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Panorama 2010
Contents Of Panorama
Sl.No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28. 29. 30. 31. 32. 33. 34. 35. 36. 37. 38. 39. 40. Department RSPAResume OreBedding&BlendingPlant CokeOvens CoalChemicalsDepartment SinteringPlantI SinteringPlantII BlastFurnace SlagGranulationPlant SteelMeltingShopI SteelMeltingShopII RefractoryEngineering(Services) LimeDolomiteBrickPlant CalciningPlantII TonnageOxygenPlantI TonnageOxygenPlantII HotStripMill PlateMill ERWPP SpiralWeldedPipePlant PipeCoatingPlant SpecialPlatePlant ColdRollingMill SiliconSteelMill RollShop MaintenanceFunction MaintenanceSystemandServices ShopsPlg&CoordinationServices ShopsFoundries ShopsMechanicalShop ShopsRepairShop(Mechanical) ShopsStructural&FabricationShop Repair&Construction(Mech) CraneMaintenance FieldMachinery(Maintenance) Transport Design CaptivePowerPlantI PowerDistribution Electronics&ElectricalServices CommunicationEngineering Department Sl.No. 41. 42. 43. 44. 45. 46. 47. 48. 49. 50. 51. 52. 53. 54. 55. 56. 57. 58. 59. 60. 61. 62. 63. 64. 65. 66. 67. 68. 69. 70. 71. 72. 73. 74. 75. 76. 77. Department Instrumentation RepairShop(Electrical) AirConditioning HeavyMaintenance(Electrical) Production,Planning&Control TrafficandRawMaterials Scrap&Salvage CivilEngineering(Services) StructuralInspection ContractCell(Works) WaterManagement EnergyManagement SafetyEngineering EnvironmentalEngineering FireServices IndustrialEngineering Research&ControlLaboratory TotalQualityManagement AMRProjectMonitoring&Spl.Cell Projects Computer&Info.Technology MaterialsManagement Finance&Accounts Personnel HumanResourceDev.Centre CentralPowerTrainingInstitute Law TownEngineering TownServices Sports CorporateSocialResponsibility PublicRelations Protocol&HospitalityServices Vigilance InternalAudit Medical&HealthServices CentralIndustrialSecurityForce
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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.
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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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) b) c) d) e) Iron Ore: Limestone: Dolomite: Manganese : Ferro Manganese and Silico Manganese: Quartzite: Coal: Captive Mines at Barsua, Kalta, Meghathatuburu, Kiriburu BF Grade - Purnapani and Kuteshwar SMS Grade - Jaisalmer and Katni BF Grade - Biramitrapur and Sonakhan SMS Grade - Bilha, Baraduar and Katni Purchased from Barajamda and Koira Maharashtra Electrosmelt Limited (MEL)
f) g)
Purchased from Local areas 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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h) Plate Mill:
i) Pipe Plants
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Coils
Pipes
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21 December 1953: Agreement signed with KruppDemag 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 SMSI. 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 SMSI. 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 Honble 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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Sl.
(i) (ii) (iii) (iv) (v) (vi) (vii) (viii)
Raw Materials
Iron Ore Lumps (IOL) Iron Ore Fines (IOF) BF grade Lime Stone BF grade Dolomite SMS grade Lime Stone SMS grade Dolomite Dolo Fines Mn. Ore
Sources
Barsua, Kalta, Kiriburu, Meghataburu, Bolani, Chiria (Manoharpur) & Gua Barsua, Kalta, Kiriburu, Meghataburu, Bolani, Gua & Manoharpur. Kuteswar, Birmitrapur & Sonakhan Jaiselmar & Gulf Countries( Dubai& Oman) Belha, Bhavaduar Birmitrapur & Sonakhan 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 Bed-3 & 5. Bed-4 & 6 Bed-7 Bed-8 & 9 Bed-10, 11 & 12 Bed-13 & 14 Unscreened Iron Ore Lump BF grade Lime Stone, BF grade Dolomite & Dolomite fines SMS grade Lime Stone & SMS grade Dolomite. SMS grade Lime Stone, Dolomite Fines & -30mm Lime Stone. Screened IOL. Iron Ore Fines. 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.
IOF Crushed Flux Dolo Fines LD Slag Fines Crushed Coke breeze
78 79 % 9- 11 % 1- 3 % 3- 4 % 5 5.5 %
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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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%.
Customers of OBBP:
Sl. No.
1. 2. 3. 4. 5.
Department
Blast Furnaces Sinter Plant I Sinter Plant-II Calcining Plant-II LDBP
Materials Supplied
Screened IOL & Mn. ore Base Mix, BF Grade Lime Stone, Dolo Fines Base Mix, Crushed Flux, Coke breeze, Dolo Fines & nut coke. Screened SMS Grade Lime Stone & Dolomite Screened SMS Grade Lime Stone
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Equipment Wagon Tipplers - 2 Nos. Car Pushers - 2 Nos. Track Hoppers - 2 Nos. Apron Feeders - 5 Nos. (AF-1, 2, 4, 5, 6) Plough Feeders - 2 Nos. Stackers - 4 Nos. Barrel Reclaimers - 3 Nos. Bucket Reclaimers - 2 Nos. Transfer Car - 1 No. Vibrating Screens - 10 Nos. Vibrating Feeders - 35 Nos. Rod Mill - 3 Nos. Impactors - 3 Nos. Roll Crushers - 6 Sets Weigh Feeders - 15 Nos. Belt Feeders - 5 Nos. Belt Conveyors - 42 Km Sampling System - 1 Lot.
