector-22 with features like auto call back, BSNL and Reliance junction dialling, conference facility etc. It is integrated with the township exchange and 200 line ISDN/ DID exchange in a closed numbering scheme. The numbering scheme for the plant exchange is 7000 to 7999, 8000 to 8999 and 6000 to 6900. For the Township exchange it is from 3000 to 3120, 4000 to 4999 and 9000 to 9999 with facilities like wake up alarm. This Township exchange caters to the residential area as well as Offices and Work sites, in the Township area like Town Services deptt, Ispat General Hospital, Power Distribution’s Sub-station etc. Both the exchanges are installed with automatic line testing facility. DID (Direct Inward Dialling) facility has been extended for Plant intercom members. Prefix “244” before Plant intercom 4 digit extension to access that particular extension from any service provider phone. ISDN (Integrated Services Digital Network) Exchange: This is the 1st. amongst SAIL units with direct inward dialling by optical fibre link (PRI 2 Mbps) from BSNL. This exchange caters to the specific needs of the Material Management department. It has an internal numbering scheme from 5500 to 5699. For access from BSNL telephones one has to prefix 244 to the exchange numbers 5500 to 5699. It has many features like voice mail, conference facility and wake up alarm, dynamic locking, detailed call billing on outgoing calls, CLI and all features of an EPABX. This exchange has a provision for further up-gradation to 34 Mbps keeping in view the introduction of Broadband services. Railway Signaling: CED maintains the Railway Signalling system for safe movement of wagons for T & RM Dept. It maintains the route relay interlocking system in the Hot Metal Movement Yard (HMMY), Raw Material Unloading Yard (RMUY) and Marshalling Yard of RSP. This includes the maintenance of 71 nos. of point machine in Marshalling yard, HMMY and RMUY; 41 nos. of track circuits in HMMY and RMUY for effective traffic movement and communication. Dispatcher Communication System: These are 24 or 56 line small Digital Exchanges catering to the internal communication needs of the shop floors. Extensions of these exchanges can access to the main Plant exchange by dialling 7. Central Internet facility: Central Internet facility has been made available to RSP’s LAN users ensuring the transparency and fairness in internet transaction to enhance the efficiency of various



departments. The scheme envisages the integration of 4 Mbps bandwidth connectivity through FO (Fibre Optic) cable from BSNL and 4 Mbps bandwidth connectivity through wireless from Reliance using internet gateway security system (UTM). The security system installed in hot standby mode comprises of Firewall, intrusion, protection and detection system, gateway antivirus, web filtering etc. With faster performance and standby mode of operation the leased line internet system is highly secured & reliable. Plant Control Conferencing System: This is a 200 line Executive Communication System dedicated for communication of Plant Control with all pivotal control rooms and Senior Officers at Residences with the special feature of conferencing. In addition to this a 100 line Digital Excom is also there to provide conferencing facility for Sr. officers inside Plant premises. Loudspeaker Communication System: These systems are used for loud and clear communication between one spot to another, when engaged in the production process. The individual units are called stations. The features included are duplex or simplex communication with selective calling, group calling, paging, one key dialling etc. there are about 290 such stations in Hot Strip mill, Plate Mill, Silicon steel Mill, Sinter Plant-II, CP-II, CCM-I etc. Radio Communication System: CED maintains this wireless network, which is used in remote or difficult areas or places, where mobility of the subscriber is essential. There are about 150 base stations at the Plant and Township with over 1000 walkie talkies for operation in the Coal Yard of Coke Ovens, Crane to ground communication in SMS-II, Yard communication in OBBP and lots of other areas in production and service units. 40 nos of mobile base stations have been installed in locomotives for smooth communication of loco operators with different zones of TRM department. Other Systems: In addition to the above CED also looks after the installation / maintenance of Road Safety Blinkers at Railway Crossings inside the Plant, Airport Communication System, Data Terminals – 500 circuits, High speed Internet with broadband 131 nos for senior executives at offices and residences and 51 nos. of Dial up Internet circuits at various locations. Also CED maintains centralized clock network consisting of 15 slave clocks with one master clock. This network is used to keep track of synchronized time in all the pivotal spots in the Plant like Main Buildings and Gates. Mobile Services from BSNL: RSP has entered into the integrated GSM technology based mobile communication in closed user group(CUG) configuration for SAIL employees on all India basis. This has been implemented by M/s Bharat Sanchar Nigam Limited (BSNL). The scheme envisages:


Panorama 2010

1) Toll free unlimited talk time within RSP SAIL CUG Cell. 2) Local/STD/National call/National Roaming for users of CUG phone. 3) International roaming, sending & receiving SMS, call conferencing and other value

added services like Blackberry, GPRS, 3G, ISD etc. on demand. 4) Toll free with unlimited talk time between RSP SAIL CUG and RSP intercom landline

telephones.

This has become the fastest and reliable communication amongst the SAIL employees of various plant units.



INSTRUMENTATION Instrumentation Department plays a key role in Process Control, Monitoring of Process Parameters, Safety and Interlocking Protection systems of Plant and equipments. Function Instrumentation Department works as a centralized department having a group of Executives and Non-executives dedicated for different sections / groups throughout the plant. Role of Instrumentation in CO-CCD

• Measurement and Control of different process signals through Client-Server based DCS in Battery-1.

• Measurement and Control of different process parameters through SLCs (30 Nos.) and PC based SCADA systems in Battery-2, Battery-3 and Battery-5.

• Measurement and Control of concentration of H2SO4 acid in acid plant of CCD. • Measurement and Control of Suction Pressure in MT and Expansion Exhauster. • Monitoring of machine and process parameters in MT, Exhauster and Booster through

PC based systems. Role of Instrumentation in Blast Furnaces

• Maintenance of DCS (4 Nos.) for Monitoring and Control of Process parameters in BF-1 to BF-4.

• Maintenance of Critical Process Parameters through Stand-alone micro processor based Controllers (40 Nos.).

• Maintenance of on-line gas analyzers for analyzing of CO, CO2 and H2 in BF Top gas. Role of Instrumentation in SMS-I/ SMS-II

• Measurement of Temperature at each stage of Steel making and determination of Cast-able steel through measurement of oxygen ppm at LHF/ARF.

• Maintenance of HMIs (7 Nos.) for Start-up, Running and Shutdown of all systems in SMS-II (for BOF, GCP, Mixer, LHF, ARF, Caster & Gas Recovery).

• Maintenance of PLCs (14 Nos.) for critical interlocks for Plant and equipment safety in SMS-II.

• Maintenance of SLCs (90 Nos.) for Process communication with PLC for different critical control through Modbus Network in SMS-II.

• Maintenance of Gas analysers (10 Nos.) for selection and recovery of LD gas. Role of Instrumentation in SP-II/TOP-II

• Maintenance of Process Control including Interlocking and Protection for SP-II. • All operating parameters including on-line production reports are generated through

DCS in SP-II. • All the weighing system operators for all the bunkers are also monitored and controlled

through DCS in SP-II.


Panorama 2010 • Maintenance of PLCs (19 Nos.) for starting, interlocking and monitoring functions of

critical equipments like Compressors, Expansion Turbines, Nitrogen and Argon compressors of TOP-II.

• Control and Monitoring of Process Parameters through DCS in TOP-II. • Quality parameters like Purity of different products are monitored by 19 nos. Analysers

in TOP-II. Role of Instrumentation in CPP-I

• Maintenance of C&I systems related to 6 Nos. of HP Boilers, 3 Nos. of MP Boilers, 5 Nos. of Turbo-Alternators and 5 Nos. of Turbo-Blowers.

• Maintenance of Process Control including Interlocking and Protection for Boilers and Turbines through DCS (3 Nos.).

• Maintenance of Process Control including Interlocking and Protection for Boilers and Turbines through PLCs (3 Nos.)

• Maintenance of Electronic Turbine Governing Systems (8 Nos.) for Turbo-Alternators and Turbo-Blowers.

• Maintenance of Vibration Monitoring Systems (8 Nos.) for Turbo-Alternators and Turbo-Blowers.

Role of Instrumentation in Rolling Mills

• Thickness Measurement Systems (15 Nos.) in HSM, PM, CRM and SSM. • Roll Force Measurement Systems (18 Nos.) in HSM, CRM and SSM. • Re-heating Furnace Temperature Control through DCS (3 Nos.) in HSM and PM. • DCS based Computerized Batch Annealing System at HAL of CRM. • Maintenance of X-ray & Ultrasonic Testing machines at ERWPP/SWPP. • Maintenance of Stand-alone Controllers (150 Nos.) for different Process parameters at

HSM, PM, SPP, CRM and SSM. • PLC based Temperature Monitoring Systems at RM Compressor Station.

Role of Instrumentation in IRS

• Calibration of Master Instruments for ISO-9001/ISO-14001. • Central agency responsible for repair and calibration of Site Instruments for the whole

plant. • Centralized maintenance of CMMS systems for Instrumentation Deptt.



REPAIR SHOP (ELECTRICAL)

Repair Shop (Electrical), the Central Captive Electrical Repair Shop of RSP caters to the need of repair and periodical overhauling of around 15000 electrical equipments which are there in the plant. It handles around 3000 work orders annually. It is a well laid out workshop of about 6000 sq.m area divided into four bays with facility to handle equipment weighing as high as 50 ton. It possesses all the facilities required to Repair/Overhaul/ Rewind all types of Motors (AC, DC & Synchronous), Electromagnets, Transformers, Welding Machines etc. Work Shop Features: Main sections of the Work Shop are: FITTING SECTIONS: There are three separate fitting areas for handling motors of large, medium & small sizes respectively. It carries out • Overhauling/repair of large , medium and small motors (HT,LT, DC & RT motors) • Repair of all types of electromagnet • Repair/Rebuilding of Slip rings & Commutator , Stator / Rotor Cores • Undercutting, Bevelling of commutator (at site also) To carry out all these activities the areas are equipped with • Four EOT cranes of 50/10 ton, 10/3 ton & 5 ton (2 nos.)capacity • Induction Heaters for bearing heating in all Fitting bays • Dedusting chambers for dedusting the equipments • Numerous customised jigs & fixtures , Hydraulic jacks & pumps WINDING SECTIONS: We are equipped with 2 nos. of Rewinding sections for Round Wire & Strip Conductor electrical equipment which can handle windings of: • All stators & rotors with super-enamelled round copper wire • 6.6 kV HT stators & rotors • Strip wound LT stators & rotors • Strip wound DC Armatures • Repair / Manufacturing of DC field coils, Magnet coils, Vibrator coils, Magnet clutch coils • Repair of all large DC & HT machines at site All windings are done with Class F insulation. To carry out all these activities it is equipped with • Coil winding machines of various sizes. • Stainless Steel / Resiglass binding facility • HT coil moulding facility


Panorama 2010

TRANSFORMER REPAIR SECTION: In this area repair of transformers from as small as control transformers to repair / recondition of 33 kV large power transformers are carried out. It is equipped with: • 6 KL/hour oil filtering machine. • A pit at 3.5 meter level to handle large power transformer. Along with transformer repair this area also takes care of repair of all types of welding machines. TESTING SECTION: Following jobs are executed by this section: • Final and in process testing of all electrical equipments repaired / overhauled in the shop. • Testing of electrical machines at site as per work order or during repair executed by RS(E). • Electrical Maintenance of the shop equipment • Intermediate tests (routine & special tests) including core flux test, HV test, impedance

test, drop test, PI test, Growler Test, Current balance test, ratio test etc.

To carry out these jobs it is equipped with a fair amount of calibrated measuring instruments & Power Source. Some of them are: • Three auto transformers for AC motor/Transformer testing • DC Power Source • Direct Switch on for 6.6 kV Motor (upto 700 kW) • High Voltage Test set • Tan delta & Surge Inter turn test set • 5 kV Digital & motorised Insulation testers • Soft starters for no-load testing of LT Motors & HT Motors (6.6 kV) up to 500 kW PLANNING PROGRESS The section takes care of all activities regarding job planning & its progress monitoring. Following jobs are executed by this section. • Receiving and delivery of jobs • Preparation of route card for each job • Preparation of all types of MIS • Progress data feeding, Planning and Monitoring of the work order/jobs through

Computerised Electrical Equipment Repair System (CEERS) • Issue of ITC / FTC for outsourced jobs Apart from the above sections it has got a small machine shop which takes care of turning & manufacturing activities of smaller spare parts of the electrical equipments. Carpenters are there for preparing formers, wedges and insulation materials. It has got a varnishing area with two hot ovens (300 kW & 100 kW) to cater to drying and varnishing needs.



Annual Capability: • Repair/rewinding of 1000 jobs and overhauling of 1100 jobs. • Repair/overhauling of

6.6 KV large AC machines 120 nos. Mill duty DC M/C & RT motors 420 nos. Welding machines 150 nos. Transformers 25 nos. Electromagnets 25 nos. Site repairs 40 nos.

Apart from handling all types of routine jobs (described above) required to keep the Plant running, handling emergencies & site repair of large machines is one of the major function of RS(E). When there is a break down in a huge machine bringing the process to a halt, on line repair is the only option. On line repair demands exceptional skill which are being handled by expert technicians of RS (E). Computerisation: RS(E) is having a computerised networked system called CEERS developed in-house through which it manages all its activities from work order raising at the customer end, planning and scheduling the jobs, repair history tracking, to delivery of jobs. The advantage of the system is that all the information is accessible for its customers sitting at their end. Main Features of the system are

• Databank of electrical equipment of the Plant • Work order handling and progress monitoring • Equipment repair history tracking • Online monthly planning • Failure reporting & analysis • Overhauling scheduling

Shop Maintenance (Electrical): One section of Repair Shop (Electrical) takes care of electrical maintenance of all equipments i.e. EOT cranes, Machine tools which includes sophisticated CNC machines, installed in Engineering Shop Complex [Repair Shop (Mechanical), Fabrication Shop, Structural Shop, Mechanical shop], Acetylene Plant, Crane Capital Repair & Crane Maintenance Workshops & RCL . Apart from routine & preventive maintenance, repair and modification work are also done on a regular basis by this group to upgrade the drive /control of all major machines in line with technological advances. A no. of units have since been replaced with new drives / VVVF controllers / PLCs etc. Import substitution is given thrust while conceiving the modification / replacement projects.


Panorama 2010

AIR CONDITIONING Air-Conditioning department of Rourkela Steel Plant maintains 6000 Tons of Air-Conditioning units located at various units of Rourkela Steel Plant comprising of:

(a) Package AC Unit 253 Nos. (b) Crane AC Unit 29 Nos. (c) Central Air-conditioning Plant 29 Nos. (d) Chilled Water Plant 23 Nos. (e) Room AC 806 Nos. (f) Water Coolers 263 Nos. (g) Split AC 124 Nos.

These units are running with environment friendly refrigerants. The availability of AC units contribute directly to major production units like Coke Oven, Blast Furnaces, Steel Melting Shops, Hot Strip Mill, Plate Mill & Power Plants. Uninterrupted reliable operation of Central Plants for Gopabandhu Auditorium, C&IT, Control Rooms and Conference Rooms of various departments in Works & Non-works has been made possible due to expertise & skill of Air-conditioning department. Major overhauling of Crane AC units through in-house expertise, erection & commissioning of Central Plants & Package AC Units are major strengths of the department. Air-conditioning department ensures operation of Room ACs for comfort and water coolers as a welfare measure throughout the Plant.



HEAVY MAINTENANCE (ELECTRICAL) This is a centralized department catering to the need of the whole plant in the areas of maintenance of mechanical aspects of heavy electrical machines and electrical aspects of EOT cranes and ground equipment. This department has two sections, i.e. Machine Section and Electrical Section. Machine Section: Machine section is located in front of CET building. This section undertakes the following Jobs: • Precision alignment of all critical electrical drives • Dismantling and assembling of large size AC & DC machines including of preparing of

white metal bearings. • Replacement of HT, LT and DC machines. In addition to this daily service is given to Hot Strip Mill to maintain roller table drives. Electrical Section: Electrical section is located in front of ED (Works) building. It undertakes the following jobs: • Manufacturing of electrical panels and panel boxes for EOT cranes and ground equipment

drives. • Revamping/ Relocation/ Commissioning of EOT cranes. • Trailing cable conversion from trolley busbar system of EOT cranes. • Pendant operation of cranes based on customer department requisition. Recently HM (E) has taken up the salvaging of master controllers, resistance boxes, and other electromechanical switch gears. The job of HM (E) covers • Weekly shutdown • Planned shutdown and capital repairs • Other supportive/ preparatory requirements based on requisition. The objective of HM (E) is to give continuous support to production departments to meet their job requirements in terms of timely completion, quality, quantity, reliability with all-round safety and without rework in order to meet their production targets.


Panorama 2010

PRODUCTION, PLANNING & CONTROL

The role of Production, Planning and Control department (PP&C) in an integrated steel plant having varied product-mix of Flat Product like RSP is very vital. The growth in production and hence its financial performance depends on the dynamic planning in tune with market demand. The major function of the department is to ensure proper & timely execution of various orders placed by various customers both in India and abroad. From receipt of order to its execution, the entire planning, coordination, follow up etc. rest with PP&C. Order Processing: • Receipt of order • Analysis of order Production Scheduling/Planning: • Issuance of Steel/slab/coil order • Issuance of Schedule/Planning • Management of Inventory both for finished / semi-finished & in-process materials. Dispatch: • Dispatch Planning both by Rail and Road. PP&C department works as a interface between Sales Resident Manager (SRM), the nodal agency of Central Marketing Organisation (CMO) and various Production/Service units of the Plant. It receives order of various customers through SRM/CMO & International Trade Division (ITD), SAIL and converts it into Production Schedule so as to ensure timely delivery of required product w.r.t. quality and quantity. For achieving the objective the department plans/coordinates from order procurement stage to its execution through Production Planning / Scheduling and dispatch of finished steel to its customers spread all over the country and export to other countries. For this round the clock planning is being done at various planning offices situated at various Shops/Mills in the Plant. Based on priority orders & requirement of Mill Scheduling, daily production of each unit is planned. Daily discussions are held at a scheduled meeting with Shipping Incharges & Traffic to plan & monitor rake dispatches. Apart from above, other sections of PP&C carrying out the following functions also: • Long Term Planning • Statistical Section • Plant Control • Sales Co-ordination (Road Dispatches) • Weigh Bridges



Long Term Planning: CMO works out the Marketing Plan called Sales Plan based on the demand & availability Market share. Based on the sales plan and keeping in view of the Capital Repair Plan of various units, availability / utilization of equipment, rate of production/rolling & consumption rate etc., the production potential at different product-mix are worked by this section. The section also generates various MIS reports, and reports for dignitaries and handles audit/ Parliament & other statutory queries/requirements. Statistical Section: The Statistical Section Maintains the Production, Consumption and Technical Parameters of various products. Various MIS inputs varying from daily to weekly, monthly, yearly are generated and serves as a input in decision making process for effective control function. Annual Statistical Books containing all important data for the Plant are also published by the section. Plant Control: The Main Plant control, the centralised control room at RSP, which works round the clock serves as the nerve centre at the plant which monitors operation, maintenance, delays & breakdown etc. and provides feedback to the Senior Officers in turn helps them in decision making at right time. Also certain emergency decision makings are done by the department in emergent situations like power failure etc. Sales Coordination: This section • Coordinates road dispatch for prime products both for home sales and export. • Issues delivery order for road dispatches both for RSP & Customer Transport. • Organises road transport/ handling of contracts. Weigh Bridges: 13 No. of weigh bridges are manned by PP&C department which spreads through out the plant for weighment of both for internal consumption and outward/inward movements for commercial purposes. Computerisation: From 1st April 2005 the total function of the department starting from receiving/ processing orders, production programming, material tracking and dispatch coordination has been computerised under production, management system. This has helped in online tracking & monitoring, production scheduling/ preparing, dispatches etc., networking of weigh bridges system, electronic preparation & transfer of key-documents like Test Certificate, Delivery orders, Invoices and other Management Information System reports.


Panorama 2010

TRAFFIC & RAW MATERIALS Traffic & Raw Materials Department plays a vital role in the working of an Integrated Steel Plant. It can be compared to circulatory system in Human body. As circulatory system carry food to all parts of body and collect wastes generated by the different units of body, Traffic Dept. Also function in similar way supplying raw material to different units of plant and collect semi finished, finished and wastes/ bi products generated by those units. Its general role consists of in

Procuring and supplying necessary raw materials to various user departments Internal movement of in-process and other materials from one section to another section Dispatching finished products to outside parties. At 1.8 MT stage of production a total of

about 14 to 15 MT of materials needs to be handled. All the materials are handled in wagons, which move on rails with the help of Diesel Electric Locomotives. Taking over of the wagons, coming from outside from Indian Railways and handing over of wagons from inside the plant to Indian Railways is done at the Exchange Yard at Bondamunda. All the incoming wagons brought to the Marshalling Yard are sorted out and are sent to the various loading and unloading points. The marshalling yard has two grids of tracks so laid out that there is minimum interference of wagon movement. The tracks, crossing and about 100 points in the marshalling yard are controlled by the automatic electrical route relay interlocking system. The Traffic and Raw Materials Department achieves its objectives through the functioning of the following sections: A) Movement (Logistics): This section looks after the supervision and control of internal and foreign wagons movement in the five zones of the plant. It is responsible for the receiving of different wagons from the railways, sorting them out and sending them to the consuming points and collecting the loaded wagons from the mills and handing over to the railways. This section also looks after the various internal movements round the clock. B) Carriage & Wagon (C&W) Section: This section has a fleet of 335 rolling stocks of different types such as BOBS, Flats, BOX, BOI, Gondola & Link car. It has two Rail cranes (828 & 829). RAIL CRANE help will be provided to other departments against their requisition as and when required. WAGON FLEET SL. No.

Type of Wagon

Carrying capacity

Qty. Detail Use

1 HB (BOBS) a. Indian b. German

60/66 T 69 08

Side Discharge, hopper type, 8 wheeler, Casnub /Diagonal bogies with coil springs or Fabricated bogies with laminated springs (8 or 10 leaves)

For transportation of Coke breeze, Hard coke, B coal, LD Slag, Mills scale, Flue dust, Quartz, Special lime stone, Sinter etc.



SL. No.

Type of Wagon

Carrying capacity

Qty. Detail Use

2 BOX Hopper BOX

56 T 39 14

Side discharge, 8- wheeler, fabricated bogie with laminated springs.

For Transportation of Coke Breeze and Hard coke and M S Scrap.

3 Flats (platform cars)

60 T 39 8 wheeler, Fabricated bogie with laminated springs (8 or 10 leaves)

For transportation of Slabs, coils and plates.

90/100 T 09 44

12 Wheeler insulated hooded, fabricated bogies with laminated springs (7 leafs). 12 Wheeler, fabricated bogies with laminated springs (7 leafs)/ 8 Wheeler, Casnub bogies with coil springs.

4 BOI (Std.) 57/60 T 81 Slanted 1m wall, 8 wheeler, Fabricated bogie with laminated springs (10 leaves)/ Casnub bogie with coil springs.

For transportation of M S Scraps and secondary steel products.

BOI (PCM)

70 T 05 Straight wall of 0.5 m ht., Heavy duty, 8 wheeler, fabricated bogie with laminated springs(10 leaves)

For transportation of Pig Iron.

Gondola 58 T 21 Slanted wall, heavy duty, 8 wheeler, fabricated bogie with laminated springs (10 leaves)

For transportation of M S Scraps and secondary steel products.

5 Link car 32 T 05 4 wheeler, Laminated springs (6 leaves), having both CBC Coupler and coupling rod.

For attaching ingot Bogies or charging cars with locomotive

6 Tool van (AKC)

30 T 01 Covered, 4 wheeler, Laminated springs, with 5 HP DG set

For Carrying Break down crew and tools tackle used for re railing.

Total 335


Panorama 2010 It is responsible for inspection, day-to-day maintenance and major repair of wagons. Re-railing of rolling stocks including HM ladle, Slag pot, Quenching Car and Foreign Wagons is the responsibility of C&W section. Joint inspection of incoming and outgoing Railway wagons is done twice in a year for fixing damage and deficiency rate. C) Permanent Way: This section is fully responsible for the maintenance of the 200 KM long railway tracks and 700 points. It takes up all civil works connected with these lines and new track line extensions etc. This section is also responsible for house keeping of yards and maintenance of track drains including removal of wild growth. D) Raw Materials: This section is fully responsible for the procurement, quality control, internal handling and supply of all raw materials and dispatch of specified by-products such as coke fractions etc. It is responsible for the unloading of various raw materials at the proper places. It also keeps an account of the receipts and dispatches of all raw materials. E) Loco Repair Shop: Loco section of Traffic & Raw Material Department has two repair shops (i) Loco Light Repair Shop (ii) Loco Heavy Repair Shop for maintenance of a fleet of 40 numbers locomotives. Loco fleet is given as below. LOCO FLEET:

Sl. No.

Fleet Type Detail Qty. in no.

Remarks

1 General Electric Loco

80 T, Double unit, 470 hp, GE make, 400 series

3 3 nos. will be phased out.

90 T, Double unit, 600 hp, GE make, 600 series

11

2 WDS 6 Loco 120 T, 1400 hp, DLW make, 1400 series

20

WDS 6ad 124 T, 1400 hp, 1400 series, DLW make

6 3 nos. will be added in lieu of above phased out GE locomotives

This shop is responsible for maintaining and up keeping of these locomotives. It is also responsible for maintaining 2 numbers of Rail Cranes for its use in different department of RSP.



F) Commercial: This section deals with Indian Railways in indenting of empty wagons for dispatching products to outside customers and in calculating the demurrage charges payable to Indian Railway wagons inside the plant for more than the allotted time. It is also responsible for lodging claims for any commercial dispute due to misinterpretations of Railway circulars. This section gives advice to Senior Resident Manager (SRM) of CMO stationed at Rourkela for any clarification regarding commercial issues.


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SCRAP AND SALVAGE Production of iron in Rourkela Steel Plant (RSP) started in January 1958 was followed by the formation of Scrap and Salvage Department (SSD) as a separate unit of the Plant in the begging of 1961. SSD working area is located between Silicon Steel Mills and Pipe Plants, extending to western side up to plant boundary. The Scrap and Salvage Department of Rourkela Steel Plant plays significant role in achieving twin objective of gainful utilization of solid waste generated in RSP and revenue maximization. The Department deals with salvaging of scrap /metallic from solid waste for use as melting scrap & also processing of LD slag for internal consumptions and external dispatch. Gainful utilization of slag helps not only in reduction of cost of steel production, but also helps in making the environment free from dust etc. Apart from these major activities, SSD also collects thin baleable scrap & other heavy scrap from length & breadth of the Plant, processes these to chargeable size for use as melting in LD converters. Thus, it plays a major role in improving the house-keeping of the Plant also. Main function of SSD is recovery of scrap & processing of LD slag, some of the other functions are as enumerated below – • Processing of tundish skull by lancing at lancing yard near SMS-II & partly by breaking at

skull cracker crane, for use as melting scrap in SMS-II. • Collection & conversion of thin baleable scrap to Bale Press for use as melting in SMS-I. • Receiving arising from Blast Furnaces, SMS-I etc. Processing these for recovery of iron

bearing scrap for charging in Blast Furnaces & SMS-II. • Collecting scattered scrap i.e. wear/maint./structural scrap from various Units of the Plant,

processing the same for charging as melting scrap in SMS -I/II. • Processing of Mill scales generated from SMS-I/II & Rolling Mills for base mix preparation

to OBBP. • Transporting sludge generated from SMS-I to OBBP for base mix preparation. • Co-ordination with Rolling Mills, PPC and T&RM etc. for supply of Mills scrap to SMS-I/II

for melting. • Processing of LD slag in the crushing unit for recovery of metallic and conversion to various

useful fractions. • Supply of various fractions of LD slag to different units of the Plant, 0 to 5 mm fractions are

sent to OBBP mainly for base mix preparation, 5 to 20 mm size is used for civil works and 20 to 40 mm size slag is used in Blast Furnaces as flux etc.

