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BHILAI STEEL PLANT

TRAINING PRESENTATION

BY MUKESH KUMAR KASHYAPROLL NO-3352808033SSITM BHILAI (CG)

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CONTENTS

Steel Authority of India Limited (SAIL)IntroductionProducts ProfileProcess flowRail and Structural MillPlate MillSteel Melting ShopsTelecommunication DeptAchievements

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Steel Authority of India Limited (SAIL) is one of the largest state

Owned steel makers in India and one of the top steel makers in the world, With a turnover of 8681crore (US $10.71billion),

the company is among top five highest profit earning corporate of the countryType State owned enterprise public

Industry Steel

Founded 1954

Headquarters New Delhi, India

Products Steel, flat steel products, long steel products, Wire Products, plates

Employees 131,910 (2006)

Website www.sail.co.in

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Special Steel Plants

oSteel Authority of India Limited (SAIL), Kanpur, Uttar PradeshoAlloy Steels Plants (ASP), Durgapur, West BengaloSalem Steel Plant (SSP), Tamil NaduoVisvesvaraya Iron and Steel Limited (VISL), at Bhadravathi, Karnataka

Ferro Alloy Plant

oChandrapur Ferro Alloy Plant (CFP) in Maharastra

SAIL integrated Steel Plants

oBhilai Steel Plant (BSP) in Chhattisgarh setup with Soviet CollaborationoRourkela Steel Plant (RSP) in Orissa setup with German CollaborationoDurgapur Steel Plant (DSP) in West Bengal setup with British CollaborationoBokaro Steel Plant (BSL) in Jharkhand setup with Soviet CollaborationoIISCO Steel Plant (ISP) at Burnpur, West Bengal

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INTRODUCTION

Bhilai Steel Plant (BSP), a unit of Steel Authority of India Ltd. Inaugurated at 1959 by the President of India Dr. Rajendra Prasad with a production capacity of 1.0 million tonne. A-public sector undertaking was conceived under aegis of Indo-USSR Treaty in the 2nd Five year plan.

The captive mines of the plant located at Dalli-Rajahara supplies iron ore and lime stone used to be available from Nandini captive mines. At present lime stone is procured from outside. The other major raw material, coal is purchased from outside either through import or from indigenous market.

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Nine times winner of Prime Minister’s Trophy for best integrated Steel Plant in the Country, Bhilai Steel Plant is India’s sole producer for the rails and heavy steel plates and major producer of structural. The Plant is sole suppliers of the country’s longest rail tracks of 260 meters. With an annual production capacity of 3.153 MT of saleable steel, the plant also specializes in other products such as wire rods and merchant products. Since BSP is accredited with ISO 9001:2000 Quality Management System Standards, all saleable steel products of Bhilai Steel Plant come under The ISO umbrella.

At Bhilai ISO:14001 has been awarded for Environment Management System in the Plant, Township and DALLI MINES. It is only Steel plant to get certificates in all these areas.

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Company Profile

Type Central Public Sector

Industries Metallurgical process

Founded 1955

Headquarters Bhilai, Chhattisgarh, India

Products Rails, Plates, Structurals

Website https://www.sail-bhilaisteel.com/

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PRODUCTS PROFILE

Product Type

Product End use Production (Tonnes/annum)

A. Finished Product

Rail and structural mill

Rails in 13m, 26m, 65/78 m length and welded panels of 130m/260m length Indian Railways, Export Heavy Structural Construction Crane Rails Cranes Crossing sleepers Broad gauge sleepers

7,50,000

Merchant Mill Light structural engineering and construction, medium rounds (plain & TMT), heavy rounds (plain)

5,00,000

Wire Rods Mill Wire rods - plain construction wire rods - TMT EQ wire rods electrodes

4,20,000

Plate Mill(upto3600mm wide)

Plates boilers, defence, railways, shipbuilding, LPG cylinders, export

9,50,000

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Product Type

Products End Use Production (Tonnes/annum)

B. SEMIS Billets (from BBM) Re-rollers 5,33,000

Blooms (from BBM)

Narrow width slabs

CC blooms

Killed slabs

C. Pig iron Foundry

D. By products Coal chemicals, ammonium sulphate (fertiliser), tar and tar products, (pitch, napthalene, creosote oil,, Anthracene oil, Dephenolised oil, PCM etc.), Benzol & its products (NG Benzene, Toulene, Xylene,solvent oilslag,granulated slag from CHSG plants & SGP for cement manufacture

Total sealable steel 31,53,000

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PROCESS FLOW at BSP

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DEPARTMENTS WE VISITED..

oRail and Structural MilloPlate MilloSteel Melting Shop(SMS)oTelecommunication Dept.