Capacity 20 wagons tippling/hour Placement of 58 wagons at a time 6000 Tonnes each hopper 900 T/Hour
1200 T/Hour 1200 T/Hour 900 T/Hour 600 T/Hour Transfer of equipment. Varying capacity from 35-450 TPH Varying capacity from 35-900 TPH 55 TPH 55 TPH 35 TPH 100 500 TPH 35 TPH 600 1200 TPH Collection of sample from JH-3, out station samples & its preparation
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Wagon Tippler
Track Hopper
Raw Materials Stock Yard & Screened Ore & Base-Mix Beds
Iron Ore
Screening Building
Sized Ore
Base Mix
PB Building
Iron Ore Fines Lime Dolo Screening Building
-30 mm
Sized Ore to BF
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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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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) (b) Imported Coking Coal (Hard) [ICC (H)] Imported Coking Coal (Soft) [ICC (S)]
The proximate analysis of the above-mentioned coal is: Proximate Analysis Ash Volatile Matter Gross Moisture Fixed Carbon Imported Coking Coals (Hard) 8% - 11% 21% - 23% 6% - 8% 64% - 71% Imported Coking Coals (Soft) 7% - 11% 26% - 35% 6% - 8% 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 Ash Volatile Matter Gross Moisture Fixed Carbon Analysis of Blended Coal 12.5 0.5% 23% - 24% 6% - 8% 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 PCC MCC SCC IMP(H) Vitrinite % 45 42 55 70 Mean Max Reflectance 1.2 .95 .95 1.15
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The analysis required for Blast Furnace: Proximate analysis Ash Volatile Matter Gross Moisture Fixed Carbon Strength of Coke M40 M10 Coke Reactivity Index (CRI) Coke Strength after Reaction (CSR) Coke size (25 mm 80 mm) Analysis of Coke 16 0.7% < 0.7% 4.5% 0.5% > 80% > 80% < 8.5% < 20% > 62% > 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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Numbers of ovens are placed side by side and together it is called a Battery. At RSP there are five batteries: Battery # 1 Battery # 2 Battery # 3 Battery # 4 Battery # 5 Total 70 Ovens 70 Ovens 70 Ovens 80 Ovens 80 Ovens 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 Hard Coke Nut Coke Breeze Coke Size 25 < X < 80 mm 15 < X < 25 mm X < 15 mm End user Blast Furnace Blast Furnace 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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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) (b) (c) Gas Holder Mixing Tank 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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1. 2. 3. 4.
End Gas 0.12 gm/Nm3 0.8 gm/Nm3 0.04 gm/Nm3 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 Ammonia 350 ppm Phenol 150 ppm Cyanide 100 ppm PH 8.5 Temperature Outlet of BOD Plant 30 ppm 1 ppm 0.2 ppm 6.5 - 7.5 35oC (Max)
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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 2. Sinter Machine 1.5 MT / Annum. 2 Nos. (125 T/hr), 125 m2 working area, Mixed gas fuel, Dwight Lloyd down draft continuous chain type machine 2 Nos. 1 No. 2 Nos. 2 Nos.(separate +6 mm & -6 mm fractions) 2 Nos.(separate +25 mm,+15 mm-25 mm,-15 mm) 2 Nos. 2 Nos. 2 Nos. 1200 T
3. Sinter Breakers 4. Primary Mixing Drum 5. Pelletising drum 6. Hot Screen 7. Cold Screen 8. Process ESP 9. Dedusting ESP 10. Exhausters 11. Capacity of Sinter Storage Bunker
Input material:
The input materials and average consumption for one ton of sinter are: 1. 2. 3. 4. 5. 6. 7.
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Iron ore fines Lime stone fines Dolomite fines Coke Breeze Return fines Mill Scale LD Slag
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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 Dwightlloyd 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 FeO SiO2 Al2O3 CaO MgO Basicity 54.0 % 9.50.5 % 5.50.5 % 3.00.2 % 10.5 0.5 % 2.8 0.2 % 1.8 - 2.0 %
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Material Flow in Sinter Plant I Base Mix, Lime Stone & Dolo Fines from OBBP Blast Furnace Returns
Water
Pelletising Drum - I
Sinter Machine-I
Hearth Layer (-25,+15 mm)
Sinter Machine-II
Breaker-I
Breaker-II
Hot ScreenI
Hot ScreenII
Cooler-I
Cooler-II
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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 Productivity Annual working days Coke consumption Gaseous energy consumption Sinter granulometry ISO tumbler index (+6.3 mm) Cooled sinter temp. Dust content in stack emission (Maximum)
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1.57 MTA (Gross Sinter) 1.13 T/Sq.m/hr 300 days / year 75 Kg/ton of skip sinters (dry) 32,000 kcal/T of gross sinter +50 mm 0% and -5 mm 3% (min) 72% (min) < 100 oC 100 mg/NM3
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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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Proportion Bin
Comp. Air
Water
Lime
ESP
STACK
+50 mm
- 50 mm
Hot Screen - 5 mm +5 mm
Sinter Cooling
50mm Screen
+15 mm
Blast Furnaces
+25 mm
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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 Capacity MT Stage BF # 1, 2 & 3 Exp. Stage BF # 4 Total 1000 T/Day each 1500 T/Day 1.8 MT/Yr. BF # 4 Commissioning on 03.07.1967 PCM Commissioning on 27.01.1959 SGP Commissioning on 23.09.1977 Modernization 1200 T/Day in 1800 T/Day 9798 2.0 MT/Yr. BF-IV Up-gradation 1200 T/Day in 2200 T/day 05-06.
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. 9.
Ladle repair Shop, Slag dump and clay preparation unit. 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.
BELT
PIG CASTING
HM
SM
STOVE
FURNACE
SM
INBA CH SGP
SLAG
SLAG GRANULATION
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INPUT
OUTPUT
AIR 2.42 T GAS 3.615 T SINTER 1.25 T ORE 0.45 T + ORE 0.45 T LDS 0.005 T QTZ. 0.001 T DUST 0.006 T
BLAST FURNACE
SLAG 0.400 T
COKE 0.570 T
The Specifications of the above raw materials are given below: Material Iron Ore Lump Chemical Analysis (Norm) Fe : 63.5 % min SiO2 : 2.0 % max Al2O3 : 2.0 % max Specification - 10 mm : 5 % max + 50 mm : 5 % max Size: 10 to 50 mm
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Material Sinter
Coke
Chemical Analysis (Norm) 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 % Ash : 16 18 % VM : 0.9 % Moisture : 4.0 5.0 % CRI : 20 22 % CSR : 62 % min SiO2 CaO MgO SiO2 Mn Fe : 99 % min : 42 44 % : 89% : 12 14 % : 30% + 1 % : 24 % + 1 %
Size : 25 80 mm + 80 mm: 4% max. - 25 mm: 5% max. M-10 : 8.4 % max M-40 : 80 % min Size : 20 40 mm Size : 20 40 mm
Quartzite Ld Slag
Mn Ore
Size: 10 50 mm
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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 Blast Furnace Gas Cleaning Plant Pig Casting Machine Slag Granulation Plant Blast Furnaces Production Capacity / Furnace Working Volume Useful Volume Hearth Diameter
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Tpd. M3 M3 M
MAIN UNITS Bosh Line Diameter Stock Line Diameter Height of hearth Height of Bosh Height of Straight section Height of Shaft Height of throat Total Height Working Height Hearth area Bosh Angle Stock Angle Tuyeres Tuyeres Size Cinder notch Iron notch Cast House Capacity of cast house crane
UNIT M M M M M M M M M M3
FACILITIES AT MTP EXPN 8.5 6.2 3.80 3.40 2.40 14.90 2.20 26.50 21.00 42.99 89o 49 85o 35 10 6.9 3.60 5.20 2.00 17.00 2.00 31.85 21.20 63.59 81o 10 85o 10 21 140 X 600 1 2 1 30 T
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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.