• Salvaging of rejected/used refractory bricks, damaged slide-gate plates etc. dumped in SSD area and to dispatch the same to external customers.



All the solid waste generated in Steel Melting Shop–II during steel making process is handled by SSD & after recovery of metallic, LD slag is crushed and screened to useful fractions which not only helps in reducing production cost of steel making, but also helps in keeping environment free from waste-disposal. Another milestone achieved by SSD is handling of 100 % residual Blast Furnace slag after partial pouring in Slag Granulation Plant. Earlier, since inception of the RSP, such slag was dumped outside the Plant premises, which was creating Law and Order problems. After modifying the dumping pits and arranging the required infra-structures from April ’2005, all the residual slag is being dumped inside the Plant premises. SSD is not only managing the dumping pits successfully for handling of BF slag as well as SMS-I slag, but also processing the slag for recovery of metallic, which is reused in Blast Furnaces as BF fines. While working under adverse and hazardous conditions, SSD has never over looked the objective of the Rourkela Steel Plant to produce “injury frees steel”. As a step towards this, by safety awareness programme and imparting Safety training to employees, SSD has a unique distinction of having “zero accident” since October ’2007. Believing on “healthy worker is a productive worker”, SSD with help of Jawaharlal Nehru Occupational Health Services Center has ensured health check up of all the employees of SSD since last 3 years. It is well known that the use of LD slag and recovery of metallic scrap in Iron and Steel making not only helps in reducing the cost of Iron and Steel making, but also helps in keeping environment clean & SSD is trying to achieve both.


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CIVIL ENGINEERING (SERVICES) The main job of the department is to provide service inside Steel Plant for maintenance of 750 Nos. of buildings, 50 Km of main roads, 50 Km underground drains, 51 Km of open drains, 30 Km of perimeter wall, 3,30,000 MT of roof structures of different units, 14,40,000 m2 of roofs, 16,96,000 m2 plinth area buildings, 7,500 Nos. of sanitary installations, 69 Nos. of public conveyance buildings, canteens, rest sheds, waste disposal yards etc. The department is also looking after the maintenance of Fertilizer Plant. Except the maintenance jobs, small value AMR projects, pollution control & debottlenecking schemes are also taken up by this department. Activities like building monuments, developing gardens, renovation of canteens, rest rooms, sanitary installations, survey supports, face lifting of plant premises during VIP visits are also taken up as & when required. Assistance is taken from approximately 40 Nos. of external agencies for delivering Civil Engineering Services for entire plant. The plant area is divided into 5 zones in Civil Engineering Services. Equipment Strength:

Sl.No. Equipment Quantity 1. Pay Loader - 2.5 m3 capacity One 2. Dumper - 5.5 m3 capacity One 3. Road Roller - 8/10 Ton capacity One 4. Truck mounted sewer cleaning machine One 5. Total station computerised survey

equipment Two



STRUCTURAL INSPECTION

Structural Inspection Department undertakes visual inspection of Industrial building structures (both steel and RCC) from ground to roof level of all plant units of RSP regularly to have well maintained buildings/shops. The functions of Structural Inspection Department are:

Regular inspection of all industrial structures, chimneys and stacks, structures in mines area, Mandira Dam and structures of NSPCL to assess quantum of defects arising due to any accident, environmental condition etc.

Preparation of technical reports citing defect list, remedial measures/suggestions in a book-let from and taking approval of competent authority for liquidation of damages/defects.

Distribution of approved reports to owners of the shops/department for liquidation of defects.

Stage-wise monitoring/rendering help during execution to liquidate defects, final inspection after rectification/liquidation.

A joint certificate with owner department is issued stating the satisfactory liquidation of the defects.


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CONTRACT CELL (WORKS)

The Contract Cell (Works) was formed in the year 1998. It processes and awards all types of contracts of the Works area. Its broad functions are as follows:

Scrutiny and clearance of indents for various types of contracts in Indent Screening committee.

Floating of tenders after preparation of tender documents. Uploading the tenders in the web-site / publishing the tender in press. Opening of tenders, techno-commercial scrutiny, opening of price bids. Negotiation with the firms to obtain reasonable rates. Award of contracts. Identify the areas for rate contracts & enter into long term rate contracts for repetitive

jobs. Regular co-ordination with different departments like indenting department, Integrated

Contract Labour Cell (ICLC), Finance, Internal Audit, Law, Vigilance etc. Interaction with Contractors. Building up data bank. Preparing MIS. Taking appropriate action in case of failure by the contractor to execute the Job.



WATER MANAGEMENT In an integrated steel plant huge amount of water is required for the process as well as for human consumption. Total industrial and potable water requirement of Rourkela Steel Plant is met from river Brahmani. To make the raw river water suitable for use, the water is treated at Tarkera Pump House. Water Management Department (WMD) has the responsibility of supplying treated make-up water to different recirculation systems and other once through systems in the plant, drinking water to the plant consumers. Supply of water is made to Tarapur Filter House for sector-22, treatment units at sector-21 and sector-8 for township drinking water system. The total water requirement of NSPCL (joint power venture of SAIIL-RSP & NTPC) is also supplied from the plant make-up system. In addition to this, operation & maintenance of total water recirculation systems of SMS-I, HSM, PM & CRM are also under WMD. Sections of WMD and the main functions thereof are as under:

1. Tarkera Pump House: Provides make-up water to the entire plant. It also provides a part of water requirement to township.

2. Drinking Water Station: Treatment and supply of drinking water to plant for various use including for fire fighting

3. Mandira Dam: Stores and supply water for maintaining water level of river Brahmani at Tarkera pump house.

4. Rolling Mill Pump House: Total recirculation water system of HSM & CRM 5. Plate Mill Pump House: Total recirculation water system of Plate Mill including soft

water system for Reheating Furnaces of PM & HSM. 6. SMS Pump House: Total recirculation system of SMS-I (excluding CCM-I), TOP-I &

CRGO complex. 7. Modernisation (Construction) Water Pump House: Provides make-up water & drinking

water to Modernization area like: OBBP, SMS-II, SP-II & TOP-II. 8. Distribution: Maintenance of make-up & drinking water pipe line network throughout

the plant including modernization area. Brief description of major Sections: Tarkera Pump House: Tarkera Water Works is constructed on the left bank of the river Brahmani by Rourkela Steel Plant and named after the village Tarkera. It comprises a pick-up weir, treatment units, raw water and make-up water pumping facility. The pick-up weir has been constructed across the river in order to raise the up–stream river level for pumping raw water. Brief data of pick-up weir is given below.

i) Total Length of Weir 1,268 feet ii) Crest level of Weir 641.5 feet iii) River bed level 630.0 feet iv) No. of Sluice Gates 8 numbers (10’ X 40’) v) No. of Falling Shutters 51 numbers (10’ X 3.5’)


Panorama 2010 The river level on upstream of pick-up weir is maintained by regulating the sluice gates, as per the requirement. Falling shutters give passage to river water during high floods. Raw water from the river is pumped to the treatment units. There are two raw water pump houses, one constructed originally at 1 MT. stage of the plant and other one under modernization scheme. The old raw water pump house is designed for vertical, dry pit type centrifugal pumps and the new one for vertical turbine wet pit type pumps. The old raw water pump house comprises two intake chambers, named upstream and down-stream chamber. Raw water flows by gravity through two nos. of 1000 mm diameter steel pipes laid from the upstream of pick-up weir to each intake chambers. Each of these pipes has been provided with 3 Nos. of stage gates which are operated during monsoon to prevent the carryover of silts from river. Six dry pit type vertical centrifugal pumps, three in each chamber, have been installed. The new raw water pump house has been constructed on the river itself on the upstream of pick-up weir. It comprises four intake wells with sluice gates at inlet ports. 3 Nos. of wet pit type vertical turbine pumps for plant water supply and two nos. of wet type vertical turbine pumps for township water supply have been installed. The capacity of raw warter pumps for plant supply is 3500 cbm per hr at 26 mtr head and 1200 cbm/hr at 80 mtr head for town ship water supply. The treatment system comprises seven units of aeration tank and sludge blanket type clariflocculators along with chemical storage, chemical solution preparation and dosing facility. Raw water enters through the aeration tanks where aeration takes place by means of fall of water and compressed air and then enters into the clariflocculators for flocculation and clarification. Proportionate quantity of solutions of ferrous sulphate and hydrated lime are dosed in raw water in the aeration tank. Clarified water which slowly rises upwards in the clari-flocculators is collected through the peripheral launder and stored in the respective clear water storage tank. Capacity of each treatment unit is 2000 cbm/hr. As the water is directly drawn from the river, the turbidity of raw water varies widely over the year. It varies from 5,000 ppm during rainy season to less than 10 ppm during summer. It also rises very rapidly in case of any flash flood. Ferrous sulphate and hydrated lime are required to be dosed during rainy season for treatment of raw water. These chemicals are dosed manually. Besides the above chemicals, compressed air is used for aeration of water. Make-up Water System: All the storage tank outlets are connected to a common pipe network to which suction of make-up water pumps are connected. There are two make-up water pump houses, one constructed at 1 MT stage of the plant and other constructed under modernization scheme. Seven pumps in old pump house and three in new make-up water pump house have been installed. There are 2 types of make-up water pumps of capacity 3500 cbm/hr, head 45 mtr (6 nos.) and 2100 cbm/hr, head 45 mtr (4 nos.). All the make-up water pumps are centrifugal, dry pit, vertical installation type. With all above facilities at Tarkera Pump House, the water requirement of Rourkela Steel Plant and a part requirement of Township is met.



Make-up water is supplied to Rourkela Steel Plant from Tarkera Water Works, which is situated at about 4 km away through 4 nos. of NB-1000 size underground rising mains. Two rising mains were laid at 1 MT Plant stage, third one was laid during 1.8 MT stage. Fourth rising main was laid during modernisation. All the rising mains are made of welded steel pipes with anti-corrosive coating on external surface. Make-up water received through the rising mains is distributed in the plant through an underground ring main of size NB 1000/NB-960 spreading in the entire Plant. A high level tank, staged at RL: 792.3 feet, is connected to the make-up water ring main to act as a surge-cum-storage tank. Local cooling water recirculation systems comprising of induced draft cooling towers, hot and cold water pumps are installed separately for CCD, Blast Furnaces, SMS-I and SMS-II, TOP-I, TOP-II, Rolling Mills, Plate Mill, Silicon Steel Mill, CPP-I, Central Air Compressor Stations etc. Evaporation, drift and bleeding losses of recirculation systems are replenished with fresh make-up water supplied through the ring main. Chemicals such as biocide, dispersant, scale and corrosion inhibitor are dosed in the circulation systems, to maintain the water quality of the recirculation systems, and to reduce the make-up water consumption. Separate cooling water recirculation systems were provided for SMS-II, CCM-I, CCM-II, Calcining Plant during modernization of RSP. There are also a number of once-through cooling water systems in various shops viz., Sintering Plant-I, Lime and Dolomite Brick Plant, Electrical Sub-stations, where make-up water is directly used for system cooling purpose and discharged to drain. The water for NSPCL, IDL in fertilizer plant area is supplied from the make-up water distribution network. In order to supply make-up water at desired pressure to the modernization units in new areas viz. SMS-II, CCM-II, Sintering Plant-II, Calcining Plant, TOP-II, OBBP, a separate pump house has been commissioned. The modernization pump house consists of make-up water pumps which pump make-up water to the modernization units. Separate make-up water pipe lines with a high level tank comprising separate chambers for make-up water have been provided in the modernization area to act as storage-cum- surge tank. Make-up water from the existing pump house is pumped to new high level tank for onward distribution to various modernization units. There are total 6 nos. of make-up water pumps having capacity of 300 cbm/hr at head of 55 mtr. Mandira Dam: The main source of water for Rourkela Steel Plant is river Brahmani, which is formed by the confluence of two rivers, Sankh and Koel at Vedvyas near Rourkela. This river is able to supply water throughout the year except during the summer months. In order to have a regulated flow in river Brahmani throughout the year, a dam named Mandira Dam, was built on river Sankh, at a distance of 26 KM upstream of the river from Rourkela by Rourkela Steel Plant. The Dam was built mainly for the purpose of storage and supply for meeting the water requirement of RSP during summer seasons, when there is a drastic reduction in water flow in river Brahmani. The salient features of Mandira Dam are as given below:


Panorama 2010

i) Catchment Area 2,366 sq. miles (6,057 sq. Km) ii) Full Reservoir Capacity 2,57,000 Acre-feet (317 Million m3 ) iii) Length of Reservoir 17 miles (27.2 Km) iv) Max Reservoir Level 690 feet v) No of Sluice Gates 2 numbers, 8 feet X 8 feet vi) No of Radial Gates 11 numbers, 51 feet X 22 feet

Plant Drinking Water System: A filter house consisting of 8 nos. of rapid gravity sand filter beds is provided within the plant premises. Make-up water is tapped from the make-up water ring main and filtered through the rapid gravity filter beds. Alum solution is added to the make-up water in the influent channel before filtration. For the purpose of disinfection, bleaching powder in solution form is added to the water after filtration. Hydrated lime is dosed in the underground storage tank for maintaining the pH level. The filtered water is collected in the storage tanks from where it is lifted to the high level tank by means of pumps for further distribution in the plant. The high level tank is staged at RL: 874.3 feet in order to facilitate smooth flow of drinking water by gravity. A separate ring main of NB-400 size, welded steel pipe, has been laid underground for distribution of drinking water. Besides for drinking purpose, drinking water is also supplied to various other process requirements viz. gas cleaning, acid regeneration, air conditioning, fire fighting etc. The drinking water pumping facility comprises horizontal, centrifugal, dry pit installation type pumps, which pump the drinking water to the High level tank. There are total 11 Nos. of pumps comprising of 2 nos. of 3 MGD capacity, 6 nos. of 2 MGD capacity and 3 nos. of 1 MGD capacity. A separate drinking water station has been constructed to supply drinking water to the modernization units. Drinking water is prepared by filtration of make-up water in the pressure filters and is then pumped to high level tank for distribution to various consumers in the modernization station area. There are 3 nos. of pressure filters comprising of 2 nos. of 60 cbm/hr capacity and 1 no. of 80 cbm/hr capacity. For supplying filtered water there are 3 nos. pumps of capacity 80 cbm/hr at 55 mtr head. Rourkela Steel Plant, being the first industrial unit in Rourkela, in the late 50s’, continues to meet its social obligations for supplying water to the various peripheral villages and colonies in and around Tarkera and Rourkela Steel Plant. Rolling Mill Pump House: This pump house comprises of main pump house, scale pit-I (SP-I) pump house and cooling water return station. The pump house supplies service water for the direct & indirect cooling of equipments of HSM & CRM and is a recirculation water system. The service water recirculation system consists of following major equipments:

a. Supply pumps for supplying treated service water to HSM & CRM at a minimum pressure of 2.8 kg/cm2. No. of supply pumps: 11, capacity: 1500m3/hr, 45 mtr head.



b. Collection Pit with bucket type EOT crane for mill scale removal near SP-I. Contaminated return water (contaminated with mill scale and oil) from HSM is collected in Collection pits where mill scale is removed by a bucket EOT crane and water is further sent to settling tanks through scale pumps situated at Scale Pit-I pump house. There are 6 nos. of scale pumps of capacity 1440 cbm/hr at 45 mtr head.

c. 4 Nos. of Settling tanks each of capacity 1550 m3/hr, size: 55 mtr long x 8 mtr width x 3.5 mtr depth, where mill scale and oil is separated with the help of scrapers and oil skimmers respectively. Overflow water from these tanks is passed to filter beds for further purification to remove oil traces and finer size mill scale. The mill scale from settling tank entry point is removed by one EOT crane for subsequent use at OBBP.

d. 6 Nos. of rapid sand gravity filter beds (capacity: 1100 m3/hr, size: 25 x 3 mtr) arrest finer scale and the filtered water is stored in 2 Nos. of storage tanks for supply. The supply pumps draws water from storage tanks. Make-up water is added in these storage tanks to recoup the losses.

e. 2 nos. of wash water pumps and 2 nos. of wash water return pumps for filter backwashing. Backwash water re-circulated through settling tanks.

f. Cooling water return collection pit in HSM to collect return water from CRM and cooling water from HSM, which is non-contaminated but with high temperature. There are 8 nos. of pumps installed in the CWRS of capacity 1200 cbm/hr at 30 mtr head. With the help of pumps the return water is passed through cooling towers to lower the water temperature and storage in the break-pit near RMPH.

Sketch showing the flow sequence is shown below: Plate Mill Pump House: This unit has following sections and the functions are as mentioned under:

a. Indirect Cooling Water system: This is a recirculation system for providing clean water for cooling of equipments of Plate Mill. The system consists of supply pumps (2 nos., discharge 315 CMH, head 55 mWC), cooling towers, storage sump.

b. Direct Cooling Water system: This is also a recirculation water system for spray cooling of Rolls, De-scaling of slabs etc. The return water is contaminated with scale and oil. For

c.

CRM CWRS PUMP HOUSE

COOLING TOWERS

STORAGE TANK

HSM BOOSTERS

OTHER UNITS OF HSM

COLLECTION PIT

SCALE PIT-I PUMP HOUSE

SETTLING TANKS

FILTER BEDS

SUPPLY PUMPS


Panorama 2010 making this water reusable, it is passed through collection pit (scale removal), scale pumps (3 nos. discharge 960 CMH, head 30 mWC), settling tanks (max flow 1150 CMH), scrapper & oil skimmer for removal of scale and oil, return pumps (2 nos. discharge 1025 CMH, head 30 mWC), pressure filters, cooling towers, sumps and supply pumps (2 nos., discharge 960 mWC, head 60 mWC). Mill scale is removed with an over-head bucket type EOT crane and oil is removed from settling tan wit oil skimmers. d. Soft Water System: This system provides soft water to Reheating Furnaces of Plate Mill

and Hot Strip Mill. Soft water is pumped to reheating furnaces (HSM: 4 pumps: discharge 650 CMH, head 55 mWC, Plate Mill: 3 pumps, discharge 550 CMH, head 55 MWC): and the return water is passed through plate type heat exchangers for cooling. For cooling of hot return soft water in the heat exchangers, industrial cooling water is circulated. This industrial cooling water system is a recirculation system with pumps (HSM: 3 pumps: discharge 930 CMH, head 30 mWC, Plate Mill: 2 pumps, discharge 655 CMH, head 30 mWC) and cooling towers. A Soft water treatment plant has been provided to supply soft water to make up the losses in the soft water circuit. The soft water treatment plant consists of aerator, iron removal filters, pressure filters, base exchangers. An overhead emergency tank is provided for supply of soft water to reheating furnaces in case of power failure up to 20 minutes. In case of extended power failure beyond this provision is also there to supply make-up water to the furnaces. Two pumps of discharge capacity 555 CMH and head 45 MWC take water from the common sump of recirculation water are installed to supply water for cooling of compressor of HSM.

SMS Pump House The purpose of this system is to supply cooling water to LD converters and to Oxygen Plant (TOP-I). Water is supplied to consumer points in SMS-I & TOP-I through a set of pumps. Return water from the consumers are collected in the hot water sump. From this sump hot water is pumped to cooling towers for cooling. From cooling towers the cold water is collected in cold water sump for further supply. Make-up water is added through a set of pressure filters to the cold sump. There are 5 pumps each for supplying water to LD and Oxygen plant respectively and 8 nos. pumps for supplying return hot water to cooling towers. There are 4 nos. of cooling towers. A new pump house named as CRGO pump house was constructed to supply direct cooling water and indirect cooling water to VAD/VOR unit of SMS-I. Each system is consisting of supply pumps, return pumps, cooling towers and sumps. This pump house is a zero discharge unit. Oxidation Lagoon The effluent water from the various plant units inside the plant is collected in the oxidation lagoon through 10 nos. of outfalls. The water is treated in the lagoon by natural oxidation process to maintain the effluent water quality. The lagoon is spread over an area of 49 hectares and is provided with 3 nos. emergency gates and a weir for discharge of water from lagoon.



Major Water Conservation Measures taken: a) Recovery of water from ash ponds for use as water for ash handling in Power Plants

(NSPCL). b) Recovery of waste contaminated water from Gas Cleaning Plant of SMS-II (highly

alkaline in nature) for use in BOD Plant of Coal Chemical Department. c) Utilization of BOD Plant over-flow water in Coke-Ovens for quenching purpose. d) Regular inspection of water pipe lines, water systems for leakages/wastages and

rectification on immediate basis. e) Regular maintenance of cooling towers to maintain cooling water temperature as per

design norms to avoid excess usage of water. The drift losses and loss due to over-flow from Cooling Tower sumps have also been controlled.

f) Conversion of once-through system to re-circulation system in pipe plants. g) Use of water treatment chemicals in major recirculation systems to maintain water

quality and reduce water wastage due to blow down. h) Introduction of localized booster stations at Coke oven and power plant to reduce

running of higher capacity pumps at Tarkera Pump House. Future Strategy for water conservation Ensuring recirculation water system in all the new units coming under 4.2 MT expansion plan. Introduction of rain water harvesting and zero discharge concepts in the new pump houses exploring the possible re-use of drain water from different outfalls.


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ENERGY MANAGEMENT Energy Management Department in Rourkela Steel Plant is primarily responsible for meeting the fuel/ energy requirements of all the consuming units both qualitatively and quantitatively, while keeping the energy cost at the minimum possible level. In order to meet the above objective, the department performs the following functions:

Planning the fuel requirements and gas / utility balances as per the production plan and consumption norms decided jointly with the consuming departments. Fuel includes Coke Oven Gas, Blast Furnace Gas, Converter Gas and Mixed Gas while utilities include steam, oxygen, nitrogen, argon and synthesis gas.

Monitoring of the optimum availability and distribution of fuel gases and utilities on round the clock basis from Energy Centre.

Preparation of daily, monthly, annual gas / utility balances, specific Energy consumption and cost reports. Analysis of deviation and taking up with the concerned agencies.

Energy conservation activities in all the energy consuming units to ensure efficient utilisation of energy. This includes maintaining of operational parameters, combustion control, condition of fuel/ energy consuming equipment, status of instrumentation and control system and inspection/ follow up for rectification of leakages.

For ensuring gas safe operation in the plant gas/ oxygen/ explosive mixture testing is done for all protocol/ non-protocol jobs as per requirement. Also gas safety equipment like masks, carbon monoxide and oxygen monitor and breathing apparatus etc. are maintained in proper condition.

Maintenance of the yard utility grid to ensure uninterrupted supply of fuel gases/ utilities to the consumers besides day to day maintenance jobs. This involves repair/ replacement activities as per requirement.

Involvement and participation in all the projects as per RSP expansion programme and under AMR and other schemes, to ensure adoption of energy efficient technologies and proper integration of the individual unit gas/ utility pipe lines with the main grid.



SAFETY ENGINEERING Iron and Steel production being a complex and hazardous activity, SAIL recognizes its moral, economic and legal obligations to prevent hazards, provide healthy working environment and guard against all foreseeable risks. The management of SAIL recognizes its obligation to endeavour to progressively identify, control and eliminate all hazards and conditions which present risk to employees and / or possible damage and loss to the plant and equipment including products. Safety Engineering Department of Rourkela Steel plant is a technical wing with a multi disciplinary team discharging all the above functions. It has been the constant endeavour of the department over the past 40 years to create a hazard free, safe environment for the employees of Rourkela. Towards this end the department has been carrying out the following major functions:

1. Safety training to all levels of the employees including Contractor labour.

2. Periodic inspection of equipment, work methods and the environment.

3. Identification of hazards and taking steps for their elimination.

4. Facilitate procurement of personal protective equipment as required for various jobs, prepare norms of issuing the same and enforce its use by the employees.

5. Creating awareness of employees through visuals like hoardings, posters, film -shows,

printed handouts, bulletins, safety campaigns, various competitions etc.

6. Publishing various safety bulletins, printing permit to work. (Holding protocol meeting for major shutdown and other hazardous jobs.), Crane Log Book.

7. Encouraging joint participation in the field of safety through the Central Safety

Committee (at the apex level) and the safety committee of departments (headed by General Managers). Monitoring implementation of the recommendations of these committees.

8. Briefing the contractors on the hazards inherent in their area of work and the safety

requirements for their jobs before start of the job. Day-to-day monitoring of the work of contractors and ensure penalty to defaulting contractors.

9. Conducting Safety Audits by internal as well as external teams and taking necessary

actions to liquidate the deficiencies noted.

10. Working in close liaison with Occupational Health Centre to promote a clean, healthy and safe environment.


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11. Monitoring compliance of the various provisions relating safety as numerated in the Factories Act, 1948.

12. Maintaining constant liaison with the various statutory authorities like the Director of

Factories, Inspector of Factories & Boilers, various Labour Institutes.

13. Introducing / strengthening the safety system as per requirement.

14. Organising various safety promotional activities like National Safety Day, Safety Housewives / school children, Road Safety Campaign.

RSP has won several National Safety Awards for its exemplary performance. RSP won Steel Minister’s Safety Shields for best performance and RSP also won many awards from the State Government and the Standing Committee on Safety in the Steel Industry. Rourkela Steel Plant thus is committed to:

a. The safety of its employees and the people associated with it including those living in its neighbourhood.

b. Pursue the safety efforts in a sustained and consistent way by establishing safety goals, demanding accountability for safety performance and providing the resources to make safety programme work.



ENVIRONMENTAL ENGINEERING Rourkela Steel Plant has established a full-fledged Environmental Engineering Department with latest monitoring and analysis facilities during early nineties. The Environmental Engineering Laboratory, attached to this department is the first unit in RSP which has got ISO-14001 certification from Bureau of Indian Standards. The main activities of Environmental Engg. Department are: • Monitoring and analysis of various pollutants of Air, Water and Wastes. • Inspection and evaluation of efficiency of various pollution control equipment installed in

different departments. • Coordination with respective departments for implementation of statutory regulations. • Coordination with State Pollution Control Board, Central Pollution Control Board, Ministry

of Environment and Forests and other Government agencies and bodies for implementation of various statutory rules and other regulations.

• Active involvement in enhancement of solid waste utilization & greenery development. • Preparation and submission of MIS & various reports to State Pollution Control Board,

Central Pollution Control Board & Ministry of Environment & Forests at regular intervals. The quality of waste water generated at different sources is regularly monitored by collecting samples from 50+ locations throughout the plant including the final discharge of effluent from Lagoon to River Brahmani. Any deviation from the norm is analysed for taking corrective actions. The stack emissions from 26+ number of active stacks are regularly monitored for Dust emissions (SPM) into environment. The fugitive emissions from Coke Ovens viz., gas leakage from oven doors, charging lids & accession pipes are regularly monitored for effective control. The dust and noise levels in shop floor of different departments are regularly monitored. The efficiency of air pollution control equipment like Electro Static Precipitators, Bag houses etc. are also monitored regularly for suggesting corrective actions. Env. Engg. Dept. has also installed 4 no. of online stack monitors at Coke Oven batteries. The cumulative effect of air pollutant emission from different sources like stacks, sources etc., are monitored at 6 no. of ambient air quality monitoring stations, which are at OBBP administration building, EED building, RDCIS building, PMPH building, BOD plant building & TOP#2 administration building. This department has established two no. of automatic ambient air quality monitoring stations; one inside the plant at ED (W) building and another at Indo-German club of Steel Township which is first time in Indian Steel Industry. These stations continuously monitor the levels of suspended particulate matter, respirable dust, Sulphur Dioxide, Oxides of Nitrogen, Carbon Monoxide, Hydrocarbons & Methane. The pollutant levels are displayed on a bill board continuously and the data is downloaded regularly from the central station installed at Environmental Engineering Department.