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RAIL AND STRUCTURAL MILL

Capacity - 7,50,000 TProducts•Rails - R52 Kg/m & R60 Kg/m ; UTS 880 N/mm2 rails as per IRST-12/96 specifications , Euronorms and international standards.•Thick web asymmetric rail Zu 1-60•Beams - 600,500,450,400,350,300 & 250.•Channels - 400,300 & 250.•Angles - 200 & 150.•Crossing Sleeper.•Crane Rails - KP80, 100,120 & 140.•Bhilai is the sole supplier of the country's longest rail tracks of 260 metres.

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Bhilai RailsLargest producer and leading rail maker of the world.Four and a half decades of experience in rail making.Produced over 15 million tonnes of rails; 2.7 lakh km in length.Indian Railways- World’s second largest rail company moves exclusively on Bhilai rails.Bhilai rails are subjected to world’s highest traffic density and axle loads.Rails exported to 10 countries with exports to South Korea, New Zealand, Argentina, Turkey, Iran, Egypt, Ghana, Bangladesh and Malaysia.

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Technological SuperioritySteel from LD Convertor – Ladle furnace - RH Degasser – Concast route; achieving world best level of degassing/refining to less than 1.5 ppm of hydrogen in liquid steel in 100% of heats.Capability to produce as rolled lengths of 80 meter and welded panels upto 260 meters.High degree of Straightness due to world’s most advanced and Laser straightness measurement based end straightening machine.World class tested rails passing through state of art online NDT equipment; Laser straightness measurement, Ultrasonic and eddy current testing machinesComputer controlled automatic rail handling system and automatic yard mapping for rail storage.Computerised Rail Tracking system for collection and storage of all process and testing related data of each rail.

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Bhilai Rails- Universally CertifiedRDSO, Indian RailwaysRITES LtdISO-9001-2000 certified by LRQA (Lloyds Register Quality Assurance)ISO 14000 certified by BISCrown Agents, LondonGeneral Superintendence Company, GenevaLloyds Register Of ShippingRobert W Hunt & CompanyOverseas Merchandise Inspection Company, TokyoEgyptian Railways Inspection TeamTuboscope Vetco Gmbh, Deutcheland

Bhilai’s Special Purpose RailsCopper Molybdenum Corrosion resistant railsHigh yield strength/ UTS vanadium micro-alloyed railsHigh conductivity metro railsCopper-Chromium alloyed High strength Rails

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PLATE MILL

Capacity - 9,50,000 TPlates thickness - 8-120 mmWidth - 1500-3270 mmLength - 5-12.5 M

The modern Plate Mill rolls out heavy and medium plates, as well as those for pipe manufacturers. Plates of wide variety, in any required size, and strength, chemical and physical properties, can be produced here. It has capacity to produce high pressure, boiler quality and high tensile steels. Shipbuilding plates, conforming to Lloyds specifications, and pressure vessel boiler plates, conforming to various ASTM, ASME standards, have withstood the challenges of nature and time. Some of the unique features of the mill are on-line finishing facilities and off-line normalising facilities.

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Bhilai has the widest plate mill in the country, and it uses continuously cast slabs as input. Liquid steel produced under controlled conditions in the LD Converters is rinsed with argon gas to homogenise the composition as well as to remove non-metallic inclusions before continuous casting so as to ensure the production of high quality feedstock for the Plate Mill. As per customers' requirement or specifications, plates are normalised in a roller hearth normalising furnace.

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STEEL MELTING SHOP (SMS)A. Steel-making through BOF, VAD/Ladle Furnace/RH-Degasser and Continuous casting route3 converters of 110/130 TVAD unit, 2 RH degasser,2 Ladle furnace4 Slab Casters, 1 bloom caster, 1 Combi casterAnnual Capacity: 1.425 MT Cast steel

Converter Shop :3 BOF 110/130 T ConvertorsSecondary Refining facilities : 1 VAD unit, 2 RH degassers, 2 Ladle furnaces, 1 Desulphurisation UnitContinuous Casting Shop: 4 Slab Casters, 1bloom caster, 1Combi caster

B. Steel-making through Twin Hearth Furnace (THF) route :4 THFs of 250 T capacity eachAnnual capacity 2.5 MT ingot steel

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TELECOMMUNICATION DEPARTMENT

Telecommunication dept. provides the employee a strong, reliable and state-of-the-art technology for Telephone Communication.The responsibility of these different Communication Equipments is entrusted by Telecomm. Dept.The different sections of this department take care of regular maintenance and upkeep of these equipments.