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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.
FACILITIES AT MTP EXPN 3 3 8 8.5 37 38 34000 43000 950 1000 100,000 140,000 Nm3/hr. Nm3/hr.
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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.
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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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DO W
CO M
ER
DUST CATCHER
E.S.P
FURNACE
WAGON
SCRUBBER
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.
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COOLING TOWER
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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 recirculation 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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BLAST FURNACE
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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%.
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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.
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 substation air intake house of size 1000 mm X 1600 mm is located and air is brought to the substation 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.
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. 2. M/s. Orissa Cement Ltd., Rajgangpur, Orissa. M/s. Chariot Cement Ltd., Kalunga. Rourkela, Orissa.
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CR-816
RECIRCULATION
GARRAGE
GRANULATION
DISPATCH BAY
CR-810
CR -814 A
ADM. BUILDING
FOR DISPATCH
CYCLE STAND
MAIN
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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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.
DOLO 11 kg/T
LIME 91 kg/T
SCRAP 98 kg/T
For disposal
Steel slab Tundish skull (19.7 Kg/T) Crop end & Arisings (6.2 Kg/T)
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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 (<1580C) 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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LD converter steel (1650C) Teeming ladle (66 T & 1600C) Transfer by EOT crane Lowering into VOR/VAR tank.
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Connection of tank and ladle argon hoses. Argon purging for a minute Initial temperature measurement. Placement of tank cover over the tank Start argon purging at required/specified rate Start steam ejector and attain required vacuum level Start arching/ oxygen blowing Continue degassing Addition of Al Fluxes (LIME, ETC.) Ferro alloys Increase argon flow for thorough mixing Discontinue evacuation Measure temperature Take sample for analysis
Degassing process
Following chemical reactions occur during degassing and processing: [ FeO] + [ C] = [ Fe ] + {CO}, 2{CO}+{O2} = 2{CO2} [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%)
o o
Providing sufficient holding time during treatment and casting. Acting as buffer between converter and casting unit.
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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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BLASTFURNACE
MIXER
MIXER
CONVERTER
CONVERTER
SSM UNITS
VAR
VOR
LHF
ARS
CASTER
PLATE MILL
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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
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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.
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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.
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Ferro Alloys
Mixer
Flux (CP-II)
Oxygen (TOP-II)
Nitrogen (TOP-II)
Aluminum
Flux
LD Converters
LHF /ARS
LD Gas
TCM
Segments
Mould
Tundish
Turret
Roller Table
Transfer Bed
Slab Storage
TTCM
Slab Disposal
HSM & PM
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2.
SMS-I Zone
3.
SMS-II Zone
4.
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.
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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.
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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
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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
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)
Gas product
Filtration Air
Cooling
Compression
Purification
C2+H2O
Expansion Heat exchange incoming air with the cold of the outgoing product
Warm Equipment
Cold Equipment
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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.
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REVERSING MILL No. of PASS R#1 MOTORS R#1 WORK ROLL DIA. R#1 BACK UP DIA. ROLL FORCE SCREWDOWN DRIVE OUTPUT THICKNESS
: : : : : : : :
4 HIGH WITH VERTICAL EDGERS 3 7 PASSES 3800 kW X 2 (DC THYRISTOR CONVERTOR) 864 911 MM 1185 1311 MM. 25000 KN (Max) 73 kW @ 485 RPM DC 32 TO 45 MM
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
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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
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
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
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HR PLATE DETAILS
THICKNESS WIDTH LENGTH : 4.0 10 MM. : 1000 1550 MM. : 5 10 METERS
Primary Descaler
R2
R1
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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:
Slabs Width
Thickness Length
: : :
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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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 recrystallization 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.
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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 Direction of Marking Characters pattern Characters Height of Characters Number of Lines Number of Characters/Line Punching Details: Direction of Marking Characters pattern Characters Height of Characters Number of Lines Number of Characters/Line
Along the centre line of the plate Lengthwise paint Standard 9 x 7 Dot Matrix (WxH) Alphanumeric 40 mm 8 (Eight) 20 Alphanumeric (Maximum)
Crosswise to Plate conveyance 9 x 7 Dot Matrix (WxH) Alphanumeric 10.5 mm (Approx) 3 (Three) 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 redeployed 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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IX. X. XI.
VIII. Faster loading and dispatching due to proper identification and traceability of various grades and sizes of plates Constant paint circulation and intermediate cleaning of spray nozzles by mixture of air and water will prevent clogging of pipelines and nozzles. Better record keeping and retrieval of marking and punching records for references. 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.
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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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 aircooling. 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
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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.
PRDODUCT RANGE:
DIAMETER (Outside Diameter): 8 5/8, 10 , 12 , 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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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
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(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 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
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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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.
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 pre- set 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.
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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.
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.
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Sticker Stand
Pre forming
Breakdown Stand
Seam Guide
Universal Cage
Cooling Jacket
Bevelling Machine
Flushing Machine
Off-Line UST
Dispatch
Works Inspection
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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 Rourkelas 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.
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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.
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.
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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.