Panorama 2010 Environmental Engineering Department has taken up a massive drive in identification of alternative uses of different solid wastes through out the plant for making them as byproducts. The utilisation of solid waste has greatly improved due to adoption of 4 R principle (Reduce, Recycle, Reuse & Recover). The Characterization and inventorisation of hazardous wastes, which are generated from steel making processes are conducted by Environmental Engineering Department as per the Hazardous Waste (Handling & Management) Rules, 1989 amended thereof. These wastes are scientifically disposed in 3 no. of Hazardous Waste Pits at present. To take care the future generations, RSP is planning to develop a Secured Landfill Facility as per CPCB guidelines for which clearance from State Pollution Control Board has been obtained. Environment Information Management System (EIMS) has been developed, which is a unique online software system developed on Oracle 10g platform using optical fiber network, first of its kind in Indian Steel Industry, to strengthen the pollution control facilities by online monitoring of various pollutants and giving first hand information to Management for taking corrective actions. A road map identifying new pollution control projects and strengthening of existing pollution control projects is prepared, to meet the future requirement in view of stringent statutory requirements and commitments given under Corporate Responsibility for Environment Protection (CREP). Environmental Engg. Department has taken up a CDM Project “Enhancement of waste gas recovery from SMS#2 and its utilization in Captive Power Generation”. This is the first CDM project in SAIL which has got registered with UNFCCC. Env. Engg. Department is also actively involved in projects for replacement of Ozone Depleting Substances (ODS) with non ozone depleting substances. The Environmental Engineering Laboratory is provided with latest instruments for analysis of various parameters. The laboratory is equipped with

• AAS (Atomic Absorption Spectro Photometer) • HACH 2010 spectrophotometers • Orion Ion Analyser • BOD(Biochemical Oxygen Demand) apparatus • BOD incubator • COD(Chemical Oxygen Demand) reactor • Phenol Distillation Sets • Auto Titrating apparatus • High volume samplers • Respirable dust samplers • Stack monitoring kits • Flue gas analysers • Flow meter for open channel flow • Noise meter

Environmental Engineering Department has recently developed facilities for biological testing of water and waste water samples.



FIRE SERVICES The Fire Services Wing of the erstwhile Hindustan Steel Security Force (HSF) was established under the provision of security scheme, compiled by the security advisor, HSL. After the induction of CISF, Fire Service was made a separate department of Rourkela Steel Plant. Objective:

1. Prevention of Fire 2. Prevent Loss of Life & Property 3. Extinction of Fire.

Different Section / Wings: Operation: The most vital of all the four wings is the operation wing. The prime responsibility of reducing the response time, minimize loss of Life & Property lies with the operation wing by responding to an emergency at its earliest. There are four strategically located Fire Stations inside RSP to cover the whole plant. These are:

• Central Fire Station (covering Iron and Steel zone, Admn. Building, Captive Power Plant-I, SP-I, Aux Mills, All shops, Air Strip and Steel Township areas etc;)

• Modernisation Fire Station (covering OB & BP, SMS-II, CCM-II, CP-II, SP-II and TOP-II units etc.)

• Coal Chemicals Department Fire Station (covering Coal Chemicals department, Coke Ovens deptt, Fertiliser Plant & Fert. Township.) and

• Rolling Mills Fire Station (Covering Rolling Mills, SSM & Pipe Plants).

These stations are fully manned round the clock in three shifts headed by a Fire Station In-Charge in each shift. An Executive (over all in-charge) is also posted in each shift at Central Fire Station to take care of any occurrence of Fire, Rescue and other emergencies in the Plant, Steel & Civil Townships & Periphery. In addition, special services like De-watering, Cooling and Stand-by duties in the plant and at Air-Port are also rendered. The Central Fire station, which is the nerve center of the Fire Service department, on receipt of any emergency call, dispatches its appliances at its earliest. On arrival at the scene of fire, rescue, special service call, the Officer I/c studies the situation and plans his strategy of attack. Further assistance of manpower or reinforcement of additional appliances / equipment is called for inter alia VHF or other mode of communication with the control room. The Operation wing,

Motto: - We Serve To Save

Aim: - Zero Fire Incidents


Panorama 2010 as a part of its pre-fire planning, also carries out regular Mock drills and Topography study. The Operation wing fulfills the mission of Fire Service department. Prevention This wing fulfils the first objective of Fire Service to Prevent Fire. The major activity of this wing is to inspection of all hazardous / fire prone areas, the detection and protection systems, checking of all fire hydrants / fire extinguishers etc. Maintenance Wing: Of all the physical resources, the appliances and equipment used by fire service must be trouble free at any point of time. The wing does all the in-house maintenance, preventive maintenance of all the appliances and equipment available with Fire Service. The list of appliances (vehicles) and equipment available with Fire Service department are as under: Fire Fighting Appliances & Critical Equipments: The fleet consisting of the following: Training Wing: Training wing has to carry out an important task in imparting in-house training to its new recruits and refresher course for old timers. Both acquiring knowledge and skill, the training wing is constantly trying to cope up with the needs of the plant employees in general and Fire Service department in particular. The Fire Control Management (FCM) programme conducted under the aegis of HRDC department is an unique venture. With faculty support from Fire Service department added with practical demonstrations this FCM programme enhances both knowledge and skill of the participants to greater extent. Scheduled Training at shop-Floors on Fire Prevention & Hand-on-training on ‘Use of Fire Extinguishers’ are carried out every month.

SN. Description Nos. 1. Foam Tender 06 2. Foam-cum-DCP (Combined Tender) 01 3. Crash Fire Tender 01 4. Water Tender 01 5. High Capacity Water Bouser (14 KL Capacity) 01 6. High Landing Hydraulic platform (Simon Snorkel) 01 7. Emergency Tender 01 8. Towing Tender 02 9. Jeeps 03 10. Portable Pumps (Petrol- 6, Diesel – 2) 08 11. Submersible Pumps (Electrical) 03 12. Trolley mounted Long Range Foam-Water Monitor 01 13. Trailer Pump 01 14. Portable fire Extinguishers 7500 15. BA sets (Oxygen type-19 & Air Type-22) 41



Specialized training programmes, pertaining to only Fire Service personnel are also conducted at regular intervals. Planning: Fire Fighting Consumables, Equipments, Appliances & Human Resources. Human Resource: Fire Service department is having 163 highly motivated & well trained / Qualified Officers & Staff. The grade-wise break up is as follows:

1. Executives 08 2. Fire Station In-Charge 03 3. Leading Fire Operators 126 4. Fire Operators 18 5. Technicians 06 6. Office Staff 02

CCaallll UUss ttoo HHeellpp YYoouu Fire Control Room: Inter-Com -7700, 7000 & 7796, BSNL-0661-

2510142


Panorama 2010

INDUSTRIAL ENGINEERING Activities of Industrial Engineering Department are mentioned below: Motivation Schemes: IED is responsible for Design, Formulation and Implementation of Motivational Schemes in RSP and Monitoring of the same on a regular basis for improving production, productivity and techno-economic/cost parameters. Procedure Orders: IED formulates various Procedures for Works & Non-Works areas. The objective is to streamline the system for efficient and smooth functioning and fixing agency-wise responsibility/accountability. Making amendments in existing procedure orders and issue of revised procedure orders are also a part of this. Srujani Creativity Award Scheme: A Creativity Award Scheme under the name “Srujani” is in vogue in RSP. Under the scheme, employees are encouraged to implement their creative ideas for any improvement pertaining to their own area of work. The scheme is decentralized for effective and quick implementation of ideas and speedier recognition of employees. The suggestions are evaluated and awarded by multi-tier review committees. Two departmental Rolling Trophies, one Best Suggestor award and five Second Best Suggestor awards are awarded each year on the basis of employees’ contribution to SRUJANI Scheme during the preceding financial year. These awards are given by our respected MD on 15th of August every year. . Delegation of Powers: Formulation and Compilation of delegation of powers for the executives of RSP pertaining to various items like Statutory, Capital, Establishment matters, Revenue powers, etc. Fixing of financial Powers for Executives of various areas, approval and issuance of the same. Modification and Amendments of Delegation of powers as and when required. Prime Minister’s Trophy for Best Integrated Steel Plant: Preparation of Application Document for participation of RSP in Prime Minister’s Trophy Scheme. Overall Coordination during visit of Assessor team and panel of judges to RSP. Communication with PM’s Trophy Secretariat and other steel plants for smooth functioning of the Scheme, etc . Manpower Proposals: Assessment and recommendation of manpower for upcoming modernisation units and additional activities under AMR Schemes. . National Awards: Coordination for sending nominations of deserving employees for various National Awards like Prime Mininster’s Shrama Awards, Rashtriya Vishwakarma Puraskar, etc.



Form Design and Control: Designing of new forms as per the requirement of the departments, modification of existing forms, allotment of O & M number, coordination with official language cell for making trilingual forms. Administrative Items: The requirement of various items under administrative category are studied and recommended for procurement for different departments. Annual Maintenance Contract Operation of Annual Maintenance Contract as a centralised agency for all the photocopier machines at RSP to facilitate smooth performance.


Panorama 2010

RESEARCH & CONTROL LABORATORY Research & Control Laboratory provides metallurgical services to the whole plant units. RCL role starts from product enquiry to till the product is delivered to the customer. It also handles customer complaints if any. The broad outline of its activities includes: a) Chemical analysis of all raw material inputs like coal, Iron ore, Manganese ore, Lime stone,

all ferro alloys, Petroleum coke etc and samples collected from vendors and sent by

inspection wing of Materials Management Deptt. spread across four Metros),

b) Chemical analysis of in process materials like hot-metal, slag, sinter, steel, emulsion, water,

acid, salt etc and output materials and products.

c) Process Control and process parameter auditing

d) Inspection of in process and finished products

e) Mechanical & Non Destructive testing

f) Refractory testing

g) Statistical Quality Control (SQC) & process capability studies

h) Certification of finished products & issuance of test certificate to customers.

i) Test support & guidance for maintenance departments for material selection

j) Failure Investigation

k) Product development and special steel making

l) Maintaining and operating product licenses

m) Coordinating with customers & their inspection agencies for plates, & pipes

n) Technical information and documentation.

o) Nodal agency for R&D projects undertaken by RDCIS

p) Nodal agency for Quality Circles.

It has more than 20 spot labs to carryout inspection, testing activities round the clock in almost all the shops of the steel plant. Central Lab building houses 10 lab facilities to test water, oil, coal& coke, refractory etc. The Centralised test house is for mechanical testing and product certification. Some of the equipments of R&C lab are given below: • Sequential and Simultaneous X-ray Fluorescence Spectrometers

• Computer Controlled Optical Emission Spectrometers,

• Leco Analysers

• Fisherscope for coating thickness measurement of Zinc & tin on steel.

• Particle count apparatus for oil testing



• Magnetic test Lab. For testing Silicon Steel

• Universal testing machines of 40, 60 & 100 T capacity

• Drop weight tear test machine

• Ultrasonic Flaw Detectors

• Isotope Radiography Camera

• Bending and Folding machine

• Erichson Cupping Testing machine

• Charpy Impact Testing machines (300 J)

• Dye Penetrant Test kits/magnetic particle tester.

• Image Analyser, Metallurgical microscopes

• Hardness testers


Panorama 2010

TOTAL QUALITY MANAGEMENT

Total Quality Management (TQM) Department started functioning independently since January 1992 with an objective to establish Total Quality Movement across RSP. TQM was adopted in RSP as the “business philosophy” and today forms the core of all our business strategies. No other strategy can be predictive of success in today’s competitive environment. We have been able to realize the “customer first” approach and percolate it down to the workmen level with associated changes in our attitude towards quality of our processes in general and quality of product in particular. Our first endeavor was to implement ISO 9002 Quality Assurance System (QAS) in both the Pipe Plants. Accordingly M/s TUV INDIA (PVT) LTD., the Indian counter part of M/s RWTUV, Germany, was appointed as the certifying agency. Pipe Plants were certified to ISO 9002 QAS in December 1993. Subsequently Plate Mill was certified to ISO 9002 QAS in December 1994. ERW & SWPP have been certified to API Q1 (American Petroleum Institute Q1) since inception. RSP participated in Quality Awards in 1991-92, organised by CII, Eastern Region, where certificate of appreciation have been awarded for making a meritorious beginning in introduction of TQM. So far 36 departments consisting of all the production departments, all the Mechanical & Electrical Shops, majority of the service departments, Personnel and Steel Township have been certified to latest version of ISO 9001:2008 Quality Management System. Being experienced in the field of Quality Management System, TQM department also was given the responsibility of facilitating implementation of other management systems like ISO 14001 EMS, OHSAS 18001 and SA 8000. Accordingly, Silicon Steel Mill was the first department to be certified with ISO 14001 Environment Management System (EMS) in the year 2000. Subsequently, SP-II, HSM, PM, SWPP, ERWPP, SPP and Steel Township were certified to latest version of ISO 14001:2004 EMS. RSP’s Steel Township is the first Township of SAIL to be certified for both ISO 9001 QMS and ISO 14001 EMS. Implementation of Occupational Health & Safety Assessment Series (OHSAS) 18001:2007 standard was done across the plant and Finally entire Rourkela Steel Plant has been certified with OHSAS 18001:2007 standard in April’ 2010. To implement, document and maintain all the management systems in RSP, a Three Tier Management Review is held regularly by HODs, GMs and ED (Works)/ED (P&A). TQM Department facilitates in monitoring and controlling Quality, Environment and Occupational Health & Safety Objectives of the certified departments.



To inculcate TQM culture among the employees of RSP, Quality Month Celebrations are held every November. Essay, Debate & Quiz Competitions related to Quality is held every year during the Quality month among employees to bring Quality Awareness and motivation. Plans are ahead, for certification of Social Accountability i.e. SA 8000 in RSP and also for integration ISO 9001:2008 QMS certificates of Iron & Steel Zone, Rolling Mills Zone and Shops & Services Zone into one certificate as RSP (Works) during 2010-11. IMS (Integrated Management System) Policy covering Quality, Environment, Occupational Health & Safety and Social Accountability of RSP has been developed with approval of MD, RSP. Integration of various management systems in RSP is there in the future plans under IMS.


Panorama 2010

ADDITION MODIFICATION REPLACEMENT PROJECT MONITORING & SPECIAL CELL (AMR PM&SC)

Functioning of AMRM&SC: AMR-M&SC is the Nodal Agency for Capital Investment Schemes. The Cell scrutinises all Capital Investment Schemes, obtains sanction and monitors the progress of the sanctioned schemes. The methodology adopted is:

Getting Capital Investment Proposals at the beginning of each financial year. Compile the schemes and obtain funds from Corporate Office. Prioritise the schemes as per allocation of funds. Scrutinise each prioritised proposal thread bare and obtain sanction. Monitor the overall progress of the sanctioned schemes.

For prioritised schemes estimated below Rs.10 lakhs the Cell itself scrutinises the proposal and puts up for sanction. For schemes estimated above Rs.10 lakhs the Cell puts up the proposals to a duly constituted “Investment Proposal Scrutiny Committee” generally known as IPSC for further scrutiny and screening. All IPSC cleared schemes of estimated value less than Rs, 20 Crore put up to an APEX Committee for prioritization. Schemes below Rs.10 Lakhs are also put up by AMR-PM&SC to the same APEX Committee for prioritisation. Thereafter necessary sanction orders are issued after obtaining MD's approval. For all IPSC cleared schemes of estimated value more than Rs, 20 crore put up to a committee known as Project Appraisal Group (PAG) for prioritization and thereafter send to corporate office for necessary sanction. All expansion plan projects are also scrutinized and processed by AMR-PM&SC for obtaining corporate sanction and thereafter local sanction orders are issued. AMR-PM&SC is the agency to constitute survey committee for write-off action and also the convenor of Central Survey Committee which recommends the “Replacement” of written off assets. AMR-PM&SC usually does not deal with assets of Administrative Category (such as Furniture, Photocopiers etc.). Some of the items sanctioned through AMR-PM&SC and seen around us are Mobile Equipment and Transport Vehicles, Hospital Equipment, High Mast Luminaries Towers, Weigh Bridges, Lease line Internet Connectivity, Re-building of Coke Oven battery, Oxygen Enrichment system for Blast Furnace and many more. In 2008-09 Rs.50 crores were allocated and in 2009-10 Rs.50 crores are allocated to RSP from Corporate Office for AMR Schemes. Awarding of consultancy to Centre for Engineering & Technology (CET) for any feasibility study and making tender specification is also undertaken by AMR-PM&SC. In addition to that AMR-PM&SC co-ordinate the dumping activity like generation of new dumping yard, issue of dumping permission for zero value items etc. and also co-ordinate security related issues like boundary wall inspection, visit of central intelligence team, review of security aspects of plant etc.



PROJECTS

The Projects Department of RSP is headed by Executive Director (Projects) supported by GMs (Projects). A multi-disciplinary IPM (Integrated Project Management) team consisting of officers from Project, Materials Management, Finance & Personnel, functions under the direct control of ED (Projects). The Project Department is also assisted by a Safety Department Team headed by DGM (Safety). The Expansion of RSP is being implemented by Projects Department. EXPANSION OF RSP: .1 Expansion programme of RSP to 4.2 Mtpa crude steel capacity with a state-of-art facility

was approved in-principle by SAIL Board in its 324th meeting held on 21st May’ 2007 at an indicative cost of Rs.7668 Crores net of CENVAT (base date: 1st Qtr. 2007).

.2 SAIL Board in its 351st & 351st (extended) meeting held on 15.06.2009 & 19.06.2009, after a

review of the expansion plans of SAIL plants (including investment in mines), approved an expenditure of Rs. 70,169 Crores. In the case of RSP, the total revised cost is Rs.11,812 crore (net of CENVAT).

.3 The production capacity of Hot Metal, Crude Steel and Saleable Steel after expansion plan

is indicated below:

Item Present After Expansion Hot Metal 2.0 MTPA 4.5 MTPA Crude Steel 1.9 MTPA 4.2 MTPA Saleable Steel 1.671 MTPA 3.9 MTPA

Techno-economic parameters Item Present After Expansion Coke/ Fuel Rate (Kg/thm) 577 392 BF Productivity (t/m3/d) 1.37 2.14 Specific energy (Gcal/tcs) 7.98 5.80 Manpower Productivity (tcs man/year) 148 262

The implementation of following packages has been deferred:

Reconstruction of Blast Furnace No. 1 Hot Strip Mill Modification New CRNO Complex New Facilities in CRM Complex


Panorama 2010 The above facilities are proposed to be taken-up after the New Plate Mill has been stabilized.

Consultants: MECON has been appointed to provide engineering & consultancy services for the facilities in the Iron & Steel Zone while M/s. M.N. Dastur & Co. shall provide the same services for the Rolling Mill Zone. M/s. CET has been entrusted with the consultancy services for the packages pertaining to Coke Oven Battery No.6 and M/s RITES for the Rail infrastructure and logistics.

The units under the Expansion Project are briefly detailed below:

Augmentation of OBBP and Blending Facilities. Execution Agency: Consortium of 1) M/s HEC Ltd, and 2) M/s Shapoorji Pallonji, Kolkata Likely date of completion: February’ 2011 The present modernization programme of RSP will increase production of hot metal capacity from 2.0 Million tonnes per annum to 4.5 Million tonnes per annum. The new material requirement of RSP will increase to about 12 Million Tonnes per year from present requirement of 5.0 Million tonnes.

RSP-REVISED 4.5 MT HOT METAL

4.2 MT CRUDE STEEL(0.820 MT SEMIS)

3.9 MT SALEABLE STEEL

RSP-REVISED 4.5 MT HOT METAL

4.2 MT CRUDE STEEL(0.820 MT SEMIS)

3.9 MT SALEABLE STEEL

SINTER PLANT 2 x 125m2(EXISTING SP1)1 x 192m2 (EXISTING SP 2)

1 x 360m2 (NEW)

SINTER PLANT 2 x 125m2(EXISTING SP1)1 x 192m2 (EXISTING SP 2)

1 x 360m2 (NEW)

BLAST FURNACE BF # 1 1250m3 (EXISTING) BF # 4 1658m3 (EXISTING)

NEW BF # 5 4060m3

BLAST FURNACE BF # 1 1250m3 (EXISTING) BF # 4 1658m3 (EXISTING)

NEW BF # 5 4060m3

COKE OVEN BATTERIES 5 EXISTING

1x67,7m,NEW BATTERY#6

COKE OVEN BATTERIES 5 EXISTING

1x67,7m,NEW BATTERY#6BF SINTER 6,760,000 1,855,000

NEW P C M (1 x 1500 t/d)28,900 COLD PIGS FOR SMS I & II

201,800 COLD PIGS FOR SALE

NEW P C M (1 x 1500 t/d)28,900 COLD PIGS FOR SMS I & II

201,800 COLD PIGS FOR SALE

SMS – I I ( 3/3 BOF OPERATION )2 x 150 t – EXISTING, 1 x 150 t – (NEW)

SMS – I I ( 3/3 BOF OPERATION )2 x 150 t – EXISTING, 1 x 150 t – (NEW))

4,500,0004,410,000

GHMNHM238,500 HM

SMS- I ( 1/2 OPERATION )2 x 65 t BOF

SMS- I ( 1/2 OPERATION )2 x 65 t BOF

SEC. REF. (EXISTING)1 LF,1 VOR,1 VAR

SEC. REF. (EXISTING)1 LF,1 VOR,1 VAR

CCP – I 1X1-STRAND (EXISTING)

CCP – I 1X1-STRAND (EXISTING)

506,500 HM

LS 508,400

LS 508,400

SEC. REFINING (150 t EACH)1 LF (EXIS.), 2 LF, 1 RH - OB (NEW)

SEC. REFINING (150 t EACH)1 LF (EXIS.), 2 LF, 1 RH - OB (NEW)

CCP – II 2 x 1–STRAND SLAB CASTER (EXIST.), 1 x 1 – STRAND SLAB CASTER (NEW)

CCP – II 2 x 1–STRAND SLAB CASTER (EXIST.), 1 x 1 – STRAND SLAB CASTER (NEW)

3,772,000 LS

3,772,000 LS

EXISTING1700 MM HSM

EXISTING1700 MM HSM EXISTING

PLATE MILL(3.1 M WIDE)

EXISTINGPLATE MILL(3.1 M WIDE)

1,850,000 SLABS3,700,000 SLABS

1,000,000

EXIS.ANN/PICK LINE

EXIS.EXIS.ANN/PICK LINEANN/PICK LINE

EXIST. CRNO FACILITIES

EXIST. CRNO EXIST. CRNO FACILITIES FACILITIES

ERWPIPE PLANT

ERWERWPIPE PLANTPIPE PLANT

SPIRAL WELD PIPE PLANT

SPIRAL WELD SPIRAL WELD PIPE PLANTPIPE PLANT

75,000CRNO SLIT COILS

& SHEETS

EXISTING PICKLING LINE

EXISTING EXISTING PICKLING LINE PICKLING LINE

1,805600 HR COILS

AS ROLLED579,500

(Controlled Rolled)350,000

NORM. PLATES240,000

EXISTING1700 mm

REVERS.CRM

EXISTINGEXISTING1700 mm1700 mm

REVERS.CRMREVERS.CRM

5 STD 1420 mm

TANDEM CRM

5 STD 5 STD 1420 mm1420 mm

TANDEM CRMTANDEM CRM

PICKL. COILS

PROC. LINES

PROC. PROC. LINESLINES

16,792ELEC. TIN PLATES

HOT DIP GALV.I & II (Existing)HOT DIP GALV.HOT DIP GALV.I & II (Existing)I & II (Existing)

SLABS500,000

3,665,000

57,000ERW

13,000SPIRAL

WELDED

164,476 CR SHEET & ANN COILS

241,000

86,000 59,500

312,713

85,000 HR COILS

NEW PIPE COATING PLANT

NEW PIPE NEW PIPE COATING PLANTCOATING PLANT

60,000COATED PIPES

18,000 42,000

120,415HDG PLAIN SHEETS

GROSS COKE- 2,443,400(2,192,000 BF Coke AND251 ,400 Under size, out of

which 270,000 BF coke willbe surplus)

325,000 HR COILS

BF COKE

ANNEAL SPM & ANNEAL SPM & ANNEAL SPM &

NEWPLATE MILL(4.3 M WIDE)

NEWPLATE MILL(4.3 M WIDE)

530,000

NORM. FACILITIESIN EXISTING FEC

NORM. FACILITIESNORM. FACILITIESIN EXISTING FECIN EXISTING FEC

AS ROLLED249,800

490,800HR COILS/SHEET/PLATES FOR SALE

1,245,400

HR COILS/SHEET/HR COILS/SHEET/PLATES FOR SALEPLATES FOR SALE

1,245,4001,245,400

SLABS FOR SALE170,000

SLABS FOR SALE170,000

197,959 114,754

SLABS INTERPLANTTRANSFER TO BSL

650,000

SLABS INTERPLANTTRANSFER TO BSL

650,000

FLOW CHART



Raw Materials being served by OBBP at present:

Blast Furnace 4 Nos. : 3 x 1139 Cu. M useful volume, 1 x 1658 Cu. M useful volume, Raw material : Iron Ore Lump

Sintering Plant

SP-I : 2 x 125 Sq. M grating area Raw material : Base Mix SP-II : 1 x 192 Sq. M grating area Raw material : Base Mix, Trimming addition Coke & Flux

Lime Calcining Plant-I 1 Nos Kilns of 150 tpd capacity Raw material : Lime stone & Dolomite

Lime Calcining Plant-II 4 Nos Kilns of 250 tpd capacity Raw material : Lime stone & Dolomite

THE TURNKEY PACKAGE CONSISTS OF:

Receiving, Unloading, Stacking, Reclaiming and finally transporting of raw materials required for Blast Furnace No. 5, Lime calcining plant (new as well as existing), Flux crushing unit and new proportioning bins for base mix facilities.

Base mix preparation Plant for SP-II & SP-III including Flux and fuel (coke) crushing units, receipt of plant arisings, base mix preparation, stacking & reclaiming to Sinter Plant—II and Sinter Plant-III.

Transportation of Flue dust, Mill scale etc. from ground hopper/ junction house to new proportion unit.

Transportation of crushed fuel and flux for trimming addition to Sinter Plant –II and Sinter Plant-III.

New conveyer line for transportation of Lime Calcining Plant grade limestone and Dolomine to consuming units.

Automatic Sampling system, 2 Nos. with Sample Cutter, Collection, Sizing, Crushing and grinding facility.

FACILITIES / EQIPEMENTS IN PACKAGE:

Unloading : Wagon Tippler: 1 No. Track hopper: 1 No.

Stacking & Reclaiming :

4 No of Beds to stack the incoming raw materials Equipments in 4 no Beds

• Twin Boom Stacker : 1 No. • Stacker cum Reclaimer : 1 No. • Barrel Reclaimer : 2 Nos. • Bucket wheel Reclaimer: 1 No.