Enlisted below are the various typed of communication equipments presently installed and used in Bhilai Steel Plant

TELEPHONE EXCHANGESHOP FLOOR TELECOM EQUIPMENTSCABLE LINE NETWORK

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A.TELEPHONE EXCHANGE

BSP is having three exchanges which altogether have an installed capacity of 7200 landline phones.

Plant exchange is located at Telephone house nearby spat Bhavan. This is having a 3000 line exchange of Ericsson make and a 1200 line of Tata make units, serving the Plant area exclusively.

An ITI make exchange is installed at Sector-5 and having 2000 subscribers capacity and caters to location from Sector-1 to Sector-10,Nehru Nagar, Maitri Nagar etc.

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The third exchange is installed at Main Hospital.Tata Telecomm supplied this 1000 line exchange. It serves Sector-8,9,HS and Hudco.

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Inter connectivity diagram of Various Exchanges under BSP

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Inter connectivity diagram of Various Exchanges under BSP

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EXCHANGE LAYOUT

Typical exchange consist of:

oSwitch RoomoOperation and Maintenance (OMC) RoomoInput Output Processor (IOP) RoomoPower Plat RoomoBattery RoomoMain Distribution Frame (MDF) Room

The various Sections Under Telephone Exchanges are: A. Telephone Repair Shop B. Planning, Stores And Workshop C. Clock Station D. Mobile Phones

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B.SHOP FLOOR TELECOMM EQUIPMENT

Despatcher Communication System

It is a hotline communication system between a central control room and a field locations.28 such despatcher sets workig in different shops catering to about 1300 subscribers.

EX-Communication System

This system helps the Executive Director(ED) to hold the conference with all HOD’s everyday morning directly from his residence and at afternoon from his office.100 line Ex-com system is installed in Plant Control.

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Wireless Communication

The shop personnel use walkie-talkies and baseunin for communication during movement.969 sets in 30 spots frequencies are being used at various Departments.

Wireless in Local Loop (WLL)

700 WLL are used in various Departments all over the Plant.These sets are supplied by BSNL on monthly rental basis. Communication is established by thedialing four digit code of the respective user. Eg.-(285-XXXX)

HotLine

This system is used in strategic points for instant communication between two pre-assigned location.154 subscribers are given this facility all over the Plant.

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Shop Announcement System

These are used for important announcement in the shop floor and propagations of safety slogans, etc.7 Such Systems are installed.

Conference System

The system is being used at the Conference hall of the senior executives to discuss matter round the table including presentations.8 Such Systems are installed in the conference hall of MD,ED(W),ED(Projects)Ispat Bhavan Conference hall, GMI/c(M&U),GM(E),GM(P,E&En) and GM(RSM).

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C. CABLE LINE NETWORK

Cables & Line section refers to the field cable network of Exchanges.The cables are laid from exchange MDF to DPs in each area.

In Plant area 30 cabinets and more than 1000 distribution points(DPs) are installed.The Cable network also provides 100-lease line link for Computer network of INCOS,C&IT,CMMS and MMIS and maintain it.

The said computer network link is provided only to those areas where Fiber connectivity is not possible.

In Sector-5 Exchange area there are 12 cabinets and associated DPs.In Hospital Exchange area there are 7 cabinets and associated DPs.

The township cable network is dedicated to auto telephone even though there are few other circuits working for the data communication.

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D.CUSTOMER CARE SERVICES

This is round the clock telephone enquiry services. Dialing “00” one can access the enquiry services and dialing 2244 we can access compliant services.This section maintains a computerized telephone directory for providing the above services.

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Achievements

SAIL was featured in the 2008 list of Forbes Global 2000 companies at position 647.SAIL was adjudged best PSU and conferred with Business and Economy Leadership and Excellence Awards 2008 by Planman Media.

BSP won CII Sustainability Award – 2008 in independent unit category.Greentech Safety Gold Award by Greentech Foundation for outstanding achievement in Safety Management to Bhilai Steel Plant.Golden Peacock Award for Combating Climate Change – 2008 for BSP.

National Safety Award to Bhilai Steel Plant announced by the Ministry of Labour & Employment, Government of India – 2008.Ispat Bhasha Bharati. the Rajbhasha Journal of SAIL has been awarded with the first prize under the All India House Journal Award Scheme - 2008-09.

Golden Peacock Award for Corporate Social Responsibility won by Bhilai Steel Plant (BSP) for the third year in a row - 2009

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Thank You