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Camera Type Principle Detector Light source Stand off Depth of filed Field of view : Close plane Far plane Average depth resolution Sample points per profile speed Data rate Dimensions Weight
Mini i/60 Active optical triangulation using structured laser beam illumination. Photo sensitive device Build in 50 MW visible laser diode. 56 . 6 mm 65 mm. 24 mm. 35 mm. 0.08 mm 478 or 238 30 / 60 profiles / sec. 14340 points per sec 112 mm X 56 mm X 30 mm 500 g.
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
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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.
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Forming Cage
Repair Welding
X-Ray Station
Grinding Station
Hydro Testing
Bevelling Machine
Ultrasonic Testing
End
Radiograph
Station
Dispatch
Final Inspection
Works Inspection
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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
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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 manufacturers 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.
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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: SAILRATH, HARDOX, TARGET DMR 249A & DMR 249B,
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).
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MATERIAL FLOW
Operation
ULTRASONIC TESTING FLAME CUTTING TO SIZE BOTTOM SURFACE GRINDING & THICKNESS CHECK
HARDENING, OIL/WATER QUENCHING AND TEMPERING HARDNESS TESTING PTP SAMPLE TESTING BTP SAMPLE
PAINTING
STAMPING
DISPATCH
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.
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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.
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.
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.
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Tandem Mill
CR-1
CAL
HAL
SP-1
SP-3
Galvanising Line
CPL
ETL
GP / GC Sheets
CR Coils
ETP
CR Sheets
CR Coils
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.
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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 H 2 SO 4 Dilute H 2 SO 4 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. 1 2 3 4 Acid Concentration 16-18(%) 18-20(%) 20-22(%) 22-24(%) Salt Concentration 400 gm/liter 350 gm/litre 300 gm/litre 250 gm/litre Temperature 70 o C 75 o C 80 o C 85 o C
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:
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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
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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 4high mills and one twin stand 4-high mill have been installed.
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Parameters Rated Capacity Type of Mill Strip Width Strip thickness Speed Work Roll Size
560-1040 mm 0.15 to 0.31 mm 1200 m/min 460 X 1200 1 st Stand 530 X 1200 2 nd Stand Purpose Temper Rolling of SG Temper Rolling of TP & Light Coil SG Coils The skin passed coils are the packed and dispatched to stock yards or Customers as CR coils.
SP I 2,70,000T/yr 1700 mm, Single Stand, 4 High 630-1550 mm 0.35 to 1.3 mm 500 m/min 460 X 1700 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:
RSPs family of coated steel sheet products includes both hot-dipped and electrolyticallyapplied coatings. The protective coatings add superior corrosion resistance to the many
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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.
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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.
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/m 2 coating weight and variety of tempers.
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Technical Details:
Continuous Galvanising Line Width of Sheet Thickness of Sheet Capacity Maximum speed Two nos. 610 mm 1220 mm 0.31 mm 1.60 mm 1,60,000 T/Yr (80,000 T for each line) 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.
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DECARB
SLITTER I
CUT TO LENGTH
PACKING
DISPATCH
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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.
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16. Mill modulus 17. Roll separating force Electrics: P.O.R. E.T.R. MILL STAND D.T.R.
- 300 kW, 1200 rpm CONT. - 1125 kW, 800 rpm - 2 X 1687 kW, 670 rpm - 1125 kW, 800 rpm
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/mm Process 0.25 to 0.55 Kg /mm, Exit 4.5 Kg /mm
DECARB ANNEALING:
Supplier: EPI / ELEC. FURNACE CO. Elec. BHEL, PLC: Siemens S-5 (135 U)
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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
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Line Features: Coil Weight Coil OD Coil ID Width Line speed Gauge Exit Sheets WidthLengthPack Ht.Pack Wt.-
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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.
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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 Kohrns 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 Kohrns 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 1 2 3 4 Department Engineering Shops Crane maintenance Design & modification Maintenance systems and services Assigned function Manufacturing / repair of spares, reconditioning of damaged assemblies, fabrication of structures etc. Inspection & Maintenance of all EOT cranes of the plant. Preparation/preservation of drawing, redesign / modification of equipments in the plant etc. 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. Centralized man power help for heavy/ specialized repair jobs.
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Sl 6 7 8 9
Department Civil Engg. services and structural inspection Central monitoring group Field machinery maintenance Transport
Assigned function Maintenance and modification of Civil work in the plant & Inspection of shop floor structures. Monitoring of maintenance activity in different departments. Suggestions as per requirement. Maintenance & operation of field machinery equipments. 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 1 2 3 Department Repair shop (Electrical) Air conditioning Assigned function Repair/reconditioning of electrical equipments. Maintenance of air conditioning units of the plant including room a/c Maintenance of electronic systems in the plant.
Electronics & Electrical Technical Services. 4 Heavy Maintenance Man power help to various units of the plant for (Elect) heavy electrical jobs. Apart from the above Maintenance Services, power generation & distribution, steam generation and blower station is also under GM (Electrical).
Repair maintenance group Preventive maintenance group 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.
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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.
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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.
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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 Kohrns system to avoid confusion to users.
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Daily W1b
BREAKDOWN RECORDING
HISTORY PM10
INSPN. SCHEDULE
PM1 / PM4
PM1a 3 Yr.
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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.
Bearings:
Providing technical guidance for substitution of bearings to different plant unit as per requirement.
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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.
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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) (b) (c) (d) (e) (f) (g) (h) (i) (j) Used oil collection & storage Dehydration to remove moisture Alkaline clay mixing Clay treatment to neutralize the acid content Cooling to avoid oxidation of processed oil Filtration to remove traces of sediment Storage of base oil in storage tanks according to viscosity gradation. Blending of oil by transporting Testing of blended oil 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.
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.
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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.
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.
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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.
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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.
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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.
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
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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.
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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.
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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.
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4. 5. 6. 7. 8.
