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RSP Panorama PDF
RSP Panorama PDF
RSP Panorama PDF
Contents Of Panorama
Sl. No. Department Page Sl. No. Department Page
1. RSP – A Resume 1 41. Communication Engg. Department 194
2. Ore Bedding & Blending Plant 11 42. Instrumentation 196
3. Coke Ovens 16 43. Repair Shop (Electrical) 198
4. Coal Chemicals Department 24 44. Air Conditioning 201
5. Sintering Plant-I 29 45. Heavy Maintenance (Electrical) 202
6. Sintering Plant-II 32 46. Production, Planning & Control 203
7. Sintering Plant-III 36 47. Traffic and Raw Materials 205
8. Blast Furnace 40 48. Materials Recovery Department 209
9. Slag Granulation Plant 55 49. Civil Engineering (Services) 211
10. Steel Melting Shop-I 59 50. Structural Inspection 212
11. Steel Melting Shop-II 68 51. Contract Cell (Works) 213
12. Refractory Engineering (Services) 72 52. Water Management 214
13. Lime Dolomite Brick Plant 74 53. Energy Management 220
14. Calcining Plant-II 75 54. Safety Engineering 221
15. Oxygen Plant 77 55. Environmental Engineering 223
16. Hot Strip Mill 83 56. Fire Services 227
17. Plate Mill 90 57. Industrial Engineering 230
18. New Plate Mill 103 58. Research & Control Laboratory 232
19. ERWPP 111 59. Business Excellence 234
20. Spiral Welded Pipe Plant 119 60. AMR-Project Monitoring & Spl. Cell 235
21. Pipe Coating Plant 123 61. Projects 238
22. Special Plate Plant 126 62. Computer & Info. Technology 267
23. Cold Rolling Mill 134 63. Materials Management 274
24. Silicon Steel Mill 143 64. Finance & Accounts 278
25. Roll Shop 150 65. Personnel 281
26. Maintenance Function 152 66. Human Resource Dev. Centre 284
27. Maintenance System and Services 158 67. Central Power Training Institute 287
28. Shops- Plg & Coordination Services 163 68. Law 290
29. Shops-Foundries 165 69. Town Engineering 291
30. Shops-Mechanical Shop 167 70. Town Services 297
31. Shops-Repair Shop (Mechanical) 168 71. Sports 299
32. Shops-Structural &Fabrication Shop 169 72. Corporate Social Responsibility 301
33. Repair & Construction (Mech) 172 73. Public Relations 310
34. Crane Maintenance 174 74. Protocol & Hospitality Services 313
35. Field Machinery (Maintenance) 176 75. Vigilance 314
36. Transport 178 76. Internal Audit 316
37. Design 180 77. Medical & Health Services 318
38. Captive Power Plant-I 183 78. Central Industrial Security Force 324
39. Power Distribution 188
40. Electronics & Electrical Services 192
Rourkela Steel Plant (RSP), a pioneer unit of the Maharatna Company Steel Authority of India
Limited, was set up with West German collaboration in the 1950s with a view to actualise the vision
of the founding fathers of a nascent India to lay the infrastructure for the rapid industrialisaton of
the country. Hindustan Steel Private Limited was set up on January 19, 1954 and initially designed
to manage only RSP. BSP and DSP were added later.
Since the very beginning RSP functioned with a three pronged strategy, viz. strengthening the
Nation with the might of steel, supporting the economy and steering progress in the entire region.
The first major industry of the state of Odisha, RSP epitomises the industrious, enterprising and
innovative spirit of the people of this land and hence has been aptly called the Industrial Konark.
The site selection for setting up of Rourkela Steel Plant was very strategic. A small tribal village
Rourkela in the mineral rich belt in the North-Western tip of Odisha, on the Howrah-Mumbai rail
line, was chosen to match the logistics of raw material availability as well as rail linkage. Encircled
by Koel and Brahmani two rivers from the north and west sides respectively, the place has the added
advantage of access to abundant amount of water, a key resource for the production of steel.
Two German firms namely Fried Krupp and Demag AG combined to form Indien Gemeinschaft
Krupp-Demag (IGKD) and signed an agreement on 21st December 1953 with the Govt. of India to set
up the RSP.
By 1958 things started taking shape and the first Coke Oven Battery was lit up in the month of
December. Then came the momentous occasion: the lighting up of the first Blast Furnace ‘Parvati,’ by
the President of India Dr. Rajendra Prasad on 3rd February, 1959. Commencement of operations of
many other units both upstream as well as downstream continued for the next few years. RSP had
the unique identity of using the LD technology for the first time in Asia and was the third in the
World. The first LD Converter was commissioned on 27th December 1959. In the next year came the
Plate Mill and the ERW Pipe Plant and the process of adding new facilities continued. Hot Strip Mill,
Cold Rolling Mill and Sintering Plant-1 were some other major additions in subsequent years.
The Plant that was initially visualised with a capacity of half a million tonne (MT) of Crude Steel per
annum, was later upgraded to produce 1.0 MT. And hence after ‘Parvati’ within 3 years came two
other Blast Furnaces ‘Laxmi’ and ‘Saraswati’. Thereafter, with a view to meeting the additional
demand for flat products in the country, the hot metal capacity of the Plant was increased to 1.8 MT
in the late sixties with the addition of the 4th Blast Furnace ‘Annapurna’. The last unit of the 1.8 MT
phase of Rourkela - the Tandem Mill of Cold Rolling Mills - was commissioned in February 1968.
Subsequently two more major facilities were added like the Spiral Weld Pipe Plant and the Silicon
Steel Mill. These two new units gave RSP the distinction of becoming the only unit in the country to
produce large diameter API grade pipes and high value Cold Rolled Non Oriented sheets for use in
the electrical industries.
Under the umbrella of SAIL that was formed on 24th January 1973, Rourkela Steel Plant further
flourished and took a fresh step towards modernisation and expansion. The foundation stone of the
next level of expansion was laid on 20th September 1991. This phase of modernisation focused on
improving the quality of raw materials so as to enhance the hot metal quality and incorporation of
the latest steel making technology. Modification of many downstream facilities was also in the
agenda.
The packages included a new Oxygen Plant, upgradation scheme for Blast furnaces, a new Calcining
Plant, a cast house Slag Granulation Plant, New Ore Bedding and Blending Plant, Coal Handling
Plant, a new Sintering Plant, a new Basic Oxygen Furnace Shop, a new Slab Casting Shop in Steel
Melting Shop-II and another new Slab Casting Shop in Steel Melting Shop-I, and modifications of
Plate Mill and Hot Strip Mill.
The debottlenecking of the Blast Furnaces led to expansion of the hot metal capacity to 2 Million
Tonnes per annum. For many years post-expansion, RSP was the only Steel Plant in the Public
Sector to produce cent percent of its steel through the energy efficient Continuous cast route.
The Steel Plant embarked upon an ambitious and futuristic journey with the laying of the
Foundation for a massive Modernisation and Expansion on 4th January 2008. And the moment that
can be called truly historic in the real sense came when the massive Modernisation and Expansion
was dedicated to the Nation by the Hon’ble Prime Minister, Shri Narendra Modi on 1st April, 2015.
* Since upgradation of existing Caster-I & II at SMS-II was not taken up, the Crude Steel and
Saleable Steel Capacity of RSP (Post Expansion) was revised to 3.7 MTPA and 3.49 MTPA
respectively.
Sl. Facilities
No.
1 Augmentation and Modification in OBBP
2 New 7 mtr Tall Battery # 6 (1 X 67 Ovens)
3 New Sinter Plant –III (1 X 360 M2)
4 New Blast Furnace # 5 (4060 M3)
5 Oxygen Plant – 2 X 700 TPD on BOO Basis
6 SMS-II – 3rd Basic Oxygen Furnace (150 T), RH-OB, 3rd Ladle Heating Furnace &
3rd Continuous Casting Machine
7 New Lime & Dolomite Plant ( 2 X 350 TPD)
8 New 4.3 mtr Wide Plate Mill
9 Auxiliary Packages, Utilities, Logistics for the whole Plant
RSP in a Nutshell:
It is noteworthy that all the major production departments and some service departments have been
certified to ISO 9001:2008 QMS. The Silicon Steel Mill, Environmental Engineering Department and
Sinter Plant – II, HSM, PM, SPP, ERWPP, SWPP & Township have been certified to ISO 14001:2004
EMS.
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.
Coils Pipes
Ore Bedding and Blending Plant of RSP came up during its Modernisation and commissioned in
three stages. Phase-I was commissioned in 1994 with the facilities of unloading, screening of Iron Ore
Lumps (IOL) and despatch of raw materials to different units like Sinter Plant-I, Blast Furnaces ! , II
,II & VI and Lime Dolo Brick Plant (LDBP). Phase-II was commissioned in 1996 with the facilities to
prepare and supply Base Mix to Sinter Plant- I &II and screened Lime Stone and Dolomite to
Calcining Plant-II with a despatch capacity of 5.0 MT of raw material per annum. PH-III was
commissioned in 2012 with facilities of unloading , preparation & despatch of Base Mix to SP-II & III
& supply of screened Lime Stone and Dolomite to Calcining Plant-II with a capacity of 7MT. The
combined capacity of OBBP at present is 12 MT
Other than the above raw materials coming from mines, OBBP also handles Coke breeze, LD slag
fines, SMS sludge, Mill scale, Flue dust, screened sinter fines & Iron Ore Fines of BF # 5 and other
spillage materials generated inside the plant and process the same
.
There are three Wagon Tipplers and three Track Hoppers for
unloading of the raw materials which comes from the mines. Only
side opening wagons (NBOBS) are unloaded in Track Hoppers.
Track Hopper-1 is dedicated for IOL and Track Hopper-2 & 3 for
IOF. All BOX Wagons unloaded in Wagon Tipplers WT # 4 ,WT #
5 & WT # 6. After unloading at Wagon Tipplers materials are
conveyed to designated bed through a series of belts and with the help of Stackers / Stacker Cum
Reclaimer (SCR)
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.
PH-III:Flux Crushing at PH-III is carried out in Two Stage Hammer crusher Here Lime Stone &
Dolomite is crushed & screened separately to -3mm size of minimum 90%. The crushed Lime Stone
& Dolomite is used for Base Mix preparation at PH-III & also supplied to SP- III for trimming
addition.
Coke Crushing:
Breeze Coke generated in Coke Ovens and old 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 +12mm known as Nut Coke is despatched to Sinter Plant-II for addition along
with sinter and transported to old BF by belts. Coke breeze of -12mm fraction is crushed in two stage
roll crushers at PH-II & PH-III to get -3mm around 85%. Coke breeze generated after screening at
BF # 5 & Battery # 6 are supplied through belts & screened to separate -12mm & it is used only at
PH-III for crushing . The generated +12mm is crushed through contract to -12mm & transported to
Coke Breeze Track Hopper for use at both PH-II & III There are two series Roll Crusher at PH-II &
four series Roll Crusher at PH-III.
Despatch of Raw Materials: The complete raw material handling and preparation system is
coordinated from OBBP main control room through PLC. Each designated destination or operation is
called a path and comprises of a series of belt running through PLC.
Customers of OBBP:
Sl. No. Department Materials Supplied
(i) Blast Furnaces Screened IOL ( Sized Ore) & Quartzite.
(ii) Sinter Plant – I Base Mix, BF Grade Lime Stone, Dolo Fines
(iii) Sinter Plant-II Base Mix, Crushed Flux , Crushed Coke , Dolo Fines &
nut coke.
(iv) Sinter Plant-III Base Mix, Crushed L/stone , Crushed Dolomite &
Crushed Coke .
(v) Calcining Screened SMS Grade Lime Stone & Dolomite & Sized
Plant-II Ore
(vi) LDBP Screened SMS Grade Lime Stone
No. of Beds 14 06 20
Wagon Tippler 2 01 03
Track Hopper 2 01 03
Barrel Reclaimer 3 04 07
Stacker-cum - Reclaimer 01 01
Auto
Sampling
Station
Raw Materials
Stock Yard Screening
& Building
Screened Ore &
Base-Mix Beds
PB
Building
Coke & Flux
Crushing
Lime
Building
Dolo
Screening
Building
Coke Breeze P/R Track
L/S & Dolo Track Hopper Hopper
to CP-II
/LDBP
Sized ore to
BF Basemix to SP Nut coke to SP-II
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)
In India, the availability of PCC coal is scarce and hence its usage is also restricted. Further due to
inherent high ash content, the coke made from above coal also has high ash rendering it unsuitable
for use in Blast Furnace. In order to lower the ash in Indian coals, it has to be suitably blended with
low ash imported coking coals. Two varieties of coals are usually imported primarily from Australia,
USA & New Zealand. They are:
(a) Imported Coking Coal (Hard) [ICC (H)]
(b) Imported Coking Coal (Soft) [ICC (S)]
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:
However proximate analysis provides only prima-facie data. Suitability of coal for coking is
ultimately based on more advanced analysis which is called petrograpic test. Petrograpic
characteristics of the different coal are as follows.
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 & despatched to all steel plants.
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.
Numbers of ovens are placed side by side and together it is called a Battery. At RSP there are five
batteries:
Battery #1 70 Ovens
Battery #2 70 Ovens
Battery #3 70 Ovens
Battery #4 80 Ovens
Battery #5 80 Ovens
Total 370 Ovens
The walls of the ovens are maintained at a temperature of >1000oC by burners which are located
inside the walls. HereCO 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.
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.
Hard coke is sent to Blast Furnaces directly through conveyor belts. Other fractions are loaded in
BOX/ BOBS wagons & despatched to the end user. Coke < 80mm size are crushed in double roll
crusher & segregated as per above fractions.
Battery-6 Complex:
As a part of expansion of Rourkela Steel Plant, a new blast furnace No-5 has been commissioned. To
meet the quality and quantity requirement of new blast furnace, a new 7 mtr tall top charge Battery
along with Coke Dry Cooling Plant has been installed. This is modern, energy efficient and
environment friendly battery. Plant was commissioned on 13th April 2013.
Major facilities of Battery -6 Complex.
Coke-Ovens Battery no-6.
Coke dry cooling Plant
Coal Handling Plant.
Coke Screening Plant.
Blending of Indigenous and Imported coal is done in silos. Proximate analysis of blend coal is as
follows.
Ash 10.2%
Volatile Matter 23.0%
Gross Moisture 80%
Fixed Carbon 66%
Battery Proper:
Coking process of Battery No-6 is same as conventional top charge underfired ovens. However its
dimensions are different from other batteries. Dimension of Battery No-6 is as follows.
Useful Length 15.16 meter
Height 7.0 meter
Width (Pusher Side) 385 mm
Width (Coke Side) 435 mm
Volume 41.6 m3
Total Ovens 67
Pushing Capacity 90 per/day
Coking Time 17 hrs 50 min.
Since the volume of oven is almost double of small batteries, output of Battery No-6 is also almost
twice making it a high productive battery.
New technology like emission free door, oven machine identification & interlocking system,
computerized heating control system has been installed which make Battery-6 a modern and
environment friendly battery.
Carbon di-oxide 6%
Hydrogen 3%
A power plant of 6.5MW capacity is installed to generate power from the steam generated in CDCP.
Due to cooling of coke by inert gases, coke coming out from CDCP contains less than 1% moisture.
CDCP technology is very energy efficient process because of recovery of waste heat and dryness of
coke.
After segregation of coke in desired size range, it is stored in Intermediate coke storage bunker
(ICSB). There are two bunkers each for centre coke and surface coke and one bunker for Coke breeze.
Coke from ICSB is dispatched to Blast Furnace-5 through pipe conveyors. Breeze coke is dispatched
to OBBP also through pipe conveyors.
There is a provision to transfer coke from small batteries to new coke screening plant through
Interplant coke transportation conveyors.
Analysis of BF Coke Produced from Battery-6
Parameter Value
Ash 13.5%
VM 0.6%
Moisture 0.5%
Fixed Carbon 85%
Strength of Coke
M10 6.5%
M40 86.0%
CRI 23.0%
CSR 66.0%
COAL CHEMICALS
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
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 1000mm 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:
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:
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.
NEW CCD
Introduction:
The New Coal Chemical Department is a by-product plant of Coke
Oven Battery#6. It was commissioned on 10-04-2013. It is
designed to treat 50,000 Nm3/hr of CO Gas through a series of
processes like condensation, tar precipitation, acid treatment and
gas scrubbing. The clean gas free from Tar, Naphthalene,
Ammonia, Benzole and Sulphur, thus obtained can be used for
under firing the Coke Ovens or can be sent into the gas line grid
controlled by EMD.
Main Products:
Tar, Ammonium Sulphate Solution, Crude Benzol and Sulphur.
Process Description:
The CO Gas from Battery comes out at around 800 to 1000 deg C, which is cooled by the ammoniacal
liquor (flushing liquor) in specially designed arrangement in CO Battery#6 for absorbing the latent
heat of the gas. The gas which is now at around 80 deg C, enters the Primary Gas Coolers (PGCs) in
New CCD, where less volatile components condenses out from bottom. Then the gas enters the
Electrostatic Tar Precipitators (ETPs) where the tar (in the form of tar fog) which has escaped the
PGCs gets precipitated out. Then the gas free from tar & other higher molecular weight compounds
enters the Exhauster’s suction.
On the discharge side of the Exhauster, the gas is first treated with weak acid solution of 2 to 8 %
concentration in Spray Saturators. It is a direct contact arrangement, where the ammonia in CO Gas
reacts with the weak acid and forms Ammonium Sulphate Solution. This solution is transferred to
Site-C of old CCD to produce Ammonium Sulphate Fertilizer.
The gas is further cooled in the Final Gas Cooler (FGC) which has gas-water direct contact
arrangement, so as to get an optimum temperature required for efficient scrubbing in the
Naphthalene & Benzol Scrubbers.
Both Naphthalene & Benzol Scrubbers use solar oil as solvent to scrub out the Naphthalene &
Benzol from the gas. The solar oil being enriched with Naphthalene, Anthracene, Benzol and other
higher aromatics is sent to Benzol Recovery Plant (BRP), which is designed to strip out benzol and
circulates back the stripped solar oil to the scrubbers, there by maintaining the process of scrubbing
followed by stripping.
The gas free from benzol and naphthalene, enters the H2S scrubber for its final treatment. Here a
wash solution which as a catalyst is used for scrubbing out the inorganic sulphur (H2S) from the gas.
The product of this plant is sulphur.
The CO Gas while going through the series of above mentioned processes is tested on routine basis
for maintaining the quality.
Battery-6
PGC-4 NOs
ETP-4 NOs
EXHAUSTER-1 EXHAUSTER-2
SATURATOR-1 SATURATOR-2
Enriched solar oil
FGC HRP
Abbreviations:
1. PGC - Primary Gas Cooler (4Nos.)
2. ETP – Electrostatic Tar Precipitator (4 Nos.)
3. BRP – Benzol Recovery Plant
4. FGC – Final Gas Cooling (2 Columns)
5. HRP – Hydrogen Sulphide Recovery Plant
SINTER PLANT - I
Sinter Making:
Sintering process was developed mainly to utilize under size of lump ore (0-8 mm size) called iron ore
fines; which otherwise, could not be charged directly in blast furnace. 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 Iron ore fines (<8 mm) by incipient fusion
of fine mineral particles with heat (1200oC to 1400oC) produced by burning of coke breeze, uniformly
distributed in raw mix bed. During the sintering process, iron ore fine particles agglomerate into a
porous compact heterogeneous lumpy mass called SINTER 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:
The huge quantity of Iron ore fines generated at mining stage are gainfully utilized.
Other solid metallurgical wastes generated in integrated steel plant are utilized in sinter
making.
Enhances the productivity of Blast Furnace, as use of super flux sinter in BF burden
eliminates use of raw flux in BF.
Decreases coke rate in BF.
Improves the permeability of BF, as sinter is porous hence increasing the ingress of reducing
gases in BF.
Material handling in BF stock house is easy and least logistics are needed.
With use of sinter, BF operation is smoother and stable.
Technical Data:
Input material:
The Norm for specific consumption of input materials per Ton of Sinter produced is given as
1. Iron ore fines - 830Kg /T
2. Lime stone fines - 80 Kg /T
3. Dolomite fines - 160 Kg /T
4. Coke Breeze - 69Kg/T (Dry)
5. Return fines - 30%(max.)
6. Mill Scale - 7 Kg / T
7. LD Slag - 35Kg
Input in the form of Base Mix (a homogeneous mixture of Iron ore fines, Flux, Coke Breeze, Plant
Returns) is received from OBBP.
Process:
The Sinter Plant-I has a rated capacity of 1.5 million tonnes
of sinter per year based on 2- strand 3 shift running. There
are two sinter machines of the Dwight-lloyd down draft type
with 125 sq. meter working area. The raw materials as
specified above are brought, stored, crushed and sent to
Proportionating bins. The different materials are drawn
from these bins in a fixed ratio on to a common belt conveyor
leading to the primary mixing drum. Here water and return
fines are added. The raw mix is stored in two intermediate
bins from where it is fed into the two pelletizing 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-300oC. 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:
-15 mm fraction is again screened with 6mm screen. +6 mm fraction is sent to the Blast furnacealong
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.
Output:
The output is sinter whose typical composition is:
Total Fe 55.0 %
FeO 9.5±0.5 %
SiO2 5.5±0.5 %
Al2O3 3.0±0.2 %
CaO 10.5 ± 0.5 %
MgO 2.4 ± 0.2 %
Basicity 1.8 - 2.0 %
Physical property:
DTI of Sinter 70.0 (Min)
Mean Size 16-23 mm
+40% 5-10%
+10% 40-60%
+5% 20-30%
-5% 5-10%
-5 mm
Sinter Sinter
Machine-I Machine-II
Hearth Layer (-25,+15 mm)
Cooler-I Cooler-II
Ω
Cold Screen
Sinter to Blast Furnace
+25 mm (+25,+5)
size
SINTER PLANT-II
Commissioned on the 29th September 1996, Sinter Plant-II was a part of the1st modernisation
programme of Rourkela Steel Plant to use more than 70% sinter in blast furnace burden. Higher
sinter proportion in the blast furnace burden improves the furnace productivity with substantial
reduction in coke rate.
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 Electrostatic Static Precipitators: one for waste gas and another for plant de-dusting.
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 (550mm) 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.
Despatch of Sinter to Blast Furnaces by belt conveyors.
Design Data:
Production 1.57 MTA (Gross Sinter)
Productivity 1.13 T/Sq.m/hr
Annual working days 300 days / year
Coke consumption 75 Kg/ton of skip sinters (dry)
Gaseous energy consumption 32,000 kcal/T of gross sinter
Sinter granulometry +50 mm 0% and -5 mm 3% (min)
ISO tumbler index (+6.3 mm) 72% (min)
Cooled sinter temp. < 100 oC
Dust content in stack emission (Maximum) 100 mg/NM3
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 (-5mm) 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
22 MCal/Ton of Sinter against DPR of 32.
PR Fines
Comp. Air
Water
Lime
25mm
-25 mm
15mm
-15 mm
+25 mm
Blast
Furnaces
SINTER PLANT-III
It was commissioned on the 3rd April 2014. Sinter Plant-III was a part of 2nd Phase of the
modernisation programme of Rourkela Steel Plant. It along with Sinter Plant-I & II fulfills the Sinter
requirement of Blast Furnaces using sinter burden of 72%-80%. Higher Sinter proportion in Blast
Furnace burden improves BF productivity with substantial reduction in coke consumption rate.
Major Equipments:
13 nos. of proportionating bunkers with electronic belt weigh feeders/ vibro feeders.
2 nos of Hi-Intensity Mixer & Nodulizer of Eirich Germany make.
1 no of Hi-intensity Granulator of 1.9 meter dia of Eirich Germany make
with 4 main burners& 4 pilot burners.
One no. sintering stand of 4 meters wide, 360 square meter sintering area.
One no. 35 meter dia X 4 meter width x 1.5 meter bed height Circular Sinter cooler with rated
capacity 667 TPH and operated by 2 x 15KW VVVF drive.
3 nos of 1600KW , VVVF drive Sinter Cooler Fans.
-2 series..
Waste gas fan with 2 x 8.4 MW LCI drive controlled synchronous motor.
Three Electro Static Precipitators: Two for waste gas and one for plant dedusting.
Three Atlas Copco centrifugal air compressors.
Two nos of Flexowell coveyors for carrying sinter fines & hearth layer material.
Salient Features:
Precise proportionating by using electronic weigh feeders & loss in weight system(LIWS).
Two no of Mixer & Nodulizer of 719 tons / hour capacity.
Closed Circuit Cooling Water System.
Use of high bed thickness (700 mm) with high under grate suction of 1650 mmWC.
Elaborate pollution control measures with three electrostatic precipitators.
5 nos. of sinter storage bins having a cumulative capacity of 5000 ton.
PLC controls for Plant operation, Distributed Control System (DCS) for process control.
Pneumatic conveyors system for transfer of dust to Granulator.
Dispatch of Sinter to Blast Furnaces by belt conveyors.
Process:
Sinter Machine
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 – III by a
series of belt conveyors from OBBP and
collected in bins. There are total thirteen bins,
seven are for base mix, one for miscellaneous,
two each for flux fines, two each coke breeze
and one for plant return fines. After
proportionating, the material comes to Hi-
Intensity Mixer and then to Nodulizer. 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.
Design Data:
Input Materials:
The input materials & average consumption for making one Ton of Sinter are:
Tfe 55 %
Feo 10 ± 0.5 %
SiO2 6 ± 0.5 %
Al2O3 2.5 ± 0.2 %
CaO 10 ± 0.5%
MgO 2.5 ± 0.2 %
Basicity 1.7 to 1.8 %
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 denseriron. 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. BF#1, BF#2, BF#3, BF#4 in
RSP were commissioned with the technical and financial
assistance of M/s Fried Krupps Essen and M/sDemag.
BF#5 in RSP was commissioned with the technology
assistance from M/S DC & M/S TPL.. BF#1 is re
constructed by M/s DC and M/s Essar.
The raw materials required for production of hot metal are Iron ore, Pellet, 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 & III), Coke from Coke
Oven and LD Slag and scrap from MRD.
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 – 1 & Pig
Casting Machine – 2 to solid iron called pigs.
COOLING TOWER
R
YO
VE
ON
C
G
IN
BF
G
AR
STOCKHOUSE
CH
IN
MA
PCM-2 SCRUBBER
MIXER
TORPEDOLADLE
TRT
SLAGGRANULATIONPLANT
STOVE-1 STOVE-2 STOVE-3
GRANULATEDSLAGFORDESPATCH
AIR 2.42 T
GAS 3.615 T
DUST 0.005 T
SINTER 1.275 T
SIZED ORE 0.425
T BLAST FURNACE HOT METAL 1.0
LD SLAG 0.0005 T
T
QTZ. 0.001 T SLAG 0.360 T
COKE 0.393 T
PCI 0.136 T
Raw materials storage bins, conveyor belts for transporting raw materials to bins, equipment’s for
screening, weighing & discharging material to skips are the major components of high line and stock
house besides the open storage yard for storing Sinter to meet exigencies.
The open storage yard is provided with a crane of 45 m span and 20 T capacities to loadmaterial into
wagons and also to stock material after it is unloaded from wagons.
There are total 33 bins for storage of various raw materials, 16 for each furnaces and one bin to store
sinter return fines falling off from the head end of sinter belt.
Out of 16 bins in each furnace 10 bins are having 246 m3
volume and called full bins. Four bins having 126 m3 volume BUNKERS
are called ½ bins and 2 bins having 186 m3 volume are called
3/4th bins. Full bins are normally meant for storing iron ore &
sinter where as ¾ bins are meant for Qtz, LD slag. Each bin is
provided with vibro-feeders to draw material from bins to
conveyor belts which subsequently feed them to weigh hoppers
and then to skips. But sinter after being drawn from the bins is
screened through +5 mm mesh size vibrating screen to weigh
hopper and – 5 mm size sinter is conveyed through sinter fines conveyor belts (SFC) to sinter fines
bunkers and subsequently to both the sinter plants.
To charge the raw materials into the furnace there are two skip cars
each of 11 m3volume inBF#1 and 10.5 m3 volume in BF-IV. The
SKIP
CAR
hauling capacity of each skip for BF-IV is 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.
Stock house is having 28 bunkers. Stock is prepared in the stock house and sent up conveyors to the
furnace top in batches.
The furnace bell-less top has two lock-hoppers with 70 m3 capacity each.
The bell-less top lock-hopper door is closed and the hopper pressure is equalized with the furnace, so
the batch can be discharged into the furnace distribution equipment,
Usually discharging a lock-hopper signals the start of sending the next batch of material for that
lock-hopper This occurs while the other lock-hopper is already filled and ready to discharge.
Two batches of stock are called a charge. A charge always consists of a batch of coke followed by a
layered batch of ore, miscellaneous material and nut coke.
For reference purposes the timing of the filing operation with an 80 cm ore layer and fuel injection
with pulverized coal will be discussed. The coke layer with this sample burden is about 50 cm.
A batch feeds onto the main stock house conveyor in about 111 second for coke and 177 seconds for an
ore batch. The time difference is due the larger batch size for the ore and misc. materials.
The belt speed of the Main Charging Conveyor (1CG01) 1.78 m/sec. The belt width is 1600 mmand
the belt has 35 degree idlers. The carrying capacity is limned by volume for coke and byweightfor ore.
The travel time from the furthest material bin in the stock house to the lock-hopper is 328 seconds
for ore and 295 seconds for coke. The difference is due to bin location. One weigh hopper of coke can
provide a typical coke batch of 36 m3.
There are three Blast Furnaces with combined installed capacity of 4.5 MT of hot metal which was
upgraded during the 2005,2013 & 2017 of hot metal per annum. Some of the technical information
about the three furnaces are 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 coal&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:
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.
To dump the material into the furnace, the lower seal valve opens and then the lower material gate is
opened. The material is dumped through a rotating chute, which can dump material at any position
of the furnace and can complete the dumping in variable number of rotation so that desired burden
distribution is achieved. The whole BLT system is hydraulically operated & PLC controlled. Besides
achieving perfect burden distribution, BLT ensures very good gas sealing at the furnace top so that
furnace can be operated at a high top pressure.
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.
BF # 4
In 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. 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.
BF # 5
The blast furnace cooling system is of major importance as it protects the shell and the lining of
theblast furnace against overheating.
The blast furnace is equipped with an “on furnace cooling system". known as the primary cooling
system. The primary system is a closed circuit system. This system transfers heat from the blast
furnace lining and equipment via cooling elements to the cooling water.
Cooling water to the cooling elements must be maintained at all times, as even if the blast furnace is
shutdown the heat load still can be significant. This must be done to prevent possible local boiling in
the cooling elements that could lead to a loss of cooling to sections of the furnace. If this is not done,
the result may be severe damage to the furnace equipment and lining.
As soon as any cooling flow is reduced to 80% of the set point, the blast furnace production shouldbe
reduced or the blast furnace should be shutdown to reduce the heat load as soon as possible,
The primary and secondary cooling systems are equipped with back up diesel pumps. The primary
system is also equipped with a gravity fed emergency water system should the diesels not start.
These systems are used in the event of power failure or when interruptions in the normal cooling
water supply occur.