Panorama 2010

Flux & Fuel Crushing Unit: Flux Crushing Unit:

To crush there will be 4 Nos. parallel closed loop crushing and screening streams to provide (-3) mm fines of SP grade Limestone & Dolomite.

Fuel Crushing Unit: To crush the coke to (-3) mm with the help of Double roll crushers. There will be two primary crushers and 4 Nos of secondary crushers.

Base mix preparation, Stacking and Dispatch.

Base mix preparation One proportion building has been envisaged where the following materials will be stored in bunkers and will be drawn through Weigh feeder in desired proportion to make base- mix. S.N. MATERIAL SIZE DISTRIBUTION (MM) 1. Iron Ore fines 0 to –10 mm 2. Lime stone / Dolomite

(crushed) -5 mm having 90% -3 mm

3. Coke breeze (crushed) -5 mm having 90% -3 mm 4. Mill scale 0 to –10 mm 5. BF Sinter return fines 0 to – 5 mm 6. LD slag 0 to – 10 mm with 20% higher size

The base mix will be stacked in 2 Nos base mix bed and reclaimed. Equipments coming in base mix Beds: Twin Boom Stacker : 1 No. Barrel Reclaimer : 2 Nos Transfer Car : 1 No.

Auto Sampling System:

Two separate Auto sampling system complete with Sample Cutter, collection, sizing, crushing and grinding shall be provided for OBBP system

Intra Plant Transportation of Materials: Conveyorisation for intra plant transportation of various bulk materials between OBBP, SP-III, BF#5, SMS-II, coal etc. Executing Agency: MBE, Kolkata Likely completion: February’ 2012 The entire work under this package will be executed on turnkey basis. This specification / scope of work shall cover the following systems,

Transportation of coal from RCC silos of New CHP for CDI injection into B.F. # 5. Transportation of coke from CDCP, de-dusting of coke in CDU, Coke Sorting, Coke

Screening, further transportation to Intermediate Coke Bunkers and conveying to stock house of BF#5 and Coke Crushing Station of new OBBP.



Transportation of coke from existing Coke Oven to Stock House of BF#5. Transportation of finish sinter from Sinter Plant # 3 to Blast Furnace # 5 and existing

Blast Furnaces. Transportation of iron ore lump, additives from new and old OBBP to Stock House of BF

# 5. Transportation of iron ore fines, coke fines and sinter fines from Fines Buildings of BF #

5 to Base Mix System of new OBBP Transportation of finish sinter from Sinter Plant # 2 to Blast Furnace # 5. Stacking of Slag and Loading into Railway Wagons.

Coke & Coal Chemical

New 7 mtr tall Coke Oven Battery # 6 with 1 X 67 ovens. Execution Agency : MECON, Ranchi Likely date of completion: February’ 2011.

To feed the coke to the new Blast Furnace #5 coming up under 4.5 Mt/yr hot metal production expansion plan, one 7m tall battery of 67 ovens is being installed in the new coke oven complex in the location of old Fertilizer Plant.

BASIC DESIGN: The battery will be top charged, compound twin flue, under jet, regenerative heating with partial re-circulation of waste gases. Ovens will have 3 nos. of charging holes and the battery will have double gas collection mains, one each on pusher side and coke side. There will be two waste gas tunnels, one each on pusher side and coke side, with common tunnel leading to chimney located on pusher side in the middle of the battery. The Computerized Heating Control System (COHC) supplied by M/s Siemens VAI, Finland will be installed for the battery operation for the process management system to improve reduction in environmental emission, improve coke quality & productivity.

Battery heating system is designed for under firing with clean coke oven gas with average heating value of 4200 kcal/Nm3 and/or mixed gas with average heating value of 1000 kcal/Nm3.

There will be a coal tower of 4000 t useful capacity for storing coal with dry equivalent bulk density of 740 Kg/m3. Buttress walls will be connected together at the top by longitudinal tie rods. To ensure proper loading, adequate numbers longitudinal tie rods will be provided with helical springs. Description of Proposed facilities to achieve air pollution norms:

Leak Proof Doors Water Sealed AP Covers


Panorama 2010

HPLA (High Pressure Ammonical Liquor Aspiration) Door & Frame cleaner High Pressure Water Jet door cleaner Land based Pushing Emission Control (PEC) System Effluent Disposal Coke Dry Cooling Plant (CDCP)

The technical data for the battery is as given below:

No. of Ovens 67 Total Height of Battery 7 M Useful Height 6.7 M Useful Volume 41.6 M3 Production of run – of – oven Coke (Dry) 0.768 MT/Y Total length (between buck stays) 16,000 mm Total useful length 15,160 mm Width at pusher side 385 mm Width at coke side 435 mm Average width 410 mm Useful volume of oven 41.6 m3 Axial distance between ovens 1.400 mm No. of flues in heating wall 32 Distance between the flues 480 mm

The Pollution Control Stipulations applicable to New Coke Oven Battery as per MOEF as follows

Leakage from Doors – 5 % Leakage from Charging Lids – 1 % Leakage from AP Caps – 4 % Charging Emissions – 16 seconds / charge (with HPLA)

New Oven Machines of 7 mtr. Tall Coke Oven Battery # 6 Execution Agency : M/s Bhilai Engineering Corporation, Bhilai Likely date of completion : August’ 2010

The scopes of supply for oven machines for COB # 6 under the subject package are as under;

Machines Nos. Coke Pusher Car (PC) 2 Coal Charging Car (CC) 2 Coke Transfer Car (TC) 2



The Coke Transfer Car will supplied along with a land based Pushing Emission Control (PEC) System.

Coke Pusher Car The Coke Pusher Car shall comprise of four distinct and independent units viz; Leveler, Pusher, Door Extractor cum Door and Door frame cleaner and long travel along with other auxiliary facilities mounted on a structural frame with air conditioned operator’s cabin. The track rail size is CR-100 with leveled gradient and nil curvature. The machine has PLC based automation.

Coal Charging Car The Coal Charging Car will be of screw feeder type having VVVF Drive for precision control of screw feeder’s speed. It will have 3 bunkers with adequate capacity for charging an oven having thee charge holes and a min. chamber volume of 41.6 m3. The coal blend will be collected from a new coal tower (No.5). The Car shall complete the charging operation within 120 seconds(simultaneous charging) Coal Charging Car will ensure emission free charging of ovens (as per statutory stipulations) with HPALA system in operation for on-main charging. All actuations of this equipment will be hydraulic, except long travel and some of the motions of AP and Gooseneck cleaner. The operator’s cabin shall be provided with air- conditioner. Coke Transfer Car The Coke Transfer Car will perform all the required functions on coke side such as to remove the door, clean the door & door frame, fix the door, clean the oven sole, transfer the hot coke into hot coke bucket, and control the pushing emission. The cycle time for Car has been envisaged as less than or equal to 11 minutes. The equipment moves on two rails (size 60 Kg/m) mounted on the coke side of the battery. One of the rails can also be mounted on the service platform on the coke side of the battery. The operator’s cabin shall be equipped with air-conditioning facility.

The oven machines such as Charging Car (2 nos.), Pusher Car (2 nos.), Coke Transfer Car (2 nos.) along with Pushing Emission Control System (PEC) have been envisaged in this package for providing and handling Input and out put of Coke Oven Battery with a cycle time of 11 minutes.

New Coke Dry Cooling Plant for 7 mtr. Tall Coke Oven Battery # 6

Execution Agency : M/s Bhilai Engg. Corporation, Bhilai Likely date of completion : December’ 2010

The Coke Dry Cooling Plant (CDCP), having four chambers and of coke cooling capacity of 0.768 Mt/yr of gross coke (dry) per annum, will be installed to cool the coke produced from Coke Oven Battery No. 6. The pushed coke from battery shall be transported to CDCP unit by means of self propelled hot coke bucket car.


Panorama 2010 The principle of coke dry quenching is based on cooling of hot coke with inert gas circulating in close loop between the chamber of hot coke and the waste heat Boiler. The heat is recovered from the red hot coke through the heat exchanger via direct contact between the circulating inert gas and red hot coke with the transfer of this heat to the Waste Heat Boiler. The quenched coke is discharged from the quenching chamber automatically by Discharging Device in pre set condition. Data analysis of Blast Furnace operation show that specific coke consumption decreases by 3-5 % by using dry quenched coke. Technological Parameters/Features of CDCP

Description Unit Value

Temperature of coke charged in the chamber 0C 1050

Temperature of coke after cooling 0C < 200

Temperature of circulating as before entering cooling chamber 0C 170-180

Temperature of circulating gas before waste heat boiler 0C 750-800

Thermal efficiency % 80-85

Pressure of steam generated ata 66

Temperature of steam generated 0C 500

Generation of steam / boiler t/h 25

Capacity of one cooling chamber t/h 52-56

Time of coke cooling in chamber h 2-2.5

The major facilities for the CDCP are Coke cooling chamber, Waste heat boiler, Coke bucket lifter, Main mill fan & Auxiliary mill fan, Circulating gas duct, Hoisting & Handling equipment, Dust catching bunker, Dust cyclones, Boiler circulating pumps, Pneumatic transport system for coke dust, Ventilation equipment, Blowing device, Coke charging device, Boiler feed water pumps, De-aeration tank & column and Passenger cum goods lift of 1t capacity.

New Coal Chemical Deptt for 7 mtr. Tall Coke Oven Battery # 6

Execution Agency : (i) M/s Sriram EPC, Kolkata (ii) M/s Hutini Project, Frydek Mistek Likely date of completion : February’ 2011.

The new CCD is being installed to process coke oven gas generated from the new Coke Oven Battery # 6. The purpose of the CCD is to clean the raw coke oven gas with removal of Tar, Ammonia, Hydrogen Sulphide and Naphthalene. The coke oven gas shall also be cooled finally to 300 0C at the outlet of final gas cooler.



The CCD shall consist of the following technological units: Gas Condensation Plant H2S removal unit & recovery of Sulphur Ammonium spray absorber system for ammonia removal & recovery and processing

concentrated solution in the existing salt handling & bagging unit of COB # 1 to 5. Final gas cooling and naphthalene removal & recovery unit. Chilled water plant Cooling water system Storage facilities for Raw Material & Finished Products

The liquid effluent generated within the CCD area shall be taken to the existing B.O.D. Plant by means of underground network. Monitoring and control of the process parameters, sequential operation and logic & interlock functions of the process and equipment of the CCD shall be achieved through DCS based automation system. New Coke Chemical Deptt will have Sulphur removal system. There will be Naphthalene Washer and Benzole Scrubber to have clean coke oven gas for use of the Plant.

Up gradation of existing CCD (11 packages) The up gradation of existing CCD (both 1.0 MT & 1.8 MT units) primary involves; i) Replacement of existing equipments with new equipments on existing foundations and

also at new locations on new foundations, ii) Installation of new equipments and new units, iii) Installation of new schemes to remove operating problems encountered in CCD. The entire work is being executed through 11 different packages, identified suitably to facilitate grouping of similar nature of work in one package. Gas pre-cooler (Primary Gas Cooler), Decanter, Pit Tank & Associated Accessories (1.0 MT & 1.8 MT) The scope broadly covers dismantling, supply of decanter and associated accessories, Strainer pot, process and utility piping, valves & fittings, electrics including electric motor, cable, push buttons control panel, civil & structures and interconnecting process & utility piping with existing Decanter system for separation of Tar & Liquor of CCD plant etc. for 1.0 MT and 1.8 MT side of RSP respectively. Total GPCs – 6 nos., Decanters, Pit Tanks - 2 nos.

Knock – out Pot Condensate Seal Pot, Gas Mixer and Interconnecting Coke Oven Gas Pipelines & Valves and Receipt & Storage Facility for H2SO4 (In Equipment Column)


Panorama 2010 Ammonia Liquor Treatment Plant/ Ammonium Sulphate Plant

Gas Booster (Turbo-Compressor at 1.0 MT Side) In CCD there are four Coke Oven gas processing streams installed with Coke Oven Batteries (under 1.0 MT & 1.8 MT stages). The clean Coke Oven gas after final cooling is admixed with BF & LD gas in gas mixer and boosted in 3 nos. mixed gas boosters to supply the gas in steel plant fuel network. In the present contract of up gradation of existing CCD, 2 nos. of electrically driven Gas Boosters shall be installed in the existing compressor house of Gas Condensation Plant (GCP) in CCD. The volumetric capacity at suction shall be 46500 m3/ hr with suction pressure of 1.01 atm (abs) and discharge pressure as 1.40 atm (abs).

Elecrolytic Tar Precipitator – 2 nos. ETPs in first stream & 2 nos. ETPs in second stream

Instrumentation – During the up gradation of CCD, a number of new technological units have been envisaged, while other technological units have been planned to be refurbished/ upgraded. Wherever possible, the Control & Instrumentation (C&I) of these units have been included in the scope of the turnkey contractors for these units. The balance C&I requirements of CCD , with a view to achieve safe, reliable, efficient and trouble free operation of the different units and safety of the operational personnel, the scope has been kept in this package. Likely completion: 10 packages (except ETP): October’ 2010 ETP: August’ 2011

Coal Handling Plant Execution Agency : M/s MBE, Kolkata Likely date of completion : December’ 2011 New Coal Handling Plant have been planned to have 15 days stock of Coking Coal for COB - 6 (@ 3500 T/day) and CDI Coal of 10 days stock @ 1500 T/day). For stocking of Coking Coal there will be 24 nos RCC silos each capacity 2500 Tons and for CDI Coal, there will be 6 nos of RCC silos, each capacity 2500 Tons. The major scope of work and supply of New Coal Handling Plant (CHP) are given below:

Installation of 2 (two) nos wagon tippler Transportation of coal unloaded by wagon tipplers to RCC silos for storing of both Coking

coal and CDI coal. Reclamation of coking coal from RCC silos by belt weigh feeders and further transportation

to crushing station by belt conveyor. 4 nos crushers in crusher building. Transportation of crushed coking coal from crushing station to coal towers by belt conveyor. Weigh feeders below coking coal silos shall be provided with automatic proportioning device

and digital system for accuracy. These feeders shall be VVVF (Variable Voltage & Variable Frequency) controlled AC drives.

Reclamation of CDI coal from RCC silos by vibro feeders and further transportation to junction house by belt conveyor.



New Sinter Plant No 3

Execution Agency : Consortium of M/s L & T & Outotec, Germany Likely date of completion: March’ 2011 This is a single strand Sinter Plant having an effective suction area of 360 m3 with an annual production capacity of 3.70 MT of gross sinter. The sinter productivity will be 1.3T/m2 /hr and the machine will operate at an under grate suction of 1650 mmWC for 330 day/Year on 24 hrs/day basis. There will be two wind mains followed by two ESPs leading to a 120 m high concrete chimney. The output stack emission will be less than 50 mg/Nm3. The sinter plant being provided with Eirich type mixer and noduliser instead of the conventional mixing & balling drum. A circular cooler is being provided for sinter cooling. Another new feature is pneumatic conveying of ESP dust. The ESP dust will be charged to the sinter raw mix bed after passing through an Eirich type Granulator. The Eirich type mixer, Noduliser & Granulator are being installed for the first time in SAIL Plants. Technical Details of SP-3

Sintering area 360 Sq meter Spec. Productivity 1.3 T/m2/hr Size of finished sinter 5- 40 mm Annual working

regime 330 days

Under grate suction 1650 mmWC Bed Height 700 mm max Circular annular dip rail deep bed type sinter cooler 396 Sq meter Tumbler Index +6.3 mm 75%

min RDI 30% max

Reducibility Index 65% min Gas consumption 15000 Kcal/T Make up water 0.18 m3/ T Sp Power

consumption 41 KWH /T

Avg. temp of cooled sinter

100 ºC Stack emission Below

50 mg/NM3

Rated Capacity of incoming raw material:

1500 tph, Belt width 1400 mm at 2.0 m/sec,

Rated Capacity of outgoing product sinter:

550 tph, belt width 1200 mm at 1.5 m/sec.


Panorama 2010 New Blast Furnace # 5 & Auxiliaries

a) New Blast Furnace # 5

Execution Agency : M/s TATA Projects Ltd & M/s Danieli Corus Likely date of completion: April’ 2011

The Furnace comprise of twin flat cast house with four tap holes. The Furnace is equipped with modern features such as pulverized coal injection system., cast house fume extraction system, cast house slag granulation system, the top gas recovery turbines of 14 MW capacity, Twin material bin BLT system, Waste Heat Recovery System, Plate/Stave Coolers, Conveyor Belt Charging System, decreased coke rate of 360 Kg/thm (min) and Level II Automation system.

The Blast Furnace # 5 complex shall be installed under expansion scheme of Rourkela Steel Plant, Rourkela, Orissa. The Blast Furnace shall be designed to operate on 60-80% Sinter, 20% Lump Iron Ore (max) and 10-20% pellet charging (future provision). The Blast Furnace plant shall be designed for a production capacity of 2.8 Mt/yr with a daily hot metal production of 7924 T (avg.) and 8320 T (max) in torpedo ladle.

The Blast Furnace will be operated at high intensification level and for a campaign life of 20 years. Accordingly the raw material handling system, interplant pipeline system, and other service facilities like water, gas facilities, power distribution, electrics, instrumentation and automation will also be designed keeping in view the production level of 8320 T/day from this Blast Furnace plant. Blast Furnace sizing Based on the quality of raw materials, high operating intensity productivity and campaign life, the selected Blast Furnace designed by the Contractor will have the following major design parameters.

Hearth Diameter, m 13.2 Number of Tuyeres 36 Furnace Working volume, m3 3470 (approx) Furnace useful volume, m3 4060 (approx.) Daily hot metal production 7924 tpd (average) 8320 tpd (maximum) Annual hot metal production 2.8 Mt / yr Campaign life 20 years (with minor intermediate

repair)



The details of operating parameters selected for the Blast Furnace are given in the following Table.

S1. No. Parameter Unit Value

1 No. of Blast Furnace No. 1 2 Working volume of BF m3 - 3470 3. Useful volume of BF m3 4060 4. Hearth diameter m 13.2

5. Production per day t/d 7924 (avg.) 8320 (max)

6. Ash content of coke % 15 7. Ash of Coal (imported) % 9-10 8. Sinter in burden % - 80 9. Sized ore in burden % -20

10. Pellet in Burden (future) % -(10-20) 11. Availability of Blast Furnace day/yr. 350

12.

Sp. cons. of input materials (Net & dry basis kg/thm

Iron ore lump As required Sinter / Pellet As required Lime stone As required Quartzite As required Coke rate (Including -20 Kg Nut Coke 8-34 mm) 360

Coal dust (CDI coal) 150 (avg.) 200 (Design)

13.

Blast characteristics Volume (dry basis) Nm3/min 6125

Temperature oC 1200 oC (avg.) 1250 oC (max)

Humidity g/Nm3 40-60

Oxygen enrichment % 4-6 %

14.

BF top gas characteristics (Net & dry)

Pressure. (Max. operating) Kg/cm2(g) 2.5 Volume Nm3/thm 1500 – 1550 Temperature deg C 100-200 oC CO % 25.2-25.7 CO2 % 21.7-21.9 N2 % 46.4-47.6 CO/CO2 Calorific value kCal/Nm3 875 (approx.)


Panorama 2010

S1. No. Parameter Unit Value

15.

Hot metal characteristics Si % 0.6 (max) S % 0.050 P % 0.15 Desired hot metal temperature Deg. C 1450-1500

16. Slag characteristics Slag rate kg/thm 290-310 Slag temperature Deg.C 1500-1550

New Turbo Blower Station

Execution Agency : M/s Bharat Heavy Electrical Limited Likely date of completion : May’ 2011

03 nos of Turbo Blowers (2 working + 1 standby) along with its all auxiliaries shall be utilized to provide cold blast to the stoves of new BF # 5. The blowers shall be axial with last stage redial type. Air Blowers with variable speed control, single shaft, and multi stage without intercoolers and directly coupled to the turbines without gearbox. The parameters of each blower shall be: Discharge flow : 2550 to 3500 Nm3 /min at 9 to 1 duty point Discharge Pressure : 4.0 to 5.2 Kg/Cm at 9 to 1 duty point Normal flow requirement of new BF#5 shall be 5500 Nm3 /min Boiler, STG, BPTG & Blowing Station

Execution Agency : M/s Thermax, Pune Likely date of completion : August’ 2010

In this package, there are 3 nos of boiler arrangement and 2 nos of steam turbo generator and one no. back pressure turbo generator. Boiler will generate steam at a rate of 300 TPH 485 +5/-2oC and 62 Ata by evaporating water with the help of Blast Furnace gas, which has calorific volume 728 Kcal/Nm3 (GCV). This steam will go to 02 no of steam turbo generator each having 18 MW power generation capacity and same steam will go to back pressure turbo generator, which will develop 6.5 MW power. This steam will also be used to run 03 nos of turbo blowers, which shall be feeding cold blast to stoves of BF#5. Torpedo Ladles & Repair Shop

Execution Agency : Consortium of (1) M/s Simplex Casting Ltd., Bhilai (2) M/s Hyundai Heavy Industries, Korea Likely date of completion : Dec’ 2010

For transferring hot metal from the new Blast Furnace to Steel Melting Shop or at PCM by 10 nos. of Torpedo Ladles of 350 T capacity each has been envisaged under the current expansion plan. These torpedoes are of first kind to be used in SAIL with features like higher capacity and lesser hot metal temperature loss. A torpedo ladle repair shop is also envisaged wherein the



jobs like refractory lining, ladle inspection, ladle heating & cooling etc. will be done.

New Pig Casting Machine Execution Agency : M/s METCO, Kolkata Likely date of completion : August’ 2010

There is a twin strand 1500 TPD capacity Pig Casting Machine envisaged under the current expansion plan. It is an auxiliary unit of new Blast Furnace # 5. it comprises of a Pig Storage Yard, Pig Wagon Haulage System, Circulating water system, Graphite & Lime Milk preparation and splashing system, Pig Dispatch Wagons etc. The average strand speed will be 9m/min.

Augmentation of SMS-II

Conventional (1 x 1 Strand) Slab Caster (# 3)

Execution Agency : SMS SIEMAG (Germany & India) Likely date of completion : February’ 2011

Technical parameters and design features of the proposed Conventional Slab Caster: The slab caster shall be of latest design with state-of-the-art technology and equipped with modern features such as ladle to tundish slag detection system, vertical high speed mould with automatic width adjustment, hydraulic mould oscillator, automatic mould level controller, break-out prediction system, air mist spray cooling system, dynamic spray cooling system, continuous straightening, automatic torch cutting machine, slab pusher cum piler arrangement, transverse torch cutting machines and computerised process control system (Level II), etc. Technological parameter of Conventional Slab Caster

Annual production of liquid steel: 3,772,000 t/yr Liquid steel to be cast through slab caster: 546,392 t/yr Quantity of cast slabs: 1,500,000 t/yr No of BOFs :3/3 x 150 t Heat size, 150 t (nominal: 165 t (maximum) Heat delivery cycle: 50 min No. of continuous slab casting machines : 1 No. of strand : 1 Type of machine Vertical mould with progressive bending/unbending Base radius, 9.0 m Approx (Tenderer to indicate)

Design Feature:

Design range: 210 - 300 x 1200 – 2500 mm x mm Machine equipped to cast: 220, 250, 300 x 1200 – 2400 mm x mm Slab length: 6000 – 10000 mm Type of unbending : Continuous straightening Casting time: ~ 50 min. (Tenderer to indicate)


Panorama 2010

Casting speed for different sizes and grades: (1.5 – 2.2) m/min, (tenderer to indicate) Machine speed: 0.6 – 6.0 m/min Preparation time: ~ 45 min. max No. of heats per sequence with one tundish: 12 - 15 Avg. no. of heats/day : 26 - 30 Caster availability: 330 days/yr approx. Tenderer to indicate Design Production capacity of CCM: 1,534,500 t/yr

3rd BOF Converter (1 X 150 T)

Execution Agency : SMS SIEMAG (Germany & India) Likely date of completion : May’ 2012

One top blown basic oxygen furnace (3rd converter) of capacity 165 m3 has been considered for this package. After installation of 3rd converter, all the three (3) converters will operate simultaneously. The 3rd converter shall be designed with provision for adoption of combined blowing/ inert gas stirring process. The salient operating parameters of new BOF converter is given below. The major design features of the BOF converter are indicated below.

No. of basic oxygen furnace proposed

1 x 150 t nominal capacity

No. of basic oxygen furnaces operating (from two existing and one new)

Shop shall be designed for three (3) converters operating simultaneously

Nominal heat size 150 t Maximum heat size 165 t Working volume with new lining 165 m3 Wear lining Magnesia-carbon bricks h/d ratio with new lining Approx. 1.4 Converter shell Shall be suitable for using bricks

with high conductivity magnesia-carbon bricks

Converter bottom Integral bottom type with provision for practicing combined blowing (inert gas stirring) process

Trunnions Hollow trunnions with bore size suitable for laying pipe lines required for practicing combined blowing (inert gas stirring) process and water cooling system (soft water) for converter top cone and vessel



Ladle Furnace (# 3) Execution Agency : M/s Sarralle Likely date of completion : August’ 2011

The contract include design, engineering, transfer of process know-how, manufacture / fabrication, procurement of bought out items, assembly, inspection and testing, painting and packing, transportation, supply of all plant and equipment, materials, site storage, spares and consumables, minor hoisting and handling equipment, technological structures, refractories, electrics, utilities, hydraulics, auxiliary facilities, testing, erection (excluding mechanical equipment), technical services in India and abroad on a fully co-coordinated basis, training of Purchaser’s personnel, supervision of erection, commissioning of all equipment / units demonstration of performance guarantees and handing over the secondary refining units along with related auxiliary facilities to the Purchaser within stipulated time schedule. Operating Parameters: 1. No. of ladle furnace No. : 1 2. Annual treatment at LF t/yr : 1,440,000 average 3. Average no. of heats to be treated at LF per day – Average: 30 4. Nominal heat size : 150 T 5. Maximum Heat size : 165 T 6. Transformer capacity : 30 MVA 7. Heating rate deg C/min > 5 deg per minute at operating top notch RH (OB) (under approval) The contract shall include: One (1) off-line RH – degasser has been envisaged for vacuum treatment of liquid steel before casting. Special value added products will be treated to achieve low level of absorbed gases, inclusion control, trimming addition of ferro-alloys and micro-alloys. The RH – degasser will be located in the ladle furnace bay of CCP II. Operating Parameters: 1. No. of unit One (1) 2. Heat size: 150 T (nominal) & 165 T (Maximum) 3. Type - A refractory lined vacuum vessel equipped with two refractory lined nozzles (snorkels)

attached to the bottom to the vessel- Lifting and lowering of vessel by hydraulic system alternatively by winch system)

4. Inert gas purging Inert gas stirring facility from one of the snorkels 5. Vacuum system Steam ejector 6. Vessel heating by top oxygen injection-cum-gas burner heating system to maintain refractory

surface temperature at 1,400 – 1,500°C. 7. Steel recirculation rate >110 t /min 8. Hydrogen level in steel, after treatment < 1.5 ppm 9. Alloy addition system Ferro-alloys and micro-alloys to be added under vacuum 10. Other features - Design provision for usage of water cooled O2 lance elf propelled transfer

car 11. Suction capacity Nominal – 550 kg/h at 0.5 mbar


Panorama 2010 12. Free board Minimum – 500 mm with 165 t heat size 13. No. of heat per day Nominal – 24 heats 14. Steel grades to be treated All low C, Micro alloyed, CRNO plate grade, high tensile steels

etc and other grades The Scope includes:

• RH vessel complete with o Vacuum vessels (1 + 2) o Hot offtakes (1+1) o Hot offtake jacking cylinders (4) o Walking pipe ( 1 set) o Gas cooler (1)

• Snorkel tube 3 pairs • Vessel bottom part heat shields & cooling pipes 3 sets • Vessel top part As required • Vessel cover As required • CCTV camera As required • Clamping screw As required • Seals As required

- Vessel refractory • Vessel handling ( Lifting & lowering) system Moving platforms and rocker system

comprising • 2 Hydraulic powerpack comprising of Vacuum pump system • Steam system comprising valves, pipe work, nozzles, ejectors, condensate traps, etc. • Water ring pump complete with motor, water separator, instruments, condensers • Booster 1 set • Spraying condenser 1 set • Seal tank 1 set • Gas cooler 1 set • Snorkel car including drives, lifting platform, hydraulic system, etc. • Snorkel & vessel deskulling machine 1 set • Exchange frame with hydraulic cylinders 1 set • Vessel bottom and top part repair facility 1 set • Drier for vessel top & bottom part 1 set • Condenser water system 1 set • Machine cooling water system 1 set • Auto ejector cleaning device 1 set • Snorkel jam breaking machine 1 set • Off-gas stack 1 set • Utility system comprising O2, fuel gas for preheater & oven • Electrics, instrumentation, automation level-1 and telecommunication-CCTV • Ventilation and air-conditioning • Fire detection and alarm system • Fire protection system



Lime & Dolo Kiln Complex for SMS-II & SP-III

Execution Agency : M/s F L Smidth & Cimprogetti Likely date of completion : February’ 2012

Addition of one Lime kiln (1x 350 TPD] Addition of one Dolo kiln (1x 350 TPD]

Addition of Lime sizing unit [Crushing Unit of Capacity 20 T / hr. to reduce lime size from 0-60 mm to 100% below 2 mm] for Sintering Plant -III The scope of work is to set up the kiln complex which includes kiln with up-stream and down stream facilities and its related material handling systems, air conditioning and ventilation system, dedusting system, waste gas cleaning system, all electrics and instrumentation, civil and structural works etc on turnkey basis. Raw material handling conveyor BC-10 will be extended towards the tail end about 20 m and conveyor will be upgrade to 400 tph. The kilns shall be constructed over the extended portion of 2 nos. of existing belt conveyors from existing kilns to flux storage building. The various equipments involved in the plant for storage, handling & screening of limestone/dolomite, vertical double shaft kiln including firing system, lime & dolomite delivery bin building including screening and storage facilities. The major equipments which are envisaged for kiln area are indicated below:

Shaft kiln complex consisting of 1 no. of 350 tpd vertical double shaft limekiln, 1 no. 350 tpd vertical double shaft dolomite kiln including refractories, skip charging system, discharging system of products, blowers for supplying air, firing system of the kilns, storage bunkers etc.