9. Gear Hobbing 10. Bevel Gear Generator 11. Grinding Machine 12. Saw Cutting Machine
13. Centring Machine 14. Hydraulic Press 15. Cranes (50/15,15/5 &15/5 T)
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A)
i) ii)
Machine Tools:
Lathes: Maxm. Job size 1350 mm dia. X 10 mtrs. Horizontal Boring Machine : Maxm. spindle dia. = 175 mm Maxm. Boring depth = 1500 mm Maxm. Boring dia. = 1400 mm Slotting Machine: Maxm. stroke of Ram = 500 mm Maximum swivel = 12 degrees. 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) Vertical Boring: Maxm. Wt.of job = 12 Tons, Maxm. Turning Dia.= 4000 mm. 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
iii) iv)
v)
vi)
B)
i) ii) iii)
Heat Treatment:
Hardening Furnace: Size 1500 X 650 X 400 mm, Maximum working Temperature = 10000C, Maximum weight of the job = 500 kg. Tempering Furnace: Size 1500 X 650 X 550 mm, Maximum working Temperature = 6500C, Maximum weight of the job = 500kg. 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 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.
iv)
C)
i) ii)
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D)
i) ii) iii) iv)
E)
i) iii) iv) v)
F)
i) ii)
G)
i) ii)
Forging Section:
Heavy forging shop: Pneumatic Power Hammers of capacity 1000 kgs and 500 kgs with mixed gas fired furnace. 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)
This section is equipped with a vertical press machine and three nos of induction heaters to facilitate assembly of bearings with gearbox internals.
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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:
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2) a) SAW Machine:
Supply Voltage Machine Type Maximum Welding Current Wire feed Wire Size 415 V, 3 phase, 50 Hz. Constant Potential Type Transformer/ Rectifier 1200 Amps DC @ 60 % Duty Cycle. 1000 Amps DC @ 100% Duty Cycle 0.1 to 4.5 m/min. 2 to 5 mm
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 plants repair welding jobs are also done.
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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.
2) Hydraulic Press:
(Capacity: 600 Tons)
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RC(M) maintains flexibility among all the zones to increase productivity of workforce.
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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 1617 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 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.
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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.
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.
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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.
8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Shifting of pug from pug mill to all Blast Furnaces. Maintenance of all Mobile heavy equipments of the Plant. Procurement/ Reconditioning of heavy equipments. Tyre puncher repairs of heavy tyre mounted vehicles. Capital repair of mobile earth moving equipments Dispensing of diesel to all crawler equipments at site. Housekeeping of different production areas. One time cleaning jobs as per requirement. Monument installation Township requirement of mobile equipments and maintenance of heavy mobile equipments. Organising Training for operators and technicians of heavy Mobile equipments. Shifting of tundish in SMS-I & SSD scrap Yard. Transportation of dead body for funeral purpose. Maintenance of de-bricking machines and dumping cranes. AMR schemes related to Heavy mobile equipments.
TYPE OF VEHICLE Haulpak Dumpers Tippers Payloaders Tyre HM2021,430z,456zx,4D Payloaders (Chain) Excavators L&T Dozers (Tyre) Dozers (Chain) Debricking M/c 300/400L/Promex/Weiger Hyd. Crane 8/12 T Crawler Crane Hyd. Crane 20T/55 T Forklifts 1.5/3 T Forklifts 16/20 T Side Loaders Compressors Road Rollers Sewage Cleaning Vacuum Loaders Road Sweeping Garbage Compactor Lime Tankers
MAKE BEML Ashok Leyland HM, JCB , TATA, Marshall CAT,Komatsu L&T,JCB, TATA-H CATerpillar BEML(BD 65,85,155), CAT (8DR) TML Germany/Promex Escorts TATA 320/655/955 TIL Grove Godrej, Voltas Godrej Fantuzzi, Baumann ELGI L&T Case, Jessop TPS TPS TPS TPS TPS
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FLEET SIZE 10 24 26 4 10 1 8 6 24 8 2 36 4 4 3 5 2 3 1 3 4
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SN 21 22 23 24 25 26
TYPE OF VEHICLE Truck Mounted Crane Trucks Mini trucks Trailer Tractors Diesel Dispensing
MAKE TIL TATA TATA, Swaraj Majda, Mahindra Ashok Leyland Mahindra TATA-Elgi
FLEET SIZE 2 55 35 1 5 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.
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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). 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. 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. 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
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B)
C)
D)
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3. 4. 5. 6. 7. 8. E)
Tyre section Body & chassis repair section Painting section Engine section Battery section Planning & procurement section
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. 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. 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.
F)
G)
The total numbers of vehicles with Transport Department pertaining to plant are as follows:
LIGHT VEHICLES :
> > > > > > > > > >
Jeep 10 Seater Jeep Ambassador Car Maruti Car Gypsy Mini bus Pick-up Ambulance Tempo Trax TMB Bus
: 58 Nos. : 14 Nos. : 13 Nos. : 20 Nos. : 36 Nos. : 08 Nos. : 22 Nos. : 13 Nos. : 01 No. : 03 Nos.
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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.
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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.
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.
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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 deproprietorised 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 RTFs (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.
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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
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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.
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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.
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
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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 &
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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--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.
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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 dayto-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
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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.
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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.
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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.
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.
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.
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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.
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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.
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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.
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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
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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.
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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
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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) (b) (c) (d) (e) (f) (g) Package AC Unit Crane AC Unit Central Air-conditioning Plant Chilled Water Plant Room AC Water Coolers Split AC 253 Nos. 29 Nos. 29 Nos. 23 Nos. 806 Nos. 263 Nos. 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 Airconditioning 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.
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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.
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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
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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.
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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.
WAGON FLEET
SL. No. 1 Type of Wagon HB (BOBS) a. Indian b. German Carrying capacity 60/66 T Qty. Detail Side Discharge, hopper type, 8 wheeler, Casnub /Diagonal bogies with coil springs or Fabricated bogies with laminated springs (8 or 10 leaves)
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Use For transportation of Coke breeze, Hard coke, B coal, LD Slag, Mills scale, Flue dust, Quartz, Special lime stone, Sinter etc.
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69 08
SL. No. 2
Carrying capacity 56 T
Qty. 39 14
Detail Side discharge, 8- wheeler, fabricated bogie with laminated springs. 8 wheeler, Fabricated bogie with laminated springs (8 or 10 leaves) 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. Slanted 1m wall, 8 wheeler, Fabricated bogie with laminated springs (10 leaves)/ Casnub bogie with coil springs. Straight wall of 0.5 m ht., Heavy duty, 8 wheeler, fabricated bogie with laminated springs(10 leaves) Slanted wall, heavy duty, 8 wheeler, fabricated bogie with laminated springs (10 leaves) 4 wheeler, Laminated springs (6 leaves), having both CBC Coupler and coupling rod. Covered, 4 wheeler, Laminated springs, with 5 HP DG set
Use For Transportation of Coke Breeze and Hard coke and M S Scrap. For transportation of Slabs, coils and plates.