These systems are not intended as a 100% operational back-up, but as a back-up which is available to
provide at least a minimum cooling water flow maintained at all times to allow the furnace to be
shutdown in case the correct flow cannot be achieved
The hot blast stoves are provided with several attachments such as burners to burn the premixed air
and BF gas in the combustion chamber. Different valves are provided for controlling the BF gas,
combustion air, waste gas, cold blast and hot blast to or from the stoves. The hot blast from stoves
passes through insulating refractory bricks lined pipes (hot blast main, bustle main & tuyeres stocks)
and then injected through tuyeres into the furnaces. The entire operation & control of stoves & hot
blast is made from a control room adjacent to stove.
The stove is a steel pressure vessel in which the following parts can be discerned:
- Ceramic burner
- Combustion chamber
- Parabolic dome
- Checker chamber
- Checker support
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.
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 and 30 T for BF – IV). BF 1 have two 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. BF # 5 cast house has four tap holes
with separate trough & runners for iron & slag. BF # 5 cast house has four dedicated mudgun and
four dedicated drill machine.
BF – 5 Cast House:
There is two cast houses for this Blast Furnace, designated as NORTH Cast house and SOUTH cast
house.
BF # 1 & 4 have Cast House Slag Granulation Plant (CHSGP) where the slag after being separated
from iron in troughs, is diverted to the granulation plant. Major units of CHSGP are hot runner, cold
runner, Blowing box, Receiving hopper, Dewatering drum & disposal belts.
As the Hot slag flows down from the Hot runner, several water jets from the blowing box, break the
slag stream into droplets & carried them into a receiving hopper as a slurry. The slurry falls on wire
nets and paddles of a rotating drum, wherein water passes through and goes to the hot water tank
whereas the granulated slag is captured by the paddles, which move along with the drum rotation.
When the paddles come over a belt running at the center of the drum, the granulated slag falls into
the conveyor and is carried away to the disposal yard. The yield of granulated slag of CHSGP is
around 90%. It has been designed by M/s Paul Wurth and can handle slag upto 6 to 10 T/ minute.
Granulated slag is a major raw material for Portland slag cement. Therefore by granulating slag not
only is the waste material used economically, it also avoids environmental problem that is associated
with liquid slag dumping.
In the granulation plant, the molten slag from the slag runner is delivered to the Granulating Chute
where water is injected through the Spray Head at a pressure of 230 kPa. The design and
construction of the Spray Head ensures an intensive controlled heat exchange between water and
molten slag, thus producing high quality granulate.
The granulation process starts with 2000 cubic meters per hour (m3/hr) of water being delivered to
the Spray Head. Water is pumped from the Pump Basin by the granulation pump to the Spray Head.
The water level in the Pump basing is monitored by a level transmitter which allows the PCSto
control the level in the tank by signaling a control valve to add make-up water as required. Up to600
cubic meters per hour (ms/hr) of make-up will be required at maximum slag flow rates. An alarm is
sounded to alert the operator in case the water level in the Pump Basin exceeds the “high-level
overflow" set point or falls below the “low-low" level setpoint. The Granulation Pump is only
permitted to operate when the water level is above the “low-low" level set point.
The granulation water supply is secured through an elevated “Emergency Water Storage Tank".The
tank has a capacity of 80 m3 which will be delivered at a rate of 480 cubic meters per hour(m 3/hr).
This protects the granulation tank for approximately ten (10) minutes, during which time slag can be
diverted to the slag pits.
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 under flow 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.
DO
W
N
CO
ME
R
DUST E.S.P
CATCHER
BF CLEAN
WAGON SCRUBBER GAS MAIN
FURNACE
WATER SEAL
SLURRY PUMP
C.B.P.F
COOLING TOWER
CLARIFIERS
FILTER CAKE
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.
The Scrubber performs gas cleaning by a two-stage process in two distinct sections: the Pre-Scrubber
(Stage 1) and RS Scrubber (Stage 2). The gas stream enters the Pre-Scrubber where a series of water
sprays cool and remove “airborne” solids carried by the gas stream. The Pre-Scrubber water is
injected via nine (9) spray nozzles arranged to provide symmetrical hollow cone spray patterns. The
resulting slurry is discharged from the Pre-Scrubber via a level control system into a clarifier.
The gas stream exits the Pre-Scrubber through three (3) circular ducts, known as RS Tubes and into
the RS-Scrubber where final gas cleaning is performed. Three (3) independent water sprays, combine
with the gas upstream of the cone shaped, annular gapped pressure control devices known as RS
elements. In addition to the cleaning function, these RS elements are used to control the furnace top
pressure. The resulting slurry is discharged from the RS Scrubber via an independent level control
system into a clarifier. The “clean” gas exits the RS Scrubber through the clean gas main and into the
Vertical demister.
The Vertical demister utilizes fixed directional vanes to create a spinning action in the gas stream.
Free moisture is collected as a result of the centrifugal forces produced by the spinning action.
Entrained moisture collected within the Demister is drained into the clarifier. Clean gas exits the
Demister for use in the stoves via the TRT.
The scrubber’s three (3) movable cones are actuated by hydraulic cylinders to accommodate
variations in the gas flow and also control the top gas pressure. The hydraulic power unit and
associated pumps are located in the Hydraulic Room located at ground level adjacent to the scrubber
vessel.
CaO 30 - 32 %
SiO2 32 – 34 %
Al2O3 20 – 22 %
MgO 10 – 11 %
MnO 1
FeO 1% Max
S 0.5 to 0.6
Process:
The Rourkela Slag Granulated Plant follows the hydraulic chipping principle which can be classified
in to the semi-dry process. The slag pots are placed in position and the solid crust is pierced by a
conical dead weight of 2.5 tonnes with the help of EOT crane. Then the slag pots are electrically tilted
over a receiving bath and from it falls in to hydro-chutes where simultaneously high pressure water
is sprayed through a nozzle plate having 53 Nos. of holes of different size. The slag is instantaneously
cooled and crushed to less then 3 mm size. The granules thus formed are thrown out in to the storage
bay to a distance of 15 to 20 meters due to the high pressure (9 kg/cm2) water spray. From the
storage bay the material is shifted by means of a 10 T – EOT crane with grab bucket arrangement to
steel hoppers for truck loading. In the process of shifting the material from the storage bay, the water
flows down to a recirculation tank system of 450 m3 capacity. The water is allowed to settle here and
the clean 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
250mm 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.
Corus lJmuiden has used this system very successfully since 1983 and, by modifying and upgrading
it. have reached the highest levels of PCI in the world. This report deals exclusively with the
Pulverized Coal Injection System for Rourkela Green Field Blast Furnace No 5.
a) The Pulverized Coal is fed from the Fine Coal Silo to the Feed Tanks, which is part of a batch
process where the Feed Tanks are either Filling, Pressurizing, Holding, Feeding, or De-
pressurizing in order to provide a continuous flow of Pulverized Coal into the Transport Line.
b) The single stream of Pulverized Coal in the Transport Line leaving the Feed Tank is
combined with Transport Gas in the Mixing Tee to convey the coal to the proximity of the
Blast Furnace.
c) The single stream of Coal/Transport Gas mixture feeds the Distributor, where the single
stream is distributed equally to each of the Injection Lines, which transport the coal to the
individual Tuyere.
The PCI System can be divided into the following main parts
While the TRT is operating, the scrubber is put into differential pressure control, where only the
minimum amount of pressure drop for effective gas cleaning is taken (approximately 0.25 Kg/cmz). In
the case of a turbine shutdown because of maintenance or other disturbances the Main BypassValve
(MBV) is opened, the TRT is shut down, and the scrubber then controls the furnace top pressure.
Design parameters
The Slag Granulation Plant of Rourkela Steel Plant is located by the side of NH-23 and at a distance
of 2 km from Tarapur Gate. It is in an area of 200mX400m and has got a separate boundary wall.
The Plant was constructed by M/S Engineering Projects (India) Ltd. and was commissioned on 31st
March 1977 and has Capacity of 0.6MT/year. The plant uses liquid Blast Furnace Slag and converts
into granulated slag which is used as input raw material in cement plants for production of slag
cement. The normally known Portland cement has almost same strength and setting properties
required for constructions but production cost of slag cement is less than Portland cement. General
lay out of the plant is shown in Fig. I.
CaO - 30-36%
SiO2 - 30-35%
Al2O3 - 18-26%
MgO - 10% Max.
MnO - 2.5% Max.
FeO - 1% Max.
S - 0.5-1.0%
CaO/ Si O = 0.96 Max
2
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 metres away from sub-station
air intake house of size 1000mm X 1600 mm is located and air is brought to the sub-station through
an underground air duct. Air is cleaned in filter panels installed in the air intake chamber and cooled
in the air washer and delivered by centrifugal fan at the rate of 40,000 m3/hr. The fan is driven by 15
kW motor.
The flow of air has branched out in the following manners:
a) For Pump House : 15,000 m3/hr.
b) For Sub-station : 13,000 m3/hr.
c) For Water Pipe Line Tunnel : 9,000 m3/hr.
d) For Control Tower : 3,000 m3/hr.
One booster fan of capacity 12,000 m3/hr driven by 3.7kW 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 200mm. Each recirculation tank has got capacity of 110m 3
located side by side. From the recirculation tank, water flows into 23m long suction channel from
which water is supplied to the suction pipes of 6 nos. of granulation pumps. The make-up water to
the system is fed to the suction chamber through a 250mm diameter pipeline in order to compensate
the loss of 40% of water during the granulation process.
PUMP HOUSE
The pump house is situated at 7metres below the sub-station building. The pump house is equipped
with 6 nos. Centrifugal Pumps having capacity of 300m3/hr each. Two dewatering pumps are
installed to take out leakage water inside the pump house. The capacity of each Dewatering Pump is
10m3/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 16mm 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 2T 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 300mm diameter each have been taken from
water ring main to nozzle box at granulation bay for granulating liquid slag. The tunnel house is
connected with ventilation system. A Centrifugal Fan andan 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 10T capacity and filled in the steel hoppers and discharged in the trucks for road
despatch.
PROSPECTIVE CUSTOMERS
1. M/s. Orissa Cement Ltd., Rajgangpur, Orissa.
2. M/s. Chariot Cement Ltd., Kalunga. Rourkela, Orissa.
WAY TO
TARAPUR GATE
PUMP HOUSE
SUB-STATION
CONTR
OL RECIRCULA
CR-816 TOWER TION
A B
WATERT
GARRAGE
GRANULATIONB
DESPATCHBAY
CR-810
CR -814 A
AY
ADM.BUILDING
FOR DESPATCH
CYCLE STAND
MAIN
NH -23
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.
In early sixties SMS-I was commissioned with LD converters and later on a Secondary Steel Making
unit and a Continuous Casting unit were added to it. Hot Metal from different Blast Furnaces is
transferred to Hot Metal Mixers of SMS-I by locomotives. Using oxygen from TOPs and Lime &
Dolomite from LDBP, hot metal is converted to steel. For smooth production of steel, SMS-I is
provided with following facilities:
BLAST FURNACE
HOT METAL
MIXER MIXER
CONVERTER CONVERTER
SSM UNITS
VAR VOR
LHF ARS
CASTER
SLABS
Mixers:
Two numbers of Hot Metal Mixers (1100T 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 vessel 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.
LIME DOLO
75 kg/T
20-25 kg/T O260Nm3/TCS
SCRAP
80 kg/T
Hot Metal
= 1070
Kg/T
INPUT
OUTPUT
Slag
Ferro-Alloys 150Kg/TCS
(Fe-Mn, Fe-Si, Si-Mn) & Al For disposal
Special Alloys
(Fe-Nb, Fe-V, Fe-Cr, Fe-Ti)
Blowing:
Start blow with water cooled oxygen lance with height (working) as per the bath height measured.
Blowing lance should be free from any skull at the nozzle and there should beno water leakage. Then
the oxygen is blown with required pressure and flow rate. 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 and rock the converter back & forth 2 to 3 times and start the oxygen blowing
process all over again by lowering the lance while maintaining the above parameters. Start adding
lime as per silicon content and loss on ignition (LOI) 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 oxygen blowing, lift
the lance and deslag the steel bath by tilting converter from backside pull pit.
Blowing oxygen pressure varies from 8 to 10 kg/cm2 and flow rate 9,000 to 10,000 Nm3/hr. Any
deviation in blow pressure contact OP, INST. and SMS-I(MECH).
Add remaining 50% lime in dozes during the second half of blow. Observe the flame, when flame
drops stop the 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 than desired limit then following actions may be taken for next blow.
Corrective actions are taken based on above and add coke during blowing, if necessary.
For low turn down temperature (<1580 °C) add 200 kg to 500 kg FeMn or SiMn in the converter by
charging box. Rock the converter once and keep vertical. Blow at referred height. For each minute of
the blow the rise in temperature 12 ±2 °C approximately.
Ladle preparation
Ladle is steel shell, which is lined with refractory bricks. After the lining is complete, ladle is lifted
from relining pit and placed under burner for minimum 2 hrs for drying. Preheated Ladle is then
placed horizontally on the ladle stand and inner surface of seating block and well block is cleaned
using compressed air. Ladle should be dry and setting of bricks should be complete before fixing of
porous plug. There are total 18 steel ladles in SMS – I, out of which minimum 7 ladles are kept ready
for use at any given point in time for smooth production.
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 Desulphurization, deoxidation, inclusion shape control, improved steel cleanliness, high isotropy
of mechanical properties.
o Hydrogen and nitrogen removal
o Attainment of prescribed casting temperature within narrow range.
o Providing sufficient holding time during treatment and casting.
o Acting as buffer between converter and casting unit.
In the continuous casting process, molten metal is poured from the ladle into the tundish and then
through a submerged entry nozzle into a copper mould cavity. The mould is water-cooled so that
enough heat is extracted to solidify a shell of sufficient
thickness. The shell is withdrawn from the bottom of the
mould at a "casting speed" that matches the inflow of
metal, so that the process ideally operates at steady
state. Below the mould, water is sprayed to further
extract heat from the strand surface, and the strand
eventually becomes fully solid when it reaches the
''metallurgical length''.
Capacity : 1300T
Operating angle : 30o
Full emptying angle : 45o
Average hot metal
temperature in mixer: 1250
to 1350o C.
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.
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
Converter Shop:
The scrap yard stores and provides the combination of light, medium & heavy scrap as per the
requirement of the shop. The crane used has magnets to do the loading and unloading.
TundishPreparationBay:
The bay is equipped to clean the used tundish and prepare this tundish for new sequence.
LHF:
One LHF is used for homogenising and final adjustment of temperature and chemical analysis of steel
tapped from Converter before being sent to Casters for casting. LHF consist of:
- Ladle Car
- Electrode heating mechanism
- Water cooled roof with dust collector system
- Alloying system
- Wire feeding machine
ARS:
One ARS is used for homogenising and final adjustment of temperature and chemical analysis of
steel tapped from converters before being sent to casters for casting. ARS consists of:
- Alloying system
- Wire feeding machine
Casters:
There are 2 single strand slab casters and two turrets forhandling the
ladles and providing steel on continuousbasis. They can rotate 3600 and
can lift two 240 T ladlesand rotate. The slab caster has a water cooled
coppermould, which gives the required dimensions of the slabsproduced.
The strand produced is further cooled by water 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 is cut by using transverse torch cutting machine, which moves along with the strand and
cuts slabs using oxygen and acetylene.
Annual capacity : 13,55,000 tonnes
Average heat size : 150 -165 tons
No. of strand / machine : 1
Slab Yards:
All the slabs produced are stored in two slab yards.Slabs sent to
Plate Mill are further cut to requiredlength before being
dispatched. Hot slabs are also beingloaded in specially made flats
to Hot Strip Mill. Twoslab marking machines have been installed
for markingslabs thereby reducing lead time.
LD Gas
Refractories Engineering (Services) department is responsible for installing and maintaining the
health of refractory lined furnaces / kilns etc situated throughout the plant. The major functions of
the department are:
Cold and hot repairs of the vessels, furnaces and kilns.
Capital Repairs and mid campaign repairs of all Refractory lined structures.
Regular jobs like relining / repair of Hot metal ladles, LD converters, Steel ladles, Torpedo
Ladles, Mixer ladles, RH-OB etc.
Capital relining & mid campaign repairs of Blast Furnaces and Blast Furnace stoves, BF
Tuyere stocks.
Providing acid proof lining and maintenance of the same for pickling tanks of Cold Rolling
Mills and Silicon Steel Mills.
Carrying out technical modifications and improvements to increase the availability and life
of Refractory lined furnaces.
Preparing qualitative and quantitative requirements of various kinds of Refractory
Materials and initiating for its procurement.
Follow up with material management to arrange supplies in time.
Preparing the refractory consumption & cost data and other statistics related to refractory
materials for the whole plant.
Regular Interaction / association with RDCIS for implementing technical advancements for
improving the life of refractory.
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.
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.
Apart from the above, the refractory lining / repair of furnaces of Sintering plants are taken up
during mid repairs & capital repairs.
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, Torpedo Ladles, Hot Metal
ladle, RHOB 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 Life and availability of
LD Converter and Steel Ladles, numbers of steps have been taken from time to time.
Lime Plant:
Lime Plant has a twin shaft kiln to produce metallurgical lime for use in LD converters of SMS-I as
flux. Twin shaft parallel flow regenerating kiln namely Kiln No.5 is of 150 T capacity per day.
Lime stone is supplied by Ore Bedding and Blending Plant. Feed size of Lime stone is 30mm to 60
mm and CaO content is 53% min. Lime stone is stored in the High Line bunkers of LDBP and
charged in the Kiln by skip. Lime produced is stored in Kiln Bunkers and Classifier Bunkers and
supplied to SMS through Belt Conveyors.
Mixed Gas is used as fuel for the calcination process and is supplied by the Energy Management
Department. Lime stone is heated in the kiln by burning mixed gas.
The Brick Plant of RSP Produces Pitch Bonded Tempered Magnesia carbon bricks which are used as
working lining of LD converters of SMS-I and SMS-II and
are also used as working lining of ladles of CCM-I & CCM-
II. Raw materials mainly used are sea water magnesia,
graphite & Pitch. Magnesia (0-25 mm size) is crushed &
ground to generate various sized fractions which are
stored in classified bunkers.
CALCINING PLANT – II
Calcining Plant-II (CP-II) was commissioned between 997 with four mixed gas fired kilns#1 to 4 each
of 250 TPD capacity and in 2015 another two Heavy Furnace oil fired kilns #5,6 of 350 TPD capacity
were commissioned in 2015 to meet the flux requirement of (+10 )mm size SMS-II for 3 x 150 Ton
capacity converter and CCM(LHF).
One LSU of 20T/Hr capacity has also been installed to generate (-2) mm flux fines to use used in SP-
III for sinter making. It also meets the flux requirement of size (-10) mm of SP-II. It also provides
iron ore and coal to SMS-II
All the six kilns are vertical twin shaft, parallel flow, and regenerative type of kilns. The four old gas
fired are ”O” shaped and new two oil fired kilns are ”D” shaped in construction.
Lime and dolomite stones of size (+30 to -60) mm as well as Iron ore are received from OBBP are
stored in RM building, RM building are having 4 Nos of lime and dolomite stone bunkers of 200 tons
and 4 Nos for iron ore bunker of 100 To capacity through Travelling Tripper Belt Conveyor BC#2.
From these bunkers lime stone and dolomite stones are transferred to kiln feed building through belt
conveyor (BC#9 and Travelling Tripper BC#10) having bunkers for kilns to feed the materials to kiln
through skip hoist system. Iron ore is directly sent to SMS-II through a separate group of belt
conveyors.
From kiln feed building the required amount of weighed lime/ dolomite stones are fed to kiln top
service hopper through PLC controlled skip and Belt Conveyors (BC#17AB and BC#22AB). Inside the
kiln required amount of lime stone / dolomite stone are fed to kilns from service hoppers through
trough charging traps in to non burning shaft. Then opening/ closing the reversal trap one shaft is
kept under firing and another shaft is kept under re-generation. The kilns operating pressure is 250-
350 Mbar. For supplying the combustion air and cooling air twin lobes blowers have been installed
and for supplying the mixed gas in kiln#1-4 Gas boosters are there. For kiln#5,6 the HFO are
transferred through transfer pump from day oil tank to the dosing pump common rail and through
the dosing pump fuel are injected inside the kiln after heating atomizing through factory steam at 4.5
bar 200 degree centigrade. In each kiln the waste gas is passed through bag filters where all the
micro dust are taken out and the clean air is left to atmosphere. The Specific heat required for
converting lime stone to Calcined lime is 850 Kcal/Kg and for dolomite stone to calcined dolomite it is
around 750 Kcal/Kg. The final product flux comes out after 24 hours of charging. The measures of
quality of product are 1) LOI (loss on ignition) and 2) Reactivity.
The final flux produced from the kilns are transferred through belt conveyor (BC#25,26) to Flux store
building having 10 Nos of bunkers of 200 Ton capacity each. From bunkers No#1 to 6 flux can be
transferred to SMS-II though group of belts and vibrating screen (BC#33, 34, 35, VS#37AB, BC#38).
Bunker No7, 8 are the reject bunkers from where the flu are loaded in trucks/ trippers for CCM,
SMS-I and to dump yards during initial start up of kilns. From Bunker No#7 there is provision to
transfer flux to LSU (lime sizing Unit). From Bunker No#9,10 the flux can also be transferred to
SMS-II through series of equipments and vibrating screens (BC#224, BE#225, BC#227, VS#228,230,
BC#236, BC#232, 234). The vibrating screen VS#37AB and VS#228, 230 are installed in screen house
where (-10) mm size flux are taken out and stored in bunker#39A,B, 240,242 of 200Tons capacity
each. These flux are used in SP-II for sinter marking and LSU for further crushing them to (-2) mm
used in SP-III.
In LSU the flux are fed through of size (-10) mm through OH bunker, BC#316, BE#324 and (-60) size
through BC#306 to storage bunker of 100 ton capacity. From these bunkers material are fed to
hammer crusher from VF#333 and the crushed material from crushers are transferred to VF#343,
VS#345 where (2)mm size of flux are screened out and stored in a bunker for transporting them to
SP-III
The Iron ore stored at RM building can be transferred to SMS-II through a series of belts (BC#42, 43,
44, 50, 51, 54).
OXYGEN PLANT
Oxygen Plant(OP) constitutes of Air Separation Units, Propane Storage and Vaporisation Plants,
Compressed Air Stations and Cylinder Filling and Distribution.
Unit-I of OP was commissioned (1 MT Plant) in 1959-60 and expansion plant (1.8 MT) in 1966-67 for
production of Gaseous Oxygen at 99.5% purity at the rate of 3300 Nm3/hr & gaseous Nitrogen
containing less than 100 ppm of Oxygen at the rate of 6500 Nm3/hr. It comprised of 4 nos. of Air
separation Units (3 X 100 TPD & 1 X 200 TPD). These plants had become obsolete and were disposed
off after commissioning of 700 TPD, Oxygen Plant, ASU-III in RSP.
The Oxygen plants available for operation are captive units ASU-I (180 TPD), ASU-II (180 TPD) &
ASU-III( 700 TPD) of Oxygen Plant and two Oxygen Plants of 700 TPD capacity each under M/s
Linde India Ltd on Build Own Operate (BOO) basis. The Oxygen, Nitrogen and Argon demand of
RSP is met through operation of these plants as per requirement.
ASU-I & II (two units of 180 TPD ) were added during modernization in 1993 to meet the growing
demand of Oxygen and Nitrogen, with the commissioning of SMS-II,
Liquid storage tanks for storage of liquid oxygen & Liquid Nitrogen are there. 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, vapourised and supplied as gas
to the product grid to meet the short-fall. Storage tanks are of following capacity;
Filtration Cooling
Air
ASU-III is 700 TPD cryogenic type air separation plant capable of producing simultaneously Gaseous
and Liquid Oxygen, Nitrogen and Argon was supplied and commissioned by M/s Linde AG,
Germany & BOC(I) Ltd., Kolkata in 2010 to meet the demand of simultaneous blowing in SMS-II.
Process Description:
The atmospheric air is compressed to different pressure levels through Main Air Compressor (MAC),
Booster Air Compressor (BAC) and Turbine Booster, pre-cooled and purified in Pre-cooling and
Purification section , distilled in the Distillation Columns where gaseous Nitrogen, Oxygen and
Argon at desired purity and pressure are obtained and supplied to the customers through the Plant
pipe line grid.
Under the corporate plan of SAIL, the expansion plan of RSP to 4.2 MT Crude Steel was envisaged.
The new technologies like, Oxygen enrichment and Coal-dust injection in Blast Furnaces required
additional oxygen and nitrogen. Similarly there was additional requirement of Oxygen, Nitrogen and
Argon in BOF shop due to addition of Converter-3 and Caster-3.
With a view to augment the supply of Oxygen, Nitrogen and Argon to these shops, it was decided to
install Oxygen plant on BOO basis. Thus, BOO Oxygen plant of capacity 2 x 700 TPD was installed
with integrated pipe line network of over 2 KM from BOO plant to OP for evacuation of the gases.
Vide agreement No. P/Proj/TOP/BOO/08049154 Dtd.02.01.2009 the contract was signed between
SAIL, RSP and M/s BOC India Ltd (presently M/s. Linde India Ltd.) for installation of 2 x 700 TPD
oxygen plant on BOO basis. The plants were commissioned in 2014.
The Compressed air requirement of various units of RSP are met from the central Compressed air
grid. The central Compressed air grid is fed from Compressors located in 3 locations under Oxygen
Plant ( Rolling Mill Air Station near Plate Mill, Compressors at Unit-I of Oxygen plant &
Modernization Area Air Station near CCM-II ).
Oxygen & Nitrogen from the main grid is compressed in high pressure compressors ( 145 kg/cm2) and
filled in cylinders at Unit-I of Oxygen Plant. Argon cylinders are filled in Unit-II of Oxygen Plant.
Filling of Oxygen, Medical Oxygen, Nitrogen and Argon in cylinders.Distribution of Oxygen, Nitrogen
and LPG cylinders, Testing of cylinders
Hot Strip Mill (HSM) is a 1700 mm semi continuous mill comprising 2 Walking Beam Furnaces of
capacity 225 T/Hr., 3 Roughing Mills i.e. One 2-high Reversing Mill with powerful edgers (Ro/Vo),
One 4 high Reversing Mill (R1) and One 4 high Continuous Mill (R2), Coil Box, Six Stand continuous
4 High Finishing Mill in tandem and 2 Hydraulic down Coilers. The Mill was originally
commissioned in February, 1961 and was subsequently revamped in 1980 for computerization of
Finishing Stands. During 1992-93 old RunOut Table (ROT) and Coilers were replaced by the state of
art ROT and Hydraulic Coilers during 1995 to 1999. Ro/Vo, Coil Box, Quick Work Roll, Change Roll
in Finishing Mill, High Pressure Descaler, Walking Beam Furnace were installed under
modernisation programme for rolling heavier and longer slabs to coils. The HSM was originally
designed and commissioned on turnkey basis by the M/s. DEMAG AG, West Germany. The main
mechanical equipment were supplied by M/s. DEMAG, M/s. SACK, M/s. SCHLOEMANN and mill
drives by M/s. SIEMENS and M/s. AEG (All firms of the then West Germany).
It is designed to roll the slabs of thickness 150 – 220 mm to finished strip gauge of 1.8 to 12.5 mm in
725 – 1550 mm width. The annual production capacity of the mill is 1.65 Million Tons of slab weight.
The HSM being an integrated unit of RSP supplies Hot Rolled Coils as input materials to its
downstream customers such as Cold Rolling Mills, Silicon Steel Mill, and Pipe Plants and also to
Dividing Line. It also caters to the requirements of external customers.
There are also 4 nos. of fixed skid pipes inside furnace on which the slabs rest while in stationary
state. Tracking and heating of slabs to required temperature is done by computerized thermal model.
Once the slab reaches the discharge end, it is detected in the discharge pulpit by the Gamma ray
system provided at the discharge side. After slab detection and getting clearance from R1 cabin, slab
is extracted from furnace by extractor and is placed on the discharge roller table and sent to Ro/Vo
through primary descaler for rolling.
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.
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
MAJOR COMPONENTS:
Entry Side Guides, Top Bending Rolls (2 Nos.), Bottom Bending Roll, Cradle Rolls # 1, Forming
Roll, Adjustable Side Guides, Mandrel Peelar Main Arm, Cradle Rolls # 2, Pinch Roll
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.
MAJOR COMPONENTS:
Side Guides, Hold Down Roll, Top Pinch Roll, Bottom Pinch Roll, Entry Table, Wrapper Rolls (3
Nos.), Mandrel with Outboard Bearing, Coil Car Upender
PARTS OF COILER
1.Top & Bottom Pinch Roll
2.Three Numbers of Wrapper Rolls.
3.One Mandrel with Two Stages of Expansion.
4.Coil Car for Taking out The Coil
5.Centering Arm for Lifting Of Coils
6.Tilter for Tilting the Coil to the Conveyor
7.Mandrel Dia: 762 – 740 – 725 Mm
Hold Down Roll for Preventing Tail end Shifting
(SHIPPING AREA)
DIVIDING LINE:
Hot Rolled Coils meant for converting into HR plates are uncoiled in Uncoiler, leveled in Leveler-I
and then sheared at Dividing Shear to the required lengths as per requirement of the customer. After
shearing, the plates are leveled 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
HR PLATE DETAILS
THICKNESS : 4.0 – 10 MM.
WIDTH : 1000 – 1550 MM.
LENGTH : 5 – 10 METERS
R1
MATERIAL FLOW INHOT STRIP
R2
Coil Box
Crop Shear
Through Scale Washer
MILL Hot Strip Mill
Coilers
HR Coils for
Shipping
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 3.1m, 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 and 170% of capacity utilization in March-2008. The
techno economic factor is one of the best tools to make judgment about the performance of this unit in
any integrated steel plant. The original installed capacity was 2.88 lakh tons. After addition of new
walking beam furnace in 1995-96 the capacity was enhanced to 3.40 lakh tons of finished plates. Now
it is operating at 160 % of its capacity consistently for many years. For the sake evaluation, data of
some of the important parameters are given below:
A hot or cold rolled flat products rolled from ingot or slab in rectangular cross section of thickness 5
mm and above with width 600 mm and above and supplied in straight length.In plate mill, plates are
produced from slabs which are mainly received from Continuous Casting Machine I (CCM I) and
Continuous Casting machine II (CCM II). Some of special quality slabs are procured from ASP, DSP
& BSP also. Detail material flow chart has been given below.
PLATEMILL MATERIALFLOWCHART
HOTLEVELLERI
(6 –20 mm) COOLING
BEDI&II
SLABYARD
REHEATING
FURNACE HOTCROP HOTLEVELLERII
SINGLESTAND SHEAR (20 –38mm)
3.1 MTS. 4 HIGH
REVERSING MILL
LEVELLER
III DIVIDING
SHEAR CIRCULARTRIMMING INSPECTION
SIDEPILER
I &II SHEAR BED
6 –20 mm
TEST
PIECE
OFFLINE FINAL
ULTRASONIC
TESTING INSPECTION FLAME
CUTTING
COLD MACHINE
LEVELLER
AB BAY(2 Nos.)