Belt conveyors for conveying the materials from one place to desired place, vibratory feeders, bin vibrators, vibrating screen, weigh hopper, chutes with liners, sector gates, switching devices, truck loading device, etc.

Waste gas cleaning and dedusting system of the kiln and all transferring points of materials.

Air conditioning & ventilation facilities at control room, office room etc. Shop electric, instrumentation & automation and illumination. Utility piping network & fuel handling facilities. Hoist and chain pulley block, elevator etc. Fire fighting facilities. Lime Sizing Unit for the new Sintering Plant –SP-III: The objective of lime sizing unit is to

reduce the lime size from 0-60 mm to 100 % below 2 mm having a capacity of 20 ton/hour comprising of Hammer mill with rod shifter with the help of electro-vibratory feeders and belt conveyors.


Panorama 2010 TOP- IV -2 X 700 TPD Oxygen Plant (BOO Basis)

Execution Agency : M/s BOC India Limited, Kolkata Likely date of completion : June’ 2011

The Oxygen Plant will be installed inside RSP premises on Build, Own & Operate (BOO) basis. The plant will produce Oxygen, Nitrogen and Argon both Gas/Liquid. RSP will purchase on a first right basis from M/s BOC India Limited. RSP will not incur any Capital Investment for the above facility. Augmentation of Power Supply Facilities

Augmentation of exiting MSDSs & Installation of new MSDS IV, V, VI

Executing Agency : M/s Siemens Ltd. Kolkata Likely Completion : October’ 2010

(i) MSDS-IV (NEW) Installation of one 220 kV GIS (Gas Insulated Substation) along with three no. of 160 MVA,

220/132 kV Transformers. The 132 kV side of Tr. shall be connected to existing MSDS-III

132 kV bus. MSDS-IV shall be connected to 220 kV Tarkera Grid S/s of OPTCL through a double circuit 220 kV line using HSL Fdr-3 towers (Existing HSL-3 132 kV line shall be converted to 220 kV and terminated at MSDS-IV).

(ii) MSDS-III (EXISTING)

Addition of one 62.5 MVA transformer at MSDS-III. Addition of One no. 132 kV Line Bay. Addition of One no. 33 kV Line Bay.

(iii) MSDS-V (NEW)

A new 132 kV GIS/33 kV S/s shall be constructed. It will feed from CPP-II and MSDS-II through double circuit 132 kV lines and have 3 nos. of 63 MVA transformers. It will feed the present loads of HSM, Plate Mill and CRM.

(iv) RM - 1 (NEW)

A 33 kV Double Bus GIS indoor switchboard for RM-1 for stable power supply to existing HRM loads.

(v) MSDS-II (EXISTING)

Addition of 4 nos. 132 kV bays, 7 nos. 33 kV bays and one 63 MVA transformer at MSDS-II. The New Plate Mill shall be fed from MSDS-II.

(vi) CPP-II (EXISTING)

Addition of 2 nos. 132 kV bays for feeding power to MSDS-V.



(vii) MSDS-VI (NEW) A new 132/33 kV S/s shall be constructed near Fertilizer Plant area. The BOO oxygen plant

shall be fed from MSDS-VI (having 2 nos. 132/33 kV 62.5 MVA transformers). It will be fed from MSDS-II and MSDS-III 132 kV system through single circuit line.

Medium Voltage Power distribution System with Intra-plant cabling & SCADA

Executing Agency : M/s L&T, Kolkata Likely Completion : February’ 2012

33 kV (4 nos.) and 6.6 kV (10 nos.) switchboards for power supply to all additional loads

including 33/6.6 kV transformers. Interplant cabling at 33 kV & 6.6 kV and new cable tunnels. Provision of Emergency power to modernization area loads. Plant SCADA & EMS.

Utility Packages: Propane/ LPG storage & Handling facilities

Executing Agency: M/s Globe Gas Equipment Industry Pvt. Ltd, Mumbai. Likely Completion: July’ 2011

Reasons for installation of Propane plant:

Cost of Propane is one third with that of Acetylene Storage for Propane is more safer than Acetylene (it is unstable ) Transportation of Propane is more safer than Acetylene Calcium Carbide is required for Acetylene plant which is scarce now a days and after use of

carbide lots of lime are generated; disposal of which is a problem.

Brief Description of the Technological Units: Propane will be received in road tankers and unloaded from the tankers by means of liquid unloading pumps and vapor compressors and filled in the storage vessels. Unloading shall be done by first liquid unloading pumps and after the complete withdrawal of liquid from the road tanker, which will be indicated from the sight glass indicator, the propane vapor shall be transferred by vapor compressor to storage tanks. Propane will be drawn from the storage vessels through the discharge liquid line and vaporised in the vaporisers. Thereafter, pressure of propane vapor will be regulated to a pressure of 1.5 – 2.5 kg/cm2 (g) and supplied to the consumers through headers. 2 nos. separate installations of Propane storage & handling system have been envisaged. One installation which shall meet the requirement of CCM-II and SRU, shall be located near existing Propane installation (2x 20t storage) in the Acetylene Plant II area, while the another installation which shall meet the requirement of CCM-I, New Plate Mill, Repair Shop & HSM shall be meet the requirement of CCM-I, New Plate Mill, Repair Shop & HSM shall be located opposite erstwhile soaking pits (SSD side) of existing area.


Panorama 2010 The following main units along with auxiliaries for Propane storage and distribution are required.

2 nos. unloading point for transfer of Propane to storage vessels in each area. 2 nos. 80 t (each) mounded storage vessels at existing Acetylene Plant-II and 2 nos. 60 t

(each) mounded storage vessels at opposite erstwhile soaking pits (SSD side) of existing area.

2 nos. (1W +1S) liquid unloading pumps (capacity 10t/h max.) for each unloading point in each area.

2 nos. (1W +1S) vapor compressors (capacity 29.2 m3/h (max.)) for each unloading point in each area.

3 nos. (2W+1S) SS coil immersed in electrically heated water bath vaporizers in each area; capacity 500 kg/h at existing Acetylene Plant-II and 250 kg/h at opposite erstwhile soaking pits (SSD side) of existing area.

Tonnage Oxygen Plant-III (sustenance package)

Execution Agency : Consortium of 1. M/s LINDE and 2. BOC India Ltd. Likely Date of Completion: August’ 2010

TOP-3 is being installed at RSP to meet the additional requirement of oxygen in BF-4 for coal dust injection and BOF-2 for simultaneous blowing. The capacity of the plant is 700 TPD and it is being supplied by M/S LINDE-BOCI consortium. The basic plant is of cryogenic type air separation plant capable of producing simultaneously gaseous and liquid oxygen, nitrogen and liquid argon. Cold box turndown ratio is 70-100%.

Augmentation of facilities

Simultaneous Blowing at SMS-II (under sustenance scheme):

Executing Agency: M/s Danieli for LHF, M/s BOC for utility package & 13 other packages Likely completion: Out of 15 packages, 13 packages have been completed & remaining 2 packages are expected to be completed in June’ 2010.

Presently, in SMS-II only one converter out of two is in operation at a time. The latent capacity of the shop can be utilized by providing infrastructure in the shop for simultaneous operation of both the existing BOF converters & slab casters. Each converter has the capacity to produce 28 heats day. Keeping in view the availability of BOF converters, it is possible to blow both the converters simultaneously to produce 56 heats a day. However, since the Slab Casters can take only 21 heats / day/ caster, the total number of heats that can be cast in the shop is 42 heats per day. Considering the downtime of both the BOFs & Slab casters, it is possible that for 219 days



in a year both the BOFs & Slab caster can be operated simultaneously & produce 42 heats per day. On remaining days, the facilities will be running as per existing practice. This will enhance the production capacity of the shop to 1.85 MT per annum. The facilities in SMSII are being augmented to facilitate simultaneous blowing of both the converters. For this purpose, secondary refining facility, piping network, for oxygen, nitrogen, water & other utilities are being strengthened. Material handling facilities like ladles, slag pots, etc have been procured.

Coal Dust Injection in existing Blast Furnace No. 4 (under Sustenance scheme):

Executing Agency: M/s Sino steel (SIDRI), China & M/s Techpro Chennai. Likely completion: December’ 2010

Modern Blast Furnaces world over are going for auxiliary fuel injection through tuyeres to reduce the coke rate. Auxiliary fuel injection takes advantage of higher hot blast temperature & oxygen enrichment of the blast. Due to high price of oil, injection of low ash non coking coal has been preferred to replace expensive metallurgical coke as a viable alternative. CDI unit in BF #4 has a design capacity to achieve injection rate of 150 Kg/THM with 6% Oxygen enrichment. Requirement of Oxygen & Nitrogen will be met from TOP III. Packages under Approval New 4.3 m wide Plate Mill Unique Features: Under the expansion plan of Rourkela Steel Plant for 3.9 MTPA of salable steel, a new 4.3 mtr wide Plate Mill is being installed. The Plate mill is proposed to be installed in two phases, initially with capacity of 1.0 MT (0.92 MT saleable), which shall be augmented, to a capacity of 1.8 MT (1.674 MT saleable). The mill will be capable of rolling a wide range of products.

Input Continuous Cast Slabs width = 1200 to 2400 mm

Length = 2200 to 4100 mm Thickness = 210 to 300mm

Output As Rolled Plate Length = 42 mtr maximum Finished Plate Thickness = 6 to 100 mm Width = 1500 to 4100 mm Length = 6000 to 15000 mm The Plate Mill shall be set-up as a green field project in an area of about Three (3) lakh square meters with newly built covered bays to accommodate the mill and associated facilities including storage of slabs and finished plates.


Panorama 2010 The Plate Mill shall have equipment with state of art technology to produce plates with close tolerances to meet stringent international standards. The 4 Hi reversing mill shall be designed for roll force up to 90 MN, with hydraulic automatic gauge control, roll bending and shifting facilities and provision of on-line thickness, profile and width measurement. The Plate Mill shall have advanced computerized control system for Plan View Rolling (PVR) process to maximize yield and an accelerated cooling system to produce high strength TMCP rolled plates including for pipe grades upto X 100 with lower cost. High capacity levelers with hydraulic control and under load positioning system, high capacity Trimming and Cross-cut-shears up 50mm capacity shall be provided to produce distortion free plates. For operation with a lean manpower and to avoid loss of material identity throughout the production process, the Plate Mill will be equipped with advanced control systems and material tracking facilities. Railway Infra structure & logistics: comprising of civil works laying of tracks, Points, Turnouts & fittings , PSC sleepers, procurement of rails etc. Packages under tendering process:

Utilities packages for augmentation of industrial, drinking & firefighting water, New Compressed Air station (including Plate Mill) Inter plant fuel gas & industrial gases piping for all units. Inter plant Tele-communication system (Server based) through fibre optical cable network Augmentation of weigh bridges Auxiliary facilities for new pate mill

Other miscellaneous packages for integration of 4.2 MT Crude Steel production SAIL Jagdishpur Unit & Steel Processing Units

Revival & Augmentation of SAIL Jagdishpur Steel Plant (Erstwhile Malvika Steel) Unit in Uttar Pradesh.

Steel processing Units at Lakhimpur-Kheri & Guwahati.



COMPUTER & INFORMATION TECHNOLOGY In Rourkela Steel Plant, computerization has been used for various activities:

• Quicker availability of information for decision making • Cost Reduction & Cost Control • Production, Planning & Control • Stricter Procurement, Inventory & Budget Control.

C&IT is equipped with following equipment:

• SUN Enterprise 3000 (E3K) & Backup Server

• SUN Hyper Sparc 712 • SUN Blade 2000 • SUN Fire 280R (2 Nos.) • SUN Fire 480R (2 Nos.) • SUN 3510 Fiber Storage • SUN Fire V440 (2 nos.) • CISCO PIX 535E Firewall

• CISCO 4240 IPS • Xeon Servers for RSP Mail, Network

Security & Anti-Virus (5 Nos.) • Enterasys N-7 Core Switch for RSP

LAN • 4 MBPS MPLS connection for

SAILNET • Windows 2000 Server for e-

Procurement Data Exchange Following are some computer application areas in RSP:

• Production, Planning & Control area covering movement plan from CMO, planning, manufacturing operation, testing & inspection, dispatches.

• Sales invoicing from DA to accounts receivable • In Finance areas from on-line sectional computerization to profit & loss accounting

including statutory requirements. • In Costing area from monthly cost sheet variance analysis to element wise cost analysis. • Human Resource Information System covering employees master data, orders, circulars,

computerization of unit personnel offices. • Employee Services area covering pay slip, PF slip, Income Tax, VRS schemes, incentive,

bonus etc. till trial balance. • CMMS module covering preventive maintenance planning, shop scheduling, FMM

equipment, Cranes, Repair Shop (Electrical). • Materials Management area from cataloging, indent, tender enquiry, order placement,

inspection, receipts, issues, budget control, ABC analysis, lead time analysis & MIS. • Secondary Sales covering preparation of catalog of items from CDY, Idle Assets &

Secondary Products for Forward Auction, award of lots, Sale/Disposal Sale Order, Delivery/Release Order, total SSSY operation.

• Town Services covering quarter allotment to employees & non-employees, shop allotment, private party billing & revenue collection etc.

• Hospital area covering indoor patient registration, non-entitled patient billing & revenue collection, central medicine store, dispensary & ward medicine accounting.

• Plant Status for MD, EDs, GMs, HoDs and Plant Control. • CISF operations covering gate pass and loading sections.


Panorama 2010 RSP Portal: • This is a corporate website designed to run on RSP intranet. • This will provide a unified window to employees to access information spread across the

organization. • The portal will provide access to departmental web sites, applications and RSP Mail

facility running on RSP intranet. • It will also provide access to websites and applications running on SAIL intranet. • This will serve as a gateway to various sources of information spread across the

organization. • Information pertaining to company profile, management, achievements, milestones,

certifications, policy, procedures, products, facilities, annual business plan, production highlights and financials is currently available on the site.

• The site also hosts useful details of various functions of the organization like Safety, Environment Management, HRD, TQM, Information Technology, Corporate Communication, Vigilance etc.

• A separate news corner has been provided to publish daily news pertaining to our organization and industry. The homepage has facility to handle messages, announcements, new launches, slogans, celebrations and competitions.

• The Gallery section consisting of selected photographs arranged across themes provides a visual treat to the users.

• Users can visit the Learning Centre to update their knowledge on available articles. • Users can access and download various publications of RSP and other SAIL units by

visiting the Publication and Download links of the site. • The site has provision for functional departments to publish useful information which will

be accessed by employees across the organization. • It features a privileged Employee Zone through which employees can view their

personal profile, salary profile and pay particulars. Process Control Computer Systems in RSP: A general process control computer system consists of the following levels of distribution of responsibility, with two-way communication among peer-level as well as with higher levels:

• Level-1 - direct digital control of process using PLC, DCS (Digital Control System) and Operator HMI (Human Machine Interface)

• Level-2 - supervisory control level, for process tracking and optimisation using a server type of computer and terminals

• Level-3 - infra-level coordination computers for production, planning and control functions

• Level-4 - scheduling, decision making, management information level The Level-2 systems communicate with the process through Level-1 interface called a gateway. Most of the systems have facility of material tracking and process monitoring, GUI (Graphical User Interface) based displays, operator data screens, set-point downloading to Level-1, communication with SUN system and MIS reports. Safety features are included in the design using interlocks and power-reboot procedures. The computer systems which have been implemented in the process areas of Rourkela Steel Plant are described below:



Sl. No.

Location Computer System Modules

1. SP-II L1: Yokogawa, L2: VAX/ VKS

• Online connection to L1-DCS for data acquisition

• Parameter display and transfer to Plant-status database

2. BOF-II Shop L1: ABB, L2: VAX/VMS • New heat preparation • Process aim calculation • Hot-metal, scrap ordering • Reblow Calculation • Main blow advice • Ladle alloy calculation • End of blow & Feedback

calculation 3. Casters

(SMS-I& II) including LHF & Argon rinsing

L1: ABB, L&T, ABIL, Siemens L2: VAX/ ALPHA/ VMS

• Material Tracking • Cut-length optimisation

advice • Laboratory Management • Dynamic secondary cooling

control • Machine status tracking • Heat/slab tracking

4. Reheating Furnace (HSM)

L1: Siemens PLC, Yokogawa DCS, L2: VAX/VMS

• Slab arrival • Slab line-up • Process tracking • Thermal tracking • Zone-wise set point

downloading • Rolling programme • Pacing control • In-process weighing

5. HSM: Roughing, Coil box, AGC, Speed Control, Coiler Controls, Coiler Conveyor

L1: Siemens Simadyn-D, R-30, PLC, MMC-216, HMI: SIFLEX, Win CC

• Automatic mill pass-R0 • Process tracking • Looper Control • Gauge Control • Speed Control • Communication among L1 • Coil shape control • Process synchronisation


Panorama 2010

Sl. No.

Location Computer System Modules

6. ERWPP L1: ABIL PLC, L2: Windows 2000

• Planning • Pipe tracking • Product analysis • Pipe testing & inspection • Dispatches

7. Energy Management

L1: ADAM signal I/O L2: Windows-2000, FIX

• Data acquisition • Analysis Management • Alarm Management • Online Mixed Gas CV • Gas balancing • Mimics and trend graph

8. Supervisory Load Control Centre

L1: ECIL-RTU L2: Windows-NT, SCO-Unix

• Data acquisition • Alarm Management • Area-wise energy balancing • Mimics and trend graph • Connectivity with Eastern

Grid 9. Environment

Functions • Online data acquisition from

field instruments • User interface system for

parameter monitoring • Periodic area-wise reporting

to Management & Statutory bodies

10. Weigh Bridges

L1: Digital weight indicators: Philips, Avery, Sanmar, Ashbee, Weitex L2: Windows-XP, DOS

• Online communication with Digital-Weight Indicator for weight

• Communication with central database server

• Logic for net weight calculation and screens for operator interface



MATERIALS MANAGEMENT The main tenets of public procurement process are economy, efficiency, fairness and transparency. Materials Management Department ensures availability of materials / services of desired quality at desired time in desired quantity and at the optimum cost (maintaining transparency) to the various consuming units of Rourkela Steel Plant. It caters to the needs of the internal customers as well as interacts with the external agencies like suppliers/ contractors etc. Evolution of Materials Management Functions to Supply Chain Management has made it imperative for the MM department to manage its supply chains efficiently. The important areas under MM department are as follows: Peripheral Industries & Vendor Development (PIVD): 1. This is a dedicated section for development of vendors and industries near RSP. 2. Acts as an interface between Local Industries, Government of Orissa, District Industries

Centre & RSP for resolving issues related to the local industries. 3. It provides help to the peripheral industries to orient their manufacturing process & end

products to meet RSP’s requirement, thereby helping in their development & growth. 4. Important functions include maximization of reservation of items for Local Small Scale

Industries (SSI) and facilitating increase in the order booking value on Local SSI, for development of SSI in Orissa.

5. Other functions include Creation of adequate vendor base for items for which sufficient vendors are not available, and timely registration and renewal of registration of suppliers

Standardisation & Rationalization Group (SRG): 1. This is RSP's central spare and consumables catalogue specification clearance agency. All

transactions of this section are on-line in Integrated Materials Management System (IMMS) and SRG operates on paperless office concept.

2. SRG is responsible for specification standardization in order to reduce the total number of catalogue numbers of RSP by reducing duplicate catalogue generation.

3. SRG plays an important part in the clearance of indents. Stores & Stock Control: The activities of the Stores section can be broadly classified as dealing with collection, receipt, handling, inspection (at stores), stock charging, preservation and issue of materials. These are important flow control activities in the Supply Chain. Regardless of the efficiency with which all preceding activities have been conducted, to a significant extent Stores activities determine to a great degree the satisfactory supply index to the production units. Receiving and Storage play a more important role in supporting and facilitating production operations. Receiving is responsible for expeditious receipt and general inspection of materials, as well as for a thorough review and comparison of all relevant documentation with the materials. Stores is responsible for identification and safe, efficient physical handling and storage of materials. The receiving operation is an important control point in a materials system. This is the only point at which the purchasing control documents actually meet the materials themselves. Subsequently, stores assume responsibility for the physical care and control of the inventory. Since this material


Panorama 2010 represents a major portion of the organizations total invested capital, this responsibility is a significant one. In Rourkela Steel Plant, Stores operations provide both service and control functions. The main receiving stores at RSP are:

1) Central stores 2) Modernization stores 3) Refractory stores 4) Plant Stores II 5) CSM stores 6) IGH Stores

In brief the various steps in the activity chain of the Receiving Stores in RSP are as follows: 1) Receiving of materials 2) Day-book generation 3) Scrutiny and verification (Counting, checking, inspection) of materials & documents. 4) Generation of GARN (Goods Acceptance/ Rejection Note) 5) Stock charging of materials by posting of GARN’s. 6) Custody & Preservation of Materials 7) Issue of Material.

Other activities of the Stores at RSP are:

1. Handling of affairs related to transporters. This is done by the Consignment Section of Stores

2. Store is also the custodian of materials not drawn by indenting department. Items which are not drawn for a long period are classified as Deemed Non-moving (items not moved for more than 4 years and less than 5 years), Non-moving (items not moved for more than 5 years), Obsolete / Surplus (items unusable and approved by MD). Materials declared as Obsolete / Surplus are disposed off by Marketing department.

3. All activities of Stores, starting from entry of material at RSP gate till issue to departments has been computerized. Payment copy of GARN (Goods Acceptance/ Rejection Note) is being electronically transferred to Finance and also to the suppliers through EPS system. All outside dispatches through Stores is also computerized.

4. Another important function of Stores is to lodge insurance claims and realise the same through F&A (Claims & Freights Section).

The Stock Control Section of Stores section is involved with the procurement, availability, control and issue of Automatic Procurement Items. In brief it carries out the following functions:

1. This is MM's material planning agency for processing indents for multi-user Automatic Procurement (AP) items (consumables as well as spares) based on previous consumption norms and procurement policy and specific projected requirements of user departments.

2. Stock Control monitors the safety stock of critical multi user items and issues materials to user departments.

3. Activities include allotment of catalogue numbers for consumables. 4. Stock Control is the nodal agency for Indent Scrutiny Committee for AP Items.



Purchase: The section of MM is involved with the procurement functions of the revenue inputs. The main focus is on the following factors:

1. Quality of purchased materials and services. 2. Reducing the total cost of acquiring of the materials or services. 3. Reducing the time to acquire the materials or services. 4. Technology: Firms supply base should provide the appropriate technology in a timely

manner. 5. Maintaining continuity of supply.

The type of activities carried out by this department can be broadly classified as follows:

1. Co-ordination with user departments to identify Purchase needs 2. Discussions/ negotiations with representatives of various suppliers/ contractors. 3. Identification and selection of suppliers. 4. Market studies for important/ critical inputs. 5. Commercial Analysis of offers 6. Placement of order. 7. Post order activities like follow-up with parties, providing clarifications (if required) etc. 8. Post receipt activities like complaint settlement etc.

The various sections in Purchase are as mentioned below:

1. General Purchase- Looks after the procurement of consumables 2. Spares- Handles the spares procurement of various departments. 3. Refractories-Caters to the refractory needs of the plant 4. Rolls-Involved in the procurement of Rolls 5. Minor Raw Material (MRM)- Procures Raw Materials 6. Import-Involved in procurement of materials of imported nature. 7. Repair Job Contract (RJC)- Only Non-Works RJC cases are processed 8. Ispat General Hospital (IGH) Purchase-Involved in medical Purchases.

The salient features of Purchase functioning are as follows:

1. The Purchase/ Contract Procedure 2009 govern the entire gamut of operations. 2. Extensive IT tools are in use in Purchase Operations. The Integrated Materials

Management System (IMMS), which is a network linking the Indentors, MM, and Finance and facilitates Purchase functioning. The procurement activities have been web enabled through the E-Procurement system (EPS). RSP is the pioneer and leading plant in SAIL regarding use of EPS. All activities from issue of enquiry, submission of offers by parties, opening of offers, generation of comparative statement, receipt of orders by parties, receipt details of materials, payment information and submission of inspection request and issue of inspection certificate is carried out over internet. Today even issue of open/ global tender and procurement through Reverse Auction route is possible through the EPS. More than 90% of the cases are processed through EPS.

3. Emphasis is being placed for maximization of long-term rate contracts with price variation clause, open/ global tendering & price bid through reverse auction route.


Panorama 2010 Inspection:

1. The broad function of the Department is to ensure that the material being supplied meets the desired specification as per the quality requirement of the user.