60 T
39
90/100 T
09
44
BOI (Std.)
57/60 T
81
For transportation of M S Scraps and secondary steel products. For transportation of Pig Iron.
BOI (PCM)
70 T
05
Gondola
58 T
21
Link car
32 T
05
For transportation of M S Scraps and secondary steel products. For attaching ingot Bogies or charging cars with locomotive For Carrying Break down crew and tools tackle used for re railing.
30 T
01
Total
335
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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.
LOCO FLEET:
Sl. No. 1 Fleet Type General Electric Loco WDS 6 Loco WDS 6ad Detail 80 T, Double unit, 470 hp, GE make, 400 series 90 T, Double unit, 600 hp, GE make, 600 series 120 T, 1400 hp, DLW make, 1400 series 124 T, 1400 hp, 1400 series, DLW make Qty. in no. 3 11 20 6 3 nos. will be added in lieu of above phased out GE locomotives Remarks 3 nos. will be phased out.
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.
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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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All the solid waste generated in Steel Melting ShopII 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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Equipment Strength:
Sl.No. 1. 2. 3. 4. 5. Equipment Pay Loader - 2.5 m3 capacity Dumper - 5.5 m3 capacity Road Roller - 8/10 Ton capacity Truck mounted sewer cleaning machine Total station computerised survey equipment Quantity One One One One Two
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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.
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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 SAIILRSP & 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.
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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 downstream 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.
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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 surgecum-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:
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Catchment Area Full Reservoir Capacity Length of Reservoir Max Reservoir Level No of Sluice Gates No of Radial Gates
2,366 sq. miles (6,057 sq. Km) 2,57,000 Acre-feet (317 Million m3 ) 17 miles (27.2 Km) 690 feet 2 numbers, 8 feet X 8 feet 11 numbers, 51 feet X 22 feet
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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:
CRM CWRS PUMP HOUSE COOLING TOWERS
COLLECTION PIT
STORAGE TANK
SUPPLY PUMPS
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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.
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.
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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.
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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 Ministers 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.
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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.
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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.
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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.
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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: SN. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Description Foam Tender Foam-cum-DCP (Combined Tender) Crash Fire Tender Water Tender High Capacity Water Bouser (14 KL Capacity) High Landing Hydraulic platform (Simon Snorkel) Emergency Tender Towing Tender Jeeps Portable Pumps (Petrol- 6, Diesel 2) Submersible Pumps (Electrical) Trolley mounted Long Range Foam-Water Monitor Trailer Pump Portable fire Extinguishers BA sets (Oxygen type-19 & Air Type-22) Nos. 06 01 01 01 01 01 01 02 03 08 03 01 01 7500 41
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.
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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. 2. 3. 4. 5. 6. Executives Fire Station In-Charge Leading Fire Operators Fire Operators Technicians Office Staff 08 03 126 18 06 02
Call Us to Help You Fire Control Room: Inter-Com -7700, 7000 & 7796, BSNL-06612510142
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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.
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.
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 Mininsters Shrama Awards, Rashtriya Vishwakarma Puraskar, etc.
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Administrative Items:
The requirement of various items under administrative category are studied and recommended for procurement for different departments.
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k) Product development and special steel making 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
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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
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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.
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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.
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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
Hot Metal Crude Steel Saleable Steel
Present
2.0 MTPA 1.9 MTPA 1.671 MTPA
After Expansion
4.5 MTPA 4.2 MTPA 3.9 MTPA
Techno-economic parameters
Item
Coke/ Fuel Rate (Kg/thm) BF Productivity (t/m3/d) Specific energy (Gcal/tcs) Manpower Productivity (tcs man/year)
Present
577 1.37 7.98 148
After Expansion
392 2.14 5.80 262
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
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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.
FLOW CHART
SINTER PLANT SINTER PLANT 2 x 125m2 (EXISTING SP1) 2 x 125m2 (EXISTING SP1) 1 x 192m2 (EXISTING SP 2) 1 x 192m2 (EXISTING SP 2) 1 x 360m2(NEW) 1 x 360m2(NEW) BF COKE
BF SINTER 6,760,000
BLASTFURNACE BLASTFURNACE BF # 1 1250m33(EXISTING) ING) BF # 1 1250m (EXIST BF # 4 1658m33(EXISTING) ING) BF # 4 1658m (EXIST NEW BF # 5 4060m33 NEW BF # 5 4060m
4,500,000 GHM 4,410,000 NHM
1,855,000
COKE OVEN BATTERIES ERIES COKE OVEN BATT 5 EXISTING ING 5 EXIST 1x67,7m,NEWBATTERY#6 EW ERY#6 1x67,7m,N BATT
NEW P C M (1 x 1500 t/d) NEW P C M (1 x 1500 t/d) 28,900 COLD PIGS FOR SMS II& II 28,900 COLD PIGS FOR SMS & II 201,800 COLD PIGS FOR SALE 201,800 COLD PIGS FOR SALE
238,500 HM
506,500 HM
3,665,000
RSP-REVISED RSP-REVISED
4.5 MT HOT METAL 4.5 MT HOT METAL 4.2 MT CRUDE STEEL 4.2 MT CRUDE STEEL (0.820 MT SEMIS) (0.820 MT SEMIS) 3.9 MT SALEABLE STEEL 3.9 MT SALEABLE STEEL
SMS IIII((3/3 BOF OPERATION )) SMS 3/3 BOF OPERATION 2 x 150 tt EXISTING, 1 x 150 tt (NEW)) 2 x 150 EXISTING, 1 x 150 (NEW)
3,772,000 LS
GROSS COKE- 2,443,400 (2,192,000 BF Coke AND 251 ,400 Under size, out of which 270,000 BF coke will be surplus)
SEC. REF. (EXISTING) SEC. REF. (EXISTING) 1 LF,1 VOR,1 VAR 1 LF,1 VOR,1 VAR