CDBAY(1 Nos.)
CHETTAHMANUAL
MACHINE
COOLING PILERIII
& IV DESPATCHBYRAIL
BEDIII &IV & ROAD
SLAB YARD:
Slab Yard is the entry point of Plate Mill. It is situated in AB bay. In plate mill input slabs are
received mainly from CCM I & CCM II. Apart from this input for special plates are also procured
from Bokaro Steel Plant and Durgapur Steel Plant. It has a capacity to store 1000-1200 slabs. For
smooth running of plate mill 600 slabs should always be present. The minimum weight of slab is 3.1
tons and maximum weight being 7.1 tons. Slabs are mainly handled in piles of 6 slabs in yard and
planned for rolling as per PPC. Slab charging into furnace roller table is done one by one by auto tong
from de-piler. There are total 5 cranes for handling of slabs. Slabs are kept in piles and 1 pile
generally has 6 numbers of slabs.
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
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 numbers of burners & is called Zone –I. Bottom preheating area has 2 numbers of
burners & is called Zone –II.
b) Heating Section: In this section heating of slabs are done. Temp in this area is kept at re-
crystallization temp of steel (which depends on % carbon in steel) i.e. 1300 ± 20 0C. 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 numbers of burners & is referred as
Zone V whereas bottom soaking area has 7numbers 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 :
Basic function of slab extractor is 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.
Slab discharging roller table having 12 nos. rolls with group drive system, transfers the hot
extracted slab to primary descaling unit.
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. There are two headers each having 24 nozzles on top and bottom respectively. 12
nos. of solid rolls along with descaling box consists the complete unit. After descaling the hot slab
is sent to mill stand through slab car.
MILL STAND:
Plate mill is 3.1m 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 1000mm x 3100mm size and two back up rolls of
1500mm x 3000mm size. Rolling takes place in forward and
reverse direction called passes only between the two rolls
called work rolls, whereas other two bigger diameter rolls
supports the work rolls, hence called back up rolls. The
function of back up rolls is to prevent bending of work rolls
when they are under load. Work rolls are driven by high
power motor whereas back up rolls are idle and they rotate
from frictional contact with work rolls. The number of passes to be given depends on slab and final
The plates after inspection bed is carried for marking the various information which give details
about the plate like Plate number, Cast number, Dimension, Destination, Quality, etc. which is
carried out with Paint Marking Cum Punching Machine. It was commissioned and put on normal
operation on 01-08-2008.Paint Marking Cum Punching Machine paints all details on plate surface
automatically from level-II data received from SAP system. There is provision of manual painting
also whenever machine goes down.
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.
Plate Parameters:
Length - 2,500 mm to 27,000 mm
Width - 850 mm to 3,000 mm
Thickness - 5 mm to 63 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
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. The shear is driven by two mechanically coupled electric motors through a speed
change gear drive. Before cutting in the dividing shear, the hold down device presses the plate on
bottom knife saddle by means of several spring loaded stems. It is designed to cut the plate thickness
up to 25mm. The dividing shear comprises of:-
1. Approach roller table.
2. Girder type gauge (scale).
3. Shifting device in front of dividing shear.
4. Dipping table device.
5. Roller table behind dividing shear.
6. Test piece pusher unit.
7. Scrap conveyor system.
Normalizing Furnace
Normalizing is a heat treatment process that aims to improve certain mechanical properties of steel
like remove internal stresses, machinability, ductility etc. It is not carried out for all plates.
Whenever it is required by customers normalizing is done on specific plates.There are two nos. of
normalizing furnace. The new normalizing furnace which was installed in 2011 is being used for
normalizing the older one is idle. 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 – 930 OC. 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.
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.
All the finished plates are stored in the yard in AB, BC, as per stacking plan. Plates are indented as
per movement plan guided by PPC. Sampling is done at test piece section and samples are sent to
test house for testing. After entering the test results, plates became ready for dispatch. These ready
plates are then loaded in railway wagons or trailers as per the daily dispatch plan.
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 3.1m, 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:
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.
Furnace Area
Furnace area can be divided into three sub groups as follows:
v) Charging Roller Table & Pusher
vi) Walking Beam Furnace
vii) Slab Extractor and Discharge Roller Table
viii) Primary Descaling
Mill
Plate mill is 3.1m 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 1000mm x 3100mm size and
two back up rolls of 1500mm x 3000mm 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
15mm or 20% of the instant thickness of plate whichever less is.
Marking Details:
Position of Marking - Along the centre line of the plate
Direction of Marking - Lengthwise paint
Characters pattern - Standard 9x7 Dot Matrix(WxH)
Characters - Alphanumeric
Height of Characters - 40mm
Number of Lines - 8 (Eight)
Number of Characters/Line - 20 Alphanumeric (Maximum)
Punching Details:
Direction of Marking - Crosswise to Plate conveyance
Characters pattern - 9x7 Dot Matrix (WxH)
Characters - Alphanumeric
Height of Characters - 10.5mm (Approx)
Number of Lines - 3 (Three)
Number of Characters/Line - 16 Alphanumeric (Maximum)
Benefits:
I. Improvement in Manpower Productivity: Earlier 6 operators/shift were engaged in manual
marking and punching operation. Now only2operators/shift are operating the new marking &
punching machine.
II. Operator gallery no 4 for inspection bed drive has been removed and dismantled which is now
being operated by marking operators in the new cabin made for marking machine. Thereby
reduction of manpower i.e. 1 operator/shift.
III. The total reduction of manpower is 5 per shift i.e. 15 nos. and same have been re-deployed
which was helped in introducing 7 days working in plate mill.
IV. Elimination of hazardous and tedious operation of manual spray paint marking and punching
and improving the safety and moral of the operation.
V. Drastic improvement in customer satisfaction as well as marketability of the product.
VI. Elimination of incidences of mix-ups in plates at the finishing/shipping stage, due to illegible
marking.
VII. Elimination of incidences of wrong shearing of plates due to illegible marking
VIII. Faster loading and dispatching due to proper identification and traceability of various grades
and sizes of plates
IX. Constant paint circulation and intermediate cleaning of spray nozzles by mixture of air and
water will prevent clogging of pipelines and nozzles.
X. Better record keeping and retrieval of marking and punching records for references.
XI. Faster processing of plates in inspection beds thereby reducing the cooling bed delays.
NEED:
I. To cater to growing demands of UST plates.
II. To match with normalized and ultrasonic tested plate demand of 10,000TPM 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.
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.
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 – 930 OC. 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.
Reheating Furnace
The Reheating furnace receives slabs from the Steel Melting Shops which are stacked in the slab
yard with the help of EOT cranes 341 & 342.
Slabs are charged one by one as per the rolling
plan given by the level-3 ERP with the help of
Depiler crane Cr-347. Slabs are heated inside the
furnace upto a temperature of 1280°C.
Temperature set points are given by level-2
system however provision is there to alter it via
human intervention from L1 HMI screens. The
waste gases leaves the furnace through a down-
take system and then are ducted to a recuperator
and finally to a natural draught chimney of 90
meters height.
LEVEL -1 Function
There are two PLCs in the furnace. The heating of slabs is controlled by combustion PLC whereas the
charging, discharging and transport of the slabs is being controlled by the Handling PLC.
Furnace is equipped with European Safety standard which is implemented in level-1 PLCs. This
system ensures shut down in a safe manner in the event of major faults or deviations like:
- Loss of electrical power
- Loss of fuel or air pressure
- Loss of instrument air pressure
- Loss of cooling water pressure and flow
The safety logic manages automatic purging of upstream & downstream gas line.
LEVEL - 2 Functions
The Level 2 System is implemented as a package of custom application software that integrates a
number of tasks. Following is a description of the functions of the system.
On-line Thermal Model
Control of Heat Supply in the Furnace Zones
Data Exchange with Level 3, Mill Level 2 and furnace level-1 system
Tracking
Automatic Management of Mill Delays and Furnace Holding Periods
Finishing mill exit temperature control by adaptive feed-back.
Reports
Finishing Mill
The New Plate Mill commenced full-fledged functioning in the
year 2014 and has already carved out a name for itself in the
Steel map of India. Set up to cater to the customised plate
market the Mill can produce a wide range of plates with close
tolerances to meet stringent international standards and heavy
and wide plates for the rising ship building, defense, construction
and boiler sectors.
Some of the key parameters of the mill are:-
Roll Force 9000 ton
Mill Modulus 8550 kN/mm
Mill stretch 2.67 mm
Main mill motor qty 2
Main mill motor 3.1KV, 8000 kW, 50/120 rpm Synchronous
Motor
2. MILL MOTORS:
Both the mill motors are of cylindrical rotor construction with 16 numbers of salient poles for
excitation supply via sliprings. Specialty of these motors is the Vacuum Pressure Impregnation
(VPI) process. In this process after winding, the stator assembly is treated by the Vacuum using a
solvent-free epoxy resin. It is then baked to cure the resin-impregnated insulation and bracing
materials. The final product is a rigid structure free from voids and impervious to moisture.
The main motors are speed controlled so to have the same peripheral speed of top and bottom
work rolls. It also performs Spindle spotting, Load balance & Impact load compensation.
Main motor drives backbone is IEGT(Insulated Enhanced Gate Transistor) based Active Front
End type drive with digital, regenerative converter- inverter units, suitable for Plate Mill
applications. For each motor there are two MV 7000 drives which supplies power to two different
windings present in the stator. Cooling of these devices is achieved by forced de-ionised water
circulation.
3. HAGC SYSTEM:
The force hydraulic cylinders are arranged in the lower section of the mill stand, one on the drive
side and one on the operator side. They are used to control the bottom backup rolls chocks
position and separating force (Hydraulic Gap Control), so that a desired WR gap can be adjusted
on the stand. Gap control is also carried out taking into consideration the screwdowns position.
For each force cylinder there is one servo valve for normal operations and two back up servo
valves. Two vent valves are installed, one for each cylinder to enable fast vent in case of any
abnormality in the mill. A high-resolution position transducer known as Magna-scale measures
the piston position.
The main configurations of the system are:
Automatic positioning of the bottom work roll at pass line,
Uniform gauge control across the rolled length,
Pass to pass correction to achieve uniform thickness based on the width gauge feedback,
Automatic force cylinder lowering to “down” position for rolls changing,
Control for PVR (Plan View Rolling),
Emergency opening (HAGC cylinder to vent and servovalves locked)
4. WORK ROLL BENDING:
It consists of a set of hydraulic cylinders that exert bending
forces on the WR chocks in the direction to separate them.
The work rolls are bent against the backup rolls. Four
cylinders are working on each work roll chock: two at the
mill entry side and the other two (located on another block)
at the exit side.
So in total there are 8 cylinders each for Top & bottom Work
Roll.
Positive bending is essentially used to:
Lower and lift the work roll during roll changing.
Maintain the work roll in contact with the backup roll during rolling and therefore apply a
balancing pressure between WR and BUR.
5. OXIDE BLOWING:
Oxide blowing sprays located at both
sides of the stand, are used to prevent
fluctuation of dust scales in proximity of
the roll bite. On/off timing of these valves
is monitored with the help of tracking to
avoid plate head end cooling and also
considering the pass number and rolling
direction.
6. MILL LEVEL-1 SYSTEM:
Mill Level consists of six level- 1 VME based controllers which are equipped with real time
operating system for very fast time based scanning. Their primary functions are:
Material tracking: to follow the material through the future roughing mill zone and finishing
mill zone up to cooling bed entry. Tracking holds the material ID, the piece head and tail
positions and thus the piece length.
In case of Level 2 fault the operator is able to modify some parameters on the last received
setup by HMI.
Control the process requirement & check interlocks for all the equipment.
Multi-Piece Thermo-Mechanical Rolling: It consists of two distinctive rolling stages. In the first
stage i.e. roughing stage, the objective is to reach a certain predefined target thickness,
typically between 2 and 4 times a final target thickness. The characteristic feature of controlled
rolling is a holding stage between first and second rolling stages.
The second stage starts when the metal cools down to a prescribed temperature. The holding
stage end temperature is also known as the resume temperature when the second rolling stage
begins. The second stage of rolling concludes at the target
thickness and temperature.
Accelerated Cooling: The cooling rate and the final cooling
temperature is controlled in order to achieve the required
metallurgical and mechanical proprieties of the plate. The
spray pattern is calculated by a computer model.
Hot Plate Leveling:
Maximum leveling force: 33000 KN
No. of force cylinders: 4 servo-hydraulic cylinders
Leveling speed: 1.0 / 2.0 m/s
Number of rolls: 4 in Top & 5 in Bottom
Bending Cylinder pressure: 315 bar
Cooling Bed: There are two numbers of Cooling Beds. Cb-1 is
Walking Beam type while CB-2 is Disc type. The residence
time of plate on the cooling bed shall be calculated on the
basis of plate material, dimensions and entry/exit temperature.
7. LEVEL-2 FUNCTIONS:
Level -2 system consists of Application server & Database servers. Database server uses a
relational database to store steel grades & process rules. Application server consists of various
mathematical models which perform following tasks:-
1. Setup and Adaptation
2. Piece Thermal Model
3. Roll Profile Model
4. Flatness & Profile Model
5. Accelerated Cooling Model
6. Plan View Rolling(PVR)
7. Event Log & Archiving
8. Engineering & Stoppages Reports
Finishing Line:
Primary Inspection Bed(PIB) : The inspection bed is
equipped with chain conveyor mechanism which also
covers entry and exit roller tables. One key feature of the
Plate Inspection Bed is the Plate turner device, that turns
the entire plate to check for any defect at the bottom and
can accommodate upto 42 meters long Mother plates.
Online Ultrasonic Machine: This machine has online ultrasonic testing facility of Plate
surface & edges. This machine adheres to all stringent domestic as well as international
standards and can test plates upto 50 mm thickness.
Plate Shape Gauge is also there after PIB to optimise the shearing line with the required Plate
product and for quality reports and data logging.
Double side trimming shear(DSTS): This machine
is meant for side trimming of the plates upto a
thickness of 50mm. The cutting line lasers are
arranged in front of the trimming shear to show the
operator the cutting line over the total plate length.
The laser lines are synchronised with the width of
shear. With the magnet shifter the operator can align
manually the plate with the help of the cutting line
lasers in order to trim both plate sides over the total
length. The knife gap for the trimming knives is
automatically set according to the plate thickness. Each shear is driven by two motors and
synchronized electrically. Two pairs of pinch rolls are there to facilitate stepwise transport of the
plate & accurate guiding. Each pinch roll is driven by a motor.
Dividing Shear: It can cut plates upto 50 mm which is
highest in India. Cross cutting of mother plates is done for
cutting of head end, tail end & dividing of the mother plate into
daughter plates as per the length requirement. The pinch roll
units are located ahead the shear. A hold down device is
mounted to the shear proper at its entry side to prevent any plate movements during the cut. The
knife gap of the cross cut shear is adjusted in order to achieve an optimum cutting result at the
plate.
Dividing Shear depressing table is arranged in the housing of the dividing shear to guide the
plates securely through the shear and it is located directly downstream of the knife. The table is
designed as a short and movable frame that carries seven table rollers. Its front end is movable
(up – down) and its rear end contains the pivot point.
The knife changing system is also there for simplified removal, transport and insert of the knife
cartridges at the dividing shear. Knife change is required after approximately 10,000 cuts.
Marking Machine: The online marking machine installed in this
Mill is one of its kinds in India as it marks, paints, punches and
does the edge machining with bar coding. Bar coding comes handy
for both RSP as well as the customers to identify the plates easily.
Piler: There are two numbers of Magnetic piler cranes used for
piling of the plates ensuring that the plate surface does not get any
scratch during the piling and stocking.
Cold Leveller: Hot rolling plates can have flatness defects of different kinds such as edge or
centre waves, through-waves or skiing. This machine is has
its own Level-2 control system and can be used for
online/offline leveling of the plates. Cold Plate Leveller has
an incredible capacity to correct any deviation in the flatness
of the plates of thickness between 6 mm to 50 mm.
Final Inspection Bed: It is the last equipment in the entire
mill. This bed can used for final inspection of plates, for this
purpose a Plate Turnover device is provided to check
possibility of a defect and same can be rectified offline.
The ready for despatch plates are then loaded in the wagons in the Shipping section and sent to
various destinations across the country.
It is not only the technology that puts the New Plate Mill of RSP many notches above the other Mills
of the country; it is also its exclusive and extensive product basket that makes it unique.
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.
PRDODUCTRANGE:
DIAMETER (Outside Diameter): 8 5/8”, 10 ¾”, 12 ¾”, 14”, 16”, & 18” OD
WALL THICKNESS: 3.2 to 12.7 mm
GRADE: API 5L GR-A, GR-B and up to X-70 PSL 1 & 2 IS 3589 grade Fe 330, 410 & 450
INPUT MATERIAL:
The orders from different customers are conveyed to the ERW pipe plant through PPC department.
After the campaign size is decided PPC plan for the required steel and subsequently gets rolled at
HSM.
Specification of HR Coils:
Width – 693 to 1550 mm, Coil weight - 15T max, Thickness - 3.2 to 12.7 mm,
Coil ID - 760 mm, Coil OD – 1100 to 1800 mm max.
All the processes are PLC controlled and all the entries,
information’s are logged and shared at the computers through
level-II automation system available at every work stations.
All the drives are powered by AC motor with VVVF control.
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
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.
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.
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 beadjusted 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
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.
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 250Kg/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 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.
H R Coil
Through Coil Saddle Coil Car, Uncoiler
Leveler and Edge Milling Machine
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.
In the pipe-forming device the coil is formed to a pipe according to the principle of multi roller
levelling. The coil edges running together with the pipe forming device are first welded inside and
then outside by Submerged Arc Welding Process.
A travelling Oxy-acetylene torch cuts off the pipes to required length, as per customer requirement.
Pipes are tested in accordance with specifications of the standard / customer.
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.
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 despatch.
Coil
Preparation
Stand
Forming
Cage
Outside
Repair X-Ray Grinding Welding
Welding Station Station (Skelp Joint)
Electronic
Final Works
Despatch WeighBrid Inspection Inspection
ge
1.1 SWPP produces Spiral Weld Pipes from 16” dia to 64” dia. Hot rolled coils are formed in to
pipes in the forming cages of M 2.1 & M 2.2 m/cs. Automatic dc submerged arc welding is done
at inside of the pipe first which is followed by outside welding. Outside welding is to be done
exactly in the same inside weld joint.
Laser Seam tracking system tracks inside weld seam & adjusts the outside weld head so that
outside welding is done exactly on inside weld joint. The laser camera is mounted at the outside
weld head such that laser light is focused sharply at 90 ° to the inside weld joint. The vision
camera continuously detects the “V” joint & sends digital signal to the controller. The
controller processes the signal & adjusts the outside weld head such that the welding torch
continuously follows the inside weld joint.
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.
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 selecting
tracking parameters is 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.
3.2 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.
Rourkela Steel Plant (RSP), SAIL, has recently set up a 3LPE Pipe Coating Plant for applying
coatings on external surface of the pipes. The products of the 3LPE Pipe Coating Plant shall be
supplied to the oil and hydrocarbon sector and shall meet all the requirements as per the DIN 30670
Specification.
The plant has been setup with Tech-know how from M/s Socotherm SpA, Italy. The Plant is in
adherence with the Pollution Control Norms as per European Standards.
CORROSION PREVENTION
The principal methods for corrosion prevention on underground pipelines are coatings and cathodic
protection.
Coatings are intended to form a continuous film of an electrical insulating material over the
metallic surface to be protected. The function of such a coating is to isolate the metal from direct
contact with the electrolyte, interposing a high electrical resistance so that Electrochemical
reactions cannot occur.
Cathodic Protection (CP) is a technique to reduce the corrosion rate of a metal surface by
making it the cathode of an electrochemical cell. This is realized by shifting the potential of the
metal in the negative direction by use of an external power source. For CP to work, current must
be discharged from an earth connection called a ground bed. In the process of discharging the
current in a sacrificial system, the anodes in the ground bed are consumed by corrosion
Three Layer
Three-layer polyethylene coatings were introduced about 1980 in Europe. They consist of:
• FBE primary coating
• Polyolefin-adhesive (or tie) layer
• Polyolefin topcoat
1. Layer 1: Immediately after abrasive blast cleaning the layer shall be formed by a film of liquid
epoxy or resin of powder. The minimum dry thickness shall be between 20 and 60 microns checked
in accordance with method 5 of ISO 2808 depending on the primer used. The thickness may be
subject to agreement by the customer, and to conform manufacturer’s recommendations.
2. Layer 2: A polymer intended to provide adhesion between first and third layers and be
compatible with those layers shall form this layer. The minimum thickness shall be between 140 and
200 microns depending on the type of adhesive and the application. The thickness may be subject to
agreement by the customer, and conform to manufacturers recommendations.
3. Layer 3: Polyethylene coating shall form this layer. The thickness shall be uniform and the
minimum total thickness shall satisfy the requirements of DIN 30670 or as per the customer
requirement. This layer gives the mechanical protection to the 1st layer and is also corrosion
resistant to some extent.
Special Plate Plant (SPP) is a valued unit of Rourkela Steel plant. SPP was set up in 1969 to cater
the needs of country’s defense and research programs. It’s the only unit of its kind in thenation. SPP
is pioneer in the field of special steel plates; with a diverse product profile thatranges from various
grades of heat treated armour plates of high hardness and strength to deadannealed plates of high
resilience and ductility. SPP is ISO 9001 QMS, ISO 14001 EMS, OHSAS 18001,SA 8000
certifications accredited.
With stringent quality control measures enforced at every stage of manufacturing process along
with continuous R& D efforts ,SPP symbolizes the quest for superior products and technology to
fulfillthe needs of Defence.SPP products are used in various high end applications e.g. T-90 tanks,
MBT Arjun tanks, Infantry Combat Vehicles, War Ship-building, Mines protected vehicle, atomic
research etc. SPP takes pride in meeting the stringent Quality control norms of defense agencies
(CQA (MET), OF CELL, DQAE (N)).
GRADES APPLICATIONS
Spade Armour Plates Main Battle Tanks & Armoured Vehicles
Jackal Armour Plates Infantry Combat Vehicles
DMR 249 A Surface Warships & Aircraft Carriers
DMR 249 B
SAILRATH Gun Carriage Applications
SAILARM Testing of strength of Ammunition
FACILITIES AVAILABLE:
Hardening Furnace with Oil/Water Quenching System.
Tempering Furnace.
Boggie Hearth Batch Annealing Furnace.
Boggie Hearth Furnace for Heat Treatment & Water Quenching of Naval Grade Plates.
Digital Hardness Testing Machine.
Hydraulic Plate Straightening Machine
Shot Blasting Machine.
CNC Profile Cutting Machine
Fracture Testing Machine.
Austenising & Tempering Furnace with Online Water Quenching Facility(New)
NOTE:
Soft Annealing not done for DMR 249A, DMR 249B & SAILRATH Grade Plates
PTP-Physical Test Piece
BTP-Ballistic Test Piece
ASP-Alloy Steel Plant
BSP-Bhilai Steel Plant
BSL-Bokaro Steel Ltd.
Alloy steel for making armour Grade plates are produced at ASP, Durgapur. DMR 249 A & DMR 249
B grade steel is produced at BSP, Bhilai & ASP, Durgapur respectively. Slabs are rolled at Plate mill
(Old & New) of RSP. Input material for SPP is plates rolled at Plate mills of RSP. The above flow
chart illustrates material flow of armour plates.
Heat treatment is the most vital operation among all. The objective of heat treatment is to impart
desired mechanical properties (Hardness, YS, UTS, %Elongation etc.) to metal by various
meticulously chosen heating and cooling schedules. It consists of following operations.
HARDENING (AUSTENISING)
Hardening comprises of heating the plates to desired temperature, soaking for specific duration
depending upon the thickness of plate and then rapid cooling (quenching) in oil/water. It transforms
microstructure of steel to Martensite.
Generally for Plates thickness upto 70mm Oil is used as a quenching media. For Plates thickness 80
mm and above Water is used. For all DMR grade plates Water is used.
TEMPERING
Steel in as hardened condition is highly brittle and requires further treatment so that 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, below critical
temperature, (which depends on thickness and required hardness) and for a fixed time and slow
cooling.
The hardness and strength obtained depend upon the temperature at which tempering is carried out.
Higher temperatures will result into high ductility, but low strength and hardness. Low tempering
temperatures will produce low ductility, but high strength and hardness.(Explained in the figure
below).
In practice, appropriate tempering temperatures are selected that will produce the desired level of
hardness and strength.
It’s used for processing armour grade plates (Spade & Jackal). There are two different furnacesfor
hardening and tempering.
Hardening Furnace:-
Its capacity is 9 meters in length and 2 meters in width. This furnace uses mixed gas as fuel.There
are two zones in the furnace; each zone has different control valves for air and fuel.
Maximum size of plate is 2 m X 6.5 m with max. wt. of 3.2 T
Tempering Furnace:-
Tempering furnace comprises of four zones; 1 and 2 are heating zones, and zone 3 and 4 aresoaking
zones. Total length of the furnace is 16 meters and width is 2 meters.
AHTL has state of the art online heat treatment facilities with following salient features:
Austenizing Furnace (Operating Temp. Up to 950 °C) having self-recuperative radiant
tube burners with hydraulic soft load & plate centering device. The furnace is having
inert atmosphere.
• Online water jet spray cooling system with quench press for superior flatness of plates.
• Tempering Furnace(Operating Temperature250 to 710 °C)
• Auxiliaries-Scale conveyor, settling tanks & pump house, cooling towers &zero discharge
of waste water treatment system. Water is recycled in the system after passing through
the scale filter. The total line is fully automated with PLC Control.
• Plate Size: 6-100mm (T) X 1250-3000mm (W) X 6000-13000mm (L)&Plate Weight (Max):
10 Ton.
• Grades: Spade, Jackal, DMR-249A/B, Hardox, ASTM 517 Gr. ’F’, ASTM -537 CL-II
etc.
Facilities for hardness testing and fracture test are in SPP, while Tensile, Charpy
and microstructure tests are carried out at RCL test house.
APPLICATIONS OF PRODUCTS
Indigenous air craft carrier INS-VIKRANT made with DMR-249A/B steel supplied by SPP.
Special grade of steel DMR-301 is presently being developed for use in Submarines.
Heat Treatment of 15CDV6 grade plates used in AGNI missile.
Development of 150 mm thick RHA plates (SAILARM) for Ordnance Factory, Khamaria for
testing the strength of Ammunitions.
MATERIAL FLOW
ULTRASONIC TESTING
SURFACE &THICKNESS
INSPECTION PAINTING STAMPING DESPATCH
Cold Rolling Mill is one of the complex units of RSP, producing bulk amounts of quality finished
steel. Purpose of cold reduction is to achieve the following:
(i) A reduction in the thickness of the final product.
(ii) A designed surface finish.
(iii) Desirable mechanical properties.
(iv) Close dimensional tolerance.
(v) Producing as per customer requirements.
The input to Cold Rolling Mills is the Hot Rolled Coils (HR Coils).
HR Coils
PL-2 PL-1
CAL HAL
SP-1 SP-3
ETL SSL-2
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.
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:
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, bymaking 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:
a) Four-high reversing mill (CR-1)
b) 5 stand tandem mill(TM)
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.
Heating Zone / Cooling Zone: In the annealing process, the temperature of annealing can be
as high as 800oC. Different annealing cycles are followed for different grade & thickness. After
annealing, the coils are given a further light tolling in a single or two strand mill, operated
without strip lubrication. This operation is called as skin passing or temper rolling.
Continuous Annealing:
In Continuous Annealing Process Coils are annealed and the cooled in controlled atmosphere
continuously. This is a much faster process compared to Hood annealing Process.
Skin Passing:
Skin passing is a cold reduction method and the steel surface or skin is hardened by cold working,
keeping the steel core soft & ductile. In Cold Rolling Mills of RSP, one single stand 4-high mills and
one twin stand 4-high mill have been installed.
At RSP we have 2 Skin Pass Mills with the following Technical Data.
Parameters SP I SP III
Rated Capacity 2,70,000T/yr 3,60,000 T/yr
Type of Mill 1700mm, Single Stand, 4 Two Stand 4 High
High
Strip Width 630-1550 mm 560-1040mm
Strip thickness 0.35 to 1.3mm 0.15 to 0.31mm
Speed 500m/min 1200 m/min
Work Roll Size 460 X 1700 mm 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 despatched to stock yards or Customers as CR coils.
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.
The Ferrous Sulphate salts from regeneration plant are used for water treatment at Tarkera
Water works. Also some quantity of these are sold to outside parties and find use in making
paints and in pharmaceutical applications.
Coating Units:
RSP’s family of coated steel sheet products includes both hot-dipped and electrolytically-
applied coatings. The protective coatings add superior corrosion resistance to the many 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.
The Entry section has two Coilers, a Double cut Crop Shear, a Welding Machine, Briddle -I,
Vertical Loopers & Briddle-II.
The Processing section has Electrolytic Cleaning Unit, Alkali Rinse Unit, Electrolytic Pickling
Unit with rinsing facility, Electroplating Unit, Hot air Drier, Melting Tower, Quenching Tank,
Chemical Treatment unit, Rinsing Unit, Hot air drier & Electrostatic strip oiler.
The electrolyte used in Plating section consists of i) Stannous sulphate, ii) Phenol Sulphonic Acid and
additive as Ethoxylated Alpha Naphthal Sulphonic Acid(ENSA). Delivery Section consists of Briddle
III & two up-coilers 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.
These lines can produce Galvanised plain, Galvanised Corruagetd as well as galvanized coils.
The material flow for Galvanising Lines is as follows:
Uncoiler Pinch Roll Double cut Hydraulic Shear Pinch Roll Loop Car1 Pinch Roll 5
Oxidizing Furnace Reducing Furnace Pit type Galvanising pot Air jet knife Deflector Roll
Cooling boxes Passivation Unit Loop car 2 Halden Shear Sheet piler Galvanised
Technical Details:
Continuous Galvanising Line Two nos.
Width of Sheet 610mm – 1220 mm
Thickness of Sheet 0.31mm – 1.60mm
Capacity 1,60,000 T/Yr
(80,000 T for each line)
Maximum speed 90m/min
Application:
Shipping Section:
All Cold Rolled products like CR Coils/Sheets are packed, weighed and
despatched through Road or Rail Wagons. ETP & GP/GC packets are
packed in the line itself. Weighment and loading is done in Shipping
Section.
Silicon Steel Mill is ISO –9001 & ISO –14001 Unit. The
CRNO stream has been awarded ISO - 9001, the International Quality Assurance System, certified
by M/s RWTUV, Germany in September 1996. And ISO –14001 Environmental Management System,
certified by M/s BIS, India in October 2000.
Meeting international standards with respect to magnetic properties, insulation coating properties,
insulation resistivity, dimensional tolerance & lamination factor is the credo at Silicon Steel Mill.
Various facilities have been added with a view to keep pace with the latest technology. The notable
features are external desulphurisation of hot metal, high purity steel making, vacuum degassing,
continuous casting,highly accurate hot rolling mill & Cold Rolling Mill complex incorporating the
most advanced technology for manufacturing CRNO steel strips. The unit has a modern Magnetic
Testing Laboratory, which is one of its kinds in the country.