2. Inspection is carried out at Stores Receipt and in the premises of vendors. 3. Inspection department develops the Quality Assurance Plan for items in consultation

with user departments. 4. Inspection also undertakes Capacity Assessment of vendors in the Vendor Registration

Process. 5. The inspection activities are carried out by the RSP Inspection Wing located at

Rourkela as well as by RSP Unit Offices located in Delhi, Kolkata, Mumbai and Chennai.

Marketing: Prime products of RSP are sold through Central Marketing Organization (CMO), all other products are sold by Marketing Department. The product range dealt by Marketing Department includes defectives, coil/sheet cuttings, rejected pipes, granulated slag, coke fractions, fertilizers such as Ammonium Sulphate, various waste products like LD Slag, Ferrous Sulphate etc. Marketing Department also looks after disposal of old/used machinery, conveyor belts, drums, electrical spares and unused / surplus obsolete spares. In addition to the above, all idle assets of plant are also disposed off by Marketing Department. For disposal of products, there are 2 yards, namely Secondary Steel Stock Yard (SSSY), which stores defectives, coils/sheet cuttings. The other stockyard is Central Disposal Yard (CDY), which handles maintenance scraps/ wastes like old/used conveyor belts, old/used electrical spares, used drums, old batteries, old vehicles etc. For disposal of above items Marketing Department has introduced latest system of e-sale through "Online Forward Auction". In this process customer bids its highest price through Internet. The present annual revenue generated through sale of secondary items is to the tune of Rs. 320 - 350 Crores.



FINANCE & ACCOUNTS

The major functions of Finance & Accounts department are as under: Financial Accounting: Finance department is responsible for recording of monetary transactions in the books of accounts and preparation of final accounts as per the provisions of Companies Act & Clause 49 of Listing agreement, complying with provisions of Income Tax Act and Wealth Tax Act. The final accounts are prepared as per the requirement of schedule VI of the Companies Act, 1956. Quarterly accounts are subject to review by the auditors appointed by the Corporate Office, SAIL. The annual accounts are examined by auditors appointed by Comptroller and Auditor General (C&AG) of India under the provisions of Companies Act. The auditors so appointed are required to report on true and fair view of the accounts amongst others. The annual accounts are thereafter reviewed by the Resident Audit Officer of Commercial Audit branch of C&AG. Memos raised by Commercial Audit are replied to with necessary clarifications and on satisfaction of the Commercial audit, the memos are dropped otherwise the comments of C&AG are reported in the Annual Accounts and placed before the Annual General Meeting of the company. Cost Accounting: Cost Accounting involves costing of products and services, preparation of standard cost, variance analysis, pricing of products and services and preparation of various MIS reports like monthly profit forecast, techno economic report, cost control report, scrutiny of make/buy proposal etc. Cost sheets are prepared on historical cost basis by following the principles of Process Costing. Standard cost sheet is prepared for control purposes. Monthly cost sheets are prepared and made available to different departments on line. Cost awareness workshops are conducted department-wise. Finance department is also responsible for cost audit under Companies Act. The cost data are examined by a qualified accountant appointed by Board of Directors with the approval of Central Government. The cost audit report is submitted to Company Law Board, Cost audit branch by the cost auditor. Preparation of annual Budget and budgetary control reports: Operation budget is prepared as per guidelines of the corporate office. Department wise budget is fixed for each expenditure head for controlling expenses bringing about cost efficiency in the operation of the plant. Quarterly budget reports are made available to different departments for their information and necessary action. Capital budgets are prepared by Project finance in consultation with head of works and project department. Stock Verification: It involves physical verification of inventory and assets. Entire inventory of raw materials and Semi/Finished goods is physically verified at the end of each quarter. The inventory of Stores and spares is physically verified over a period of three years. However the inventory of high value items is verified every year. The fixed assets are physically verified over a period of three


Panorama 2010 years in a phased manner. RSP's assets at Rourkela are verified by RSP's SV Section. The outstation Liaison offices assets of RSP are verified by CMO's SV Section. Preparation of pay roll and complying with the provisions of Provident Fund Act, Income Tax Act: Monthly payrolls are prepared on the basis of master data in the computer duly updated from time to time on issue of relevant office orders by Personnel Department and Plant departments. Attendance of all the employees is collected and fed into the computer by the Finance department. Finance department is also responsible for disbursement and recovery of loans, deduction and deposit of income tax at source. Employee wise accounts are maintained for the Provident Fund deducted every month from the salaries of the employees. Scrutinizing purchase/contract/expenditure proposals and giving concurrence: Proposals involving funds and requiring approval of MD are routed through ED (F&A). Other proposals are checked by finance department as per delegation of power. The representative of Finance department is nominated in various tender/negotiation committees for obtaining the best price and commercial terms. Examining the financial viability of investment proposals: Various investment proposals are thoroughly examined from financial point view. Payment of Suppliers/Contractors Bills: Bills of suppliers/contractors are received, checked and paid as per the terms of contract with them.

OB&A This section deals with Payment and accounting of contractors/small value purchase order bill, telephone and mobile bills, stipend and honorarium bills, CISF bills, electricity bills of NSPCL, GRIDCO/ WESCO, advertisement, journal & newspaper bills, transport and taxi bills, land rent and water cess, picnic subsidy bills, funeral expenses bills, entertainment and function expenses bills, recovery from contractors towards demand from PF and ESI, sales tax authorities etc. Accounting of materials received from sister plant for further processing.

RMB&A

It deals with Payment and accounting of bills of suppliers of limestone, dolomite, quartzite, sand, clay, coke etc and of contractors for handling, screening public analyst, internal shifting of materials etc., Accounting of receipts of materials from RMD mines and sister plants, imported coal from BTSO, indigenous coal from CCSO, Accounting of materials transferred/ diverted to sister plants.

Claims and Freight

This section deals with Payment of railway freight, railway staff bills, demurrage bills and accounting thereof, Insuring the assets of RSP, taking marine, transit and contingency insurance policy. Lodgment and settlement of claims with railway and insurance companies toward wrong/ overcharge of freight, transit loss of material and loss of assets of RSP.



Stores Bills and Accounts Stores bills section deals with payment to supplier of stores & spares, Refractories, Rolls and Minor Raw Materials and accounting thereof. All stores and spares (indigenous as well as imported) purchased for revenue consumption are paid by stores bills section. In addition to these stores bills section make payment of freight bill to authorised and unauthorized transporters, handling bills, testing charges, Accounting of payment made by BTSO toward custom duty, port rent, ocean and airfreight. Accounting of material received from and dispatch to sister plant. Form ‘C’ and Form ‘F’ are issued to suppliers and sister concern respectively against supply of stores and spares.

Preparation of invoices: Invoices are prepared for dispatch of materials from the plant in compliance with provisions of related laws like Orissa VAT Act, Central Excise Act, Service Tax Act, Entry Tax Act and Income Tax Act.


Panorama 2010

PERSONNEL While managing human resource is an integral job of the Manager at all levels, in a business organization, a nodal agency is required to oversee and monitor the myriad human processes and also to carry out specific functions required to optimize the available human resources. The Personnel Department of Rourkela Steel Plant is primarily responsible for this. The functions of Personnel Department can be broadly categorized as follows: Rationalization of Manpower: To meet the present and future manpower needs, Personnel department makes strategic personnel planning and ensures induction of competent personnel in the organization. Personnel department analyses the requirement of manpower and existing profile on a continuous basis leading to a systematic deployment plan, which comprises of both redeployment from within and recruitment for ensuring right man on the right job. An annual manpower budget is prepared taking care of various oragnaisational requirements and objectives. Besides, thrust is also put for optimum utilization of the human resource by way of redeployment, retraining etc. Motivating Employees: In order to encourage the employees to maintain consistently high levels of performance, Personnel department facilitates the introduction & implementation of various financial & non-financial motivational schemes & awards. The schemes are both group and individual-based. Various schemes are in place linked to achievement of departmental targets based on production, productivity, cost control, quality-consciousness etc. There are also some schemes that reward individual/ group creativity and accomplishments. Apart from this good performance is recognised through in-house newsletters, magazines, RSTV, Departmental Notice Boards, appreciation letters etc. Grievance Redressal System: Effective and quick redressal of grievances of employees is a vital Personnel function especially in a labour intensive industry like Rourkela Steel Plant. There is an effective system of informal grievance handling through Employee Assistance Register (EAR) to settle employees’ grievances at the shortest possible time. The EARs are available in all the Personnel Unit Offices and in Control Rooms of some major departments. The aggrieved employees can record their grievances/ difficulties relating to a number of areas attendance, pay, house allotment/ maintenance, promotion, seniority, etc. The Unit Personnel Officers take appropriate follow-up actions to sort out the grievances at the earliest and also keep the employee concerned informed by making appropriate entries in the EAR. In addition to the above, there is also a formal two tier grievance redressal machinery called Grievance Redressal Committee for Employees (GRCE) and an apex body called Grievance Redressal Apex Committee for Employees (GRACE) for redressal of the employees’ grievance on a time bound basis.



Employees’ Welfare and Social Security: Employees welfare is of utmost priority among various Personnel commitments in any organization. Personnel department takes utmost care for ensuring & up keeping of vast array of welfare facilities both statutory and non-statutory. Some of the main Welfare facilities include canteens, rest rooms, drinking water, public convenience buildings, first aid, medical facilities, baby crèche etc. Besides Personnel department facilitates the implementation of all social security measures in vogue in the organization viz. PF, Gratuity, Workmen’s Compensation, Employee Family Benefit Scheme, Employee Family Benefit Voluntary Scheme, Life Cover Scheme, SESBF etc. Performance Management System (PMS) and growth of employees: For an objective assessment of the performance and potential of the employees and to distinguish between different levels of performance, the Personnel department implements the Performance Management System in vogue in the company. Besides to motivate the employees for their better performance, Personnel department takes care of the aspiration of the employees by effecting promotion, career planning and succession planning. A comprehensive appraisal system for the employees has been developed to ensure an objective assessment of performance and potential of the employees and to integrate company's and individual goals. There are also systematic Promotion Policies for promotion within executives, within non-executive employees and also for promotion from non-executive to executive cadre.

Communication: Communication is the lifeline of any organization. It can help establish a performance oriented culture in the organization. Communication helps not only in disseminating information to the employees, it also helps in enhancing employees morale, inculcating a sense of participation and belongingness, fostering team-spirit and a motivation to perform better. To facilitate involvement of employees in all spheres of their activity Personnel department facilitates various structured communication programmes viz:

MD’s Mass Contact Exercise: With an aim to synergise employees towards

organizational goals, a unique and unprecedented programme started on 19-04-2002. It is held once in a week, where around 500 employees participate and contribute their constructive idea/suggestions for growth of the organization and interact with the Managing Director. A presentation highlighting the areas of concern and good performance is also made to aware the important issues affecting the plant and the employees.

General Manager’s Communication Meeting: Every General Manager holds a

monthly meeting of groups of employees of his area of control and major departmental issues, action plans, performance highlights, etc. are discussed.

HOD’s Communication Meeting: Heads of departments hold weekly/ fortnightly

meetings with employees where departmental issues, safety aspects, improvement plans etc. are discussed.


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Sectional In-charge’s Communication Meeting: Sectional In-charges of major units hold weekly meetings of employees to discuss day-to-day shop-floor issues.

Issue Based Workshops: It is held whenever required and all agencies concerned with

the issue are encouraged to evolve improvement plans. Besides these Unit Personnel Executives also communicate various plant related issues to the employees at shop floor.

Building a Responsive Work-force: Discipline plays an important role in an Industry. It is a bare minimum necessity for sustaining the Production & Productivity. While emphasising positive discipline like quick grievance redressal, ensuring proper welfare facilities, improving quality of work life etc. Prompt and consistent disciplinary action is taken against the employees concerned under the disciplinary rules & procedures of the company. In order to ensure the employees availability on the shop floor in time, the Direct Reporting System (DRS) is in vogue whereby employees report at their place of work directly and put their signature in the attendance register both at the beginning and end of the shift. The Unit Personnel Executives undertake periodic surveillance on DRS to make the system more effective. Away from the traditional fire-fighting management, the Personnel collective believes in pro-active IR management through involving the employees in all spheres of work activities, cultivating a participative culture and creating a atmosphere of creativity. Various committees and bodies are in place at both the departmental and central level so as to involve the employees in various issues of significance for the Plant as well as the welfare of the employees. Besides the above some key Personnel functions in RSP are: • Formulation and ratification of human resources policies, in line with the business

strategies. • Designing and redesigning of organization and work systems. • Designing and regulating compensation systems. • Ensuring compliance to statutory requirements. • Functioning as convener of all job contracts in the works departments. • Ensuring compliance of all statutory matters in respect of final bills of contractors.



HUMAN RESOURCE DEVELOPMENT CENTRE The Human Resource Development Centre of Rourkela Steel Plant was set up during 1959 and was then called “Technical Institute” imparting technical knowledge and skill to all new entrants to the then Hindustan Steel Limited. Over the years, the institute was entrusted with the responsibility of training not only new entrants, but also of developing the skill and competence of the existing employees. In line with the changing focus of the organization, the activities of the Centre also grew to encompass a wide spectrum of developmental activities and the centre was rechristened as “Training and Development Centre” and subsequently “Human Resource Development Centre”. It is the first HRD Centre among SAIL steel plants to have been certified under ISO 9001 Quality Management System during November 2003. In line with its growing scope of the activities, the infrastructure of the HRD Centre has grown over the years. The earlier building and workshop complex was installed in 1959. In 1984 the ground floor of the present MDP wing was installed and in 1993 the first floor of the MDP wing was built. The Refractory Shop came up in 1993. Keeping in view the need to increase the competency level of employees to cope with the advent of latest technologies, the Hydraulics & Pneumatics Laboratory was commissioned in 1993 with the equipment supplied by M/s Amatrol INC, USA and the Electronics Laboratory was commissioned during 1994 with equipments from M/s Feedback UK. The Computer Centre was installed in 1989. Over the past years the HRD Centre has redefined its horizon and has become a center stage for the transformational process of Rourkela Steel Plant and, has played a vital role in the turnaround initiatives of Rourkela Steel Plant. Apart from carrying out activities towards the competence development of employees, the HRD Centre has also become the venue for several professional development activities by playing host to several national and international workshops, seminars and conferences. Focus of HRD Centre While making efforts towards bringing about continuous improvements and fostering a culture of learning and innovation, the focus of HRDC has been on linking training events and outcomes to the business needs and strategic goals of the company. Our major activities include: Organizing HR interventions to bridge the gaps in competence and skill. Development of competence of employees posted to work in Hi-tech areas including

Computer application. Addressing specific needs of the various departments for enhancing performance. Building capability of employees for multi-skilling and multitasking. Enhancing Managerial Skills of executives.


Panorama 2010 Designing and conducting specific interventions to enhance managerial effectiveness. Evaluating the effectiveness of training programmes in all In-house technical training

programmes. Continuously improving the quality of training. Creating and maintaining a learning environment

The process of Training & Development at HRDC & CPTI The process of training and development of employees is represented in the diagram below:

Areas of Training:

To streamline the reporting and monitoring system of training MIS in SAIL the following broad areas of training have been identified as per which the Annual Training Plan (ATP) is prepared every year:

• Induction Training: Training of all new entrants • Competence Enhancement: All technical and

managerial training • Training in Specific Areas: All programmes on

Safety, Health, Environment, IMS, OHSAS, SA, etc.

• Foreign & External Training: All outstation programmes conducted by agencies other than SAIL and its units and all training abroad

• Other Areas: Various workshops / seminars, Hindi Training etc.

Training Need Assessment

Competence Mapping

Prepare Annual Training Plan

Does Programme

Exist? No

Design New Programme

Yes

Conduct Programme

Create & maintain Learning

Environment

Maintain & Provide Training

Aids Review

Evaluation parameters

Organizational Requirement



Infrastructure Facilities at HRD Centre: Located inside the works premises and close to the Main Gate, the HRD Centre has sprawling green lawns bordered with seasonal flowerbeds and encircled by lush green trees. The Centre is well equipped with modern facilities and infrastructure required for conducting different types of training programmes. Some of them are:

• Classrooms/ Syndicate Discussion Rooms • Workshop Facilities: All skill development/ multi-skill technical training

programmes are carried out in the following workshops: Machine shop Welding Shop Fitting Shop Electrical Shop

• Hydraulics & Pneumatics Laboratory • Electronics Laboratory • Computer Hall • Gopabandhu Auditorium- Having a capacity for sitting 500 persons. • Library • Model Room • Trade Testing Centre • Customer Care Cell • Documentation Cell • Trainees’ Hostel Complex • 3 Trainees’ Hostels with

Training Hall Dining Room Recreation Room Indoor Badminton Court Basket Ball and Volley Ball Court Play ground (for Football, Cricket etc.)


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CENTRAL POWER TRAINING INSTITUTE

In 1985, the Government of India had constituted a high level committee to look into the various aspects of training in the Power Sector. Recognising the importance of specialized training for power plant personnel, the SAIL board in April 1990 approved the setting up of the Central Power Training Institute (CPTI) at Rourkela under the administrative control of Management Training institute, Ranchi. CPTI was accordingly established in October 1993 to provide specialized training to power plant personnel not only of

SAIL but also of all major power plants in India. The Institute was accorded the highest recognition of being a Category – I Institute by Central Electricity Authority (CEA) in 1996 empowering it to train operation and maintenance personnel of Thermal Power Plants having unit size up to 500 MW. Recipient of the Golden Peacock Award in 1999, CPTI was brought within the fold of HRD Centre, Rourkela Steel Plant in July 2004. During February 2007, CPTI was also certified under the ISO 9001 Quality Management System. As an ISO 9001 QMS certified and Category –I Institute, recognised by Central Electricity Authority, Govt of India; which also has the proud distinction of being a winner of the Golden Peacock National Quality Award, the Central Power Training Institute has been conducting power related training programmes, workshops, seminars etc and facilitating the conduct of Special Events for SAIL and Non SAIL personnel to integrate the process of human resource development with the overall corporate vision of the organisation. The activities at CPTI are primarily directed towards providing training to personnel engaged in the field of Operation and Maintenance of Thermal Power Plants, Power Instrumentation, Power Management, Transmission and Distribution. It also identifies and assesses special training needs so as to fulfill obligations under IE Rules regarding mandatory qualification of power plant operators thereby enhancing the competence of personnel in power related areas in and around Orissa. Focus of CPTI: • To contribute towards fulfilment of technical training needs of the personnel in the area of

captive power generation to meet organizational goals. • To train employees of SAIL as well as non-SAIL organisations in the area of power. • To provide a conducive environment for learning through excellent facilities, hospitality and

other support services. • To facilitate and organize company wide workshops and seminars in the area of power. • To extend facilities in organizing special events for Rourkela Steel Plant.



Infrastructure Facilities at CPTI: Located inside the Project and modernization Complex, close to the Traffic Gate of Rourkela Steel Plant, the Central Power Training Institute is centrally air-conditioned and reflects an ambience befitting a learning centre. Equipped with state of art infrastructure facilities and team of dedicated workforce, CPTI continues to contribute steadily toward enhancing the HRD functions in the organization as well as in other power related organizations within the country. • Operator Training Simulator:

It has a replica operator training simulator of 60 MW Coal fired Captive Power Plant of Rourkela Steel Plant (Presently M/s. NSPCL). It is the first of its kind in India with indigenous technology and the only one in non-utility sector. The application software ensures high degree of fidelity in reproducing the exact response of the actual power plant to various operator actions. It consists of simulator computer station, control panels; Microprocessor based input / output system, field device terminals to simulate local operations, Instructor station and data acquisition system (DAS). The total plant is functionally divided into process simulation, interlock simulation and control simulation for boiler, turbine, generator and electrical system. As on date, it is in the process of being upgraded functionally.

• Lecture Halls and Simulator Hall:

The Institute is centrally air-conditioned. Main sessions are conducted in the three Lecture halls and one screening room well equipped with audio-visual aids. Hands on sessions are conducted at site.

• Information Centre :

The information centre has a large collection of books, handbooks, journals and courseware from Indian / foreign publishers on all areas of power engineering and management. Documentation and drawings related to all SAIL power plants, video cassettes on power plant operation and control are also available. It has a collection of more than 850 books and 49 manuals on power plant engineering and allied subjects. It also subscribes to 5 journals / magazines, 5 newspapers and 10 house magazines.

• Syndicate Rooms :

Syndicate discussion is a regular feature in problem solving workshops and other action plan oriented programmes, particularly for executives. CPTI has three well designed syndicate rooms for smooth conduct of workshops.

• Facility for corporate programme:

CPTI organizes corporate programmes in an auditorium having a seating capacity for 82 persons. The compact auditorium is equipped with a captive public address system and attached projection facility. An additional Conference Room capable of accommodating 30 -35 participants is also available.


Panorama 2010 • Personal Computers:

It has a network of 8 PCs. Every staff has access to the PCs. Correspondences, trainee manuals, reading material, teaching notes and trainers’ manuals are prepared using these computers. The Institute has adequate number of laser / other printers for this purpose. Formats are standardized and computerized to ensure adherence to ISO norms.

• Modern training/ teaching tools:

LCD projector, OHP, TV, VCR, DVD Player, Electronic copy board, Document binder, photocopy machine, laminator, Laser printer and personal computers are used for enriching the programmes. Training related Video cassettes have been converted into CD/DVDs and these are extensively used in the programmes. Teaching Notes/ Reading Material are distributed to participants in only CD form now. Facilities for audio / video recording of proceedings and syndicate discussions are hired whenever needed.

• Model Room:

Large number models of power plant equipment, exhibits and schematic drawings are on display in the Institute. Exclusive model room for housing working models and mimic display boards also exist.



LAW In an integrated steel plant like RSP, the role of Law department is manifold. It acts as an adviser to the Top Management and gives a shape to the policies relating to Production, Marketing, Administration, Health, Welfare, Safety, Land, Estate, Finance, Taxation etc. Law Department concentrates for achieving organizational goal by:-

• Cost effective management of litigation through qualitative and quantitative disposal. • Developing In-house legal expertise to advise Management and draft legal documents

without assistance of outside Advocate. • Organising seminar/training program for line manager on current legal issues and

apprise higher Executive on its implication on business/strategy related decision Law department undertakes the responsibilities of defending/ protecting the policies of the Company/ actions of the Management, when challenged in any Court of Law or before any Statutory Authority. Matters relating to Personnel, Contracts, Sales Tax, Central Excise, Customs and other Taxation Laws are handled in Law department. Vetting/Drafting of contracts, schemes, statutory petition/applications are routine function of the Law department. The department deals with matters/cases pending before different courts/fora/authorities of different jurisdiction (Civil Courts, Criminal Courts, Tribunals, Labour Courts, Consumer Fora, different High Courts and Supreme Court). The statistics of the last 10 years reveals that the success rate achieved by Law Department is always maintained above 90%. It is motto of the Law Department to promote settlement, encourage mediation/conciliation and implement all order/judgment as far as possible. Law Department is instrumental in saving substantial amount for the company arising out of litigation and it has successfully defended the policy of the Company. Without depending on outside agencies, Law department gives Legal opinions and guidelines to line managers on various issues and acts as an in-house attorney. Thus the Law department touches upon the working of every department and is associated with all function of Rourkela Steel Plant.


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TOWN ENGINEERING Town Engineering Department looks after the maintenance of 19 sectors in the Industrial Township of Rourkela Steel Plant spread over an area of 45.13 Sq. KM. The department is responsible for repair and maintenance works in 25,499 buildings including residential quarters, public buildings like Socio/cultural centers, Educational Institutes, Sports Complex, Medical & Health facilities, Market Complex, Company Officers, Parks and vital installations including Air Strip. The total maintenance is achieved through the Civil, Electrical, Water Supply, Horticulture and Public Health Sections of the Department. The various repair and maintenance works are executed through the 15 Civil Maintenance Booths and 09 Electrical Maintenance Booths located in the various Sectors of the Steel Township. The Contract Cell of the Town Engineering Department deals with the tendering process and finalizes outsourced agencies for the several jobs executed in the townships by Town Engineering, Town Services, Sports and Horticulture Departments and Peripheral areas by CSR Department. Town Engineering – Civil: The Civil Wing of Town Engineering Department takes care of the repair and maintenance work of the residential quarters in the township. Apart from this, regular maintenance is carried out in 27 Socio-Cultural Centers including Civic Centre, Bhanja Bhawan Complex, Utkalmani Gopabandhu Ispat Library, Adarsha Pathagar, Deepika Mahila Sanghati and Social Homes/Community Centers spread over the townships. These also include the two clubs i.e. Indo German Club and Rourkela Club. For encouraging sports, the number of sports complexes like Ispat Stadium, Biju Patnaik Hockey Stadium, Basket Ball Court, Indoor Stadium and various other Sector playgrounds are kept in good condition. The Civil Wing of the Department maintains 382 KMs of roads and drains, 465 KMs of sewerage system spread over the entire townships. As part of the drive for a clean and hygienic Rourkela, Door-to-Door garbage collection and its systematic disposal from all the residential quarters and market complex, project has been started, which is the first of its kind among all the SAIL Units. As a part of environment upgradation, beautification and road safety campaign, various important chowks and roads are continuously modified with recarpeting and widening, providing adequate parking space and installation of monuments and fountains. The department also provides logistic support during various socio-cultural functions held in the Township as part of the cultural calendar for enhancing the quality of life of the residents and creating an atmosphere of entertainment and enjoyment.



Vital installations are also maintained timely to meet the statutory provisions of the Factory Act and State Pollution Control Board, 32 vital installations, which include 33 kV/11 kV Sub-Stations, Booster Pump Houses, Intake Wells, Water Treatment Plants and Air Strips, are kept clean and in good condition with proper approach. The department in close liaison with the Corporate Social Responsibility Department also provides various basic facilities like class rooms for Schools, Community Centres, roads, etc. in the peripheral villages. Providing drinking water facilities through new tube wells and repair of old defunct tube wells, repair of roads and drainage system in the 57 identified slums are some of the activities undertaken by the department as a part of fulfilling RSP’s Corporate Social Responsibility. The department as a part of its constant endeavour for larger cause towards the Community is also engaged in different projects for Rain Water Harvesting in the Industrial Township. Public Health: The Public Health Section of Town Engineering Department provides conservancy services and anti malaria services in the Steel Township. Apart from regular road cleaning, sanitization of the dumping yards in the Township and adjoining areas are undertaken. Collecting water samples for bacteriological tests and analysis, de-chlorination of the wells and spray of anti-large on swampy areas and on stagnant water are also some of the major activities of the department. Town Engineering- Electrical: Town Engineering (Electrical) Department caters power to nearly 24, 000 houses in addition to the public utility service like Water Supply system, Hospital, Clubs, Office premises etc. In the process, a vast network of HT, LT and Street Lighting are to be maintained round the clock. This network consists of the following: • 33 kV Distribution Network:

Two Receiving Sub-Stations at Sector-6 & Sector-2 consisting of 33 kV/11 kV power transformer & auxiliaries are to be maintained round the clock. The capacity of Sector-6 Receiving Sub-Station is 29 MVA and that of Sector-2 Receiving Sub-Station is 12 MVA. Power is fed at 33 kV level from Plant through overhead lines to these Receiving Sub-Stations.

• 11 KV Distribution Network:

There are 18 numbers of 11 kV feeders to cater power to the entire Steel Township. Of these 14 numbers feeders originates from Sector-6 Receiving Sub-Station and 4 numbers from Sector-2 Receiving Sub-Station.

• 440 Volts Distribution System:

137 NUMBERS OF 11 kV/440 V distributions Sub-Station scattered over the entire Steel Township have to be maintained round the clock for supplying electricity. The total length of 440 V overhead line and underground cable covers a distance of nearly 1500 KM.