LS 508,400
SEC. REFINING (150 ttEACH) SEC. REFINING (150 EACH) 1 LF (EXIS.), 2 LF, 1 RH --OB (NEW) 1 LF (EXIS.), 2 LF, 1 RH OB (NEW)
3,772,000 LS
CCP II CCP II 2 x 1STRAND SLABCASTER (EXIST.), 2 x 1STRAND SLABCASTER (EXIST.), 1 x 1 STRAND SLAB CASTER (NEW) 1 x 1 STRAND SLAB CASTER (NEW)
3,700,000 1,850,000 SLABS SLABS
SLABS INTERPLANT SLABS INTERPLANT TRANSFER TO BSL TRANSFER TO BSL 650,000 650,000 325,000 HR COILS EXISTING EXISTING EXISTING PICKLING LINE PICKLING LINE PICKLING LINE 197,959 312,713 PICKL. COILS 114,754 5 STD EXISTING 5 STD EXISTING 5 STD EXISTING 1420 mm 1700 mm 1420 mm 1700 mm 1420 mm 1700 mm TANDEM CRM REVERS.CRM TANDEM CRM REVERS.CRM TANDEM CRM REVERS.CRM
SLABS SLABS FOR SALE FOR SALE 170,000 170,000 85,000 HR COILS/SHEET/ HR COILS/SHEET/ HR COILS/SHEET/ PLATES FOR SALE PLATES FOR SALE PLATES FOR SALE 1,245,400 1,245,400 1,245,400
530,000
1,000,000
ERW ERW ERW PIPE PLANT PIPE PLANT PIPE PLANT 18,000
EXIST. CRNO EXIST. CRNO EXIST. CRNO FACILITIES FACILITIES FACILITIES 75,000 CRNO SLIT COILS & SHEETS
NEWPIPE NEWPIPE NEWPIPE COATING PLANT COATING PLANT COATING PLANT 57,000 ERW 60,000 COATED PIPES
NORM. FACILITIES NORM. FACILITIES NORM. FACILITIES IN EXISTING FEC IN EXISTING FEC IN EXISTING FEC
AS ROLLED 249,800 AS ROLLED 579,500 (Controlled Rolled) 350,000
HOT DIP GALV. PROC. HOT DIP GALV. PROC. HOT DIP GALV. PROC. II& II (Existing) LINES I & II (Existing) LINES & II (Existing) LINES
120,415 164,476 16,792 HDGPLAIN SHEETS ELEC. TINPLATES CR SHEET & ANN COILS
The units under the Expansion Project are briefly detailed below:
Sintering Plant
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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 basemix. MATERIAL SIZE DISTRIBUTION (MM) Iron Ore fines 0 to 10 mm Lime stone / Dolomite -5 mm having 90% -3 mm (crushed) 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 S.N. 1. 2.
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.
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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 Total Height of Battery Useful Height Useful Volume Production of run of oven Coke (Dry) Total length (between buck stays) Total useful length Width at pusher side Width at coke side Average width Useful volume of oven Axial distance between ovens No. of flues in heating wall Distance between the flues 67 7M 6.7 M 41.6 M3 0.768 MT/Y 16,000 mm 15,160 mm 385 mm 435 mm 410 mm 41.6 m3 1.400 mm 32 480 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)
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The Coke Transfer Car will supplied along with a land based Pushing Emission Control (PEC) System.
New Coke Dry Cooling Plant for 7 mtr. Tall Coke Oven Battery # 6
Execution Agency Likely date of completion : M/s Bhilai Engg. Corporation, Bhilai : 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.
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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 Temperature of coke charged in the chamber Temperature of coke after cooling Temperature of circulating as before entering cooling chamber Temperature of circulating gas before waste heat boiler Thermal efficiency Pressure of steam generated Temperature of steam generated Generation of steam / boiler Capacity of one cooling chamber Time of coke cooling in chamber Unit
0C 0C 0C 0C
Value 1050 < 200 170-180 750-800 80-85 66 500 25 52-56 2-2.5
% ata
0C
t/h t/h h
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 Likely date of completion : (i) M/s Sriram EPC, Kolkata (ii) M/s Hutini Project, Frydek Mistek : 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.
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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.
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)
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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
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.
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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.
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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.
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The details of operating parameters selected for the Blast Furnace are given in the following Table. S1. Parameter Unit Value No. 1 No. of Blast Furnace No. 1 2 Working volume of BF m3 - 3470 3 3. Useful volume of BF m 4060 4. Hearth diameter m 13.2 5. 6. 7. 8. 9. 10. 11. Production per day Ash content of coke Ash of Coal (imported) Sinter in burden Sized ore in burden Pellet in Burden (future) Availability of Blast Furnace Sp. cons. of input materials (Net & dry basis Iron ore lump Sinter / Pellet Lime stone Quartzite Coke rate (Including -20 Kg Nut Coke 8-34 mm) Coal dust (CDI coal) Blast characteristics Volume (dry basis) 13. Temperature Humidity Oxygen enrichment BF top gas characteristics (Net & dry) Pressure. (Max. operating) Volume Temperature CO CO2 N2 CO/CO2 Calorific value
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12.
As required As required As required As required 360 150 (avg.) 200 (Design) Nm3/min
oC
g/Nm3 %
14.
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S1. No.
Parameter Hot metal characteristics Si S P Desired hot metal temperature Slag characteristics Slag rate Slag temperature
15.
16.
Execution Agency :
jobs like refractory lining, ladle inspection, ladle heating & cooling etc. will be done.
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.
Design Feature:
Design range: Machine equipped to cast: Slab length: Type of unbending : Casting time:
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210 - 300 x 1200 2500 mm x mm 220, 250, 300 x 1200 2400 mm x mm 6000 10000 mm Continuous straightening ~ 50 min. (Tenderer to indicate)
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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
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 No. of basic oxygen furnaces operating (from two existing and one new) Nominal heat size Maximum heat size Working volume with new lining Wear lining h/d ratio with new lining Converter shell 1 x 150 t nominal capacity Shop shall be designed for three (3) converters operating simultaneously 150 t 165 t 165 m3 Magnesia-carbon bricks Approx. 1.4 Shall be suitable for using bricks with high conductivity magnesiacarbon bricks Integral bottom type with provision for practicing combined blowing (inert gas stirring) process 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
Converter bottom
Trunnions
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Ladle Furnace (# 3)
Execution Agency Likely date of completion : M/s Sarralle : 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 Purchasers 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
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 1,500C. 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
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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
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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.