FLOW SHEET
SLITTER
CUT TO LENGTH
PACKING
DISPATCH
MAIN UNITS:
Line Features:
1. Hydrochloric acid pickling (HCL) 5 tanks for pickling.
2. Acid conc. 8 To 12 %. Salt conc. 12 % max.
3. Acid bath temp. 70 + / - 3 o c
4. Taylor - Winfield shifting head seam welding m/c
5. Line speed 10-35 mpm ( Entry-90 / Process 60 / Exit 90 mpm)
6. Tension - Entry 0.35 to 1.05 Kg/mm2
Furnace - 0.35 to 1.05 Kg/mm2
Pickling - 1.05 Kg/mm2
Exit - 2.5 Kg/ mm 2
7. Pickling Tanks - 5 (L - 25. 7 m, W - 2.13 m, Depth - 1.207 m)
Capacity - 36,000 Lts each (1 to 3) 4A - 16800,4B-19600 lts.
8. Cascade rinse unit 3 compartments.
9. Hot water washing
10. Hot air Dryer
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. Rockwell Control Logix PLC
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.
Electrics:
P.O.R. – 300 KW, 1200 rpm CONT.
E.T.R. - 1125 KW 800 rpm
MILL STAND - 2 X 1687 KW 670 rpm
D.T.R. - 1125 KW 800 rpm
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
Line Features:
1. Scrubber unit.
2. Elec. F/C, Length 153 mts., decarburizing zones 1 to 9 temp. 840 +/ - 10 o C
Annealing zones 10 to 12temp. 1000 o C 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 600 oC.
Line speed – 8 to 40 mpm
Input –0.30 to 0.70 mm
I.D. 510 mm / O.D. 1650 mm
Line Ten Entry – 0.35 Kg/ mm²
Process – 0.25 to 0.55 Kg / mm², Exit 4.5 Kg / mm²
DECARB ANNEALING:
Supplier: EPI / ELEC. FURNACE CO. Elec. BHEL, PLC: Rockwell Control Logix
This line is used for decarburizing annealing & C-3 (Organic) & C-6 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 tension-meter
4. Elec. F/C
Length 153 mts., decarburizing zones 1 to 8 temp. 840 + / - 20 oC, Annealing zones 9 to 11 temp.
1000 oC 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 450 oC.
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/mm 2
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
Electrical Drive- Parker Digital Drive
PLC : Siemens S7 300
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
Line Features:
Coil Weight - 15 MT
Coil OD - 1700 mm
Coil ID - 432 to 510 mm
Width - 600 to 1150 mm
Line speed - 60 mpm
Gauge - 0.27 to 0.70 mm
Exit Sheets - Width- 580 to 1150 mm
Length - 900 to 4000 mm
Pack Ht. - 600 mm
Pack Wt. - 15 MT
FACILITIES INSTALLED:
1 Magnetic test console MPG C500, Brockhaus Nesstechnik
2 Fischer Coating thickness gauge
3 Franklin resistivity tester.
4 Sample shear.
Cold Rolled Non-Oriented (CRNO), the energy efficient steel, is an essential raw material, recognized
the world over for manufacturing electrical equipments like generators, motors, relays, small
transformers etc. Used primarily in special rotating & static electrical equipments, the CRNO steel is
characterized by low watt loss (core loss) & high permeability.
ROLL SHOP
Roll Shop caters to the requirement of Ready Roll Assemblies to all customer mills namely PM, HSM,
CRM, SSM & New Plate Mill as per schedule. Accordingly, for smooth feeding of Roll chock
assemblies to all these units four shops are located at four different locations known as Roll Shop-I,
II, III & IV. Other than turning & grinding of rolls, Roll Shop performs various other functions
asdetailed 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 and chock tilter & chock
extractor equipments.
Record keeping of rolls & bearings through SAP based 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 came into existence with commissioning of New Plate Mill in the year 2014. Following
equipments are installed in Roll Shop-IV located in New Plate Mill complex:
a) Maschinenfabrik Herkules make Combination-CNC Roll grinding machine for grinding of work
Rolls, Back-up rolls & leveller rolls of New Plate Mill.
b) Gustav Göckel Maschinenfabrik make CNC-Knife grinding machine for grinding of shear
knives.
c) Chock tilting unit & Chock extractor unit.
Roll Shop - V:
Order for new 3 MTPA HSM is being executed now. A new Roll Shop will come in new HSM
complex. The following equipments will be installed at Roll Shop-V.
MAINTENANCE FUNCTION
The maintenance system of at RSP has been designed and implemented by Mr. K.H. Kohrn, a
German expert, way back in early seventies. Though Kohrn’s system vouched for a centralized
system of maintenance for various production units of the integrated steel plant, with pressing needs,
RSP switched over to decentralized system in 1991. By this, maintenance management is now
responsibility of Head of the different production units. This switch over, and also timely
computerization of the maintenance information system, however has not jeopardized the core
Kohrn’s system design. The decentralized system also enjoys many centralized services, which have
been described in following paragraphs.
CENTRALIZED SERVICES
The centralized services can be categorized as Mechanical and Electrical, each one being headed by
separate General Managers. The mechanical services are –
Apart from the above maintenance services, utility service of Compressed Air is also under
G.M.(Mechanical).
Group Function
Planning group Material planning, Job cataloguing, Job planning, B/D
& delay analysis etc.
Inspection group Inspection of machineries by schedule and defect
recording.
Repair maintenance group B/D maintenance / Shut down maintenance jobs.
Preventive maintenance Lubrication, adjustments, cleaning etc.
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.
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.
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.
The total maintenance job requirement of different machines is first chalked out from PM
recommendations from the supplier or from experienced personnel. They are categories as time based
jobs and condition based jobs. Out of the time based jobs, on daily basis, inspection, lubrication,
adjustments etc. jobs (PM7) are carried out as per schedule in each department on regular basis. For
other time based jobs like, periodic over hauls, checking and to take up defect based repair or
replacement jobs, shutdowns are planned in advanced. In fact, shutdowns affecting production (PM
1) and not affecting production (PM 4) are separately planned on monthly basis before the start of the
month and consent of the operation head is taken. Before the start of the actual shutdown, time
based and condition based jobs are planned in a job list (PM 3). Actual execution detail of each job is
recorded in job history format (PM10). A compliance report is made for each department on plan
fulfillment on monthly basis (PM 9). While in mill side shutdown planning is a feature for the whole
mill (usually weekly), in the iron and steel side, separate shutdowns are taken for different
equipment/systems at required frequencies in a staggered manner.
Apart from regular inspection and shutdown jobs capital/ major repair is also carried out in all units
of the plant based on the condition and life cycle of the equipment. For better spare part and capital
item planning, a three year rolling plan ( PM1a) is made, which is updated every year with a detail
plan (PM1b) for the current year. Capital repair plan is prepared after discussion and approval from
Head of works. Just before execution, a PERT/ BAR chart scheduling (PM1c) 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 (PM10) with details of
maintenance jobs.
Breakdowns are encountered in emergency basis, particularly when it affects production. Each
breakdown is also recorded (W1b) 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.
2. Preventive Maintenance & Repair Planning: This module is the heart of CMMS. It
comprises of the following sub module which are self explanatory.
a. Job cataloguing
b. Inspection Schedule and feedback
c. Defect recording
d. Shutdown planning and feedback.
e. History monitoring
f. Breakdown/delay recording and analysis
g. Capital repair planning
3. Captive Engineering Shops Module: This module handles the following activities which
concerns with job planning for the machines in the captive engineering shop. They are-
a. Work order forecasting & planning.
b. Process planning of jobs & route card generation.
c. Rolling Master plan for different shops.
d. Machines database maintenance.
e. Shop scheduling.
f. Feedback and MIS system.
4. Material Requirement Planning: This module in fact is a part of the bigger computerized
system namely, Integrated Material Management System or IMMS. IMMS covers both
material planning function of Maintenance wing and Purchase/Store function of Materials
management department. Most of the activities in IMMS are at present, electronically done to
reduce paper work and lead time. The activities of maintenance wing of different department
that are computerized are –
a. Annual requirement planning and budget preparation
b. Budgeting and budgetary control
c. Indenting & recommendation on suppliers.
About 50 terminals have been provided in planning cells of different departments to carry out data
feeding and data retrieval. The output reports are printed at users’ terminal as and when required.
The computer reports are also titled as per Kohrn’s system to avoid confusion to users.
Vibration monitoring: Data collector and analyzers (FAST TRACK and DATAPAC1500 from
Entek IRD) are used by CBMS to collect data from about 475 rotating machines around the plant on
regular basis. The analysis report is sent to departments with recommendation on action to be taken
up. For problem of unbalance, this causes vibration in particularly fans and impellers; CBMS also
takes up In-situ balancing job. RSP is first to start and is pioneer in vibration analysis and In-situ
balancing job in SAIL plants. This expertise can also be shared with other plants with suitable
arrangement.
Thermography: Condition monitoring of electrical cables, vessel & ladles walls, pipelines is done by
thermal imaging method by use of a thermo-vision camera. At present, Power distribution and
Energy Management department are adopting this method for condition monitoring of high tension
lines and pipelines respectively.
Oil Analysis: Samples of lubricating oils are collected by CBMS/LUHP department from critical
machines like gear boxes etc. These samples are analyzed for concentration of ferrous particle in oil
sample by DR Ferrography method. The analysis reports are made from their finding and
communicated to department. The concentration of metallic particles shows the extent of wear in the
equipment and that calls for timely action before a breakdown.
Motor Monitoring: This activity monitors the condition of rotor bars in electrical motors. RSP
initially started this project with RDCIS. At present it is being done on few important motors using
the equipment available in CBMS department. Plan for large scale motor monitoring throughout the
plant is on the anvil.
MAINTENANCE
JOB CATALOGUE
PREVENTIVE CORRECTIVE
MAINT. JOBS MAINT. JOBS
Daily BREAKDOWN
W1b RECORDING
LUBN.,O/H,
INSPECTION JOBS
SERVICEING JOBS PM8
INSPN. PIE
PLAN INSPN.&
SCHEDULE CHART
FULFILMENT DEFECT
HISTORY RECORDING
REPORT PM10
PM9
ROOT CAUSE
DEFECT BASED ANALYSIS &
JOB LISTING INDENTIFY
JOB EXECUTION
& HISTORY JOBS TO AVOID
RECORDING REOCCURENCE
Maintenance Systems & Services Department (MSS) was formed in 2000 by merging following six
departments:
1. Lubrication (Organization Planning) - LU(OP)
2. Hydraulics & Pneumatics (Organization Planning) - HP(OP)
3. Computerized Maintenance Management Systems - CMMS
4. Condition Based Maintenance Systems - CBMS
5. Maintenance Planning (Organization Planning) - MP(OP)
6. Investigation & Evaluation - IE(OP)
Accordingly all the functions of the old departments are being carried out by MSS department. The
major areas with activities in each section are discussed below:
Lubrication:
Provide assistance to the Materials Management Department in procurement of lubricants with
respect to technical specifications.
Monitor & review the quota of lubricants of various departments w.r.t. past consumption & Task
force recommendations.
Monitor the stock of lubricating & hydraulic oil by keeping liaison with oil godown of Central
Stores, Stock Control & Purchase to avoid stock out situations.
Collect oil samples of various lubrication systems of departments as per sampling schedule.
Samples are sent to R&C lab for testing and reports are communicated to respective departments
for remedial action in time.
Monitoring of wear trend in critical equipment through Ferrography by sending samples to
RDCIS, Ranchi periodically.
Coordinate projects by different external agencies like RDCIS on lubrication systems.
Bearings:
Providing technical guidance for substitution of bearings to different plant unit as per
requirement.
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.
Presently, 5 numbers of CPT make compressors are being replaced by 2 Nos. of Centrifugal
Compressors of 15,000 m3/hr capacity (Atlas Copco make) under AMR scheme. It is being installed at
Modernisation zone. The compressors are expected to be operational by Dec’09.
The Customers of Central Compressor Station are SMS-II, CO, BF, CCD, MS-I, CPP-I, LDBP, Shops,
TOP-I, RS(E), SPP, PM, HSM, CRM and SSM.
Oil 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.
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.
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.
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.
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
Engineering Shops planning and scheduling ; Process Planning, Forecasting, Master
planning, Rout card preparation, Shop scheduling, Feedback, Status monitoring
Material Requirement Planning: Prepares indents, budgets, tracks requirement.
Benefits:
Better equipment availability due to reduction in breakdown and sustained health of equipment.
Cost effective maintenance.
Reduction in lead time in procurement.
Maintaining history of equipment and procurement and retention of expert knowledge.
Scientific planning of jobs, decision support and reduction in routine job efforts.
Consumption and Expenditure Control:
This section has the following functions:
a. Projection of ‘Stores & Spares’ (Spares, Consumables, Rolls, Refractory and Internal
consumption) and ‘Repair & Maintenance’ ( Repair contract and Job contract) revenue budget
requirement for coming financial year based on discussion with each department, APP targets
and market situation.
b. Distribution of approved budgets in above categories to each department/sections based on
need and budget availability by feeding the same in IMMS.
c. Management of budget re-appropriation between departments/sections/months based on
approval.
d. Management of allotment of ED(W) reserve fund in above budget heads to departments in
case to case basis based on urgency.
e. Monitoring of consumption and procurement budget utilization and inventory.
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.
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 equipment& 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
Finalization of Capital Repair jobs in consultation with different Customers & Engineering 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 (O5).
Allocation of the above Work Order to Planner.
Process planning of jobs indicating details like place of execution, raw materials required, weight
of the job, sequence of operations indicating work center, sequence and process along with
catalogue number, drawing number etc.
Estimation of time as per approved Norms for each operation
Preparation of Cost Tickets as per the estimated time.
Inspection:
Inspection of job on completion of different stages of operation
Inspection of job on completion in shop complex / local SSI units
Inspection of job at shop floor of different plant units as per requirement
Preparation of quality report acceptance of inspected jobs in shops.
Off-loading Cell:
Placement of orders on local SSI units against indented quantities cleared for "BUY through
PCS"
Co-ordination with Engineering Shops & Indenting Customers for issue of raw material to local
SSI units against the PC (S) orders
Follow-up with local SSI units for delivery of jobs as per schedule
Processing of Bills for payment.
SHOPS-FOUNDRIES
The primary activity of this department is to make castings of spares used in various units of the
plant. Some of the products manufactured at foundry are as follows:
a) Ferrous castings like door frame, flash plate, wharf plate, sinter breakers, grate bars, hammer
heads etc.
b) Slag pots required by BF & SMS-II.
c) Steel, cast iron and non-ferrous castings of other spares needed by the plant.
d) Salvaging of copper coils from rejected electrical cables & fittings and converting them in to
ingots.
e) Conversion of Al ingots into nuggets for SMS.
f) Making of ternary alloys of zinc, aluminum and lead for use in galvanizing line of CRM.
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 3MT capacity.
(c) One EOT crane with a SWL of 25MT.
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.
i) Welding Shop
ii) Rolling Stock
iii) Structural Shop
i) Welding Shop:
This is basically a reconditioning unit where worn out steel plant equipment/ spares are built up
by welding through conventional and modern welding machines like Metal Inert Gas (MIG)/
Metal Active Gas (MAG) & Submerged Arc Welding(SAW). A selected typical application jobs are
also manufactured here.
The details of these machines are as follows:
Fabrication of Impeller fans, Zn Pot, Hood Annealing Inner Cover, Hammer head etc. and
reconditioning Jobs like Hot Sinter Screen, Wobblers, Adaptors for Mills, BLT-chute, , CC Roll,
Caster roll, Breast roll, TT roll etc. are done in Welding Shop. 90% of plant’s repair welding jobs are
also done.
2) Hydraulic Press:
(Capacity: 600 Tons)
Repair & Construction (Mechanical) [RC(M)] was established in the sixties in RSP, known by the
name Heavy Maintenance and Construction and was later on christened Repair& Construction
(Mechanical) – RC (M). It takes part in the weekly shutdown programmes, capital repairs and
breakdown restoration besides fabrication and erection of equipment or facilities depending on
resources available throughout the plant.
The services are rendered through a number of zones set up at different locations of the plant and
each zone has developed expertise in the respective zonal jobs. All the zones have the flexibility to
take up any job of other zones in the plant. Specialised jobs/activities are being carried out through
its six special sections .The zones/sections are:
6. SSM SSM
1. Joint inspection of 950 nos of total 180km
long Fabric/Steel Cord conveyor beltings in
RSP
2. Repair/replacement of fabric conveyor belts
by hot/cold splicing
3. Repair/Replacement/Splice monitoring of 02
nos of Steel Cord Pipe Conveyor belts each
7. Vulcanising Section having length of 2.1km.
4. Repair/replacement/Splice monitoring Steel
cord type Main Charging Belt in BF#5
having length of 1km
5. Ceramic /Rubber lagging of conveyor pulleys
6. Salvaging of used conveyor belts and reuse of
salvaged conveyor belts as a cost control
measure
1. Centralised repair of manually operated
portable Lifting tools like Chain Pulley
Block, Hub-zug & Ratchet Lever Hoist etc.
Mechanical 2. Testing and certification of every repaired
8.
Workshop tools through RS(M) in a frequency of six
months to meet statutory obligation
3. Temporary Issue of lifting tools to different
departments in RSP
RC(M) maintains flexibility among all the zones to increase productivity of workforce.
CRANE MAINTENANCE
EOT Cranes are the most vital material handling equipment in Steel Plant. Smooth and continuous
operation of all the units depends to a large extent on safe and efficient operation of these
equipments.
From raw materials to finished products the materials are required to be handled minimum 16-17
times at every stage, be it hot metal, slabs, coils, plates or pipes the handling has to be safe and
prompt. This handling is being done by EOT Cranes. The mechanical and structural maintenance of
these equipments is being done by Crane Maintenance department. Rourkela Steel Plant is the only
Plant in SAIL family where cranes are being maintained centrally. It not only saves maintenance
cost of crane but also results in less inventory maintenance. Total 241 EOT Cranes in different
production units of the plant are being maintained by the department.
The department is broadly divided into 4 sections viz 1) Iron & Steel Zone 2) Rolling Mill Zone 3)
Modernization Zone& New Plate Mill Zone. In Iron & Steel zone , the cranes of Blast Furnaces
including Old PCM, SMS-I, Sintering Plant-I,CPP-I, Foundries, LDBP, Coke Ovens, CCD & SSD are
being maintained. In Rolling Mill Zone maintains the cranes of Old Plate Mill, HSM, CRM, SSM,
SPP, Pipe Plants, & RS (E). In Modernization Zone, the cranes of SMS-II (i.e. BOF & CCM-II),
LRS-II and New PCM Crane & Blast Furnace -V Cranes are being maintained by the department.
Similarly in New Plate Mill Zone, cranes of New Plate Mill are being maintained.
Maintaining statutory records as per requirement of Inspector of Factories & Boilers, Government of
Odisha. Apart from the above 4 a zones, the department 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 of smaller sizes.
All Mobile Heavy equipments like Dozers, Pay loaders, Hydraulic Cranes, Crawler Cranes, Forklifts,
De-bricking machines, side loaders, Excavators including Trucks, Mini trucks, and tractors in
Rourkela Steel Plant are maintained by Field Machinery (Maintenance) Department. All These
mobile equipments are utilized by various production / service departments for their production,
operation, maintenance, housekeeping & erection /repair activities. Area of utilization of equipments
is wide spread in the whole Plant area. Due to this, FM (M) has different zones (Eight Nos.) to cater
to these areas.
Operational Activities:
1. SMS-I Zone: Operation of Pay-loaders and Dozers at SMS-I and Slag loading, attending
breakdowns at CO, BF, SMS-I related to Dozers and Pay-loaders.
2. Customer Care: 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,
Service Contracts:
TATA Trucks, Mini Trucks & Tippers, Ashok Leyland Tippers, Swaraj Mazda Mini-Trucks, JCB Pay-
loaders, TPS make Vacuum Loaders, Sewage cleaning machines, Road Sweeping Machines, Garbage
Compactors are cover under Service Contracts.
FM (M) is having 10 executives along with strong dedicated workforce of 213 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, Tundish Removal in CCM-I, maintenance of de-bricking machines during de-bricking of
converters which are one of the most critical activities in Steel making Process.
TRANSPORT
Transport department was formed to provide Transport services, as required for men and materials.
This department is a unit of Centralized Maintenance (Mechanical) department. This is an essential
service department which operates round the clock throughout the year.
The total transport service at present is reached to customers through two of its control rooms. The
major units of the department are as follows;
A) Central Pool
B) IGH Pool at IGH campus
C) Repair & maintenance centre at Central Pool
D) Registration Cell
E) Record keeping cell
F) Store & Fuel Dispensing Unit.
A) At present Transport department provides service with a fleet of 240 Nos. Light Motor
Vehicles. The department takes up repairs through departmental resources excepting for
reconditioning of vehicles as a whole. It issues fuel to all 650 Nos. of Vehicles & Earth Moving
Equipment of RSP, NSPCL, Raw Materials Division & Quality Assurance Estate (Metal).
B) Central Pool: - Central Pool located inside the plant premises to provide light motor vehicles
and buses to different user departments. It provides Transport facility to senior officials of
RSP by deploying chauffeur driven cars.
1. Vehicles to the Plant control.
2. Vehicles to Flood Control during monsoon.
3. Providing vehicles to valued customers of Transport Department include Central
Govt. & State Govt. staff, different plant units, Township, Sports, Social welfare,
Periphery development department, Dignitaries of SAIL, Various visitors &
inspectors. Transport services for ceremonial and various occasions of State and
National importance. Provides Ambulance Service to JNC OHS Centre at Plant
premises round the clock throughout the year. Provides Ambulance services at
Fertilizer Hospital round the clock throughout the year.
E) Registration Cell:-
Registration Cell looks after all statutory obligations of the whole plant vehicles i.e., Road
Tax, Fitness, Insurance, Pollution control & Legal complications as arise for all vehicles and
Earth moving equipments of RSP.
The total numbers of vehicles with Transport Department pertaining to plant are as follows:
LIGHT VEHICLES :
Jeep : 58 Nos.
10 Seater Jeep : 14 Nos.
Ambassador Car : 13 Nos.
Maruti Car : 20 Nos.
Gypsy : 36 Nos.
Mini bus : 08 Nos.
Pick-up : 22 Nos.
Ambulance : 13 Nos.
Tempo Trax : 01 No.
TMB Bus : 03 Nos.
DESIGN
Design Department is the think tank of the entire Steel Plant. Basically Design Dept. caters to the
maintenance needs of the plant by way of providing modification schemes, spare part drawings,
feasibility reports and technical specifications for small projects etc. to all the departments.
For all types of Engineering Jobs to be taken up by Design Department, other departments raise 'O3'
Engineering Work orders. These work orders are raised on line through SUN systems by the
Planning groups of departments and are electronically cleared by HODs, General Managers, General
Manager (Mechanical) and HOD of Designs so as to reach the sections concerned. The types of jobs
include modifications, spare parts, re-tracings, replacement specifications, technical studies,
standardization 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 centralized 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.
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
digitization 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.
The standardization 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
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 output in this case is in form of detailed report.
c) Category 3 jobs:
In this category, the jobs are in form of replacement drawings. Drawings are made indicating
the outer dimension details, technical specification & location in the equipment so that
particular equipment / a part of the equipment can be de-proprietorised or import
substitutions of an imported equipment is made at lesser cost.
d) Category 4 jobs:
Category 4 jobs are popularly known as indigenization 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 stabilizing the
procurement and maintenance activities. Drawings are made generally by taking
measurements from worn out or broken spares and subsequently converted into detailed
manufacturing drawings.
e) Category 5 jobs:
This category deals with rejuvenation of drawings. Some of the earlier drawings were in the
form of RTF’s (reproducible tracing films), polyester films, tracing cloths, prints etc. Due to
repeated use the tracings have become soiled and opaque thereby rendering them unusable.
The disadvantage with prints is that copying to produce more prints was not possible.
Therefore rejuvenation of drawings is done by either retracing on another tracing paper. In
case this is not possible it is redrawn using AutoCAD software.
f) Category 6 jobs:
This deals with jobs involving standardization. Standardization 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.
Equipment Details:
Captive Power Plant 1:
There are 6 nos. of High Pressure Boilers to generate High Pressure Steam at 59 kg/cm2(gauge) &
485 0C for running of the Turbo-Blowers as well as the Turbo- Alternators.
1. 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.
2. 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.
3. 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. ALSTOM make ESPs.
There are 5 nos. of Turbo Blowers out of which 4 nos. run continuously to cater to the requirement of
the four Blast Furnaces. The function of the Turbo-Blower is to supply the Cold Blast required by the
Blast Furnaces. Turbo Blower # 5 can be connected to any of the Blast Furnace. The combined Steam
consumption in the running of 4 nos. of blowers is 105 T/hr., which is equivalent to approx. 21 MW of
electrical power. There are 5 nos. of Turbo-Alternators (TA). TA #1 is presently not in service.
The Turbines of TA # 2 & 3 originally of Siemens make have been replaced along with condenser and
pre-heaters during 1990 by M/s. BHEL make. Insulation of Generators for TA # 2, 3 & 4 have been
up graded from Class “B” to Class “F” and their original conventional excitation system has been
replaced with static excitation system during the period of 2003-2010. The turbine of TA # 4 was
refurbished in February 2004.
During refurbishing all the rows of rotor and stator blades of the turbine were changed. The turbine
rotor was straightened; condenser tubes and pre-heater tubes were changed. Both turbine and
generator along with auxiliaries were completely changed for TA #6 with a new BHEL make machine
in 2004. State of the art ‘Brush less excitation system’ was installed. This TA is in successful
operation since October 31, 2004.
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) of60 T/hr. capacities.
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.
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.
Captive Power Plant2: It is under NTPC SAIL POWER SUPPLY COMPANY PRIVATE
LIMITED, which is a joint venture of SAIL& NTPC. It is having 2 units of 60 MW. Total capacity=
60x2=120 MW. Boilers are RAFAKO make(POLAND) of 280 T/hr steaming capacity at 90 kg/cm2 pr
& 540degree cent. Temp. Turbo alternators are BHEL make (INDIA) of HNK271 design.
Captive Power Plant 3: It comprises of Power & Blowing Station& TRTG(Top Recovery Gas
Turbine) which is attached to BLAST FURNACE#5. Also there is CDCP(Coke Dry Cooling Plant)
Boilers (4 Nos.) & BPTG(Back Pressure Turbo Generator) which is attached to expansion Coke Ovens
(Battery#6).
Equipment Details:
# TURBINE SIDE :
- Output ;maximum output : 24,113 kw
- Design rating (economical rating) : 14,519 kw
- Speed
Speed turbine (5) : 4782 rpm
Speed range : 3964-5814 rpm
- Pressure
Specified initial steam pressure : 60 kg/cm2 abs
Permissible deviation without limitation : 60 kg/cm2 abs
# BLOWER SIDE :
- Power Input : 14519 Kw
It is having 2 nos. of turbo generators of 18 mw each, total gen. capacity=2x18=36 mw. The
specifications of TAs are:
1. Type of steam turbine:
Type: Horizontal, impulse, multi-stage, multi-stage, valve, axial flow, condensing, extraction &
geared (Down Exhaust type)
1 Pressure 63 Kg/cm2
2 Temperature 485 0C ± 5
3 Flow 56,800 Kg/hr
4 Exhaust Pressure 8 Kg/cm2
5 Exhaust Temperature 249 0C
The Turbines of TA # 2 & 3 originally of Siemens make have been replaced along with condenser and
pre-heaters during 1990 by M/s. BHEL make. Insulation of Generators for TA # 2, 3 & 4 have been
up graded from Class “B” to Class “F” and their original conventional excitation system has been
replaced with static excitation system during the period of 2003-2010. The turbine of TA # 4 was
refurbished in February 2004.During refurbishing all the rows of rotor and stator blades of the
turbine were changed. The turbine rotor was straightened; condenser tubes and pre-heater tubes
were changed. Both turbine and generator along with auxiliaries were completely changed for TA #6
with a new BHEL make machine in 2004. State of the art ‘Brush less excitation system’ was
installed. This TA is in successful operation since October 31, 2004.
POWER DISTRIBUTION
Introduction
The prime responsibility of Power Distribution (PD) Department is to ensure continuous adequate &
quality (Voltage -10% to +6%, Frequency -3% to +3%) power to all its customers – All units of RSP,
Steel Township & Fertilizer Township. To meet this responsibility, Power Distribution department
operates and maintains a vast transmission and distribution network.
PD department coordinates with all its customers & power suppliers i.e. CPP-1, CPP-2 (NSPCL),
CPP-3(PBS) &GRID. 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 PD Department Electrical Maintenance of some
service departments, which do not have an electrical section, is also looked after by Power
Distribution. Apart from these, it maintains SCADA System, Islanding System & Solar Plants.
Average daily power consumption of RSP (including Steel Township) is 230-280 MW, with a peak
demand of 300 MW. This power requirement is met from four sources viz. CPP-1, CPP-2, CPP-3 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 CPP-2 is 120 MW. CPP-3 produces approximately 25 MW &
balance requirement 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. Broadly speaking, PD
Department has following power related infrastructure:
• 220kV Switchyard – 1 No.
• 132kV Switchyards – 4 Nos.
• 33kV Switchyard – 3 Nos.
• 33kV Indoor Substations – 15 Nos.
• 11kV Substations – 3 Nos.
• 6.6kV Substations – 115 Nos.
• LT Substations – 150 Nos.
• HT Breakers – 4000 Nos.
• Transformers – 850 Nos.
• Compressors – 20 Nos.
• Battery & Charger Sets – 75 Nos.
• 220 kV Overhead lines – 9 Kms
• Capacitor Banks – 25 Nos.
• High Mast Towers – 100 Nos.
• Street Lights – 1100 Nos.
• Buildings – 80 Nos.
• 132 kV Overhead Lines – 18 Kms
• 11kV Overhead Lines – 18 Kms
• Cable Tunnels – 16 Kms
• Cables (33kV) – 300 Kms
• Cables (6.6kV) – 2300 Kms
• HT Motors (TPH) – 15 Nos.
• 6.6kV DG Sets (TPH) – 4 Nos.
220kV MSDS-IV s/s have 3 Nos. 160 MVA Auto-Transformers. It has double Bus 220kV GIS.
132kV MSDS-II Switchyard is having Double bus with Transfer bus facility. These buses have ACSR
‘MOOSE’ conductor. The 33kV Buses have 2 ½” IPS Aluminum tube. There are 4 Nos. 63 MVA
132/33kV EHV Transformers with 11kV tertiary winding. Primary is solidly grounded and secondary
is Reactor 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.
132kV MSDS-III Switchyard has 7 Nos. EHV grade 63 MVA 132kV/33kV Transformers. All have
11kV tertiary winding. Both Primary and secondary of the transformers are solidly grounded. Circuit
breakers of MSDS-III are 2500 A, 25 kA Outdoor MOCB.
33kV Indoor substations – RM-1 is 33kV double bus GIS type, whereas RM-2 is double bus having
VCB. Other 33kV substations are single bus having VCB. At BF-1, 33kV double bus GIS panel has
been installed & commissioned.