Panorama 2010 • Water Supply Installations:

Power supply to Intake Wells and Booster Pump Houses are maintained round the clock within availability of dual source. 128 numbers LT Motors and 3 numbers EOT Cranes are maintained by the Department.

• Street Lighting:

An elaborate network of Street lighting is maintained for safety & security of the entire Steel Township. Town Engineering (Electrical) has to maintain nearly 8000 Street lighting fixtures consisting of HPSV, Semi High-Mast, High Mast, Metal Halide and MV fittings etc. which also covers 14 numbers recently erected monuments.

One 11 KV overhead line comes from the Plant supplies emergency power to the vital areas of Township like Ispat General Hospital( IGH), Rourkela House, Booster Pump Houses and VIP Bungalows. In addition to the above, all the commercial buildings, Central & State Government Offices, Police Stations, and Socio-cultural Organizations located inside the Township are also provided power supply by the Department. In this process Town Engineering (Electrical) handles a maximum demand of 35 MW with an average of nearly 21 MW of power. • Water Supply – Town: Water Supply (Town) meets the potable water requirement of Steel Township, Rourkela. It supply potable water as per IS : 10500 – 1993 Quality norms to approx. 24000 residential quarters apart from hospitals, schools, market places, State & Central government organisations and public utilities. It also provides drinking water to some of the designated slums/ Bastis inside the Steel Township. Apart from this, raw water also been supplied to parks, nursery and gardens. It maintain water tankers (2 Nos.) to supply potable water to ceremonies and functions organised inside Steel Township including functions organised by employees on daily basis. Basic objectives of the Water Supply (Town) is, "To supply potable water 1500 litres/day/Quarter (as per norm) conveniently, economically &

uninterruptedly, in a sustainable manner, twice a day."

Source of Raw Water a. River Koel

b. River Brahmani Intake Wells a. Jhirpani Intake Well – located on the bank of

river Koel in Jhirpani. 3 no. of Intake wells of total pumping capacity 36 MGD.

b. Tarkera Intake Well – Located on the bank of river Brahmani for Township area. 2 X 6.4 MGD capacity.



Water Treatment Plants a. Water Purification Plant, Hill Top, Sector-2 with filtration Capacity : 18 MGD.

b. Brahmani Water Works, Sector-8 Capacity : 9 MGD filtration capacity.

Chemicals used for Water Treatment

a. Ferric Alum as a coagulant. b. Poly Aluminum Chloride (PAC) as a coagulant. c. Lime as pH neutraliser. d. Disinfectant (Bleaching Power).

Production Process:

Raw water comes from intake well pump house of Koel river and passes through the bubbling tank in the Water Purification Plant. Here the speed of water is reduced and heavy particles present in the raw water settle down to the bottom of the tank, which is finally disposed off. Chemicals are added (coagulant) for vigorous mixing. The water then passes through the flocculator tank where floc formation takes place, then to the clarifier where sedimentation takes place and almost all the impurities settle down and come to sludge chamber, from where it is disposed off. From the clarifier the water goes to filter house, rapid sand filter, to further filtrate the water and brings down the turbidity to a value of less than 10 NTU. Bleaching power is added to filtered water to maintain free residual chlorine concentration in drinking water to 0.1 – 0.2 mg/litre. Free chlorine in bleaching powder acts as a disinfectant.

Process Flow Chart of WPP Hill-Top


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The filtered water is collected in 4 drinking water reservoirs and supplied to the beneficiaries through gravity feeders. As the Township is situated in a hilly area, there are 12 no. of Booster Pump Houses located strategically at different locations of different sectors to supply water by collecting in sumps and then pumping the potable water to over head reservoirs where from, water been distributed to different quarters situated at higher elevations. Apart from drinking water, Water Supply (Town) also treat the domestic sewage generated from the Steel Township quarters and collected at sewage pumping and treatment plant located at Sector-14 (at the far end of the Township). The sewage water treated through 3 No's. of stabilisation ponds (oxidation process) and the total sewage treatment capacity is 4.5 Million Gallon per day. The treated sewage meets the statutory norms before being discharged to river Koel through open channel storm water drain.

• Horticulture: The commitment of Rourkela Steel Plant towards making its environment clean, green and safe is achieved to a large extent by the Horticulture Department. At present, 2300 acres of intensive green areas with 200 acres of gardens, 4 central Nurseries and 38 Parks and gardens are being maintained by the department to enhance quality of life in the Townships. Over 150 varieties of roses of these gardens have won laurels at the national level. So far over 40 lakhs trees have been planted in and around Rourkela. Over 2300 acres of land has been covered with plantation blocks. Few such blocks are Green Park of 225 acres land with 2,25,000 trees, Green Valley of 68 acres of land with 66,000 trees, Green Meadows of 85 acres of land with 84,000 trees, Lagoon Park of 50 acres of land with 27,000 trees. The efforts of the department aiming at ecological restoration by massive afforestation programmes in and around Rourkela has been widely acclaimed as RSP won the prestigious Indira Priyadarshini Vriksh Mitra Award for the year 2003 from Ministry of Environment and Forest, Government of India. Indira Gandhi Park developed in early fifties is the most prestigious park in Rourkela. Set in the backdrop of a scenic hill range, the park contains a rich collection of flora, which is a major source of attraction for nature lovers. A Toy Train encircling a small lake, Boating facility, Doll Museum, Aquarium, Zoo and Musical fountain are some of the added attractions in the park. The Jubilee Park developed in the eighties in Sector-8 along with Deer Park is also maintained by the department and is a major attraction of the steel city. More than 150 animals and birds of 19 species are being nourished in the zoo, maintained by the department. Deer Park with 91 spotted deer running hither and thither in an area of 5 acres is another spot of attraction near Jubilee Park.



The Horticulture Department also plays a vital role in maintaining the greenery in the plant premises. The gardens in the Administration complex and in the HRD Centre are maintained, adding beauty to the buildings and its surroundings. The department also supplies materials and necessary horticultural skills to all the departments to enable them to develop gardens inside the works. Apart from this Horticulture Department is creating awareness among Rourkelites regarding environment and its protection. The department is regularly organizing Annual Horticulture show, Rose and Chrysanthemum show and garden lay out competition with huge participation. The department is also organizing essay, quiz and elocution competition among school children on the various topics related to our environment. Regular Zoo Education programs are being conducted at Indira Gandhi Park Zoo to create awareness among participants from various schools for the conservation of wildlife and its importance.


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TOWN SERVICES Rourkela Steel Plant, the first Public Sector Integrated Steel Plant of the country came up as a Greenfield project in the backward and remote district of Sundargarh. For establishment of the Steel Plant & its Captive Township land was acquired under the provisions of Orissa Development of Industries, Irrigation, Agriculture, Capital Construction & Re-settlement of Displaced Persons (Land Acquisition) Act, 1948 (Orissa Act, XVIII of 1948) by the Govt of Orissa after complying with all the formalities and there after handed over possession of Ac 19722.69 of land comprising 33 villages in & around Rourkela to Rourkela Steel Plant. Elaborate arrangements were made for rehabilitation of the displaced persons. Besides the payment of compensation for the land acquired, all the displaced persons were provided with house site / plots in the adjacent resettlement colonies at Jalda and Jhirpani etc. Besides this, development works such as roads, parks, schools, etc. were also carried out in these colonies. A Lease Agreement in respect of the land under possession of RSP was executed between RSP & the Govt. of Orissa on 01.07.1993. Over a period of time on the request of the Govt. of Orissa, RSP has surrendered a vast expanse of land measuring Ac 4506 to cater to the requirements of Govt. such as construction of Regional Engg. College, expansion of South eastern Railway Stock yard, development of Civil Town ship as area no 7 & 8 of Rourkela, Industrial Estate, Private Housing Colonies of Orissa Housing Board at Basanti Colony & Chhend Colony, Koel Nagar Housing complex etc.. The remaining land now in possession of RSP has been / is being utilized for integrated steel plant, industrial Township Colony, roads, drainage & Sewer systems, schools, parks, playgrounds, green belts, underground cable lines, water lines, overhead electric lines etc. Situated on the bank of river Koel & Brahamani, Rourkela is acclaimed as Industrial Capital of Orissa. Adding to the glory of Rourkela, RSP Township enjoys the status of “FIRST INDUSTRIAL TOWNSHIP” in the country w.e.f 15th April 1995 as declared by Hon’ble Governor of Orissa. The Steel Township of RSP is not only famous for its green environment but also for its planning and architecture. The Steel Township is well planned with all civic amenities like motorable roads, drainage, sewerage system, parks, schools, gardens, play grounds, clubs, recreation centres & other modern amenities etc. Rourkela Steel Plant has been maintaining the entire township covering 24395 quarters of different categories & about 3716 shops spreading over in 19 sectors. It maintains several market complexes out of which, one Ispat central market situated in the heart of the city consisting of more than 1800 shops which caters to the needs of the residents of Rourkela as well as the outskirt villages in and around Rourkela. The township has about 350 kms pucca road. All the main roads of the sectors are connected to the ring road spreading over 16 kms within the Steel Township.



Rourkela Steel Plant has its own water supply system to cater to the needs of the residents of Steel Township. It supplies 12 million gallons of water per day through a net work of around 500 KM of water supply line. In its township there is a well-laid electrical distribution system which provides electricity to residential houses, shopping complexes, public buildings, roads and different colonies. The entire electrical system consists of two 33 kV receiving station, 125 electrical sub station and 1812 KM of transmission lines. Rourkela Steel Plant has been maintaining a sewerage system in the township and undertaking public health activities for disposal of wastes and garbage by door to door collection of garbage. To maintain a clean and green environment about Ac 4000 of land have been covered under plantation with more than 39 lakhs of trees. There are 2 major parks viz. Indira Gandhi Park equipped with boating facilities, Toy Train & Musical Fountain facilities along with a Zoo and Jubilee Park in the heart of Township. In the township, to provide recreational facilities there is a big library namely Utkalmani Gopabandhu Ispat Library having 51748 nos of books in 12 different languages with the membership of 5790 persons. There is one large auditorium called Civic Centre, 6 nos of Social Homes & 16 nos of Community Centres situated in different sectors. RSP actively encourages and supports socio-cultural activities. RSP runs and maintains 04 vernacular (Oriya Medium) schools, 02 English Medium School and one +2 school spreading over in different parts in the Township. RSP has also provided various infrastructures like buildings, electricity, Land etc. to a number of schools both in English and Vernacular Medium. It has also provided infrastructures to some of the colleges in the Township.


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SPORTS Rourkela Steel Plant is a pioneer in the field of sports and games. Since inception the plant has taken several initiatives to develop sports and also to provide recreational facilities to its employees and their wards including the periphery inhabitants through Sports and games. Rourkela Steel Plant has provided massive infrastructure facilities in the township for the development of sports. Three main stadiums are – (i) The Ispat Stadium at Sector-6 which is a multi purpose Stadium, (ii) Biju Patnaik Hockey Stadium at Sector 6 which is an exclusive Hockey Stadium of international standard with Synthetic turf facility and (iii) Ispat Indoor Stadium in Sector-20 with all facilities for Badminton and Table Tennis. In addition to this there is an Ispat Basketball Complex, Chess and Weight Lifting Halls, Volleyball Courts, a Boxing Hall where all the modern facilities for the training of the sports persons have been provided for improving their standard to national and international level. Rourkela Steel Plant has not only taken the initiative of providing infrastructure but has also taken initiative in providing scientific coaching through reputed trained coaches and Senior Players of national and international repute. While initiative is taken for imparting training in 12 disciplines, a special thrust has been given in the area of Athletics, Hockey, Chess, Cricket, and Table Tennis. For tapping the hidden potential of the young and budding talents, Day Scholar Scheme is being operated in Hockey and Athletics where the selected players - 25 in Hockey and 20 in Athletics are being provided free kits for their practice. As a special initiative a Chess learning Centre is being run by Rourkela Steel Plant for the last five years. These centres had groomed a number of players of regional/ national/ international level under the watchful eyes of Coaches. Summer Coaching Camps are organized in 12 disciplines for imparting scientific training to the budding talents. This being started by RSP in the year 1986, is continuing till date with increase in number of participants every year. This year 1300 boys and girls participated in the Camp which was organized for a period of 30 days instead of 21 days earlier.

Rourkela Steel Plant has also taken several initiatives in organizing tournaments and Championships at different level like local, State and National level. The presence of the Indian Hockey stalwarts at Rourkela for a period of 2 months before their participation in Doha Asiad was a great pleasure and honor for the Rourkelites. Similarly, the Federation Cup Basketball tournament organized by Rourkela Steel Plant at its Ispat Basketball Complex



saw all the Indian Internationals in action. The Public Sector Hockey tournament and the Sub Junior Girls National Hockey are the other major events organized at Rourkela. The sports persons developed under the watchful eyes of Trained Coaches and Senior players of Rourkela Steel Plant have brought many laurels for the organization and the State as a whole. The Rourkela Steel Plant teams became Champion in Inter Steel Plant Cricket tournament, Inter Steel Pant Kabaddi tournament, Inter Steel Plant Hockey tournament and became runners up in Inter Steel Plant Football, Inter Steel Plant Basketball and Inter Steel Plant Table Tennis during the year 2008-09. The efforts of Rourkela Steel Plant for honing the hidden potential of the budding talents have gone a step further in the form of operating the SAIL Hockey Academy which has 32 Cadets. The Cadets are not only given scientific training and the opportunity to practice on the Synthetic turf but also given monthly stipend, furnished accommodation & free food, medical treatment, education, kits and ceremonial dresses on a regular basis for a period of 5 years. The Cadets of the Hockey Academy showed wonderful performance and have won the National Under-18 Championship twice in the year 2006-07 & 2007-08. This was only possible due to the dedicated effort of the Coaches and the modern facility of Synthetic turf provided by SAIL management. Today, Rourkela and its periphery with the encouragement of Rourkela Steel Plant is fast emerging as a centre of excellence in the field of Sports and Games.


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CORPORATE SOCIAL RESPONSIBILITY (CSR) DEPARTMENT

RSP IS NOT STEEL ALONE We care. CSR is not just another item on the agenda. RSP has been contributing towards the development of its peripheral zones on a continuing basis since 2nd October 1974 and has been closely linked the community that lives in and around the plant is giving special thrust on peripheral development that covers a wide range of activities like healthcare, education, farming, environment care, training etc. It has focused on providing infra-structural assistance in terms of school building, roads, community centers, providing game and educative materials, drinking water supply, health, sanitation etc. Sustainable income generation and vocational training for enhancing employment have also been taken up. Activity on women empowerment taken up through Science & Technology modular exposure to create master trainers who in turn train others in the Women Resource Centers at their respective villages. Rourkela Steel Plant has adopted 16 peripheral villages as Model steel Villages for holistic development: List of Villages:

1 Bankibahal Re-Settlement(RS) Colony 9 Dumerjore 2 Jagdishpur 10 Jabapanposh 3 Jamsera 11 Jabaghat 4 Bijadih 12 Kapatmunda 5 Laing RS colony 13 Dalposh 6 Baniguni 14 UsraRS colony 7 Pograbahal 15 Lodsera 8 Chikatmati 16 Jaidega RS colony

Rourkela Steel Plant has been doing many developmental activities at the peripheral villages under Corporate Social Responsibility. Most of these peripheral villages have a large tribal population, who are the ultimate beneficiaries. 1) Institute for Peripheral Development (IPD): An Institute for Peripheral Development (IPD), has been set up at Sector-20, Rourkela at a cost of Rs. 2 crore with all infra-structural facilities for imparting training to the people of the peripheral villages on Agro-Horti-Forestry, nursery & grafting, floriculture, water harvesting etc. towards their capacity building for sustainable livelihood and income generation. Demonstration models are available.



2) Project Parshwanchal Vikas: An integrated Field project named Parshwanchal Vikas (Phase-I) has been taken up, in association with BAIF Development Research Foundation, Pune in 16 villages of three revenue blocks (Bisra, Kuarmunda & Lathikata). Field programme consists of two types of major interventions i.e. (a) Community focused and (b) Family focused. Project includes various sustainable livelihood programme like Agro-Horti-Forestry, improved agriculture practices, live stock development, entrepreneurship development, watershed development, post harvest management, community health & sanitation and establishment of functional people’s organization. Estimated cost for the 5 year project is 5.8 Crores. Wadi: Imparting skills by which the unemployed could use their only capital: land. So WADI (agro-horti-forestry) concept was tried to improve yield and income. Now the programme is being implemented in 16 villages under 3 blocks. Poultry Improved poultry breed (VANRAJ) was launched in the 16 villages of Bisra and Kuanrmunda & Lathikata Blocks. Beneficiaries were sent to the Regional Poultry Farm, Sundargarh for availing training and after that all the participants were provided with 15 days old chicks. Goatery A small ruminant intervention covering 15 project villages of Bisra & Kuarmunda cluster was done by providing them (5 goats and 1 buck each per family) of Black Bengal breed. AI Centre: Breed improvement program of cows conducted regularly through Artificial Insemination (AI) Irrigation Check dam- At Kapatmunda MSV constructed to irrigate 88 acres of land benefiting 200 families Village Level Organisation SHG (Self Help Groups) have been created and are functioning in 15 Model Steel Villages. 3) Education: For motivating village students to improve their zeal for education RSP has taken up various CSR projects as under:

• Infrastructure like Hostel Building, class rooms, halls, computer cum library buildings, play ground have been provided for village students. Most of the peripheral village schools have also been provided with teaching aids, laboratory apparatus, dictionaries.


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• A free school (class I to V) for the underprivileged section of the society residing in and around Rourkela Industrial Town operates in Sector-4 w.e.f. 1st July 2007 under the name of Deepika Ispat Sikhya Sadan. In addition to imparting free education they have also been provided with study kits, shoes, uniform. Mid-day meal has been introduced w.e.f.1st August 2009.

• L2R( Learn to Read) a 3 years programme for improvement of learning of class I to III in the Government Schools has been taken up in association with Govt of Orissa.

• Under Public Private Partnership (PPP) up gradation of ITI, Rourkela has been taken

up.

• Financial assistance provided to Rourkela School for Deaf for procurement of Mass hearing Aid, computer & other items.

Scholarships for Peripheral Village Students

• Merit award scholarship to 30 peripheral village High school passed boy and girl students. (Rs 5000/-, 4000/-, 3000/-, 2000/- & 1000/- respectively to 1st, 2nd, 3rd, 4th & 5th rank holder of each school).

• Merit award scholarship to 45 peripheral village Middle school passed boy & girl

students. (Rs 3000/-, 2000/- & 1000 respectively to 1st, 2nd, 3rd rank holder of each school).

• Financial assistance provided to SC / ST (5 boys and 5 girls) students pursuing

professional courses like Engineering, Medical & Agriculture @ Rs.25,000/- per year per student (every year for full course of 4 years duration). Maximum amount disbursed per student is Rs.1 lakh.

• Scholarships of Rs.900/month (Class I to V) and Rs.1000/month (Class VI to X) being

provided to 100(max) nos of children from the underprivileged section of the society residing in re-settlement colonies/camps (identified by the govt.)

3) Health Care: Free Health Centers: Two free Health Centers are being run at Jalda & Chikatmati with diagnostic support Medical Aid Centers: Weekly 28 free medical aid centers operate in 17 peripheral village locations. During inspections conducted by CSR executives feedback was taken from random patient population of the concerned villages and it was inferred that the population is taking the full benefit of the free medical centres.



• 02 free Health Centers constructed and operating at Jalda Resettlement Colony & Chikatmati Model Steel village where free medicine and free diagnostic facility provided six days a week

• ISPAT SANJEEVANI, a free medical center functioning 6 days a week for the underprivileged people from Rourkela and nearby area.

• Rehabilitation of disabled children – Monthly camps at 3 villages for treatment of Physically & Mentally challenged children

• Project Sunayana (Cataract surgery) – Peripheral villagers underwent cataract operation Patients are operated in IGH and provided IOL free of cost.

• Project Baljyoti (treatment of visually impaired children of 2 yrs to 16 yrs) – School children studying in peripheral village schools were covered by intensive eye check up. Patients of Bisra, Kuarmunda, Bonai, Nuagaon & Rourkela Municipality operated in IGH free of cost.

• Women were provided training in Advance nursing services in RSP’s Nursing Training Institute at IGH.

• Mega medical camps conducted in Bolangir and Kalahandi district of Orissa during in which 12752 patients were treated free of cost in 8 camps Health camp organized at Pisawan, District Sitapur of Utter Pradesh. Total 12703 patients treated in 3 days camp.

• Samarthya Sibir Camp (Single window medical assesment camp for the persons with disability (PWD) in association with Government of Orissa & Rourkela Municipality.

• Financial assistance of Rs 6 lakhs to Gayatri Yoga Sadhana Trust for procurement of apparatus “Sauna Bath” for nature cure.

EYE TREATMENT: Project Baljyoti: Treatment of visual impaired children of different blocks of Sundargarh District. Feedback was taken and this approach of RSP to reach the rural populace has been appreciated by all. 100% satisfaction level was also noted as regards the quality of medical care. HEALTH CAMPS: Mega medical camps conducted in Bolangir and Kalahandi district of Orissa during in which 12752 patients were treated free of cost in 8 camps . Another mega camp was conducted at Pisawan, Sitapur (UP) where 12073 patients were given free treatment. 5) TRAINING: Improving Income generation potential through skill development & empowerment of rural people through training programme conducted. Different modules of training programmes undertaken at the Institute for Peripheral Development of Rourkela Steel Plant are given below:

S.No. Modules Target Population 1 Sewing & Embroidery Village Women 2 Wadi (Agri-Horti-Forestry) Farmers 3 Soil Fertility& Organic Farming Farmers 4 Soil & Water Conservation Farmers 5 Water Resource Management Farmers


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S.No. Modules Target Population 6 Improved Agriculture Farmers 7 Nursery Raising For Self-Help Group Village Women 8 Community Organisation Village Men/ Women 9 Improved Chullah Making Village Women

10 Mushroom Cultivation Village Women 11 Vermicompost Preparation, Use & Benefit Farmers 12 Female Health Guides & Midwifery Village Women 13 Skill Development

(Welding & Gas Cutting, Electrician) Unemployed Village Youth

14 Cross Breed Cow & Goat Farming Farmers In view of the above RSP strives for excellence, through continual improvement in the quality of life of the peripheral populace and deserves accolade for going beyond its primary function of steel making to reach the rural populace. 6. INFRASTRUCTURAL Development: As a part of CSR activity a number of activities to develop infrastructure for use of peripheral population have been provided:

Roads, Culverts & Drains Village Community Centres Market Complex-2nos at Jalda & Jhirpani Resettlement colonies

7. Participative Approach: Participation in activities jointly with local administration and government are: • Electrification work completed in collaboration with WESCO, Govt. of Orissa

1. Bankibahal ( Model Steel Village) 2. Jagdishpur (Model Steel Village)

and continuing at Lachhada Resettlement Colony and Jaidega. • New tube wells provided for drinking water in collaboration with Rural Water Supply &

Sanitation, Govt. of Orissa • Pipeline water supply to 16 model steel villages are completed/ongoing • In collaboration with the local administration and Govt. agencies undertake many

awareness and health check-up programmes. Some of the joint programmes conducted by IGH during the year for the people belonging to different strata of the society like below the poverty line persons, labourers, tribal people and orphans including educational institutions is as given hereunder:

World Breast feeding week Laparoscopic surgery IPPI (Pulse Polio) programmes SAIL AIDS Control Programme (SACP) Family planning activities Health Camps National Nutrition week Vitamin A Campaign World population day Health& Hygiene Programmes for SHGs



8. Other Developmental Activities: Provided Low density Polyurethane sheets to State Govt for flood relief (27 Tonne) Rs27.34

lakhs medical help and material help & consultancy like cyclone shelter houses towards rehabilitation in Orissa

Provided 02 ambulances to the Chief District Medical Officer, Sundergarh.

Financial assistance to 2 mentally challenged children to participate world games at

Sanghai, China and also to the following organizations to procure vehicles/other utility items: • Ramakrishna Mission, Rourkela ; Ambulance • Vedvyas Gosala Samiti, Rourkela : Ambulance for animal care • Home & Hope- (A special school for disabled children): Ambulance • Asha, Sector-22 (A special school for disabled children): Ambulance • Deepika Mahila Sanghati: Ambulance • Gayatri Yoga sadhana Trust : Sauna accessories • Youth Hostel association of India(YHI); Ambulance • Seven Anath Ashrams of Rourkela have been provided with financial assistance for Rs

4.48 lakhs for procurement of utility items for the use of inmates. • Financial assistance provided for Development of Netaji Subhas Birth place Museum at

Cuttack and Development of Library in Rourkela by Pragati Utkal Sangha.


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PUBLIC RELATIONS Defining PR: Public Relations is the deliberate, planned and sustained effort to create mutual understanding between an organisation and its stakeholders. Functions & Areas of Responsibility

Image building among stakeholders Dissemination of information regarding the organisation Media relations – local & regional Local advertising & publicity Events

A pre-requisite of effective communication is a thorough understanding of the company, the nature of its stakeholders and the dynamics of the environment (business, political, social et al) in which it is operating. Target Audience

INTERNAL (Employees) EXTERNAL (Govt., financial institutions/banks, customers, community neighbours,

Policy makers, govt. agencies, suppliers, general public, other stakeholders)

Objectives Reinforcing the image of Rourkela Steel Plant as a profitable, progressive and vibrant

plant that cares for all its stakeholders Acting as a catalyst in employees adopting the philosophy of ‘Spreading SAMRIDHI’ Establishing RSP as a Socially Responsible Corporate Citizen To create a sense of pride among the stakeholders Corporate image building

Challenges

To propagate the vision and values of the organisation and help achieve business goals in changing scenario

Facilitating the change in the mindset for adjusting to new situations Establishing effective communication channels both internal and external to promote

company’s policies and image amongst the employees of the organisation and different groups

Creating a climate of confidence and trust amongst the employees and stakeholders To keep pace with the growing media requirement Obtaining and evaluating opinions to provide feedback to the management and enlist

employees’ involvement. Analysing information on a continuous basis and using this information to launch first strike programme.

Reaching out to employees/people as individuals and being environmentally sensitive.