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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.
(iv) RM - 1 (NEW)
A 33 kV Double Bus GIS indoor switchboard for RM-1 for stable power supply to existing HRM loads.
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Medium Voltage Power distribution System with Intra-plant cabling & SCADA
Executing Agency Likely Completion : M/s L&T, Kolkata : 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.
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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.
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
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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.
= = = = = = =
1200 to 2400 mm 2200 to 4100 mm 210 to 300mm 42 mtr maximum 6 to 100 mm 1500 to 4100 mm 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.
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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.
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.
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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.
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Sl. No. 1.
Location SP-II
Modules Online connection to L1DCS for data acquisition Parameter display and transfer to Plant-status database New heat preparation Process aim calculation Hot-metal, scrap ordering Reblow Calculation Main blow advice Ladle alloy calculation End of blow & Feedback calculation Material Tracking Cut-length optimisation advice Laboratory Management Dynamic secondary cooling control Machine status tracking Heat/slab tracking Slab arrival Slab line-up Process tracking Thermal tracking Zone-wise set point downloading Rolling programme Pacing control In-process weighing Automatic mill pass-R0 Process tracking Looper Control Gauge Control Speed Control Communication among L1 Coil shape control Process synchronisation
2.
BOF-II Shop
3.
4.
5.
HSM: Roughing, Coil box, AGC, Speed Control, Coiler Controls, Coiler Conveyor
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Sl. No. 6.
Location ERWPP
Modules Planning Pipe tracking Product analysis Pipe testing & inspection Dispatches Data acquisition Analysis Management Alarm Management Online Mixed Gas CV Gas balancing Mimics and trend graph Data acquisition Alarm Management Area-wise energy balancing Mimics and trend graph Connectivity with Eastern Grid Online data acquisition from field instruments User interface system for parameter monitoring Periodic area-wise reporting to Management & Statutory bodies Online communication with Digital-Weight Indicator for weight Communication with central database server Logic for net weight calculation and screens for operator interface
7.
Energy Management
8.
9.
Environment Functions
10.
Weigh Bridges
L1: Digital weight indicators: Philips, Avery, Sanmar, Ashbee, Weitex L2: Windows-XP, DOS
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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:
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 GARNs. 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.
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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.
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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.
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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.
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
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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 concurrence:
purchase/contract/expenditure
proposals
and
giving
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.
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.
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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 & nonfinancial 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.
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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: MDs 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 Managers 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. HODs 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-charges 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.
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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
Competence Mapping
Organizational Requirement
No
Yes
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.
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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.
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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.
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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.
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 SubStations, 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 RSPs 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 antilarge on swampy areas and on stagnant water are also some of the major activities of the department.
33 kV Distribution Network:
Two Receiving Sub-Stations at Sector-6 & Sector-2 consisting transformer & auxiliaries are to be maintained round the clock. Receiving Sub-Station is 29 MVA and that of Sector-2 Receiving Power is fed at 33 kV level from Plant through overhead lines Stations. of 33 kV/11 kV power The capacity of Sector-6 Sub-Station is 12 MVA. to these Receiving Sub-
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.
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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) 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 Intake Wells a. River Koel b. River Brahmani 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.
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for
a. Water Purification Plant, Hill Top, Sector-2 with filtration Capacity : 18 MGD. b. Brahmani Water Works, Sector-8 Capacity : 9 MGD filtration capacity. 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.
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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.
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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 & Resettlement 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 Honble 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.
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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
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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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List of Villages:
1 2 3 4 5 6 7 8 Bankibahal Re-Settlement(RS) Colony Jagdishpur Jamsera Bijadih Laing RS colony Baniguni Pograbahal Chikatmati 9 10 11 12 13 14 15 16 Dumerjore Jabapanposh Jabaghat Kapatmunda Dalposh UsraRS colony Lodsera 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.
Wadi:
Imparting skills by which the unemployed could use their only capital: land. So WADI (agrohorti-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
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.
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 RSPs 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. 1 2 3 4 5
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Modules Sewing & Embroidery Wadi (Agri-Horti-Forestry) Soil Fertility& Organic Farming Soil & Water Conservation Water Resource Management
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S.No. 6 7 8 9 10 11 12 13 14
Modules Improved Agriculture Nursery Raising For Self-Help Group Community Organisation Improved Chullah Making Mushroom Cultivation Vermicompost Preparation, Use & Benefit Female Health Guides & Midwifery Skill Development (Welding & Gas Cutting, Electrician) Cross Breed Cow & Goat Farming
Target Population Farmers Village Women Village Men/ Women Village Women Village Women Farmers Village Women Unemployed Village Youth 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 IPPI (Pulse Polio) programmes Family planning activities National Nutrition week World population day Laparoscopic surgery SAIL AIDS Control Programme (SACP) Health Camps Vitamin A Campaign Health& Hygiene Programmes for SHGs
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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.
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 companys 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.
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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
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Presentation of albums to VVIPs 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
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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 todays economic scenario.
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).
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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 Companys 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.
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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.
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1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22.
Fully automated Olympus AU-640 clinical chemistry Autoanalyser Automated X-Ray film processor Uretero Renoscope High Speed Sterilizer in OT Ventilator with compression compact for Anesthesia unit Phaco Surgical Instruments Cardiac Defibrillator and Monitor in ICU Whole body ultra sound Digital Flame Photo meter (Bio-Chemical Lab) Laproscopic Hysterectomy Instrument Color Doppler Fully automated Ac.T 5 diff CP Coulter Monitor Yag Laser New Super X Ray 15 Tesla M.R.I 16 slice spiral CT Centralised Blood Collection Centre Emergency Lab Information Centre State of the Art, Air-conditioned Physiotherapy Centre Post-operative recovery room in OT-I 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.
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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.
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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.
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.
Air-conditioning:
All the wards on the second floor have been air-conditioned.
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Information Centre:
An information centre has been started in the lobby in front of main gate for the benefit of patients and attendants.
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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 Contractors 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.
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