6.6kV Indoor substations – Taking all new substations, we have about 90 substations. Gradually, we
are replacing old German supplied panels with new state of the art VCB panels. Already completed
in I&S area. In Rolling Mill area, it will start soon. In many new panels, we have introduced Auto-
changeover system, so that in case one section loads can be given automatically on other section in
case of power failure.
Likewise, we are taking up replacement of older Transformers from German AEG make. Power &
furnace Transformers are water cooled but others are Air cooled.
PD Department maintains other equipments as mentioned in the above table.
Organization
Power Distribution department is administratively under GM (Elect.). The major activity of the
department is divided into two parts – Operation and Maintenance. Operation group looks after the
total power system monitoring, its operation and control on round the clock basis. 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 , Rolling Mill, Modernization, Switchyards (Includes Tarkera Pump
House), Cables & Lighting; each headed by one area In-charge. Planning Section of the department
looks after procurement, stores, administration, documentation etc.
System operation
RSP power plants – CPP-1, CPP-2 & CPP-3 normally remain synchronized with utility grid.
Monitoring and control of captive generation vis-à-vis the import of power from the grid is done on
continuous basis. Moreover monitoring of system frequency, Grid drawl power factor, maximum
demand, voltage and other parameters is also done from the main control room with help of SCADA
system. Revival of power after any interruption and normal switching operations for shut down etc.
are also part of the operation activity.
Islanding
“Islanding” refers to the system for Isolation of running Thermal generator with its connected loads
from Grid when Grid is having some problem. For this purpose, there are sensitive ‘Relays’ to sense
Grid unstable conditions which trigger Isolation. Generally, Islanding takes place by tripping
synchronizing breakers. The Isolated Unit is synchronized with the Grid after unstable conditions
become normal.
CPP-I Islanding takes place when its 33kV Section-2 Bus coupler breaker is Tripped. For this
purpose, always healthy matching of CPP-1 generation & connected loads is maintained by CPP-I
control room.
CPP-II Islanding has undergone many modifications since its beginning in 1989. Earlier, it was
introduced for one Unit only. Later it was upgraded for Double Unit which had mixed success. After
discussion with CPP-II, it was decided and now Double channel Islanding system is in service, which
has been 100% successful since its incorporation in 2016 end.
Likewise, CPP-3 Isolated with one Generator i.e. STG-1 or STG-2.
A successful Islanding avoids power failure or interruption to our loads and increase of Demand. Also
Unit restarting cost is avoided. Thus successful Islanding is a Win-Win situation. For Islanding to
work reliably, we have dedicated Islanding panels at substations like MSDS-III, LBSS-I, MSDS-V &
CPP-I, CPP-II.
Electronics:
The Electronics Section provides reinforcement to different Electrical Maintenance Units of the plant
for maintenance of advanced Electronic Equipment and Electronic Weighing Systems commissioned
in modernization package. 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 and service support for process weighing
systems.
Service support to production units maintaining of drives, power electronics, UPS, PLC 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.
Service support of analytical equipment of R&C Lab and Environmental Lab.
Maintenance of CCTV system at HSM, Plate Mill & Plant gates and service support to
different units of the plants.
Maintenance of Electronics/Analytical equipment of IGH.
In-house development of new PCBs/modules for electronic controls, PLC & weighing system.
Training on Drives & PLC of ABB, Siemens, Rockwell & SSD Parker in departmental
Laboratory, simulation and testing of 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 along with HT
Power distribution network. Its main function is testing of Magnetic & Numerical 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 like Islanding and Load Sharing of power distribution
network. They are also involved in commissioning of electrics of latest testing /diagnostic equipment
being purchased by the plant. The ETS section maintains Fire Detection and Alarm systems of C&IT,
Design, EMD building and Oil Godowns. They also provide service support to all protection units in
maintaining the fire alarm system installed in their respective departments.
Testing of Transformer oil BDV (Dielectric strength) and DGA (Dissolved gas Analysis) as per
requirement of Power distribution and all other consumer departments.
Testing of Current Transformer, Potential Transformer whenever required by Power
distribution and other consumer dept.
Scheme testing of power systems.
Railway Signaling:
CED maintains Railway Signalling System for safe movement of wagons for (T&RM ) Dept. It
maintains the Route Relay Interlocking (RRI) System in the Hot Metal Movement Yard(HMMY),
Raw Material Unloading Yard(RMUY) and Marshalling Yard. Electronic Interlocking (EI) Signalling
System, Make- ANSALDO STS Transportation System along with Multi Section Digital Axle
Counter( MSDAC), Make - ELDYNE Electro Systems Pvt Ltd for track monitoring has been installed
and commissioned at New Coal Complex Yard( NCCY). This includes the maintenance of 102
numbers of Point Machines in Marshalling Yard, Hot Metal Movement Yard(HMMY), Raw Material
Movement Yard (RMUY)and New Coal Complex Y Yard (NCCY). 59 numbers of Track Sections of
MSDAC( Axle Counter) and 52 numbers of Signals( Main & Shunt) in NCCY.
CED maintains VHF wireless network, which is used in remote or difficult areas or places, where
mobility of the subscriber is essential. There are about 200 base stations at the Plant and Township
with over 1000 walkie-talkies for operation in the Coal Yard of Coke Ovens, Crane to ground
communication in SMS-II / SMS-/HSM, Yard communication in OBBP and lots of other areas in
production and service units distributed throughout the plant. 40 nos of mobile base stations have
been installed in locomotives for smooth communication of loco operators with different zones of TRM
department.
This has become the fastest and reliable communication amongst the SAIL employees of various
plant units.
INSTRUMENTATION
Instrumentation Department plays a key role in Process Control, Monitoring of Process Parameters,
Safety and Interlocking Protection systems of Plant and equipments.
Function
Instrumentation Department works as a centralized department having a group of Executives and
Non-executives dedicated for different sections / groups throughout the plant.
It is a well laid out workshop of about 6000 sq.m. area divided into four bays with facility to handle
equipment weighing as high as 50 ton.It possesses all the facilities required to Repair/Overhaul/
Rewind all types of Motors (AC, DC & Synchronous), Electromagnets, Transformers, Welding
Machines etc.
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
De-dusting chambers for de-dusting the equipments
Numerous customized 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-enameled 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
It is equipped with
6KL/hour oil filtering machine
A pit at 3.5 meter level to handle large power transformer.
Along with transformer repair this area also takes care of repair of all types of welding machines.
TESTING SECTION:
Following jobs are executed by this section:
Final and in process testing of all electrical equipments repaired / overhauled in the shop.
Testing of electrical machines at site as per work order or during repair executed by RS(E).
Electrical Maintenance of the shop equipment
Intermediate tests (routine & special tests) including core flux test, HV test, impedance test, drop
test, PI test, Growler Test, Current balance test, ratio test etc.
To carry out these jobs it is equipped with a fair amount of calibrated measuring instruments &
Power Source. Some of them are:
Three auto transformers for AC motor/Transformer testing
DC Power Source
Direct Switch on for 6.6 kV Motor (upto 700 kw)
High Voltage Test set
Tan delta & Surge Inter turn test set
5 kV Digital &motorized Insulation testers
Soft starters for no-load testing of LT Motors &HT Motors(6.6 KV) up to 500 kw
PLANNING PROGRESS
The section takes care of all activities regarding job planning & its progress monitoring.
Following jobs are executed by this section.
Receiving and delivery of jobs
Preparation of route card for each job
Preparation of all types of MIS
Progress data feeding, Planning and Monitoring of the work order/jobs through Computerised
Electrical Equipment Repair System (CEERS)
Issue of ITC / FTC for outsourced jobs
Apart from the above sections it has got a small machine shop which takes care of turning &
manufacturing activities of smaller spare parts of the electrical equipments. Carpenters are there for
preparing formers, wedges and insulation materials. It has got a varnishing area with two hot ovens
(300 KW & 100 KW) to cater to drying and varnishing needs.
Annual Capability:
Repair/rewinding of 1000 jobs and overhauling of 1100 jobs.
Repair/overhauling of
6.6 KV large AC machines 120 nos.
Mill duty DC M/C & RT motors 420 nos.
Welding machines 150 nos.
Transformers 25 nos.
Electromagnets 25 nos.
Site repairs 40 nos.
Apart from handling all types of routine jobs (described above) required to keep the Plant running,
handling emergencies & site repair of large machines is one of the major function of RS(E). When
there is a break down in a huge machine bringing the process to a halt, on line repair is the only
option. On line repair demands exceptional skill which are being handled by expert technicians of
RS(E) .
Computerization:
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
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:
These units are running with environment friendly refrigerants. The availability of AC units
contribute directly to major production units like Coke Oven, Blast Furnaces, Steel Melting Shops,
Hot Strip Mill, Plate Mill & Power Plants. Uninterrupted reliable operation of Central Plants for
Gopabandhu Auditorium, C&IT, Control Rooms and Conference Rooms of various departments in
Works & Non-works has been made possible due to expertise & skill of Air-conditioning department.
Major overhauling of Crane AC units through in-house expertise, erection & commissioning of
Central Plants & Package AC Units are major strengths of the department. Air-conditioning
department ensures operation of Room ACs for comfort and water coolers as a welfare measure
throughout the Plant.
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 bus-bar 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.
The role of Production, Planning and Control department (PP&C) is to orient the production process
in an efficient manner to maximize the “Order fulfillment” as well as “Capacity Utilization” of all the
production units so as to maximize the profit of the company.
The Process starts with working out the production potential of different production units keeping in
view of the Capital Repair Plan of various units, availability / utilization of equipments, rate of
production/rolling & consumption rate. Various Operation parameters, Techno-economic parameters
and Key Project commissioning schedules are also decided. The “Production Plan” of different mills
were converted to the “Sales Plan” based on the demand & Market share. While preparing the sales
plan of product-mixes, the focus is on increasing the customer base, launching new products, entering
new segments and improving NSR by selling value added and special quality steels. The IPT and
conversion plans are also decided. Based on the “Production Plan”, the “Raw-material consumption”
plan is finalized. Taking into account all these plans, the “Profitability Parameters” such as
Turnover, Gross margin/EBITDA, Net Profit etc., are worked out.
Once the ABP is approved by SAIL board, the annual targets were sub-divided to monthly production
targets. Once the plan & targets were finalized, the actual performance of every month is compared
with the ABP targets at the end of the month.
- 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.
- Despatch:
Despatch Planning both by Rail and Road.
Rail Despatches:
The Rail dispatch constitutes more than 80% of the total despatches. The function of rail dispatch
section is to form rakes of different types of wagons available from Railways. The rail rakes are
primarily of two types viz. Concord rake consisting of 43 nos BOST/BRN wagons and SML rake
consisting 59 nos of NBOX wagons. The rail dispatch section forms the rakes out of material ready
(Movable) at different mills in consultation with PP&C Product managers and Sales Resident
Manager (SRM) of CMO. Daily discussions are held at a scheduled meeting with Shipping In-charges
& Traffic to plan & monitor rake despatches.
Sales Coordination:
This section
Handles road transport contract for road despatch for prime products.
Coordinates Issues delivery order for road despatches both for RSP & Customer Transport.
Exports:
To export our products in International markets on a sustained basis, and to ensure our continued
presence in the market, it is necessary, as a policy, to earmark certain percentage of the saleable
steel production for export, and SAIL has earmarked 10% of our saleable steel production towards
export. The function of this section is to coordinate with International Trade division (ITD) of CMO to
achieve execution of the export orders.
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.
Weigh Bridges:
13 No. of weigh bridges are manned by PP&C department which spreads throughout the plant for
weighment of both for internal consumption and outward/inward movements for commercial
purposes.
Plant Control:
The Plant control works as the central as well as emergency control room of RSP. This works round
the clock and collects &monitors hourly / intermittently production figures and delays & breakdown
etc. and provides feedback to the Senior Officers to helps them in decision making at right time. Also
certain emergency decision makings are done during emergent situations like power failure etc.
All the materials are handled in wagons, which move on rails with the help of Diesel Electric
Locomotives. Taking over of the wagons, coming from outside from Indian Railways and handing
over of wagons from inside the plant to Indian Railways is done at the Exchange Yard at
Bondamunda. All the incoming wagons brought to the Marshalling Yard are sorted out and are sent
to the various loading and unloading points. The marshalling yard has two grids of tracks so laid out
that there is minimum interference of wagon movement. The tracks, crossing and about 100 points in
the marshalling yard are controlled by the automatic electrical route relay interlocking system. The
Traffic and Raw Materials Department achieves its objectives through the functioning of the
following sections:
A) Movement (Logistics):
This section looks after the supervision and control of internal and foreign wagons movement in the
six zones(ZONE-I: Traffic control/Marshalling yard, OBBP & NCCY), Z-II (Coke ovens), Z-III:
(BF#1.2,3,4 & BF#5), Z-IV:(SMS-I,CCM-I), ZVI(Rolling mills such as HSM,CRM,PM etc.),Z-VII:
(NEW PLATE Mill) 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 such as transfer of hard coke, boiler coal, MBC) round the clock.
Traffic & Raw Materials Department plays a vital role in the working of an Integrated Steel Plant. It
can be compared to circulatory system in Human body. As circulatory system carry food to all parts of
body and collect wastes generated by the different units of body, Traffic Dept. Also function in similar
way supplying raw material to different units of plant and collect semi-finished, finished and wastes/
bi products generated by those units. Its general role consists of in
Procuring and supplying necessary raw materials to various user departments
Internal movement of in-process and other materials from one section to another section
Despatching finished products to outside parties. At 1.8 MT stage of production a total of
about 14 to 15 MT of materials needs to be handled.
All the materials are handled in wagons, which move on rails with the help of Diesel Electric
Locomotives. Taking over of the wagons, coming from outside from Indian Railways and handing
over of wagons from inside the plant to Indian Railways is done at the Exchange Yard at
Bondamunda. All the incoming wagons brought to the Marshalling Yard are sorted out and are sent
to the various loading and unloading points. The marshalling yard has two grids of tracks so laid out
that there is minimum interference of wagon movement. The tracks, crossing and about 100 points in
the marshalling yard are controlled by the automatic electrical route relay interlocking system. The
Traffic and Raw Materials Department achieves its objectives through the functioning of the
following sections:
WAGON FLEET
Sl. Type of Wagon Carrying Qty. Detail Use
No capacity
1. HB Side Discharge, hopper type, For transportation of
a) Indian 60T 101 8 wheeler, Casnub/ Diagonal Coke breeze, Hard
b) German 66T 08 bogies with coil springs or coke, B coal, LD Slag,
Fabricated bogies with Mills scale, Flue dust,
laminated springs (8 or 10 Quartz, Special lime
leaves) stone, Sinter etc.
2. BOX(HSL) & 56T 48 Side discharge, 8- wheeler, For Transportation of
BOX N 60T fabricated bogie with Coke Breeze and Hard
Laminated springs. coke and M S scrap
3. GONDOLA 57T 18 Slanted wall, heavy duty, 8 - For transportation of
wheeler, fabricated bogie M S Scraps and
with laminated springs secondary steel
(10leaves) products.
6. LINK CAR 32T 03 4 wheeler, Laminated For attaching ingot
springs (6 leaves), having Bogies or charging
both CBC Coupler and cars with locomotive
coupling rod.
7. STD. BOI 60T 92 Slanted 1m wall, 8wheeler, For transportation of
Fabricated bogie with M S Scraps and
laminated springs secondary steel
(10leaves)/ Casnub bogie products.
with coil springs.
8. PLATFORM CAR a) 60T 51 a) 8 wheeler, Fabricated For transportation of
bogie with laminated Slabs, coils and plates.
springs (8 or 10 leaves)b) 12
Wheeler insulated hooded,
b)90T/100T 104 fabricated bogies with
laminated springs (7leafs).
12 Wheeler, fabricated
bogies with laminated
springs (7 leafs)/ 8Wheeler,
Casnub bogies with coil
springs.
9. STC 102T 12 8 wheeler, Casnub bogies For transportation of
with coil springs Hot Slab.
10 RELIEF VAN 30T 01 Covered, 4 wheeler, For Carrying
Laminated springs, Breakdown crew and
tools tackles used for
re-railment.
TOTAL 438
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 555 sets
of turn outs . It takes up all civil works connected with these lines and new track line extensions etc.
This section is also responsible for housekeeping of yards and maintenance of track drains including
removal of wild growth.
D) Raw Materials:
This section is responsible for the procurement, quality control, internal handling and supply of all
raw materials. It also handles by-products such as coke fractions, -30 mm L/stone etc. It is
responsible for the manual unloading of various raw materials at the proper places. It also keeps an
account of the receipts and dispatches of all raw materials. The detailed jobs involved are as follows.
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.
Production of iron in Rourkela Steel Plant (RSP) started in January 1958 was followed by the
formation of the then Scrap and Salvage Department (SSD) as a separate unit of the Plant in the
begging of 1961 and presently renamed as ‘Material Recovery Department (MRD)’. MRD working
area is located between Silicon Steel Mills and Pipe Plants, extending to western side up to plant
boundary.
The Material Recovery Department of Rourkela Steel Plant plays significant role in
achieving twin objective of gainful utilization of solid waste generated in RSP and revenue
maximization.
Major Activities:
The Department deals with salvaging of scrap /metallic from solid waste for use as melting scrap &
also processing of LD slag for internal consumptions and external despatch. Gainful utilization of
slag helps not only in reduction of cost of steel production, but also helps in making the environment
free from dust etc.
Apart from these major activities, MRD also collects ferrous scrap, thin baleable scrap & other heavy
scrap from length & breadth of the Plant, processes these to chargeable size for use as melting in LD
converters. Thus, MRD plays a vital role in overall housekeeping of the plant to clean different areas
& develop strategic locations inside the Plant premises.
Main Functions:
Main function of MRD is recovery of scrap & processing of LD slag, some of the other functions are as
enumerated below –
Processing of tundish skull by lancing at lancing yard near SMS-II & partly by breaking at skull
cracker crane, for use as melting scrap in SMS-II.
Collection & conversion of thin baleable scrap to Bale Press for use as melting in SMS-I.
Receiving arising from Blast Furnaces, SMS-I etc. Processing these for recovery of iron bearing
scrap for charging in Blast Furnaces & SMS-II.
Collecting scattered scrap i.e. wear/maintenance/structural scrap from various Units of the Plant,
processing the same for charging as melting scrap in SMS –I/II.
Processing of Mill scales generated from Rolling Mills for base mix preparation to OBBP.
Co-ordination with Rolling Mills, PPC and T&RM etc. for supply of Mills scrap to SMS-I/II for
melting.
Processing of LD slag in the crushing unit for recovery of metallic and conversion to various
useful fractions.
Supply of various fractions of LD slag to different units of the Plant, 0 to 5 mm fractions are sent
to OBBP mainly for base mix preparation, 5 to 20 mm size is used for civil works and 20 to 40
mm size slag is used in Blast Furnaces as flux etc.
Salvaging of rejected/used refractory bricks dumped in MRD area and to despatch the same to
external customers.
For gainful utilization of the accumulated Defective/Joint/Rejected slabs of plant, MRD processes
them as melting scrap and supplies to SMS-II.
All the solid waste generated in Steel Melting Shop–II during steel making process is handled by
MRD & 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 MRD 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 infrastructures from April ’2005, all the residual slag is being dumped
inside the Plant premises. MRD 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. Also BF-5 dry pit slag handling started since August 2013 and
continuing successfully without fail supporting uninterrupted production.
While working under adverse and hazardous conditions, MRD 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, MRD has a unique distinction of having
“zero accident” since 2007.
Believing on “healthy worker is a productive worker”, MRD with help of Jawaharlal Nehru
Occupational Health Services Center has ensured 100% health check up of all the employees of MRD
every year. 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 & MRD is trying to achieve both.
The main job of the department is to provide service inside Steel Plant for maintenance of 750 Nos. of
buildings, 50Km of main roads, 50Km underground drains, 51Km of open drains, 30Km of perimeter
wall, 3,30,000MT of roof structures of different units, 14,40,000m2 of roofs, 16,96,000m2 plinth area
buildings, 7,500 Nos. of sanitary installations, 69 Nos. of public conveyance buildings, canteens, rest
sheds, waste disposal yards etc. The department is also looking after the maintenance of Fertilizer
Plant.
Except the maintenance jobs, small value AMR projects, pollution control & debottlenecking schemes
are also taken up by this department. Activities like building monuments, developing gardens,
renovation of canteens, rest rooms, sanitary installations, survey supports, face lifting of plant
premises during VIP visits are also taken up as & when required.
Assistance is taken from approximately 40 Nos. of external agencies for delivering Civil Engineering
Services for entire plant. The plant area is divided into 5 zones in Civil Engineering Services.
Equipment Strength:
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.
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.
The Contract Cell(Works ) was formed in the year 1998. It processes and awards all types of
contracts of the Works area.
WATER MANAGEMENT
In an integrated steel plant huge amount of water is required for the process as well as for human
consumption. Total industrial and potable water requirement of Rourkela Steel Plant is met from
river Brahmani. To make the raw river water suitable for use, the water is treated at Tarkera Pump
House. Water Management Department (WMD) has the responsibility of supplying treated make-up
water to different recirculation systems and other once through systems in the plant, drinking water
to the plant consumers. Supply of water is made to Tarapur Filter House for sector-22, treatment
units at sector-21 and sector-8 for township drinking water system. The total water requirement of
NSPCL (joint power venture of SAIIL-RSP & NTPC) is also supplied from the plant make-up system.
In addition to this, operation & maintenance of total water recirculation systems of SMS-I, HSM, PM
& CRM are also under WMD. Sections of WMD and the main functions thereof are as under:
1. Tarkera Pump House: Provides make-up water to the entire plant. It also provides a part of
water requirement to township.
2. Drinking Water Station: Treatment and supply of drinking water to plant for various use
including for fire fighting
3. Mandira Dam: Stores and supply water for maintaining water level of river Brahmani at
Tarkera pump house.
4. Rolling Mill Pump House: Total recirculation water system of HSM & CRM
5. Plate Mill Pump House: Total recirculation water system of Plate Mill including soft water
system for Reheating Furnaces of PM & HSM.
6. SMS Pump House: Total recirculation system of SMS-I (excluding CCM-I), TOP-I & CRGO
complex.
7. Modernization (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.
The river level on upstream of pick-up weir is maintained by regulating the sluice gates, as per the
requirement. Falling shutters give passage to river water during high floods.
Raw water from the river is pumped to the treatment units. There are two raw water pump houses,
one constructed originally at 1 MT. stage of the plant and other one under modernization scheme.
The old raw water pump house is designed for vertical, dry pit type centrifugal pumps and the new
one for vertical turbine wet pit type pumps.
The old raw water pump house comprises two intake chambers, named upstream and down-
stream chamber. Raw water flows by gravity through two nos. of 1000 mm diameter steel pipes laid
from the upstream of pick-up weir to each intake chambers. Each of these pipes has been provided
with 3 Nos. of stage gates which are operated during monsoon to prevent the carryover of silts from
river. Six dry pit type vertical centrifugal pumps, three in each chamber, have been installed. The
new raw water pump house has been constructed on the river itself on the upstream of pick-up weir.
It comprises four intake wells with sluice gates at inlet ports. 3 Nos. of wet pit type vertical turbine
pumps for plant water supply and two nos. of wet type vertical turbine pumps for township water
supply have been installed. The capacity of raw water 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 clari-
flocculators 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 clari-flocculators for flocculation and clarification.
Proportionate quantity of solutions of ferrous sulphate and hydrated lime are dosed in raw water in
the aeration tank. Clarified water which slowly rises upwards in the clari-flocculators is collected
through the peripheral launder and stored in the respective clear water storage tank. Capacity of
each treatment unit is 2000 cbm/hr.
As the water is directly drawn from the river, the turbidity of raw water varies widely over the year.
It varies from 5,000 ppm during rainy season to less than 10 ppm during summer. It also rises very
rapidly in case of any flash flood. Ferrous sulphate and hydrated lime are required to be dosed during
rainy season for treatment of raw water. These chemicals are dosed manually. Besides the above
chemicals, compressed air is used for aeration of water.
Make-up water 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
modernization. All the rising mains are made of welded steel pipes with anti-corrosive coating on
external surface.
Make-up water received through the rising mains is distributed in the plant through an underground
ring main of size NB 1000/NB-960 spreading in the entire Plant. A high level tank, staged at RL:
792.3 feet, is connected to the make-up water ring main to act as a surge-cum-storage tank.
Local cooling water recirculation systems comprising of induced draft cooling towers, hot and cold
water pumps are installed separately for CCD, Blast Furnaces, SMS-I and SMS-II, TOP-I, TOP-II,
Rolling Mills, Plate Mill, Silicon Steel Mill, CPP-I, Central Air Compressor Stations etc. Evaporation,
drift and bleeding losses of recirculation systems are replenished with fresh make-up water supplied
through the ring main. Chemicals such as biocide, dispersant, scale and corrosion inhibitor are dosed
in the circulation systems, to maintain the water quality of the recirculation systems, and to reduce
the make-up water consumption. Separate cooling water recirculation systems were provided for
SMS-II, CCM-I, CCM-II, Calcining Plant during modernization of RSP.
There are also a number of once-through cooling water systems in various shops viz., Sintering Plant-
I, Lime and Dolomite Brick Plant, Electrical Sub-stations, where make-up water is directly used for
system cooling purpose and discharged to drain. The water for NSPCL, IDL in fertilizer plant area is
supplied from the make-up water distribution network.
In order to supply make-up water at desired pressure to the modernization units in new areas viz.
SMS-II, CCM-II, Sintering Plant-II, Calcining Plant, TOP-II, OBBP, a separate pump house has been
commissioned. The modernization pump house consists of make-up water pumps which pump make-
up water to the modernization units. Separate make-up water pipe lines with a high level tank
comprising separate chambers for make-up water have been provided in the modernization area to
act as storage-cum- surge tank. Make-up water from the existing pump house is pumped to new high
level tank for onward distribution to various modernization units. There are total 6 nos. of make-up
water pumps having capacity of 300 cbm/hr at head of 55 mtr.
Mandira Dam:
The main source of water for Rourkela Steel Plant is river Brahmani, which is formed by the
confluence of two rivers, Sankh and Koel at Vedvyas near Rourkela. This river is able to supply
water throughout the year except during the summer months. In order to have a regulated flow in
river Brahmani throughout the year, a dam named Mandira Dam, was built on river Sankh, at a
distance of 26 KM upstream of the river from Rourkela by Rourkela Steel Plant. The Dam was built
mainly for the purpose of storage and supply for meeting the water requirement of RSP during
summer seasons, when there is a drastic reduction in water flow in river Brahmani. The salient
features of Mandira Dam are as given below:
A separate ring main of NB-400 size, welded steel pipe, has been laid underground for distribution of
drinking water. Besides for drinking purpose, drinking water is also supplied to various other process
requirements viz. gas cleaning, acid regeneration, air conditioning, firefighting etc. The drinking
water pumping facility comprises horizontal, centrifugal, dry pit installation type pumps, which
pump the drinking water to the High level tank. There are total 11 Nos. of pumps comprising of 2
nos. of 3 MGD capacity, 6 nos. of 2 MGD capacity and 3 nos. of 1 MGD capacity.
A separate drinking water station has been constructed to supply drinking water to the
modernization units. Drinking water is prepared by filtration of make-up water in the pressure
filters and is then pumped to high level tank for distribution to various consumers in the
modernization station area. There are 3 nos. of pressure filters comprising of 2 nos. of 60 cbm/hr
capacity and 1 no. of 80 cbm/hr capacity. For supplying filtered water there are 3 nos. pumps of
capacity 80 cbm/hr at 55 mtr head.
Rourkela Steel Plant, being the first industrial unit in Rourkela, in the late 50s’, continues to meet
its social obligations for supplying water to the various peripheral villages and colonies in and
around Tarkera and Rourkela Steel Plant.
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 COOLING TOWERS
PUMP
HOUSE
HSM BOOSTERS
OTHER UNITS OF
HSM
COLLECTION PIT
FILTER BEDS
SUPPLY PUMPS
There are 5 pumps each for supplying water to LD and Oxygen plant respectively and 8 nos. pumps
for supplying return hot water to cooling towers. There are 4 nos. of cooling towers.
A new pump house named as CRGO pump house was constructed to supply direct cooling water and
indirect cooling water to VAD/VOR unit of SMS-I. Each system is consisting of supply pumps, return
pumps, cooling towers and sumps. This pump house is a zero discharge unit.
Oxidation Lagoon
The effluent water from the various plant units inside the plant is collected in the oxidation lagoon
through 10 nos. of outfalls. The water is treated in the lagoon by natural oxidation process to
maintain the effluent water quality. The lagoon is spread over an area of 49 hectares and is provided
with 3 nos. emergency gates and a weir for discharge of water from lagoon.
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 utilization
of energy. This includes maintaining of operational parameters, combustion control, condition
of fuel/ energy consuming equipment, status of instrumentation and control system and
inspection/ follow up for rectification of leakages.
For ensuring gas safe operation in the plant gas/ oxygen/ explosive mixture testing is done for
all protocol/ non-protocol jobs as per requirement. Also gas safety equipment like masks,
carbon monoxide and oxygen monitor and breathing apparatus etc. are maintained in proper
condition.
Maintenance of the yard utility grid to ensure uninterrupted supply of fuel gases/ utilities to
the consumers besides day to day maintenance jobs. This involves repair/ replacement
activities as per requirement.
Involvement and participation in all the projects as per RSP expansion programme and under AMR
and other schemes, to ensure adoption of energy efficient technologies and proper integration of the
individual unit gas/ utility pipe lines with the main grid.
SAFETY ENGINEERING
Iron and Steel production being a complex and hazardous activity, SAIL recognizes its moral,
economic and legal obligations to prevent hazards, provide healthy working environment and guard
against all foreseeable risks. The management of SAIL recognizes its obligation to endeavour to
progressively identify, control and eliminate all hazards and conditions which present risk to
employees and / or possible damage and loss to the plant and equipment including products.
Safety Engineering Department of Rourkela Steel plant is a technical wing with a multi-disciplinary
team discharging all the above functions. It has been the constant endeavour of the department over
the past 40 years to create a hazard free, safe environment for the employees of Rourkela. Towards
this end the department has been carrying out the following major functions:
1. Safety training to all levels of the employees including Contractor labour.
2. Involving all the employees in a scheme called “Surakshya Chakra “in improving safety
standard of RSP & to develop safe behaviour amongst employees. All the employees are
divided in small groups in their respective departments (10-12 person in a group) .Each
group is headed by a Surakshya chakra captain. Periodic inspection of equipment, work
methods and the environment.
3. Identification of hazards and taking steps for their elimination.
4. Implementing various safety management systems like OHSAS18001 & SA8000 in
departments of RSP.
5. Facilitate procurement of personal protective equipment as required for various jobs,
prepare norms of issuing the same and enforce its use by the employees.
6. Creating awareness of employees through visuals like hoardings, posters, film -shows,
printed hand-outs, bulletins, safety campaigns, various competitions etc.
7. Publishing various safety bulletins/leaflets/posters/stickers etc.
8. Monitoring implementation of Safety protocol for major shutdown and other hazardous
jobs
9. Encouraging joint participation in the field of safety through the Central Safety Committee
(at the apex level), Zonal Safety Committee (at Zonal level chaired by GMs) and the safety
committee of departments (at department level chaired by HODs). Monitoring
implementation of the recommendations of these committees.