Units of Public Relations Communications Rourkela Steel Television Centre Photo Unit Documentation Centre Ispat Press

Communication

Daily news for RSTV Press Releases : a) regular b) paper specific c) special features Media Liasioning Ispat Sahayog in three languages. Brochures, posters, hoardings etc Inputs for SAIL news, website & corporate publications Messages of MD, Speeches, Appeals Etc Scripts and story boards of documentaries & films Creating and Facilitating Advertisement Campaigns

Content of Communication

Priorities of the Plant Future Challenges Production and productivity Achievements of employees/ family members Safety Quality Cost Control Environment Management

Rourkela Steel Television Centre

Daily News in Oriya, Hindi & English Weekly News Round Up on Sundays Yearly Round Up Health File Documentaries, reports Live Recording/Telecast of important programmes Interviews & Panel Discussions Cultural Programmes, Quiz and other special programmes etc Messages of important dignitaries

Photo Unit (Still & Video Photography)

Glimpses for RSTV News Ispat Sahayog


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Special Purpose Still Photography :

• Press releases • Statutory, Insurance, Factories Inspector, Police inquest etc • Booklets & Brochures • Exhibitions

Documentation Centre

Daily Press Clippings to MD and all EDs Computerised data bank on clippings & different topics Media Analysis Record Keeping Library

Ispat Press

All Technical stationeries for Internal Use Office Stationery, Medical Books, coupons, Park tickets APP Booklets Messages, speeches, appeals etc Risograph of different communication materials

Miscellaneous Jobs

Goodwill Advertisements Releasing of Statutory Advertisements (Tenders, Inquiry Notices, Appointment Ads etc) Distribution of SAIL News/ Wallsheets/Posters/Diaries



PROTOCOL & HOSPITALITY SERVICES Liaison Cell: The prime responsibility of the Liaison Cell is to assimilate, analyse and synthesize internal and external intelligence on the plant affairs. It monitors important internal and external developments of relevance to Rourkela Steel Plant and sensitizes the Higher Management on the ensuing as well as forthcoming developments/issues in the fields of political, social and trade unionism etc. Besides it coordinates with the appropriate authorities and agencies as per requirement from time to time. Protocol Unit: The Protocol unit coordinates and handles visit of VIPs, dignitaries and other important persons to Rourkela Steel Plant as well as visit of students from various educational institutions. It also coordinates visit of customers as well as suppliers to the Administration Building. It ensures observance of protocol requirements during visit, functions and events, in association with the Government Authorities. Hospitality Services: The prime activity of this section is to extend due hospitality services to the Company's guests and dignitaries. It is responsible for the effective management of the Guest Houses of Rourkela Steel Plant at Rourkela, i.e. at present the

• Rourkela House containing 21 No. of air-conditioned suits, • Guest House at Sector-20 containing 3 No. of air-conditioned rooms and • Ispat Niwas containing 27 No. of air-conditioned as well as Non-air conditioned rooms.

Further, the maintenance and management of the Rourkela Air Strip is the responsibility of the Hospitality Services unit.


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VIGILANCE ‘Vigilance’ is a management function required to bring and sustain propriety and integrity at all levels in an organization. This is very relevant and important in Government Departments and Undertakings for safeguarding against the misuse of public money so that survival of the undertakings will be possible in today’s economic scenario. Vigilance Set Up in Rourkela Steel Plant: At Rourkela Steel Plant, Vigilance set up is headed by Addl. Chief Vigilance Officer (ACVO) and assisted by a number of executives and Vigilance Inspectors who are in the rank of non-executives. All postings in Vigilance are for a tenure of 3 years extendable up to 5 years. Vigilance Department reports directly to Chief Executive of RSP & CVO, SAIL. Responsibility & Functions of Vigilance Department: Prime responsibilities of Vigilance are

• to plug loopholes in the system and procedure • to protect the honest employees • to ensure deterrent punishment to wrong doers

The functions of Vigilance Department in RSP can be categorized into two types:

Preventive Vigilance Punitive Vigilance

Preventive Vigilance: Prime focus of Vigilance is prevention of corruption rather than investigation of corruption. Preventive vigilance activities consists of –

Surprise checks in different areas particularly in sensitive areas i.e. places prone to corruption such as shipping, finance, purchase, sections dealing with execution of contracts etc.

Identifying weaknesses in existing procedures/rules & regulations and suggesting improvements to plug loopholes and bring greater transparency in exercise of power.

Initiating formulation of new procedures/guidelines Scrutiny of AIPR (Annual Immovable Property Return) files of employees Scrutiny of contract/purchase files to check any violation of Purchase & Contract

Procedure 2009 (PCP 09) Rotation of employees in sensitive postings. As per Central Vigilance Commission

(CVC) guidelines, employees manning a sensitive post should be rotated after completing 3 years.

Developing vigilance awareness through regular training programs. Punitive Vigilance: This deals with providing adequate punishment to the wrong doer promptly so that it serves as a deterrent for others. An employee is given major punishment only after the charges are established against him through a regular departmental inquiry (RDA).



Conviction under Departmental inquiry is based on ‘Preponderance of Probability’ rather than ‘Proof beyond reasonable doubt’ which is the rule for conviction in judicial proceedings. Standing Order and Conduct Discipline & Appeal Rule 1977 provide a non-exhaustive list of misconducts for which an employee can be punished. Direct punitive vigilance functions involve the following:

Carrying out prompt investigation into the complaints, which are not pseudonymous/anonymous and are having clear vigilance angle. Besides complaints, surprise checks also reveal discrepancies that are taken up for detailed investigation.

Guiding Disciplinary Authority in preparation of charge memoranda/Charge sheets Presenting cases of vigilance before Inquiry Committee Recommending type of punishment (whether Major or Minor) for errant employees

of E3 level and below Taking advice of Chief Vigilance Officer (CVO) on the type of inquiry (First Stage

Advice) and type of punishment (Second Stage Advice) to be awarded to errant employees of E4 grade and above.

Refer vigilance cases involving employees of E8 and above to CVC through CVO for advice on quantum of punishment to be awarded.

Ensuring inquiry is completed within 6 months from the appointment of Inquiry Officer and punishment order passed promptly.

Ethics, transparency and fair play form the core of our democratic values and as such are of paramount importance to an organization like RSP. It is possible to make profit through good governance, which requires each and every officer and worker of our company to maintain absolute integrity and follow ethical practices in their day to day functioning. Every manager MUST remember that he is a vigilance officer in his own area of supervision.


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INTERNAL AUDIT

Internal Audit Department of RSP is an integral part of Corporate Internal Audit (SAIL). It is a statutory requirement as per Company’s Act. Accordingly an Audit Committee was constituted by SAIL Board. For effective functions of the same, Internal Audit department of various plants/units of SAIL functions as a part of the Corporate Internal Audit. It examines, evaluates and provides professional opinion on its systems of financial, operational and management controls. It is an effective management tool to ensure that management controls are working effectively and operations are being carried out in consonance with the overall organisational objectives. One of its major functions is to check the compliance with established and statutory accounting system and procedures to ensure that the final accounts represent a true and fair financial position of the company. Internal Audit Areas:

Audit of sanction Proprietary Audit Audit of expenditure Audit of conformity with generally accepted accounting principles/standards, accounting

policies of the company and statutory provisions of Companies Act, Income Tax Act (Security Exchange Board of India) etc.

Scope & Functions:

Reviewing the reliability and integrity of financial and operating information and means used to identify, measure, classify and report such information.

Reviewing the means of safeguarding the assets. Appraising the economy, efficiency and effectiveness with which resources are deployed.

In particular to ensure that: o The Inventory levels are managed to the best commercial advantage and for

improved market presence. o The Funds are managed to the best commercial advantage. o The appropriate expenditure is incurred.

Reviewing operations, activities or programmes to ascertain whether results are consistent with set objectives and goals and whether they are being carried out as planned.

Conducting special/management audits and other special assignments so directed by the Chief Executives/ Chairman/ACB.

Coordinating the replies to the Government Audit Queries, Inspection Reports, Draft Audit Paras, Comprehensive Appraisals and COPU Questionnaires.

Maintaining liaison with the Statutory Auditors and to provide all assistance to them as may be required.

Assisting Audit Committee in ensuring transparency in the management functions to make it an effective tool of Corporate Governance.



The exact scope of an audit, nevertheless is decided on the basis of risk analysis, previous reports, resource availability, time and cost constraints prior to commencing an audit. Follow up/ Review of Audit activities: On completion of Audit of a particular area/department a Preliminary Report (PR) is issued to the Auditee department for compliance/ further comments. On receipt of Auditee’s comment, the Final Report (FR) is issued to the Principal HoD incorporating the Auditee’s comments and further comments of Audit. A copy of FR is also sent to Corporate Internal Audit for perusal and further actions, if required. The Action Taken Report (ATR) is subsequently issued by the Auditee. Regular follow up is done with Auditee Department to ensure implementation of various audit suggestions. Special emphasis is given for identification of Significant Audit Findings (SAF). The same is regularly followed up for due compliance and the same is monitored by the Corporate Internal Audit on a regular basis till implementation.

Heads of Internal Audits (HOIA) conduct monthly review meetings to review the progress and status of various Audits and also the findings there-of. Wherever necessary the matter is taken up with higher authorities for necessary action against various Audit observations.

A monthly report as per standard proforma is sent by HOIA to Corporate Office detailing the number of audits scheduled, done, number of PR & FR issued with details and various Significant Audit Findings (SAF) status thereof.

Similarly, a monthly report is also submitted to MD, RSP by HOIA detailing the various activities and significant observations for kind perusal of MD.

Quarterly HOIA meetings are held by ED (IA) to review the audit activities of various units, status of SAF etc and also to discuss various other issues like new rules/ regulations or modifications there-of.

Action taken/proposed to be taken (with time frame) are to be indicated by the auditee for the audit recommendations which are acceptable to them. Wherever the auditee does not agree with the observation/suggestion/recommendation, the same is to be clearly mentioned with reasons for disagreement/suitable explanation.


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MEDICAL & HEALTH SERVICES Rourkela Steel Plant's concern for a healthy workforce is symbolised by its Medical and Health Services functions. This concern has led RSP to establish a modern, multidisciplinary, comprehensive and premier medical centre in the eastern region which has been functioning since 1959 to provide quality medical & health services to the employees of RSP, members of their family, supporting population and inhabitants of the neighbouring areas of Orissa and its adjoining states. Equipped with state of art diagnostic facilities, equipment and a committed collective of competent professionals, the hospital is a centre for curative, preventive, promotive and rehabilitative functions.

A 685 bed hospital, Ispat General Hospital (IGH), was the first hospital in the industrial sector to initiate the concept of Intensive care, Burn care, Haemo-dialysis, Nuclear medicine laboratory, Molecular Biology Laboratory, Whole body Ultra Sound, 16 Slice Spiral CT Scan, M.R.I, New Super X-Ray etc. It was also among the first industrial hospitals to start innovative medical procedures which include implantation of Single and Dual Chamber Pacemaker, Total Hip replacement, Total Knee replacement, Phaco emulsification cataract

surgery, Pyloplasty, Percutaneous Nephrolithotomy (PCNL)-a key hole surgery for removal of kidney stone, THD-Transanal Haemmorhoidal Dearterialisation- a latest painless technique for piles operation etc. IGH of RSP was first among SAIL Steel Plants and within Orissa to install "Vapoclave" for comprehensive biomedical waste management. To provide basic health care and also to impart health education four Health Centres are there spread across the Steel Township. There is also a hospital in Sector-22 with bed strength of 30. To provide free medical care to the poor section of the society, three no. of Free Medical Consultation Centres have been set up in Sector-6 (Ispat Sanjivani), Chikatmati and Jalda areas. RSP was the first to start a full-fledged Occupational Health Service (OHS) Centre in SAIL and in Orissa. The OHS activities include 3 Ps of Health care, namely pre-employment, pre-placement and periodic check ups. All the employees are covered under 'Man Maintenance Programme'. Special health check up for ‘high risk groups’ is being done regularly. A health center has been established by RSP in a unit taken over by SAIL at Jagdishpur, UP. Various sophisticated diagnostic and therapeutic instruments have been installed for quick diagnosis and better health care such as:



1. Fully automated Olympus AU-640 clinical chemistry Autoanalyser 2. Automated X-Ray film processor 3. Uretero Renoscope 4. High Speed Sterilizer in OT 5. Ventilator with compression compact for Anesthesia unit 6. Phaco Surgical Instruments 7. Cardiac Defibrillator and Monitor in ICU 8. Whole body ultra sound 9. Digital Flame Photo meter (Bio-Chemical Lab) 10. Laproscopic Hysterectomy Instrument 11. Color Doppler 12. Fully automated Ac.T 5 diff CP Coulter Monitor 13. Yag Laser 14. New Super X Ray 15. 15 Tesla M.R.I 16. 16 slice spiral CT 17. Centralised Blood Collection Centre 18. Emergency Lab 19. Information Centre 20. State of the Art, Air-conditioned Physiotherapy Centre 21. Post-operative recovery room in OT-I 22. Renovated clinical Pathology Lab The Paediatric unit in IGH has the distinction of being chosen as one of the centres of excellence out of five in India. Working in collaboration with University of Maryland USA for prevention of neonatal sepsis, it has contributed significantly towards reducing infant mortality rate in adjacent rural areas. Post graduation training (DNB): Eleven Departments of IGH, namely, General Medicines, General Surgery, Pediatrics, O&G, Orthopedics, Anesthesia, Pulmonary Medicine, Ophthalmology, Maternal & Child Health, Pathology and Family Medicine have been accredited by National Board of Examinations for DNB training. Efforts are on to have DNB training in other disciplines as well. Treatment of around 15 lakh out door patients and 33,000 indoor patients annually is an indication of the gamut of operations of the Medical department. But statistics alone are not the identifying criteria of the commitment of IGH towards society. The commitment is visible in the continually improving quality of life of the citizens of Rourkela. The various units of IGH: Surgery: The Surgery unit includes General Surgery, Neurosurgery, Burns & Plastic Surgery, Orthopaedics and Trauma Surgery. The unit is accredited for post graduate teaching. It runs three operation theatres and a round the clock emergency operation theatre. It carries out microsurgery, sophisticated orthopaedic and neurosurgery in addition to urological procedures.


Panorama 2010 Laparoscopic surgery for Gall Bladder is carried out for the last 15 years. So far more than 1000 patients have received the benefit of this button hole surgery. Many critical cases are also successfully operated by the doctors of this unit. Advanced Neurosurgeries – Acute Subdural Haematoma, Brain Stem Haematoma, Huge Haematocele, Deep Brain Tumor Surgery, Spinal Fixation, Paediatric Neuro Surgery & Vascular Surgery, Nephro-Ureteroctomy, and Abdominal Rectoplexy are some of the critical surgeries carried out at IGH. Medicine: The Medicine unit has combined services along with academics. It has various sub-specialities like Nephrology & Dialysis unit for renal failure patients, Cardiology and Gastroenterology. It has a modern 11 bed Intensive Care cum Coronary Care unit with facilities for artificial ventilators, central monitoring and central oxygen. This unit holds the record of implanting a permanent pacemaker in a boy of eight years age. The Gastroenterology unit performs upper and lower GI endoscopy along with facility for band ligation, sclerotherapy and foreign body removal. This unit is recognised at national as well as international level for the research activities in tropical medicine which has brought laurels to SAIL. It has established collaboration with World Health Organisation (WHO), Council of Scientific and Industrial Research (CSIR) and Indian Council of Medical Research (ICMR). Malaria Research NIMR (ICMR) Govt. of India with Ranbaxy Research Lab sponsored project on study (Phase III) of comparasion of Arterolane & Piperaquine phosphate with Coartem in patients with acute uncomplicated PF Malaria. IGH has always been in the forefront in research activities. IGH has been recognised by the World Health Organisation as a training centre for doctors from SAARC countries on malaria case management. It is also one of the 4 centres in South East Asia to conduct SEAQUAMET trials in severe ‘Falciparum malaria’. Several landmark papers have been published on malaria in international journals. Doctors of IGH have played key role in formulating the drug policy for the treatment of severe malaria in India. New molecules have been developed in collaboration with CDRI (Lucknow) and MMV (WHO), which will go a long way in the treatment of malaria. WHO has prepared a documentary film on treatment of severe malaria at IGH for educating doctors and community on the subject in other parts of India. Paediatrics and Neonatology Unit: It has a well equipped Neonatology Unit and Paediatric Intensive Care Unit. It is the first hospital in the Public Sector Undertakings to establish collaboration with University of Maryland, USA through a Global Network Funding.



UMB NICHD Research Network Ispat General Hospital is proud to find a prominent place in the international medical research map, by way of association in this multi-centric medical research project. This was started in the year 2002 under the banner of Global Network Project, in association with University of Maryland (USA), National Institute of Health (USA), ICMR and Govt. of Orissa. In September-2008 the banner was renamed as UMB NICHD Research Network with the project titled “Prevention of Neo-Natal Infection in the Indian setting using Probiotics”. Under this project, currently field intervention is going on in 131 Anganwadi centres in the operational area, where there has been significant reduction in the infant and neo-natal mortality Obstetrics & Gynaecology Unit and Family Welfare Unit: In addition to the responsibility of the mother care, these units involve in the national programme for the family welfare. These units organise monthly camps for family welfare, awareness and immunisation. Chest & TB, Psychiatry and Dermatology Units: These units engaged in both preventive and curative aspects of the employees and the general population. With the help of SAIL-National AIDS Control Organisation (NACO) initiative, it has established a voluntary consultation unit for suspected HIV-AIDs patients. It conducts regular awareness programmes for the employees, general public, students etc. DOTS treatment is provided free of cost to TB patients under RNTCP. SNEHA- a project under CSR has been initiated for underprivileged leprosy patients of the society. The project envisages of fundamental medical management and rehabilitative surgeries of the leprosy patients. KIRAN- a project started for the benefit of employees to break free from the clutches of addiction and bringing them back to normalcy. Counseled by the psychiatrists of IGH and supported by the family, colleagues and personnel officers, many employees have been benefited, thus reducing absenteeism. Eye, ENT and Dental Units: The Ophthalmology unit is well equipped with modern gadgets for phacoemulsion, micro-surgery etc. SUNAYANA- the community ophthalmology project for patients of the peripheral villages adopted by RSP for free cataract removal operations and medicare. BALJYOTI- a project for free treatment of visually impaired children in the age group 3-16 years of peripheral villages and industrial slums was taken up with the assistance of CSR dept. The ENT unit is recognised as the centre of excellence for removal of foreign bodies from the respiratory tract in the infants and children.


Panorama 2010 SUSHRUTI- a project under CSR has been initiated for children up to 15 years of peripheral villages and slums, with hearing impairment. The Dental unit is equipped for dental surgeries and artificial dentures. Laboratory Services: The laboratory services are the backbones of any good hospital. The Bio-Chemistry Lab is recognised as one of the finest Labs in the country, as it regularly occupies top ranks in the external quality control tests conducted by Association of Clinical Bio-Chemists of India (ACBI) and Christian Medical College (CMC), Vellore for about 2000 hospitals and laboratories in India. It stood first four times so far in this ranking. To facilitate the patients in general and the employees in specific, centralized blood collection system has been introduced for all laboratories. DBT Sickle Cell Project Ispat General Hospital along with Dept. of Biotechnology, Govt. of India, Ministry of Science & Technology has undertaken a project “Study of morbidity patterns in sickle cell disease in western Orissa and its correlation with different genetic factors, foetal haemoglobin concentration and epistatic factors like malaria”. Occupational Health Service Centre (OHSC): This unit is the first Occupational Health Centre established in SAIL as well as in any Public Sector Undertaking in Orissa. It organised the first ever conference of Occupational Health in the Steel Sector, at Rourkela about two decades back. Library: IGH has an air-conditioned Library with two internet terminals and four computers, a scanner and a photo-copier. It is equipped with latest edition of books on various subjects in addition to more than 40 Journals from India and abroad. In addition to the above facilities IGH is linked to the Computer & Information Technology department of RSP through on-line SUN system, which supports a near total computerisation of the Stores, Statistics, Registration and Finance Sections. Conference Hall: IGH is equipped with a fully air-conditioned conference hall where various conferences, seminars, workshops etc. are conducted regularly. DNB Reading Room: DNB doctors are provided with a room for reading purpose. Air-conditioning: All the wards on the second floor have been air-conditioned.



Information Centre: An information centre has been started in the lobby in front of main gate for the benefit of patients and attendants. Special Features of IGH:

Established first Dialysis unit in Eastern India Established first Intensive Care Unit in SAIL Established first Burns Care Centre in Public Sector Undertakings First Industrial Hospital in India to start implantation of Pace-Makers First Industrial Establishment in India to implant the Pace-Maker in the youngest

person (8 years old boy) Organised first All India Steel Doctors Conference PHACO Surgery for cataract started at IGH for the first time in SAIL hospitals First Industrial Hospital to establish collaboration with University of Maryland, USA in

Paediatrics & Neonatology WHO recognised the training centre of IGH for Severe Malaria. For the first time the Bio Chemistry Laboratory achieved the recognition of Zero

variance index score under the external quality assurance scheme conducted by Christian Medical College, Vellore.


Panorama 2010

CENTRAL INDUSTRIAL SECURITY FORCE ORIGIN OF CISF Govt of India created the post of Industrial Security Advisor in 1961 as a need was felt to review existing security arrangements in various Public Sector Undertakings in the country. Shri S N Dutt was appointed as Security Advisor in the Department of Industries and he recommended that a uniformed Force is to be raised to look after the security of the Public Sector Undertakings. The need for a specialized security Force came into sharp focus after the disastrous fire in Heavy Engineering Corporation Plant at Ranchi on 29th January 1964. A Commission headed by Justice B Mukherjee was appointed to enquire into the cause of fire. Since in the enquiry it was revealed that sabotage was committed, he recommended for creation of a Central Security Force for providing better protection and security to Public Sector Undertakings (PSUs). A Bill was brought before the Parliament for setting up of Central Industrial Security Force (CISF) in August 1966 and after thorough security and certain amendments, it was finally passed by both houses of Parliament and received President’s consent on 02.12.1968 by a notification in official Gazette. CISF came into existence in 1969 with a sanctioned strength of only three Battalions. In the beginning CISF was inducted in only two Undertakings. Currently CISF is providing security coverage to 272 Industrial Undertakings (including 54 airports out of which 12 are international) spread all over the country in 77 different establishments Fire Protection is also being provided. CISF Act was amended in 1983 and the Force was declared the Armed Force of the Union on June 15, 1983. The original charter of CISF was to provide protection and security to the property of Public Sector Undertakings. It was amended in 1989 by Act No.20, which entrusted the responsibility for providing protection to the employees of Public Sector Undertakings within their premises to CISF. CISF Act was further amended by Act No.40 of 1999 which enlarged the charter of -

(i) Providing Technical Consultancy Services related to security of any private Sector industrial establishments (ii)

(ii) To protect and safeguard the organizations owned or funded by the Govt and the employees of such organizations as may be entrusted by Central Govt and

(iii) Any other duties which may be entrusted by Central Govt from time to time. CISF, which made a beginning with a sanctioned strength of 3192 in 1969, has grown to strength of more than 1 lakh. CISF is the only Para Military Force to have a Fire Fighting Wing. Now a day the functioning of CISF is not only existed within the periphery of Industrial Undertakings because CISF is deployed for Election Duties, Internal Security Duties, VIP duties, Govt Building Security, Metro Rail Security, Rescue Operation duties, UN Mission duties etc.



Induction of CISF in RSP, Rourkela In order to provide effective security coverage in RSP Rourkela including Barsua Iron Mines, Barsua/ Tensa CISF was inducted on 08.11.1971 with the strength of 1275 headed by Deputy Inspector General. In the intervening period there was increasing/decreasing of strength of CISF. The strength of CISF posted at Barsua Iron Mines, Barsua/Tensa that was placed under Raw Material Department of SAIL, Kolkata, was separated in Dec 2008 and it was declared a separate Unit headed by an Asstt Commandant under the administrative control of DIG CISF Unit RSP Rourkela. Due to such declaration, the strength of CISF at RSP Rourkela comes to 1177. In the year 2004 there was a need of increasing of strength of CISF because of creation of some new duty posts in Modernization Plant, Power Gate and few of the location in Township area of SAIL RSP Rourkela. Accordingly re-survey was conducted and the strength of CISF was increased from 1147 to Now the strength of CISF in RSP Rourkela is 1277 to 1247 headed by Deputy Inspector General. Beside the above, various Mines Units such as MIOM/KIOM Meghahataburu, BOM Bolani, OMDCL Thakurani, GOM Gua, BLSM Bhawanathpur, BIM Barsua/Tensa and NSPCL Rourkela have been placed under the administrative/operational control of DIG CISF Unit RSP Rourkela. Physical Security Measures Available In RSP Rourkela RSP Rourkela has total 33.89 Sq. KM covered by 25 Kms long perimeter wall with proper overhang and gates for entry/exit of men and materials. There are about 19 watchtowers in the plant. Inside patrolling road along with the perimeter wall is also available. Adequate lighting arrangements with Tower lights are also available. Communication facilities are also available with sensitive duty posts. Modern Gadgetry equipments like VHF (GM) Motorola, VHF Hand Set, Dragon Lights, HHMD, DFMD, Trolley Mirror, Prescopic Mirror, Bomb Suppression Blanket, Bullet Proof Jackets etc. are available with CISF. Keeping in view the present security scenario and increasing of naxalite/terrorists activities, morchas have been placed in various gates, road blockers have been provided at the gates, Quick Reaction Team has been introduced who are carrying out patrolling in the plant area round the clock, Crime prone areas were identified, Major threat to the plant has also been assessed. Beside the above Pass system is also available in RSP Rourkela. Passes are issued by CISF on the authentic recommendations of authorized signatories. Various types of passes are available for making entry/exit in RSP Rourkela. Photo Passes are issued to all RSP Employees. Separate passes are issued to Contractor Labourers and Supervisors only on proper recommendations of RSP Management. Laser System Identity cards for the plant’s employees are issued from CISF Pass Section on submission of filled up applications in a prescribed proforma duly forwarded by the HODs. Visitors are also issued passes on submission of applications duly recommended by CLC Department to CISF Pass Section. Access Control and Administration Security of RSP Rourkela including various sensitive posts located in Township area as well as located at a distant place such as Mandira Dam, Air Strip, Tarkera Pump House, Slag Granulation Plant etc. is effectively looked after by CISF.


Panorama 2010 As per the re-survey report, 21 gates are operating in RSP Rourkela, which is being guarded by CISF round the clock besides 28 vital installations situated inside/ outside the plant. The security system in the plant for countering criminal activities, are being up dated from time to time according to the need of the day and round the clock guarding around the vital installations, important stores, all gates, escorting of railway wagons, patrolling inside and outside the plant premises etc. is ensured by CISF. Keeping in view of crime prone areas, common modus operandi adopted by criminals and to stop unauthorized entry, following remedial measures have been taken to ensure effective security coverage in the plant: -

a) Computerized inventories in the Stores are maintained b) Thorough verification of material movements is maintained c) Combing operations/ambush is conducted at regular intervals d) Strict checking of passes of employees, contractor labourers, visitors at the gates is

ensured e) Thorough checking of vehicles are made at the gates f) Random checking is being conducted at Contractor’s stores, loading g) points and canteens h) Patrolling has been intensified i) Surprise re-weighment of loaded vehicle is being conducted j) Dogs are being utilized during ambush/patrolling k) Existing modern gadgetry equipment are utilized at gates l) Scrap materials have been stored in a safer place m) Character and antecedents of employees are verified n) Control Room has been established at Main Gate to receive/pass over of various

informations to concerned authorities o) Checking/surprise checking of various posts and activities are conducted frequently p) All the movements through the gates are monitored by Control Room. q) Flow of traffic, movement of vehicles and safety within the plant is also

regulated/controlled r) Stores, Mandira Dam, Air Strip, TPH, SGP and Cash counters are guarded

effectively by deployed static duty round the clock. Achievement of CISF Beside effective and strenuous security duties, CISF deployed in RSP has also achieved good fame in excellent performance during Independence Day, Republic Day Parades organized by RSP Rourkela and Civil authorities. Various religious functions are also organized by CISF in Birsa Camp Complex & CISF Auditorium. Due to effective security coverage in the plant and township by CISF, crime cases have drastically been minimized. For making appreciable correspondences and other implementation works in Hindi, this Unit was awarded with the Best Official Language Trophy and 1st Running Shield by the Town Official Language Implementation Committee, Rourkela in the year 2006.

MOTO OF CISF:

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Editorial Team: • Ms Sangeeta Misra, DGM (HRD)

• Shri Suresh Kumar, Senior Manager (HRD) • Shri PK Das, Senior Instructor (HRD)

panorama 2010, aug 16 2010

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