10. 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.
11. Conducting Safety Audits by internal as well as external teams and taking necessary
actions to liquidate the deficiencies noted.
12. Working in close liaison with Occupational Health Centre to promote a clean, healthy and
safe environment.
13. Monitoring compliance of the various provisions relating safety as numerated in the
Factories Act, 1948.
14. Maintaining constant liaison with the various statutory authorities like the Director of
Factories, Inspector of Factories & Boilers, various Labour Institutes.
15. Introducing / strengthening the safety system as per requirement.
16. Organising various safety promotional activities like National Safety Day, Road safety
week, Safety Week campaign at different departments& Road Safety Campaign at strategic
locations etc.
RSP is a OHSAS18001 certified company.RSP has also won several National Safety Awards for its
exemplary performance. RSP won Steel Minister’s Safety Shields for best performance and RSP also
won many awards from the State Government and the Standing Committee on Safety in the Steel
Industry.
ENVIRONMENTAL ENGINEERING
Rourkela Steel Plant is the first Public sector Integrated Steel Plant, set up in India, is fully
committed to prevention of pollution, create a clean, green and sustainable environment in and
around Rourkela. The clear sky line over Steel Plant and clear water of river Brahmani on its
downstream side explain the commitment of RSP, which is well documented in its IMS Policy, which
is in line with SAIL Corporate Environment Policy.
Rourkela Steel Plant integrated its pollution control activities with the day-to-day production
activities so that Environment is well taken care of. Environmental Strategies are well planned to
take care,
Minimising water consumption by adoption of water recycling and marching towards Zero
Liquid Discharge.
Energy conservation by maximization of waste gas utilization
Minimizing raw material consumption by utilization of Solid Wastes
Rourkela Steel Plant has given maximum importance in adopting latest energy efficient and
environment friendly steel making technologies in progressive manner for keeping the pollution to
minimum levels. Rourkela Steel Plant installed different types of pollution control systems in
different production processes, to control;
Air Pollution Control: Different types air pollutants viz., Suspended Particulate Matter (SPM)
generally known as dusts & Gases are treated at their sources of generation in different departments
by Air Pollution Control Equipment. The different types of Air Pollution Control equipments
installed are,
Water Pollution Control: Dedicated Waste Water Treatment Plants are provided in
different departments to treat the waste water generated from the process. The treated
water is recycled back to the process. The different water treatment systems used are,
-- Equalization Units
-- Dissolved Air Floatation Unit
-- Activated sludge treatment
-- Trickling Filter
-- Sludge Digestion
-- Sludge Drying beds
Environmental Engineering Department was established in the year 1989 along with an
Environment Laboratory with state of the art monitoring and instruments for analysis of
pollutants. Environmental Engineering Department is responsible for regular monitoring
and analysis of various pollutants entering into Environment from RSP’s operations.
Formulation of strategies for prevention of pollution, meeting the stakeholders concerns,
implementation of various statutory requirements are taken care of by Environmental
Engineering Department.
For monitoring the pollutant levels, Environmental Laboratory is equipped with various
latest monitoring and analytical instruments viz,
Sl Type of Online
Parameter/s monitored Installed At
No. Monitoring System
PM2.5 - Dust
PM 10 - Dust
SSSY Building (East)
SO2 - Sulphur Di Oxide
Ambient Air Quality ERWP Plant (West)
1. NOX - Oxides of Nitrogen
Monitoring Systems IG Club Sector#2 (North)
CO - Carbon Monoxide
Hospital Sector#22 (South)
Ammonia
Ozone
Temperature
Wind Speed Environmental Engineering
Meteorological Data
2. Wind Direction Department roof top.
Logger
Rainfall Hospital, Sector#22 roof top.
Relative Humidity
PM – Particulate Matter Sinter Plants
SO2 - Sulphur Di Oxide Coke Ovens
Blast Furnaces
Continuous Emission Steel Melting Shops
3.
Monitoring Systems LDBP
The data monitored through continuous monitoring systems is uplinked with the servers of
State Pollution Control Board and Central Pollution Control Board through GPRS systems
and is available to general public.
FIRE SERVICES
The Fire Services Wing of the erstwhile Hindustan Steel Security Force (HSF) was
established under the provision of security scheme, compiled by the security advisor, HSL.
After the induction of CISF, Fire Service was made a separate department of Rourkela Steel
Plant.
Objective:
1. Prevention of Fire
2. Prevent Loss of Life & Property
3. Extinction of Fire.
Operation:
The most vital of all the four wings is the operation wing. The prime responsibility of
reducing the response time, minimize loss of Life & Property lies with the operation wing by
responding to an emergency at its earliest.
There are four strategically located Fire Stations inside RSP to cover the whole plant.
These are:
Central Fire Station (covering Iron and Steel zone, Administration Building, Captive
Power Plant-I, SP-I, Aux Mills, All shops, Air Strip and Steel Township areas etc.)
Modernization Fire Station (covering OB & BP, SMS-II, BF-V, P&BS, CP-II, SP-II&
III and TOP-II units etc.)
Coal Chemicals Department Fire Station (covering Coal Chemicals department,
Coke Ovens department, &Fertilizer Township.) and
Rolling Mills Fire Station (Covering Rolling Mills, SSM & Pipe Plants).
These stations are fully manned round the clock in three shifts headed by a Fire Station In-
Charge in each shift. An Executive (over all in-charge) is also posted in each shift at Central
Fire Station to take care of any occurrence of Fire, Rescue and other emergencies in the
Plant, Steel & Civil Townships & Periphery. In addition, special services like De-watering,
Cooling and Stand-by duties in the plant and at Air-Port are also rendered. Operation wing
is also operating a 24x7 “Snake Helpline”.
The Central Fire station, which is the nerve center of the Fire Service department, on
receipt of any emergency call, dispatches its appliances at its earliest. On arrival at the
scene of fire, rescue, special service call, the Officer I/c studies the situation and plans his
strategy of attack. Further assistance of manpower or reinforcement of additional
appliances / equipment is called for inter alia VHF or other mode of communication with the
control room. The Operation wing, 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 fulfills the prime 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 running maintenance, preventive
maintenance etc. of all the appliances and equipment available with Fire Servicein-house.
The list of appliances (vehicles) and equipment available with Fire Service department are
as under:
Fire Fighting Appliances & Critical Equipments: The fleet consisting of the following:
Training Wing:
Training wing has to carry out an important task in imparting in-house training to its new
recruits and refresher course for old timers. Both acquiring knowledge and skill, the
training wing is constantly trying to cope up with the needs of the plant employees in
general and Fire Service department in particular. The Fire Control Management (FCM)
programme conducted under the aegis of HRDC department is an unique venture. With
faculty support from Fire Service department added with practical demonstrations this
FCM programme enhances both knowledge and skill of the participants to greater extent.
Scheduled Training at shop-Floors on Fire Prevention & Hand-on-training on ‘Use of Fire
Extinguishers’ are carried out every month. Specialized training programmes, pertaining to
only Fire Service personnel are also conducted at regular intervals. In addition, Fire Safety
Awareness programmes are also being organized in Township areas for Hospitals, Shop
owners, School & Colleges, Housewives, Ladies Clubs etc.
Planning:
Fire Fighting Consumables, Equipments, Appliances & Human Resources.
Human Resource:
Fire Service department is having 138highly motivated & well Trained / Qualified Officers
& Staff. The grade-wise break up is as follows:
1. Executives 05
2. Fire Station In-Charge 11
3. Leading Fire Operators 121
4. Fire Operators 01
5. Technicians 06
INDUSTRIAL ENGINEERING
Activities of Industrial Engineering Department are mentioned below:
Motivation Schemes:
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:
Formulation of various Procedures for Works & Non-Works areas. The objective is to
streamline the system for efficient and smooth functioning and fixing agency-wise
responsibity/accountability. Making amendments in existing procedure orders and issue of
revised procedure orders are also a part of this.
All the RJC, JCC(W) and OOC Purchase Requisitions (PRs) of Works area are scrutinized
and compliance as per the checklist/guidelines is ensured. IED clears the above PRs as
Nodal as well as Convener of Indent Screening Committee.
Manpower Proposals:
Assessment and recommendation of manpower for upcoming modernization units and
additional activities under AMR Schemes.
National Awards:
Coordination for sending nominations of deserving employees for various National Awards
like Prime Minister’s Shrama Awards, Rashtriya Vishwakarma Puraskar etc
Administrative Items:
The requirement of various items under administrative category are studied and
recommended for procurement for different departments.
Research & Control Laboratory provides metallurgical services to the whole plant units.
RCL role starts from product enquiry to till the product is delivered to the customer. It also
handles customer complaints if any.
It has more than 20 spot labs to carryout inspection, testing activities round the clock in
almost all the Major Units of Steel Plant. Central Lab building houses Lab facilities to
carry out Chemical Analysis of Tundish Samples of SMS 1, Metallography Lab for
Microstructure Analysis, Testing of Water and Oil samples, Analysis of Coal & Coke,
Refractory etc. The Centralized Test House is for mechanical testing and product
certification.
Some of the equipment of R&C lab is given below:
Micum Drum
Proximate Analyzer
Coke Reactivity Index (CRI), Coke Strength after Reaction (CSR) measuring apparatus
X Ray Diffraction Spectrometer
Reducibility Degradability Index (RDI)-Reducibility Index (RI) apparatus
Pneumatic Sampling System
Product Area:
Fisher scope for Coating thickness measurement of Zinc on steel
Magnetic test Lab for testing Silicon Steel
Franklin Insulation Resistivity (IR) Tester
Universal testing machines of 40, 60 & 100 T capacity
Drop weight tear test machine
Ultrasonic Flaw Detectors
In house developed attachments for Through Thickness Testing
Various Sample preparation Machines like Lathe Machine, Milling Machine, Band Saw
Machine, Broaching Machine, Test Piece (TP) Machine etc.
Bending machine
Charpy Impact Testing machines (300 J)
Dye Penetrant Test kits/magnetic particle tester.
Image Analyzer
Metallurgical microscopes
Hardness testers
Miscellaneous Area:
Particle Testing apparatus for oil testing
Viscosity Meter
Conductivity Meter
PH Meter
Business Excellence
At the outset, Total Quality Management (TQM) Department started functioning
independently since January 1992 with an objective to establish Total Quality
Movement across RSP. TQM was adopted in RSP as the “business philosophy” and today
forms the core of all our business strategies. Subsequently, the department was renamed
as Business Excellence in view of its changing nature of responsibilities that included
ensuring system certification as well as demonstrating Organizational excellence.
So far 44 departments consisting of all the production departments, all the Mechanical
& Electrical Shops, majority of the service departments, Personnel and Steel Township
have been certified to latest version of ISO 9001 Quality Management System. Being
experienced in the field of Quality Management System, BE department also was
given the responsibility of facilitating implementation of other management systems
like ISO 14001 EMS, OHSAS18001, SA 8000 and
API Q1. Accordingly, Silicon Steel Mill was the first
department to be certified with ISO 14001
Environment Management System (EMS) in the
year 2000. Subsequently, SP-II, HSM, PM, Pipe
Plants, SPP and Steel Township were certified to
latest version of ISO 14001 EMS. RSP’s Steel
Township is the first Township of SAIL to be
certified for both ISO 9001 QMS and ISO 14001
EMS. RSP is also so far the only SAIL unit to have
independent ISO 9001 QMS certification of Finance
Department. RSP has subsequently been certified to
OHSAS 18001 & SA 8000 standards. Its Pipe Plants
are certified to internationally acclaimed API Q1.
To implement, document and maintain all the management systems in RSP, a Three
Tier Management Review is held regularly by HODs, GMs and ED Works)/ED
(P&A). BE Department facilitates the monitoring and controlling Quality,
Environment, Occupational Health & Safety and Social Accountability Objectives of the
certified departments through regular supervision, conducting Internal Audits as well
as facilitating External Audits. BE Department has also been entrusted with
facilitation job for various awards like PM’s Trophy & CII Exim.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.
The department co-ordinates for sanction and monitors AMR projects and does many other
functions as follows:
1) AMR(projects) monitoring:
AMR-M & SC department is the nodal agency of the plant for coordinating and
monitoring of capital investment schemes under AMR from concept to completion.
Capital Investment Projects under AMR are classified under the following three
categories:
i. A(Addition): Adding capital facility of similar nature or improved version in
an area for achieving greater output, improved quality, introduction of new
products, attaining optimum production etc. to the existing capital facility in
operation.
ii. M(Modification/Revamping): Improvement to the existing capital facility for
reduction of cost, manual jobs, materials, power, energy consumption and
improved quality of products, etc.
iii. R(Replacement): Substituting the existing capital facility which has outlived
its useful life as per financial and technological standards by similar facility
or improved version in the same location of the existing facility.
Considering the value of the project, capital investments under AMR are of two types.
i. Local AMR schemes (scheme with value less than Rs 20 crores).
ii. Corporate AMR schemes(scheme with value more than Rs 20 crores).
AMR-M & SC department does all its activities w.r.t. AMR schemes as per the
guidelines of ED(W) procedure order. The department functions under ED(W).
Getting capital investment proposals under AMR at the beginning of each financial
year as per the procedure order.
Compiling the schemes and obtaining capital budget from corporate office.
Prioritizing the schemes as per allocation of fund.
Scrutinizing each prioritized proposal in line with the guidelines and co-ordinates
with the departments for compliance of deficiencies.
Scrutinized proposals which are in order are then processed for further scrutiny by
IPSC(Investment Proposal Scrutinizing Committee). The proposal cleared by IPSC
are then put up to APEX committee for clearance for further functioning for
sanction.
Necessary co-ordination is done with ED(W)’s sect, GM I/C(Services), GM(F & A),
GM(Mechanical), GM(Electrical) and others.
Schemes cleared by the APEX committee are then processed for approval of CEO.
Sanction orders are issued by ED(W)’s office for the schemes approved by CEO.
These are for local AMR schemes.
Proposals from various departments for award of consultancy services to M/S CET
are received by AMR-M & SC department. The proposal is processed for concurrence
of finance and approval of ED(W). Award of consultancy is issued to M/S CET after
approval of ED(W).
Communications with M/S CET and the concerned departments are made for
progress of the scheme. Status is monitored and a data base is maintained for this.
The AMR-M & SC department co-ordinates with inspection team members and
organizes inspection of boundary wall, perimeter road, lighting, etc.
Important security issues of the inspection report are discussed in the security
meeting of GM I/C(Services).
AMR –M & SC department follows up with the concerned agencies for compliance.
The inspection is done once in a month.
The department co-ordinates visit of IB team as and when required along with GM
I/C(Services),GM(P & A), CISF and other agencies.
Follows up with the departments for compliance of IB team report.
Takes up the points of IB team report in the security meeting of GM I/C(Services)
and necessary follow up is done.
Required record keeping is done.
9) Theft cases:
AMR-M & SC department co-ordinates and issues circular for nomination of two
executives at any level from two different departments once in every six months.
CISF contacts these nominated persons for identification of seized materials after
theft.
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 Projects, Materials Management, Finance & Personnel functions under the
direct control of ED (Projects).
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-the-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) meetings held on 15.06.2009 & 19.06.2009
respectively, reviewed the expansion plans of SAIL plants (including investment in
mines) and approved an expenditure of Rs 70,169 crores. In the case of RSP, the total
revised cost is Rs.11,812 crores (net of CENVAT).
3. The production target of Hot Metal, Crude Steel and Saleable Steel after expansion plan
is indicated below:
Techno-economic parameters:
The above facilities are proposed to be taken-up after the New Plate Mill has been
stabilized.
CONSULTANTS
M/s MECON has provided engineering & consultancy services for the facilities in the Iron &
Steel Zone while M/s. M.N. Dastur & Co. has provided the same services for the Rolling Mill
Zone. M/s. CET has provided consultancy services for the packages pertaining to Coke Oven
Battery No.6 and M/s RITES for the rail infrastructure and logistics packages.
FLOWCHART
BF COKE
SINTER
SINTERPLANT
PLANT BLAST
BLASTFURNACE
FURNACE COKE
3 COKEOVEN
OVENBATT
BATTERIES
ERIES
22xx125m 2
125m2(EXISTING
(EXISTINGSP1)
SP1) BF SINTER 6,760,000 BF
BF##11 1250m
1250m3(EXIST
(EXISTING)
ING) 1,855,000 55EXIST
EXISTING
ING
11xx192m2 3
192m2(EXISTING
(EXISTINGSPSP2)
2) BF
BF##44 1658m
1658m3(EXIST
(EXISTING)
ING) 1x67,7m,N
11xx360m 22 1x67,7m,NEW
EWBATT
BATTERY#6
ERY#6
360m (NEW)
(NEW) NEW
NEWBFBF##55 4060m
4060m3
3
4,500,000 GHM
NEW
NEWPPCCMM (1(1xx1500
1500t/d)
t/d) 238,500 HM 4,410,000 NHM
28,900
28,900COLD
COLDPIGS
PIGSFORFORSMS
SMSII&&IIII GROSS COKE- 2,443,400
201,800
201,800COLD
COLDPIGS
PIGSFORFORSALE
SALE 3,665,000 (2,192,000 BF Coke AND
506,500 HM
251 ,400 Under size, out of
SMS-
SMS-II((1/2
1/2OPERATION
OPERATION)) SMS––IIII((3/3
SMS 3/3BOF
BOF OPERATION
OPERATION)) which 270,000 BF coke will
22xx65
65ttBOF
BOF 150tt––EXISTING,
22xx150 150tt––(NEW
EXISTING,11xx150 (NEW))) be surplus)
3,772,000 LS
RSP-REVISED
RSP-REVISED LS 508,400
SEC.
SEC.REF.
REF.(EXISTING) SEC.
SEC.REFINING
REFINING(150(150ttEACH)
EACH)
4.5
4.5MTMTHOT
HOTMETAL
METAL (EXISTING)
11LF,1
LF,1VOR,1
VOR,1VAR
VAR 11LF
LF(EXIS.),
(EXIS.),22LF,
LF,11RH
RH--OB
OB(NEW)
(NEW)
4.2
4.2MTMTCRUDE
CRUDESTEEL
STEEL LS 508,400 3,772,000 LS
(0.820
(0.820MT
MTSE
SEMIS)
MIS)
CCP–– II
CCP CCP–– IIII
CCP
3.9
3.9MT
MTSALEABLE
SALEABLESTEEL
STEEL 1X1-STRAND
1X1-STRAND(EXISTING)
(EXISTING) 22xx1–STRAND
1–STRAND SLAB
SLABCASTER
CASTER(EXIST.),
(EXIST.),
500,000 SLABS 11xx11––STRAND
STRANDSLAB
SLABCASTER
CASTER(NEW)
(NEW)
3,700,000 SLABS
1,850,000 SLABS 1,000,000
530,000
SLABS
SLABSINTERPLANT
INTERPLANT SLABS
SLABS EXISTING
EXISTING
TRANSFER
TRANSFERTOTOBSL
BSL FOR
FORSALE EXISTING NEW
SALE 1700
1700MM
MMHSM
HSM EXISTING NEW
650,000
650,000 170,000
170,000
1,805600 HR COILS PLATE
PLATEMILL
MILL PLATE
PLATEMILL
MILL
325,000 HR COILS (3.1
(3.1MMWIDE)
WIDE) (4.3
(4.3MMWIDE)
WIDE)
85,000 HR COILS 86,000 59,500
EXISTING
EXISTING
EXISTING 490,800
HR
HRCOILS/SHEET/
HR COILS/SHEET/
COILS/SHEET/
PICKLING
PICKLINGLINE
PICKLING LINE
LINE EXIS.
EXIS.
EXIS. ERW
ERW
ERW SPIRAL
SPIRALWELD
SPIRAL WELD
WELD
PLATES
PLATESFOR
PLATES FORSALE
FOR SALE
SALE ANN/PICK
ANN/PICKLINE
ANN/PICK LINE
LINE PIPE
PIPEPLANT
PIPE PLANT
PLANT PIPE
PIPEPLANT
PIPE PLANT
PLANT 241,000
312,713 PICKL. COILS 1,245,400
1,245,400
1,245,400
197,959 114,754 18,000 42,000
NORM.
NORM.FACILITIES
NORM. FACILITIES
FACILITIES
5
55STD
STD
STD EXISTING
EXISTING
EXISTING IN
EXIST.
EXIST.CRNO
EXIST. CRNO
CRNO INEXISTING
IN EXISTINGFEC
EXISTING FEC
FEC
1420
1420mm
1420 mm
mm 1700
1700mm
1700 mm
mm NEW
FACILITIES
FACILITIES
FACILITIES NEWPIPE
NEW PIPE
PIPE
TANDEM
TANDEMCRM
TANDEM CRM
CRM REVERS.CRM
REVERS.CRM
REVERS.CRM COATING
COATINGPLANT
COATING PLANT
PLANT
NORM.PLATES AS ROLLED AS
75,000 13,000 240,000 249,800 ROLLED
HOT 57,000 60,000 SPIRAL 579,500
HOTDIP
HOT DIPGALV.
DIP GALV.
GALV. PROC.
PROC.
PROC. ANNEAL
ANNEALSPM
ANNEAL SPM&&&
SPM CRNO SLIT COILS
III& & SHEETS ERW COATED PIPES WELDED (Controlled
&II
& II(Existing)
II (Existing)
(Existing) LINES
LINES
LINES
Rolled)
350,000
120,415 16,792 164,476
HDGPLAIN SHEETS ELEC. TINPLATES CR SHEET & ANN COILS
The important units under the expansion project are briefly detailed below:
Executing Agency: M/s Heavy Engineering Corporation Ltd., Ranchi, India &
M/s Shapoorji Pallonji & Company Ltd., Mumbai, India
The present modernization programme of RSP will increase production of hot metal capacity
from 2.2 million tonnes per annum to 4.5 million tonnes per annum. The new material
requirement of RSP will increase to about 12 million tonnes per year from present
requirement of 5.0 million tonnes.
Facilities / equipments:
Unloading :
One proportion building is there, where the following materials are stored in
bunkers and drawn through weigh feeder in desired proportion to make base-mix.
The base mix is stacked in 2 nos. base mix beds and reclaimed. The following
equipments are in base mix beds:
Two separate Auto Sampling Systems complete with sample cutter & provisions for
collection, sizing, crushing and grinding are provided.
Executing Agency: M/s McNally Bharat Engineering Company Ltd., Kolkata, India
It consists of conveyorisation for intra plant transportation of various bulk materials among
OBBP, SP-III, BF-V, SMS-II, etc.
The entire work under this package has been executed on turnkey basis and consists of the
following:
Transportation of coal from RCC silos of New CHP for CDI injection into BF-V.
Transportation of coke from CDCP, de-dusting of coke in CDU, coke sorting, coke
screening, further transportation to Intermediate Coke Bunkers and conveying to
stock house of BF-V and Coke Crushing Station of new OBBP.
Transportation of coke from existing Coke Ovens to Stock House of BF-V.
Transportation of finish sinter from Sinter Plant-3 to Blast Furnace-V and existing
Blast Furnaces.
Transportation of iron ore lump, additives from new and old OBBP to Stock House of
BF-V.
Transportation of iron ore fines, coke fines and sinter fines from Fines Buildings of
BF-V to Base Mix System of new OBBP.
Transportation of finish sinter from Sinter Plant-II to Blast Furnace-V.
Stacking of slag and loading into railway wagons.
To feed coke to the new Blast Furnace-V installed under 4.5 MT/yr hot metal production
expansion plan, one 7m tall battery of 67 ovens has been installed in the new Coke Ovens
complex in the location of old Fertilizer Plant.
Basic Design:
The battery is of top charged type with compound twin flue, under jet, regenerative heating
with partial re-circulation of waste gases. Ovens have 3 no. of charging holes and the
battery has double gas collection mains, one each on pusher side and coke side. There are
two waste gas tunnels, one each on pusher side and coke side, with common tunnel leading
to chimney located on pusher side in the middle of the battery.
The Computerized Heating Control System (COHC) shall be installed for battery operation
and process management system so as to improve reduction in environmental emission,
improve coke quality & productivity.
Battery heating system is designed for under firing with clean coke oven gas with average
heating value of 4200 kcal/Nm3 and/or mixed gas with average heating value of 1000
kcal/Nm3.
There is a coal tower of 4000 T useful capacity for storing coal with dry equivalent bulk
density of 740 kg/m3.
Buttress walls are connected together at the top by longitudinal tie rods. To ensure proper
loading, adequate numbers of longitudinal tie rods are provided with helical springs.
The Pollution Control Stipulations applicable to New Coke Oven Battery as per MOEF are
as following:
Machines Nos.
Coke Pusher Car (PC) 2
Coal Charging Car (CC) 2
Coke Transfer Car (TC) 2
Executing Agency: M/s Bhilai Engineering Corporation Ltd., Bhilai, India, M/s SE
GIPROKOKS, Ukraine & M/s UKRINDUSTRY (CUI), Ukraine
The Coke Dry Cooling Plant (CDCP), having four chambers and coke cooling capacity of
0.768 MT/yr of gross coke (dry) per annum, is installed to cool the coke produced from Coke
Oven Battery No. 6. The pushed coke from battery is transported to CDCP unit by means of
self-propelled hot coke bucket car.
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 transfer of heat to waste heat boiler. The
quenched coke is discharged from the quenching chamber automatically by
dischargingdevice in preset condition. Data analysis of Blast Furnace operation shows that
specific coke consumption decreases by 3-5 % by using dry quenched coke.
The major facilities for 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 1 T capacity.
Executing Agency: M/s Shriram EPC Ltd., Chennai, India & M/s Hutni Projekt,
Czechoslovakia
The new CCD has been installed to process coke oven gas generated from the new Coke
Oven Battery-VI. 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 is also finally cooled
to 23 0C at the outlet of final gas cooler.
The liquid effluent generated within the CCD area is 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 is achieved through DCS based
automation system.
New Coal Chemical Department has sulphur removal system. There are naphthalene
washer and benzol scrubber to have clean coke oven gas for use in the plant.
The up gradation of existing CCD (both 1.0 MT & 1.8 MT units) involves:
Executing Agency: M/s McNally Bharat Engineering Company Ltd., Kolkata, India
Commissioned : April, 2013
New Coal Handling Plant has 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 are 24 nos. RCC silos each of capacity 2500 T and for CDI coal, there are 6 nos. of RCC
silos, each of capacity 2500 T.
The major equipments / units of New Coal Handling Plant (New CHP) are given
below:
Executing Agency: M/s Larsen & Toubro Ltd., Kolkata, India & M/s Outotec
GmbH,Germany
Commissioned : April, 2014
This is a single strand Sinter Plant having an effective suction area of 360 m3 with an
annual production capacity of 3.70 MT of gross sinter. The sinter productivity is envisaged
to be 1.3 T/m2 /hr and the machine will operate at an under grate suction of 1650 mm WC
for 330 days/year on 24 hr/day basis. There are two wind mains followed by two ESPs
leading to a 120 m high concrete chimney. The output stack emission is less than 50
mg/Nm3. The sinter plant has been provided with Eirich type mixer and noduliser instead of
the conventional mixing & balling drum. A circular cooler is provided for sinter cooling.
Another new feature is pneumatic conveying of ESP dust. The ESP dust is 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.
Executing Agency: M/s TATA Projects Ltd., Secunderabad, India & M/s Danieli
CorusBV, Netherlands
The furnace comprises of twin flat cast houses with four tap holes. The furnace is equipped
with modern features such as pulverized coal injection system, cast house & stock house
fume extraction system, cast house slag granulation system, 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 has been designed to operate on 60-80% sinter, 20% lump iron ore (max.)
and 10-20% pellet.
The Blast Furnace has been designed for a production capacity of 2.8 MT/yr. The Hot metal
will be transported to SMS-II / PCM by Torpedo Ladle Cars.
The Blast Furnace will be operated 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 have also been
designed keeping in view the high production level from this Blast Furnace.
The new Blast Furnace has the following major design parameters:
The details of operating parameters for the Blast Furnace are given in the
following table:
S1.
Parameter Unit Value
No.
1 Working volume of BF m3 3470
2 Useful volume of BF m3 4060
3. Hearth diameter m 13.2
7924 (avg.)
4. Production per day T/d
8320 (max.)
S1.
Parameter Unit Value
No.
5. Ash content of coke % 15
6. Ash of coal (imported) % 9-10
7. Sinter in burden % 80
8. Sized ore in burden % 20
9 Pellet in Burden (future) % (10-20)
10. Availability of Blast Furnace days/yr 350
Sp. cons. of input materials (net &
kg/THM
dry basis)
Iron ore lump as required
Sinter / Pellet as required
Lime stone as required
11.
Quartzite as required
Coke rate (including -20 kg nut
360
coke 8-34 mm)
150 (avg.)
Coal dust (CDI coal)
200 (design)
Blast characteristics
Volume (dry basis) Nm3/min 6125
1200 oC (avg.)
Temperature oC
12. 1250 oC (max.)
Humidity g/Nm3 40-60
Three nos. of Turbo Blowers (2 working + 1 standby) along with its auxiliaries are utilized to
provide cold blast to the stoves of new BF-5. The blowers are axial with last stage redial
type. Air blowers are of variable speed control type, single shaft, and multi stage
withoutintercoolers and directly coupled to the turbines without gearbox.
In this package, there are 3 nos. of boilers, with capacity 100 TPH each and 2 nos. of steam
turbo generators with capacity 18 HW each and one no. of back pressure turbo generator.
Boiler generates steam at a rate of 300 TPH 485 + 5/-2 oC and 62 Ata using BF gas as main
fuel from Blast Furnace-V, BF gas calorific value is 728 kcal/Nm3 (GCV). Steam generated
from PBS boilers is used to run 2 nos. Turbo-Blowers to supply air blast to BF-V. Balance
steam is used to generate power with 2 nos. STGs. Generation of power is dependent on
availability of steam.
BPTG located at CDCP gets steam generated from WHRB (Waste Heat Recovery Boilers)
after nitrogen quenching of coke.
Executing Agency: M/s Simplex Castings Ltd., Kolkata, India & M/s Hyundai Heavy
Industries Co. Ltd., South Korea
For transferring hot metal from the new Blast Furnace-V to Steel Melting Shop or PCM,
there are 10 nos. of Torpedo Ladles of 350 T capacity each. These torpedoes are first of its
kind to be used in SAIL with features like higher capacity and lesser hot metal temperature
loss. A torpedo ladle repair shop is there, wherein jobs like refractory lining, ladle
inspection, ladle heating & cooling etc. are done.
Executing Agency: M/s Metal Engineering & Treatment Company Pvt. Ltd.,
Kolkata, India
A twin strand 1500 TPD capacity Pig Casting Machine has been installed under the current
expansion plan. It is an auxiliary unit of new Blast Furnace-V. It comprises of a pig storage
yard, pig wagon haulage system, circulating water system, graphite & lime milk preparation
and splashing system, Pig Dispatch Wagons, etc. The average strand speed is 9m/min.
AUGMENTATION OF SMS-II
Executing Agency: M/s SMS SIEMAG AG, Germany & M/s SMS India Pvt. Ltd.,
Gurgaon, India
One new top blown basic oxygen furnace (3rd converter) of capacity 165 m3 has been
installed under this package. After installation of 3rd converter, all the three (3) converters
will operate simultaneously. The 3rd converter is designed with provision for adoption of
combined blowing / inert gas stirring process. The salient operating parameters of new BOF
converter are given below.
The major design features of the BOF converter are indicated below:
Previously in SMS-II only one converter out of two used to be in operation at a time.
The facilities in SMS-II have been augmented to facilitate simultaneous blowing of both the
converters. For this purpose, secondary refining facility, piping network for oxygen,
nitrogen, water & other utilities have been strengthened. Material handling facilities like
ladles, slag pots, etc. have also been procured.
Executing Agency: M/s SMS SIEMAG Aktiengesellschaft, Germany & M/s SMS
India Pvt. Ltd., Gurgaon, India
Technical parameters and design features of the new Conventional Slab Caster
are given below:
The slab caster is 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 computerized process control
system (Level II), etc.
Design Features:
LADLE FURNACE-3
Executing Agency: M/s Sarralle Equipos Siderurgicos, Spain & M/s Sarralle
Equipment India Pvt. Ltd., Kolkata, India
Operating Parameters:
1. Annual treatment at LF T/yr : 1,440,000 avg.
2. Average no. of heats to be treated at LF per day: 30
3. Nominal heat size : 150 T
4. Maximum heat size : 165 T
5. Transformer capacity : 30 MVA
6. Heating rate C/min > 5 per minute at operating top notch
0 0
Executing Agency: M/s Primetals Technologies GmbH, Germany & M/s Primetals
Technologies India Pvt. Ltd., Mumbai, India
Operating Parameters:
1. Heat size: 150 T (nominal) & 165 T (max.)
2. Type - A refractory lined vacuum vessel equipped with two refractory lined nozzles
(snorkels) attached to the bottom of the vessel. Lifting and lowering of vessel is
done by hydraulic system / winch system.
3. Inert gas purging / inert gas stirring facility from one of the snorkels.
4. Vacuum system steam ejector
5. Vessel heating by top oxygen injection-cum-gas burner heating system to maintain
refractory surface temperature at 1,400 – 1,500°C.
6. Steel recirculation rate ~100 T /min.
7. Hydrogen level in steel, after treatment < 1.5 ppm.
8. Alloy addition system - Ferro-alloys and micro-alloys to be added under vacuum.
9. Other features - Water cooled O2 lance &self-propelled transfer car.
10. Suction capacity nominal – 550 kg/h at pressure 0.5 mbar
11. Free board min. – 500 mm with 165 T heat size
12. Nos. of heats per day nominal – 24 heats.
13. Steel grades to be treated - all low C, micro alloyed, CRNO plate grade, high tensile
steels, etc.
Executing Agency: M/s FLSmidth, Pvt. Ltd., Chennai, India & M/s Cimprogetti,
S.p.A.,Italy
There is one lime sizing unit with Crushing Unit of capacity 20 T / hr to reduce lime size
from 0-60 mm to below 2 mm for Sintering Plant-III
The kiln complex includes kiln with up-stream and downstream facilities and its related
material handling systems, air conditioning and ventilation system, de-dusting system,
waste gas cleaning system, all electrics and instrumentation, civil and structural works, etc.
Raw material handling conveyor BC-10 has been extended towards the tail end about 20m
and conveyor has been upgraded to 400 tph.
The various facilities 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.
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, vibratory feeders, bin vibrators, vibrating
screens, weigh hoppers, chutes with liners, sector gates, switching devices, truck loading
device, etc.
Waste gas cleaning and de-dusting system of the kiln at 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-III: The objective of lime sizing unit is to
reduce the lime size from 0-60 mm to below 2 mm having a capacity of 20 T/hr. It
comprises of hammer mill with rod shifter, electro-vibratory feeders and belt conveyors.
Addition of 4 nos. 132 kV bays, 7 nos. 33 kV bays and one 63 MVA transformer at
MSDS-II. The New Plate Mill is fed from MSDS-II, at 33KV.
Installation of one 220 kV GIS (Gas Insulated Substation) along with three nos. of 160
MVA, 220/132 kV transformers. The 132 kV sides of the transformers are connected to
existing MSDS-III 132 kV bus. MSDS-IV is connected to 220 kV Tarkera Grid
Substation of OPTCL through a double circuit 220 kV line.
A new 132 kV GIS/33kV substation is constructed. It is fed from CPP-II and MSDS-II
through double circuit 132 kV lines and has 3 nos. of 63 MVA transformers. It is feeding
the loads of HSM, Plate Mill and CRM, SP-I, SMS-I, LHF-I. One 63.5 MVA dedicated
transformer is further installed to cater to the load of Steel Township.
A new 132/33kV substation has been constructed near Fertilizer Plant area. The BOO
oxygen plant is fed from MSDS-VI (having 2 nos. 132/33kV 62.5 MVA transformers). 132
KV single circuit line is feeding power to MSDS-II and MSDS-III 132 kV system.
33 kV line feeder is connected at LBSS-IV (COB #6).
(vii) RM - 1 (NEW)
A 33 kV double bus GIS indoor switchboard for RM-1 & PM for stable power supply to
existing HRM loads.
LBSS-IV, feeding COB-VI, LBSS-V feeding BF-V, LBSS-VI feeding SP-II, SP-III
arecompleted.
33kV (4 nos.) and 6.6kV (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.
New substation 33/6.6 kV with 2 nos. 33kv I/C and 6.6 kV board has been made at TPH.
Power at 33 kV fed from CPP-I & MSDS-II.
Executing Agency: M/s Globe Gas Equipments India Pvt. Ltd., Mumbai, India
There are 2 nos. separate installations for propane storage system. One installation meets
the requirement of CCM-2 and SRU and is located near existing propane installation (2x 20
T storage) in the Acetylene Plant-II area, while the other installation which meets the
requirement of CCM-1, New Plate Mill, Repair Shop & HSM, CCM-I, New Plate Mill, Repair
Shop & HSM is located opposite erstwhile soaking pits (SSD side).
The following are the main units along with auxiliaries for propane storage and
distribution:
2 nos. unloading points 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 to erstwhile soaking pits (SSD side).
2 nos. (1W +1S) liquid unloading pumps (capacity 10 T/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 near slab yard at
HRD ( i.e. for New Plate Mill, etc.)
OXYGEN PLANT
Executing Agency: M/s Linde AG, Germany & M/s BOC India Ltd., Kolkata,
India
Commissioned : July, 2012
ASU-III has been installed at RSP to meet the additional requirement of oxygen in BF-IV
for coal dust injection and BOF-2 for simultaneous blowing. The capacity of the plant is 700
TPD. The basic plant is of cryogenic type air separation unit capable of producing
simultaneously gaseous and liquid oxygen, nitrogen and liquid argon. Cold box turndown
ratio is 70-100%.
Executing Agency: M/s Linde AG, Germany & M/s BOC India Ltd., Kolkata,
India
Commissioned : July, 2012
This Oxygen Plant has been installed inside RSP premises on Build, Own & Operate (BOO)
basis. The plant produces oxygen, nitrogen and argon both gas & liquid. RSP procures the
products on first right basis from M/s BOC India Ltd.
Executing Agency: M/s Tecpro Systems Ltd., Chennai, India & M/s Sinosteel
Engineering Design & Research Institute Company Ltd.,
China
Commissioned : June, 2015
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. Injection of low ash non coking coal has been
preferred so as 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 is met from Oxygen Plant.
Executing Agency: M/s Enova S.P.A, Italy, M/s Danieli & C. Officine Meccaniche
SpA, Italy, M/s SMS Siemag Aktiengesellschaft, Germany,
M/s SMS India Pvt. Ltd., New Delhi, India & others.
Unique Features:
Under the expansion plan of Rourkela Steel Plant for 3.99 MTPA of saleable steel, a new 4.3
m wide Plate Mill has been installed. The Plate mill will be installed in two phases, initially
with capacity of 1.0 MT (0.92 MT saleable), which shall be augmented, to a capacity of 1.8
MT (1.674 MT saleable). The mill is capable of rolling a wide range of products.
Input:
Continuous Cast Slabs
Length = 2200 to 4100 mm
Width = 1200 to 2400 mm
Thickness = 210 to 300mm
Output:
As rolled plate
Finished plate
Length = 6000 to 15000 mm
Width = 1500 to 4100 mm
Thickness = 6 to 100 mm
The Plate Mill has been set-up as a green field project in an area of about three lakhs square
meters with newly built covered bays to accommodate the mill and associated facilities
including storage of slabs and finished plates.
The Plate Mill has equipment with state-of-the-art technology to produce plates with close
tolerances to meet stringent international standards. The 4 Hi reversing mill is 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 measurements.
The Plate Mill has 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.
High capacity levelers with hydraulic control and under load positioning system, high
capacity trimming and cross-cut-shears up 50mm capacity has been 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 has been equipped with advanced
control systems and material tracking facilities.
It comprises of civil works laying of tracks, points, turnouts & fittings, PSC sleepers,
procurement of rails, etc. for providing logistics to the new facilities.
Brief Description:
This package comprises re-orientation of existing yards, creation of a green field coal
complex yard, additional rail head connection to Dumetra station of Indian railways,
optimal electrification of yard lines and rationalization of traffic movement with Engine-on-
Load system incorporating the state-of-the-art Signaling & Telecommunication system.
This is required for handling traffic for 15.119 MT of inward and 5.164 MT (including slag)
of outward traffic for production target of 4.5 MTPA.
A new “Green Field” yard is developed and named as New Coal Complex yard (NCCY). All
coal/CDI rakes required for RSP will be unloaded here except those for boiler coal required
for NSPCL.
This yard is connected to Bondamunda (BNDM) exchange yard and Dumetra (DMF) station
of Indian railways. NCCY will have a connecting line for emergency RSP loco movement
from Marshaling Yard. One full rake siding for loading of granulated slag with connection
from post tippling lines via a shunting neck has been constructed.
OBBP Yard:
Major augmentation in rail infrastructure proposed for dealing with the increased inflow of
inward raw materials includes provision of a direct link from Dumetra station for receiving
iron ore rakes directly from Barsuan side bypassing BNDM yard. Empty rakes after tippling
/ hopping will be dispatched directly from OBBP yard itself without drawing them to
Marshaling Yard.
A new yard had been developed at New Plate Mill front with 3 full lines for rake formation
to cater to the demand of new Plate mill.
Civil Engineering:
Considering introduction of trains with wagons having higher axle load of 30 Tons, the track
structure for all new construction in the yard is as under:-
Rails: 60 kg (90 UTS) IU Quality in Yards, 52 kg (90 UTS) IU rails in check rails on Curves.
Sleepers: 60 kg PSC Sleepers Density M+7, 60 kg PSC Special sleepers for curve, L X-ing.
Ballast and Cushion: Machine crushed stone ballast 65 mm gauge 305 mm cushion on new
tracks.
Fastening: Joints welded and sleepers with Pendrol fastenings.
Turnouts: 60 kg (90 UTS) 1 in 8.5 with CMS crossing
Turnout Sleepers: PSC Sleepers.
In total 51 km of new tracks have been added and 19 km of existing tracks have been up
graded as per above specification.
Electronic Interlocking system (EI system) has been installed for NCCY, OBBP and
Marshaling Yard. For train detection system multi section digital axle counter system
(MSDAC) is used in major portion of above yard. Multiple aspect colour light (MACL)
signals are provided.
In NCCY, OBBP and MY new panel building has been constructed and signaling
arrangement for direct reception of trains from BNDM `J’ cabin / Dumetra is provided.
Signaling arrangement has been provided up to the point where Railway’s loco has to work.
A total of 11 nos. service buildings have been constructed for S&T system installation inside
RSP.
Two new rail links from Dumetra station are proposed to NCCY and OBBP yards. New
electronic Interlocking system shall be provided at Dumetra station. Trains pertaining to
RSP can be received directly on full length Y-loops. Block working between Dumetra and
NCCY shall be introduced using TLBI with block proving axle counter. Train working
between Dumetra and OBBP shall be governed by inter panel slotting with digital axle
counter and direction panel.
Electrical Engineering:
In total 80 TKM (Track km) length of Over Head Electrification (OHE) will be done in
NCCY,OBBP, MY and track connecting BNDM and DMF station.
The OHE system will function with 25 kV power supply. For extending power supply to
different yards 4 nos. Sectioning and Switching Post (SSP) at NCCY, MY, DMF, BNDM
have been constructed.
A new 25 kV Traction Sub Station (TSS) has been constructed near MSDS-VI for feeding the
OHE system of RSP yard. 2 nos. 132/25 kV 21.6/30 MVA transformers have been installed.
For the control of power supply to the various elementary section of the yard, the Sectioning
Isolator, section insulators, Insulated overlaps have been shown in the Section diagram. It is
also proposed to provide auxiliary transformers in each of the yards for alternative power
supply to station area lighting and to meet signaling requirement in addition to the power
supply arrangement from the 6.6 kV/433 V compact indoor substation.
Yard Lighting:
35 nos. High Mast Lights have been installed at different locations of NCCY, OBBP and MY
for illumination of railway yard. 2 nos. 6.6 KC Compact Sub Station (CSS) were also
installed for supplying power to these High Mast lights.
Wagons:
41 nos. Platform Cars, 14 nos. BOI, 16 nos. BOBSN, 14 nos. Slab Transfer Cars have been
also procured for catering to increased production and internal movement of different types
of materials.
Normally the water grid pressure at the plant is around 2-2.5 kg/cm2 which is inadequate to
meet the required pressure at different units of the expansion project. Also there should be
provision of emergency water at the expansion projects, in case of power failure. To meet the
required head water and exigency need of water at various units, this package has been
envisaged with a pump house with 50 m stage height, 2000 m3 overhead tank(OHT) and
piping network of 25 km length. The pumps boost the water to the OHT which maintains
min. 5kg/cm2 pressure and acts as reservoir to meet the exigency demand of water for at
least 30 minutes at a pressure of 5kg/cm2. The maximum boosting capacity is 3200 m3/hr (4
Pumps working + 4 stand by@ 800 m3/hr)
There is also a provision of interconnection between the new and old grid of water to have
flexibility for maintenance of the grids and meet the emergence need of water in case of
any grid failure.
The 2000 m3 OHT is having concentric outer chambers of 1740 m3 of makeup water and
inner chamber of 260 m3 of drinking water with stage height of 50 m. From this OHT,
drinking water is being fed to all expansion units of RSP.
Executing Agency: M/s Blue Star Ltd., Kolkata, India & M/s CICB-Chemicon Pvt.
Ltd., Bangalore, India
This package was envisaged to augment the requirement of compressed air for the
expansion projects. In this package, two air compressors (1W+1 S) each having capacity of
220 Nm3/min at pressure of 8 kg/cm2 have been provided. There is a provision for
interconnection of the new air grid with that of the existing grid. After interconnection with
the existing grid, there is a remarkable improvement in stability of pressure in the grid, i.e.;
above 5 kg/cm2.
INTER PLANT FUEL GAS & INDUSTRIAL GASES PIPING FOR ALL
UNITS
Executing Agency: M/s UB Engineering Ltd., Pune, India & M/s Vimal Organics
Ltd., Ghaziabad, India
This package is envisaged for transportation of various fuel & industrial gases such as CO
gas, BF gas, LD gas, mixed gas, propane, LP/MP/HP nitrogen, MP/ HP oxygen, argon,
compressed air, cold blast, MP/HP steam, DM water, service water, etc. from one unit to
other unit, i.e., from the producer to the consumer so as to meet the requirements of the
expansion projects. Interconnection with the existing units/ grid has also been done. Besides
this there is energy monitoring system for data acquisition, monitoring, control & gas /
energy balancing of different IPPL parameters of expansion units.
Executing Agency: M/s CAN-Eng Furnaces International Ltd., Canada, M/s Empire
Industrial Equipment, Kolkata, India and M/s Reliable Hi-Tech
Infrastructure (Pvt.) Ltd., Rourkela, India
Special Plate Plant (SPP) of Rourkela Steel Plant was commissioned under technical
collaboration of M/s Welman, Germany in 1969 with an installed capacity of 3000 tons of
plates per annum. The shop performs heat treatment and finishing operations of the plates
for special applications mainly on defence sector. Of these, SPADE and JACKAL grades
constitute the majority of the production. Additionally, plates for fabrication of rocket
launching station, ammunition testing, marine application, etc. are also processed at SPP.
In view of increased demand of above grade of plates, an Additional Heat Treatment Line of
capacity 12,000 T/yr was conceived. The contract was awarded upon a consortium
comprising of M/s CAN-Eng Furnaces International Limited, Empire Industrial Equipment
and Reliable Hi-Tech Infrastructure (Pvt.) Ltd, Rourkela.
The facilities include a charge table for loading of plates, an Austenitising Furnace, water
quench system, intermediate roller table, Tempering Furnace, discharge roller table. The
system also includes many auxiliary facilities viz. charge table hydraulic system, auto
greasing system of rolls, air dryer system, cooling tower, pressure sand filter, caking system,
hoist for Pump House, etc. Entire facilities have been commissioned in December, 2016.
Executing Agency: M/s Mitsubishi Corporation, Japan, M/s Larsen & Toubro Ltd.,
Mumbai, India
Rourkela Steel Plant (RSP) produces a large variety of steel products which include Heavy
Plates, Hot Rolled (HR) Coils/ Sheets, Cold Rolled (CR) Products, Pipes and Cold Rolled
Non-Oriented (CRNO) Products. Various rolling and finishing units at RSP include Plate
Mill, Hot Strip Mill, Cold Rolling Mill, Electric Resistance Welded (ERW) Pipe Plant, Spiral
Welded (SW) Pipe Plant and Silicon Steel Mill.
Hot Strip Mill (HSM) is a major finishing unit at RSP which produces hot rolled coils/sheets
for direct sales as well as to feed material to downstream units like Cold Rolling Mill, ERW
& SW Pipe Plants and Silicon Steel Mill.
The existing HSM of RSP was installed in mid-1960’s for producing 1.15 MTPA of HR Coils/
Sheets, mostly of normal carbon steels. In the modernization carried out at RSP in the early
1990’s, the rated capacity was enhanced to 1.65 MTPA of input slabs. The quality of its
products, viz., thickness & width tolerances, profile & shape and metallurgical properties
are inferior to those produced from modern mills and also by the competitors. As these
products lack in quality, these are not competitive.
Installation of New HSM is needed to produce the most competitive quality in terms of (a)
thickness & width tolerances, profile & shape and metallurgical properties, (b) to enrich the
product range with thinner & thicker strips, (c) wider strip & higher coil weight, (d) higher
grades of products including API X-100 and (e) to retain & increase SAIL’s market share.
Location:
The new HSM will be located adjacent to RSP’s Slag Granulation Plant after necessary site
development. This site was earlier used for dumping BF slag and is not in use at present.
Major Facilities:
Production Capacity:
1. Input slab : 3.00 MT/yr
2. Hot rolled Coil : 2.94 MT/yr
3. Sheet Shearing Line : 0.40 MT/yr
Material to be rolled:
New Hot strip products envisaged shall include carbon structural steels, low carbon steels,
high strength steels, LPG cylinder steel, HSLA(High Strength Low Alloy), API 5LX80 grade,
API 5LX100 grade steel, steel for automotive application (IF,IFHS,BH,DP,TRIP, AHSS,
etc.), boiler and pressure vessel quality, DDQ and EDDQ steels, CQ-steels, Electric Steel
(CRNO and CRGO). The mill will produce quality strip products in terms of thickness
tolerance, profile & shape and metallurgical properties.
The mill shall include the latest features including hydraulic roll force cylinders, roll
bending & roll shifting with controlled roll, crop optimization, low inertia hydraulic loopers,
microstructure model, strip surface inspection, automatic width control, gauge control &
shape control. Automation up to level-3 shall be provided including latest models for quality
control, material tracking, slab & coil yard management.
BLAST FURNACE-I
Executing Agency: M/s Danieli Corus BV, Netherlands, M/s Danieli Corus India
Pvt. Ltd., New Delhi, India & Essar Projects India Ltd.,
Mumbai, India
Rourkela Steel Plant (RSP) was having BF-I with working volume 995 m3 (useful volume
1139 m3 each) which was installed in 1.0 MTPA ingot steel stage in the year 1959.
BF-I, which was last relined in Nov., 2001 is under shut down from Aug., 2013 after 12th
year of campaign and has produced more than 4.0 MT of hot metal. The furnace had
developed several cracks in the bosh area causing continuous leakage on the working
platform and had outlived its life.
This furnace is now being upgraded along with its auxiliaries by incorporation of modern
and proven design features to increase its productivity and make it environment friendly.
Cast house de-fuming system is being installed to take care of the fumes generated during
tapping of hot metal and CDI system has been installed to increase productivity and make it
more environment friendly.
OTHER UNITS
Revival & augmentation of Jagdishpur Steel Unit (erstwhile Malvika Steel) in Uttar
Pradesh.
Steel processing units at Lakhimpur-Kheri & Guwahati.
ERP at RSP:
RSP has joined the league of leading global steel producers by successfully
implementing Enterprise Resource Planning (ERP) software SAP. The GO LIVE was
initiated on 1st April 2012 with the deployment of the following modules.
Finance & Controlling (FICO)
Materials Management (MM)
Sales & Distribution (SD)
Production Planning(PP)
Plant Maintenance(PM)
Quality Management(QM)
The ERP infrastructure comprises of two state of the art data centres and a 10 GBPS
optical fibre network backbone. The Primary Data Centre(PDC) is located at the ground
floor of MECON building in the Administrative Building Complex where as the Secondary
Data Centre(SDC) is located in the HRD Centre. Both the data centres run on 24*7 basis
and provide uninterrupted IT services to the plant and township. The SDC is designed to
maintain continuity of business in case of a disaster.
.
The ERP Data Centres are equipped with the latest range of servers, storages,
backup devices and switches from the leading manufacturers. The database services are
provided by a set of clustered enterprise class Sun M9000 servers whereas the application
services are rendered by a bank of SUN T2 plus servers and Dell X86 servers. A central data
repository has been created with the deployment of enterprise class HITACHI SAN storage
at each location. The storages are connected through a pair of redundant CISCO SAN
switches with 4 GBPS dark fibre link. The automated data backup services of ERP is being
handled by Net Vault back-up management software with the help of tape libraries located
at both the data centres. The server farm of each data centre is connected to the RSP LAN
through an enterprise core switch. Each server farm is protected from unwanted intrusion
by a unified threat management device. The entire ERP landscape is being centrally viewed
and managed through an enterprise management software.
Physical access to the Data Centres and server rooms is being controlled by proximity card
and biometric readers. Indoor and outdoor cameras have been deployed at each site for
continuous monitoring of the activities in and around the centre. The centres are also
equipped with latest fire detection and FM200 gas based fire suppression system. The server
rooms are equipped with very early smoke detection apparatus (VESDA) and water leakage
detection system. The centres are powered by two transformers having independent power
sources for zero power outage. All the subsystems like power, UPS, AC, access, fire detection
etc. are being monitored through a Building Management system from a desktop.
ERP system integrates various shop floor activities like production planning, quality
assurance, maintenance planning with services covering marketing, materials procurement,
financial accounting & product costing. It has built interfaces with Central Marketing
Organization, Metal junction, level-II/III process computer systems & Enterprise legacy
applications. The system covers all major production units starting from OBBP & Coke oven
to Pipe Plants. In addition to the core functions, ERP provides for business intelligence by
aggregating data from ERP & Non-ERP systems. Another module called Enterprise Portal
has been put in service for providing MIS to the senior management.
In Rourkela Steel Plant, computerization has been used for various activities:
Quicker availability of information for decision making
Cost Reduction & Cost Control
Production, Planning & Control
Stricter Procurement, Inventory & Budget Control.
Production, Planning & Control area covering movement plan from CMO, planning,
manufacturing operation, testing & inspection, dispatches.
Sales invoicing from DA to accounts receivable.
In Finance areas from on-line sectional computerization to profit & loss accounting
including statutory requirements.
In Costing area from monthly cost sheet variance analysis to element wise cost
analysis.
Human Resource Information System covering employees master data, orders,
circulars, computerization of unit personnel offices.
Employee Services area covering pay slip, PF slip, Income Tax, VRS schemes,
incentive, bonus etc. till trial balance.
Maintenance area covering preventive maintenance planning, shop scheduling,
FMM equipment, Cranes, Repair Shop (Electrical).
Materials Management area from cataloging, indent, tender enquiry, order
placement, inspection, receipts, issues, budget control, ABC analysis, lead time
analysis & MIS.
Secondary Sales covering preparation of catalog of items from CDY, Idle Assets &
Secondary Products for Forward Auction, award of lots, Sale/Disposal Sale Order,
Delivery/Release Order, total SSSY operation.
Town Services covering quarter allotment to employees & non-employees, shop
allotment, private party billing & revenue collection etc.
Hospital area covering indoor patient registration, non-entitled patient billing &
revenue collection, central medicine store, dispensary & ward medicine accounting.
Plant Status covering entire Plant
CISF operations covering gate pass and loading sections.
RSP Portal:
This is a corporate website designed to run on RSP intranet. This provides a unified window
to employees to access information spread across the organization. The portal provides
access to departmental web sites, applications and RSP Mail facility running on RSP
intranet. It also provides access to websites and applications running on SAIL intranet. This
serves as a gateway to various sources of information spread across the organization.
Separate sections for News &Announcement and Events &Notifications are available for
information of the employees. At Employee Zone, an employee can view/save/print his Pay
particulars, update and view various HR and Pay and Income Tax related
declaration/nominations/advances. Appointment can be taken for OPD for medical
treatment through this site.
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 Knowledge Management portal site has
provision for functional departments to publish useful information which will be accessed by
employees across the organization.
Gateway level network traffic is monitored and protected by Unified Threat Management
Devices (Cyberoam 1000ia). Server security within RSP LAN is also maintained by using
UTMs. Client security is managed by using end user Antivirus those are updated online
through Anti-Virus Servers.
The Level-2 systems communicate with the process through Level-1 interface called a
gateway. Most of the systems have facility of material tracking and process monitoring, GUI
(Graphical User Interface) based displays, operator data screens, set-point downloading to
Level-1, communication with SUN system and MIS reports. Safety features are included in
the design using interlocks and power-reboot procedures. The computer systems which have
been implemented in the process areas of Rourkela Steel Plant are described below:
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:
Plant, Stores operations provide both service and control functions. The main receiving
stores at RSP are:
1) Central stores
2) Modernization stores
3) Refractory stores
4) Plant Stores II
5) CSM stores
6) IGH Stores
In brief the various steps in the activity chain of the Receiving Stores in RSP are as follows:
1) Receiving of materials
2) Day-book generation
3) Scrutiny and verification (Counting, checking, inspection) of materials & documents.
4) Generation of GARN (Goods Acceptance/ Rejection Note)
5) Stock charging of materials by posting of GARN’s.
6) Custody & Preservation of Materials
7) Issue of Material.
The Stock Control Section of Stores section is involved with the procurement, availability,
control and issue of Automatic Procurement Items. In brief it carries out the following
functions:
1. This is MM's material planning agency for processing indents for multi-user
Automatic Procurement (AP) items (consumables as well as spares) based on
previous consumption norms and procurement policy and specific projected
requirements of user departments.
2. Stock Control monitors the safety stock of critical multi user items and issues
materials to user departments.
3. Activities include allotment of catalogue numbers for consumables.
4. Stock Control is the nodal agency for Indent Scrutiny Committee for AP Items.
Purchase:
The section of MM is involved with the procurement functions of the revenue inputs. The
main focus is on the following factors:
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.
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.
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 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.
Coordination:
Registration of Demands from Customers and Vendors with respect to PF, ESI, Income Tax
Sales Tax, and Service Tax circulating it to all sections in time to recover the dues,
Preparation of Purchase Requisition for local Purchase Post office, Consultants and
Miscellaneous Bills, Maintenance of Services and Leave Records. Preparation of monthly
attendance sheet and feeding the same in Online Attendance system.
RMB&A
It deals with Payment and accounting of bills of suppliers of limestone, dolomite,
quartzite, sand, clay, coke etc. and of contractors for handling, screening public analyst,
internal shifting of materials etc., Accounting of receipts of materials from RMD mines
and sister plants, imported coal from BTSO, indigenous coal from CCSO, Accounting of
materials transferred/ diverted to sister plants.
Preparation of invoices:
Sales Invoices are prepared for despatch 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 . With effect from 1.7.2017, RSP”s Sales
Invoices are GST compliant. All provisions of GST Act are taken care of in invoices.
Taxation:
Taxation section deals with Payment of Excise duty, Orissa VAT and Service Tax,
Reverse charges and availment and maintenance of records for Input Tax Credit, CENVAT
credit on account of Excise duty and VAT. With effect from 1.7.17, GST has been introduced
and compliance with respect to payment of Tax, availment of Credit, Filing of Return,
Conduct of Audit and maintenance of all relevant records are taken care of.
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 organizational requirements
and objectives. Besides, thrust is also put for optimum utilization of the human resource by
way of redeployment, retraining etc.
Motivating Employees:
In order to encourage the employees to maintain consistently high levels of performance,
Personnel department facilitates the introduction & implementation of various financial &
non-financial motivational schemes& awards. The schemes are both group and individual-
based. Various schemes are in place linked to achievement of departmental targets based on
production, productivity, cost control, quality-consciousness etc. Besides these the
personnel department also plays an active role in facilitating nominations for
national and International level awards.. Apart from these, good performance is also
recognized through in-house newsletters, magazines, RSTV, Departmental Notice Boards,
appreciation letters etc.To motivate the employees, the family of the awardee in
some awards is also felicitated in special functions.
aid, medical facilities, baby crèche etc. Besides Personnel department facilitates the
implementation of all social security measures in vogue in the organization viz. PF,
Gratuity, Workmen’s Compensation, Group Personal Accident Insurance Scheme (GPAIS),
Employee Family Benefit Scheme, Employee Family Benefit Voluntary Scheme, Life Cover
Scheme, SESBF etc.
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:
Besides these Unit Personnel Executives also communicate various plant related issues to
the employees at shop floor.
Away from the traditional fire-fighting management, the Personnel collective believes in
pro-active IR management through involving the employees in all spheres of work activities,
cultivating a participative culture and creating a atmosphere of creativity. Various
committees and bodies are in place at both the departmental and central level so as to
involve the employees in various issues of significance for the Plant as well as the welfare of
the employees.
Online HR Service
To improve the responsiveness of the Personnel department and to provide better services to
the employees, Personnel department is continuously working on simplification of various
rules and policies and also to incorporate new technologies to improve various HR services.
Accordingly, many HR services are now available Online to provide latest information and
better services to employees.
Employee Engagement
The employees apart from various communication forums are also engaged through in-house
activities, games and various competitions to keep them informed and also to ensure their
participation in the development of various initiatives of the organization. Some of the
engagement initiatives like Spouse Visit (Pragati ra Pathe Ama Paribar Ama Sathi), Annual
Synergy competition, Quiz competition, Rangoli competitions, slogan competitions etc.
Apart from Regular employees, thrust is also given to engage employees even after
separation through online portal Sampark and other forums.
In line with its growing scope of the activities, the infrastructure of the HRD Centre has
grown over the years. The earlier building and workshop complex was installed in 1959. In
1984 the ground floor of the present MDP wing was installed and in 1993 the first floor of
the MDP wing was built. The Refractory Shop came up in 1993. Keeping in view the need to
increase the competency level of employees to cope with the advent of latest technologies,
the Hydraulics & Pneumatics Laboratory was commissioned in 1993 with the equipment
supplied by M/s Amatrol INC, USA and the Electronics Laboratory was commissioned
during 1994 with equipments from M/s Feedback UK. The Computer Centre was installed
in 1989.
Prepare
Annual Training Plan
Does
Programme No
Exist?
Create &
maintain Yes Design New
Learning Programme
Environment
Conduct
Programme
Maintain &
Provide Training Review
Aids Evaluation
parameters
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, Cost,
IMS, OHSAS, SA, etc.
Other Areas: Various workshops / seminars, Hindi Training etc.
The Institute was accorded the highest recognition of being a Category – I Institute by
Central Electricity Authority (CEA) in 1996 empowering it to train operation and
maintenance personnel of Thermal Power Plants having unit size up to 500 MW.
Recipient of the Golden Peacock Award in 1999, CPTI was brought within the fold of HRD
Centre, Rourkela Steel Plant in July 2004. During February 2007, CPTI was also certified
under the ISO 9001 Quality Management System.
As an ISO 9001 QMS certified and Category –I Institute, recognized by Central Electricity
Authority, Government of India; which also has the proud distinction of being a winner of
the Golden Peacock National Quality Award, the Central Power Training Institute has been
conducting power related training programmes, workshops, seminars etc. and facilitating
the conduct of Special Events for SAIL and Non SAIL personnel to integrate the process of
human resource development with the overall corporate vision of the organization.
The activities at CPTI are primarily directed towards providing training to personnel
engaged in the field of Operation and Maintenance of Thermal Power Plants, Power
Instrumentation, Power Management, Transmission and Distribution. It also identifies and
assesses special training needs so as to fulfill obligations under IE Rules regarding
mandatory qualification of power plant operators thereby enhancing the competence of
personnel in power related areas in and around Orissa.
Focus of CPTI:
To contribute towards fulfillment 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.
team of dedicated workforce, CPTI continues to contribute steadily toward enhancing the
HRD functions in the organization as well as in other power related organizations within
the country.
Personal Computers:
It has a network of 8 PCs. Every staff has access to the PCs. Correspondences, trainee
manuals, reading material, teaching notes and trainers’ manuals are prepared using
these computers. The Institute has adequate number of laser / other printers for this
purpose. Formats are standardized and computerized to ensure adherence to ISO norms.
Modern training/ teaching tools:
LCD projector, OHP, TV, VCR, DVD Player, Electronic copy board, Document binder,
photocopy machine, laminator, Laser printer and personal computers are used for
enriching the programmes. Training related Video cassettes have been converted into
CD/DVDs and these are extensively used in the programmes. Teaching Notes/ Reading
Material are distributed to participants in only CD form now. Facilities for audio / video
recording of proceedings and syndicate discussions are hired whenever needed.
Model Room:
Large number models of power plant equipment, exhibits and schematic drawings are on
display in the Institute. Exclusive model room for housing working models and mimic
display boards also exist.
LAW
In an integrated steel plant like RSP, the role of Law department is manifold. It acts as an
adviser to the Top Management and gives a shape to the policies relating to Production,
Marketing, Administration, Health, Welfare, Safety, Land, Estate, Finance, Taxation etc.
Law department 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.
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.
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 12 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 contracts for the jobs executed in the township by different departments like
Town Engineering, Town Administration, IGH etc.
For encouraging sports, the number of sports complexes like Ispat Stadium, Biju Patnaik
Hockey Stadium, Basket Ball Court, Indoor Stadium and various other Sector playgrounds
are kept in good condition.
The Civil Wing of the Department maintains 365 KMs of roads and drains, 315 KMs of
sewerage system spread over the entire townships. As part of the drive for a clean and
hygienic Rourkela, Door-to-Door garbage collection and its systematic disposal from all the
residential quarters and market complex, project has been started, which is the first of its
kind among all the SAIL Units.
The department also provides logistic support during various socio-cultural functions held in
the Township as part of the cultural calendar for enhancing the quality of life of the
residents and creating an atmosphere of entertainment and enjoyment.
Vital installations are also maintained timely to meet the statutory provisions of the Factory
Act and State Pollution Control Board, 32 vital installations, which include 33 KV/11 KV
Sub-Stations, Booster Pump Houses, Intake Wells, Water Treatment Plants and Air Strips,
are kept clean and in good condition with proper approach. The department in close liaison
with the Corporate Social Responsibility Department also provides various basic facilities
like class rooms for Schools, Community Centres, roads, etc. in the peripheral villages.
Providing drinking water facilities through new tube wells and repair of old defunct tube
wells, repair of roads and drainage system in the slums of Steel Township are some of the
activities undertaken by the department as a part of fulfilling RSP’s Corporate Social
Responsibility. The department as a part of its constant endeavor 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. De-
chlorination of the wells and spray of anti-larva on swampy areas and on stagnant water are
also some of the major activities of the department. Public Health also has undertaken one
project on dog sterilization in collaboration with Rourkela Municipal Corporation.
33 Kv Distribution Network:
Two Receiving Sub-Stations at Sector-6 & Sector-2 consisting of 33 KV/11 KV power
transformer & auxiliaries are to be maintained round the clock. The capacity of Sector-6
Receiving Sub-Station is 41.4 MVA and that of Sector-2 Receiving Sub-Station is 18
MVA. Power is fed at 33 KV Volt level from Plant through overhead lines to these
Receiving Sub-Stations.
11 KV Distribution Network:
There are 23 numbers of 11 KV feeders to cater power to the entire Steel Township. Of
these 15 numbers feeders originates from Sector-6 Receiving Sub-Station and 8 numbers
from Sector-2 Receiving Sub-Station.
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 LED of various wattages, HPSV, Semi High-Mast, High Mast, Metal
Halide and MV fittings etc. which also covers all the erected monuments in & around the
Steel Township.
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 38 MW with an average of nearly 24 MW of power.
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.
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 stabilization 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, 2870 acres of
intensive green areas with 200 acres of gardens, 4 central Nurseries and 41 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 45 lakhs trees have been planted in and around Rourkela. Over 2870 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.
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. Boating facility, Doll Museum, Aquarium, Zoo
and Musical fountain are some of the added attractions in the park. A Children Play Arena
having 7 nos. of play items create jubilation amongst the toddlers at all times. 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 169 animals and birds of 22 species including 6 species of mammals, 13 species of
birds and 3 species of reptiles are being nourished in the Indira Gandhi Park Zoo,
maintained by the Department. Among the animals, 118 spotted deer are being housed in a
separate section named as Deer Park at Sector-8 in an area of 5 acres near Jubilee Park.
Ispat Nehru Park at Sector -19 with an area of 27.5 acres was dedicated to the public on 2nd
June 2013. The park with its natural beauty has a boating facility at small lake, XD theater
and kiosk for refreshment. The undulating grassland with fitness path among the seasonal
flower beds attracts many morning walkers and visitors to the park
The Horticulture Department also plays a vital role in maintaining the greenery in the
plant premises. The gardens in the Administration complex and in the HRD Centre are
maintained, adding beauty to the buildings and its surroundings. The department also
supplies materials and necessary horticultural skills to all the departments to enable them
to develop gardens inside the works.
TOWN SERVICES
Rourkela Steel Plant, the first Public Sector Integrated Steel Plant of the country came up
as a Greenfield project in the backward and remote district of Sundargarh. For
establishment of the Steel Plant & its Captive Township land was acquired under the
provisions of Orissa Development of Industries,
Irrigation, Agriculture, Capital Construction & Re-
settlement of Displaced Persons (Land Acquisition)
Act, 1948 (Orissa Act, XVIII of 1948) by the
Government of Odisha 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 Government of Odisha on
01.07.1993. Over a period of time on the request of the Govt. of Odisha, RSP has
surrendered a vast area of land measuring Ac 4514.62 to cater to the requirements of Govt.
such as construction of Regional Engineering 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 Odisha 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 & Brahmani, Rourkela is acclaimed as Industrial Capital
of Odisha. Adding to the glory of Rourkela, RSP Township enjoys the status of “FIRST
INDUSTRIAL TOWNSHIP” in the country w.e.f 15th April 1995 as declared by Hon’ble
Governer of Odisha. 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 centers & other modern amenities etc.
Rourkela Steel Plant has been maintaining the entire township covering 24297 quarters of
different categories & about 4534 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 2400 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 365 kms pucca
road. All the main roads of the sectors are connected to the ring road spreading over 16 kms
within the Steel Township.
Rourkela Steel Plant has its own water supply system to cater to the needs of the residents
of Steel Township. It supplies 12 million gallons of water per day through a network of
around 510 KM of water supply line. Due to drying up of river Koel during summer,
augmentation of water supply from the alternate reliable source –river Brahmani has been
connected to ensure uninterrupted supply of water to the residents of Township.
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, 154 electrical
substations and 1826 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.
In the township, to provide recreational facilities there is a big library namely Utkalmani
Gopabandhu Ispat Library having 51058 nos of books in 12 different languages with the
membership of 3500 persons. There is one large auditorium called Civic Centre, 6 Social
Homes & 16 Community Centers situated in different sectors. RSP actively encourages and
supports socio-cultural activities.
RSP runs and maintains 02 English Medium School and one +2 school in different parts of
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.
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 multipurpose 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.
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.
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
theState as a whole. The Rourkela Steel Plant teams became Champion in Hockey in Inter
Steeland Runners up Badminton, Football in 2016-17. Received many individual medals at
national level on Cycling, Boxing and weigh lifting in 2016-17.
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. Three Cadets from Hockey Academy selected to play for Jr. India in Asiad as well
as Olympics Championship in 2016-17. 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.
Though the concept of corporate social responsibility has assumed importance globally in
the last couple of decades only, Rourkela Steel Plant has recognized the importance of this
concept and practicing it religiously since last nearly four decades, from 2nd October, 1974
to be precise, through various community development and peripheral developmental
programs.
Corporate
Peripheral Community
Social
Development Development
Responsibility
The CSR interventions are focused in the peripheral areas of Rourkela, i.e. in the adjoining
revenue villages, Resettlement colonies and Model Steel Villages.
The CSR interventions have been taken up in and around Rourkela in multifarious domains
such as,
1. Promoting Education,
2. Promoting Health Care,
3. Infrastructural Development,
4. Income Generation & Livelihood,
5. Water & Sanitation,
6. Women Empowerment,
7. Support for physically/mentally challenged,
8. Promotion of Sports & Culture, etc.
The CSR Committee of Rourkela Steel Plant, comprising of Senior Executives from different
disciplines, formulate the CSR plan in line with CSR Policy of the Company.
For effective implementation of the CSR plan and strategies, an exclusive CSR Department
has been created. A facility called the Institute for Peripheral Development has been
established, which serves as a hub for all the CSR activities of Rourkela Steel Plant.
The major CSR activities of Rourkela Steel Plant are described below.
EDUCATION:
Deepika Ispat Sikshya Sadan, a school for the underprivileged children established since
2007 is imparting free education and with free uniform, books, shoes and free mid-day
meals. The school is presently having classes up to X with 575 students.
In order to promote education of tribal students from the remote interior areas, Rourkela
Steel Plant has sponsored 18 such students for their education at the Kalinga Institute of
Social Sciences (KISS), Bhubaneswar.
Education is the backbone of any developed Nation. The mid-day meals scheme of the Govt.
aimed at improving the nutritional status of the children and also to improve the school
attendance and reducing school dropout rates. The growing instances of poor hygiene and
inefficiency in the implementation led to taking up of this scheme along with State Govt. &
Akshay Patra Foundation.
Rourkela Steel Plant-CSR has supported the establishment of a hi-tech centralized kitchen
with a capacity of cooking 45000 meals a day and distribution methodology ensuring high
degree of efficiency, hygiene & balanced nutritional diet.
An idle building of Rourkela Steel Plant has been utilized for the purpose. The entire capital
expenditure of Rs.823 Lakhs has been incurred by Rourkela Steel Plant. Operational
expenses are partly incurred by Govt. & partly by
Rourkela Steel Plant which translates to Rs.260
Lakhs per year. Presently, up- gradation of the
kitchen infrastructure is being carried out with
additional support of Rourkela Steel Plant to the
tune of Rs.80 Lakhs.
The Mid Day Meal facility through Akshay Patra at
Rourkela is covering around 52000 students from
418 schools of Rourkela Municipality area, in
addition to the entire Lathikata & Bisra Blocks. The
first distribution system started on 16th November,
2013 with Rourkela Municipality Schools and then for all areas from 2nd December, 2013.
The facility got formally dedicated by Hon’ble Chief Minister of Odisha on 23rd February,
2014.
Healthcare facilities are made available & accessible through free medical aid centres
functioning on bi-weekly basis at 34 peripheral locations including the Model Steel Villages
and Resettlement Colonies.
Community Based rehabilitation (CBR) Program: Monthly camps held at four peripheral
locations for the mentally & physically challenged:– Kalunga, Kuarmunda, Bandamunda
and Jalda.
Multi-disciplinary medical camps are organized in various locations in the peripheral areas
where patients are examined and treated by Specialist Doctors for problems such as eye,
ear, pediatrics, gynecological, surgical & skin
problems, cleft lip & Palate Disorder and patients
are also identified for advanced treatment at the
Ispat General Hospital under the specialized
targeted projects such as:
Sunayana (for visually impaired)
Sushruti (for hearing Impaired)
Surabhi (for gynecological disorders)
Swabalamban (correction of cleft lip & palate, hair lip, congenital cataract, club foot
etc.)
RCH & Family Welfarecamps are also conducted at IGH, in association with Govt.
Backyard Poultry: A project on backyard poultry has been taken up in Jamsera village,
which will be expanded to other villages as well.
Steel Fabrication: A program on Skill and Entrepreneurship Development has been taken
up through the Institute for Steel Development & Growth (INSDAG) for 30 persons from
peripheral areas, to enable them to have their own steel fabrication units.
INFRASTRUCTURE DEVELOPMENT:
Various infrastructural facilities such as roads, culverts, village community centers, class
rooms, school boundary fencing, shopping complex, market platforms etc. have been
constructed in Model Steel Villages and other peripheral locations.
Major infrastructural developments carried out in recent years include roads at Lachhada
and Jhandapahad RS Colonies, class rooms at Sovaniya Sikhyashram (Lathikata),
Kansbahal College (Laing), Jalda School and Vedvyas High School, science laboratory
building at Bisra High School, open market platforms at Munda Market (Ispat Haat),
renovation of health centres at Jalda &
Chikatmati villages, development of river ghat at
Jhirpani etc.
Construction of new gynecology
ward(1st Floor) at RGH, Rourkela is
completed.
Construction of kennel, OT & isolation
ward at Govt. Veterinary Hospital,
Rourkela is completed.
Construction of Health Center at Telijore is completed.
Construction of bituminous road from Ushra Colony to Mandira is completed.
Repair/Construction of roads in Jalda RS Colony done.
Sinking/repair of tube wells in slums areas of Rourkela.
Construction of public convenience facilities at Rourkela Railway Station is
completed.
Construction of Kalyan Mandap and Public Toilet at Bargaon, Sundargarh.
Construction of Entrance Gate and area development at Rourkela Railway Station.
The following infrastructural development activities are under progress:
Construction of ramp for Missionaries of Charity at Nirmal Bhawan Hansen’s Care
Centre.
Construction of Community Centre at Laing (Mahuldihi)
The typical scene used to be people, particularly the women, lining up before the stand
points or hand pumps or dug wells, or covering a distance to go to the nearby stream, river
or pond. In the sanitation domain, open defecation had been the normal practice.
Besides, corpus fund for major maintenance/expansion has also been generated through
contribution of amount upto Rs.1000/- from each villager.
The project has been planned in 20 villages in the peripheral areas. The project is completed
in 9 such villages and further 9 villages are in progress.
Rourkela Steel Plant has contributed to the Hon’ble Prime Minister’s vision of Swachh
Bharat, by constructing 247 Toilets in schools located in Bisra, Gurundia & Nuagaon blocks
and in Rourkela Municipality areas.
WOMEN EMPOWERMENT:
Project Kishori:
Women, especially in the Indian context, assume a
pivotal role in the development of the society. It is said
that educating a woman means educating a family
and hence empowering a woman would tantamount to
empowering a family. It is in this context that an
exclusive project – The Project Kishori, has been
adopted under CSR activities of Rourkela Steel Plant,
for women empowerment.
This project envisages to create a significant impact in enhancing the women's sense of self-
worth, right to have and to determine choices, to have access to opportunities and resources,
to have the power to control their own lives, both within and outside the home and their
ability to influence the direction of social change to create a more just social and economic
order at the local level, which would subsequently have a cascading effect at regional,
national and international levels. In order to sustain the initiative even after completion of
the project period, the project has been designed with four distinct phases of Development –
Sustenance – Stabilisation - Withdrawal. Its main focus is village women, adolescent girls,
pregnant women and lactating mothers. The project has been implemented in 50 no. of
peripheral villages.
Women Resource Centres (WRCs) are created in each village which serves as the hub of
women empowerment activities in the village concerned. From each WRC, Master Trainers
are selected and trained on different modules involving soft & hard skills. The Master
Trainers in turn train and equip the girls and women in villages. Total 200 no. of Master
trainers, belonging to 50 peripheral villages, are already trained on different training
modules. Total number of members enrolled in the WRCs is more than 1000.
In order to deal with the hardware and software development of women & girls, the training
modules have been carefully planned and strategically designed like:
Food Processing
Mushroom Cultivation
Improved Chullah
Health & Hygiene
Women’s Rights
Leadership
Food Adulteration Test
Vermicomposting
Soil Testing
Land and Water Management
Artificial Jewellery Making
Handicrafts & Paper Bag Making
COMMUNITY RECOGNITION:
The CSR endeavors of Rourkela Steel Plant have been well appreciated by the community,
media and the society in general. The Media, both print as well as electronic media, have
highlighted the CSR efforts of Rourkela Steel Plant from time to time. The Community,
particularly the peripheral population, has also highly appreciated the endeavors. An
independent assessment was conducted by the NABARD’s Consultancy Wing which
revealed that majority (more than 85%) of the population is satisfied with the CSR
interventions of Rourkela Steel Plant. Further, in a study conducted among Sarpanchs of
peripheral areas, they have rated the CSR interventions of Rourkela Steel Plant at 4.5 in a
scale of 1 to 5.
PUBLIC RELATIONS
Defining PR:
Public Relations is the deliberate, planned and sustained effort to create mutual
understanding between an organization and its stakeholders.
Target Audience
INTERNAL (Employees)
EXTERNAL (Govt., financial institutions/banks, customers, community neighbours,
policy makers, govt. agencies, suppliers, general public, media et al)
Objectives
Corporate image building
Reinforcing the image of SAIL, Rourkela Steel Plant as a profitable, progressive and
vibrant organization that cares for all its stakeholders
Acting as a catalyst in employees adopting the philosophy of ‘SAMVARDHAN’ the
mission statement of RSP that focuses on ushering in sustainable and inclusive
growth in the entire region.
Establishing the organization as a Socially Responsible Corporate Citizen
To create a sense of pride among the stakeholders
Challenges
To propagate the vision and values of the organisation and help achieve business
goals in a changing scenario
Facilitating the change in the mindset for adjusting to new situations
Establishing effective communication channels both internal and external to
promote Company’s policies and image amongst the employees of the organisation
and different groups
Creating a climate of confidence and trust amongst the employees and stakeholders
To keep pace with the growing media requirement
Obtaining and evaluating opinions to provide feedback to the management and
enlist employees’ involvement.
Focusing employees in every communication initiative
Communication
Daily news for RSTV.
Daily uploading of news in RSP Portal
Uploading of visuals and other important communications in RSP portal
Uploading of news and photos on Facebook and Twitter
Making creatives for Social Media
Press Releases : Regular and paper specific
Special features for newspapers and magazines
Media Relations
e-Ispat Sahayog in three languages.
Printing of brochures, folders, posters etc. and designs for hoardings
Exhibitions
Messages of CEO, Speeches, Appeals etc.
Scripts and story boards of documentaries & films.
Creating and Facilitating Advertisement Campaigns.
Inputs for SAIL news, website & corporate publications
Promoting the social media ventures of SAIL at local level
Content of Communication
Priorities of the Plant
Future Challenges
Production and productivity
Achievements of employees/ family members
Safety
Quality
Cost Control
Environment Management
Cultural Programmes
Other events and happenings etc
A/V Unit
Glimpses for RSTV News
Photos for e- Ispat Sahayog
Photos for various Corporate publications, notebook, calendar and exhibitions
Operation and regulation of photo printing contract
Presentation of albums/DVDs/USB drives carrying photographs to VVIPs
Special Purpose Still Photography :
Press releases
Statutory, Insurance, Factories Inspector, Police inquest etc.
Booklets & Brochures
Exhibitions
Documentation Centre
Daily Press Clippings to CEO and all EDs
Computerised data bank on clippings & different topics
Media Analysis
Record Keeping
Library
Miscellaneous Jobs
Releasing of Statutory Advertisements (Tenders, Inquiry Noticesand Appointment
Ads etc.)
Releasing of Goodwill Advertisements
Distribution of SAIL News/ Wall-sheets/Posters/Diaries
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
AdministrationBuilding. 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 andIspat Niwas
containing 27 No. of air-conditioned as well as Non-air conditioned rooms.
Hill View Ispat Guest House at Sector-4 having 36 rooms
Further, the maintenance and management of the Rourkela Air Strip is the responsibility of
the Hospitality Services unit.
VIGILANCE
‘Vigilance’ is a management function required to bring and sustain propriety and integrity
at all levels in an organization. This is very relevant and important in Government
Departments and Undertakings for safeguarding against the misuse of public money so that
survival of the undertakings will be possible in today’s economic scenario.
The functions of Vigilance Department in RSP can be categorized into two types:
Preventive Vigilance
Punitive Vigilance
Preventive Vigilance:
Prime focus of Vigilance is prevention of corruption rather than investigation of corruption.
Preventive vigilance activities consists of –
Surprise checks in different areas particularly in sensitive areas i.e. places prone
to corruption such as shipping, finance, purchase, sections dealing with execution
of contracts etc.
Identifying weaknesses in existing procedures/rules & regulations and
suggesting improvements to plug loopholes and bring greater transparency in
exercise of power.
Initiating formulation of new procedures/guidelines
Scrutiny of AIPR (Annual Immovable Property Return) files of employees
Scrutiny of contract/purchase files to check any violation of Purchase & Contract
Procedure 2009 (PCP 09)
Rotation of employees in sensitive postings. As per Central Vigilance
Commission (CVC) guidelines, employees manning a sensitive post should be
rotated after completing 3 years.
Developing vigilance awareness through regular training programs.
Punitive Vigilance:
This deals with providing adequate punishment to the wrong doer promptly so that it serves
as a deterrent for others. An employee is given major punishment only after the charges are
established against him through a regular departmental inquiry (RDA). Conviction under
Departmental inquiry is based on ‘Preponderance of Probability’ rather than ‘Proof beyond
reasonable doubt’ which is the rule for conviction in judicial proceedings. Standing Order
and Conduct Discipline & Appeal Rule 1977 provide a non-exhaustive list of misconducts for
which an employee can be punished.
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.
INTERNAL AUDIT
Internal Audit Department of RSP is an integral part of Corporate Internal Audit (SAIL). It
is a statutory requirement as per Company’s Act. Accordingly an Audit Committee was
constituted by SAIL Board. For effective functions of the same, Internal Audit department of
various plants/units of SAIL functions as a part of the Corporate Internal Audit.
o The Inventory levels are managed to the best commercial advantage and for
improved market presence.
o The Funds are managed to the best commercial advantage.
o The appropriate expenditure is incurred.
Heads of Internal Audits (HOIA) conduct monthly review meetings to review the
progress and status of various Audits and also the findings there-of. Wherever
necessary the matter is taken up with higher authorities for necessary action against
various Audit observations.
A monthly report as per standard proforma is sent by HOIA to Corporate Office
detailing the number of audits scheduled, done, number of PR & FR issued with
details and various Significant Audit Findings (SAF) status thereof.
Quarterly report is submitted to CEO, RSP by HOIA detailing the various activities
and significant observations for kind perusal of CEO.
Quarterly HOIA meetings are held by ED (IA) to review the audit activities of
various units, status of SAF etc. and also to discuss various other issues like new
rules/ regulations or modifications there-of.
Action taken/proposed to be taken (with time frame) are to be indicated by the auditee for
the audit recommendations which are acceptable to them. Wherever the auditee does not
agree with the observation/suggestion/recommendation, the same is to be clearly mentioned
with reasons for disagreement/suitable explanation.
A 600 bed hospital, Ispat General Hospital (IGH) was the first hospital in the industrial
sector to initiate the concept of Intensive care, Burn care, Haemo-dialysis, Nuclear medicine
laboratory, Molecular Biology Laboratory, Whole body Ultra Sound, 16 Slice Spiral CT
Scan, M.R.I, New Super X-Ray etc. It was also
among the first industrial hospitals to start
innovative medical procedures which include
implantation of Single and Dual Chamber
Pacemaker, Total Hip replacement, Total Knee
replacement, Phaco emulsification cataract
surgery, THD-Transanal Haemmorhoidal
Dearterialisation- a latest painless technique for
piles operation etc.
The Steel Township has three Health Centres to provide basic health care and also to
impart health education. There is also a hospital in Sector-22 with bed strength of 10. Three
nos. of Free Medical Consultation Centres have been set up in Sector-6 (Ispat Sanjivani),
Chikatmati and Jalda areas to provide free medical care to the poor sections of the society.
Treatment of around 15 lakhs outdoor 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.
RSP was the first to start a full-fledged Occupational Health Service (OHS) Centre in SAIL
and in Orissa. The OHS activities include 3 Ps of Health care, namely pre-employment, pre-
placement and periodic checkups. All the employees are covered under 'Man Maintenance
Programme'. Special health checkup for ‘high risk groups’ is being done regularly. The aim
is to check health status of all employees every year.
A new training hall “Avigyan” and a library based unique Museum were inaugurated in
April 2017. The waiting area for employees has been air-conditioned. A new 30 bedded
Disaster Management Unit “Dhanwantri” was inaugurated at OHSC of RSP. The aim is to
extend immediate and expert medical care to the employees in case of any exigency inside
the plant premises. The unit also organised the first ever conference of Occupational Health
in the Steel Sector, at Rourkela about two decades back.
Diagnostic and therapeutic Hi-Tech instruments have been installed for quick diagnosis and
better health care such as:
1. Fully automated Olympus AU-5800, I-1000 SR immunoassay, C-111 auto analyzer, B-
121 blood gas analyzer and Digital Flame Photo meter in the biochemistry lab.
2. Digital X-Ray system
3. Uretero Renoscope
4. Plasma Sterilizer & High Speed Sterilizer in OT
5. Phaco Surgical Instruments
6. Cardiac Defibrillators and Monitors in ICU
7. Whole body ultra sound & Color Doppler
8. Laparoscopic Hysterectomy Instrument
9. Fully automated Ac. T 5 diff CP Coulter Monitor
10. 15 Tesla M.R.I
11. 16 slice spiral CT
12. State of the Art, Air-conditioned Physiotherapy Centre
13. Electro Hydraulic Orthopedic OT Table
14. Portable USG Machine in OT
15. Thoracoscope
16. Central Oxygen Delivery System with Liquid Oxygen plant.
For the benefit of economically weaker sections of the society staying in and around
Rourkela, surgical procedures are carried out, free of cost, under projects Charaka and
Swawalamban as the CSR initiatives of RSP.
Medicine:
The Medicine unit has combined services along with academics. It has various sub-
specialties 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. ERCP has now become a routine procedure
and many specialized procedures like endoscopic stone removal, ballooning, stenting, etc.
are also performed. This unit is recognized 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 Organization (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 comparison 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 recognized by the
World Health Organization 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.
In addition to the responsibility of the mother care, these units involve in the national
programme for the family welfare. These units organize monthly camps for family welfare,
awareness and immunization.
SURABHI- a project under CSR provides free consultation and treatment to women
related to gynecological problems, including operative management.
SNEHA- a project under CSR has been undertaken for underprivileged leprosy patients of
the society. The project envisages of fundamental medical management and rehabilitative
surgeries of the leprosy patients. The Dental unit is equipped for dental surgeries and
artificial dentures.
The renovated Mental Health department was inaugurated in Dec 2016 by CEO. The goal of
this department is to help disabled individuals to develop the emotional, social and
intellectual skills needed to live, learn and work in the community with the least amount of
professional support. In order to achieve the same a meditation centre has also been
developed in this unit.
SUNAYANA, the community ophthalmology project for patients of the peripheral villages
adopted by RSP for free cataract removal operations and Medicare.
SUSHRUTI- a project under CSR has been undertaken for children up to 15 years of
peripheral villages and slums, with hearing impairment.
EYE BANK - “Ispat Drushti Daan” started functioning since 1st April 2014. The goal of
this is to provide a new life to a blind person. Till date the results have been very
encouraging and many people are coming forward to donate eyes of their deceased relatives.
Laboratory Services:
These are the backbones of any good hospital. The Bio-Chemistry Lab is recognized as one of
the finest Labs in the country, as it regularly occupies top ranking 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.
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
computerization 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. The patient waiting area in
Nehru OPD of the hospital has been fully air-conditioned for the benefit of patients. The
dispensary hall, waiting areas in front of OT’s I & II have also been air-conditioned.
Information Centre:
An information centre has been started in the lobby in front of main gate for the benefit of
patients and attendants.
ORIGIN OF CISF:
Government of India created the post of Industrial Security Advisor in 1961 as a need was
felt to review existing security arrangements in various Public Sector Undertakings in the
country. Shri S N Dutt was appointed as Security Advisor in the Department of Industries
and he recommended that a uniformed Force is to be raised to look after the security of the
Public Sector Undertakings.
The need for a specialized security Force came into sharp focus after the disastrous fire in
Heavy Engineering Corporation Plant at Ranchi on 29th January 1964. A Commission
headed by Justice B Mukherjee was appointed to enquire into the cause of fire. Since in the
enquiry it was revealed that sabotage was committed, he recommended for creation of a
Central Security Force for providing better protection and security to Public Sector
Undertakings (PSUs). A Bill was brought before the Parliament for setting up of Central
Industrial Security Force (CISF) in August 1966 and after thorough security and certain
amendments, it was finally passed by both houses of Parliament and received President’s
consent on 02.12.1968 by a notification in official Gazette.
CISF came into existence in 1969 with a sanctioned strength of only three Battalions. In the
beginning CISF was inducted in only two Undertakings. Currently CISF is providing
security coverage to 336 Government establishments as well as private sector
establishments (including 61 International and domestic airports) spread all over the
country in 84 different establishments Fire Protection is also being provided. It is a
testimony to the level of professional competence by the Force over the decades that its
services are being sought for consultancy by more than 140 different private sector also.
CISF Act was amended in 1983 and the Force was declared the Armed Force of the Union on
June 15, 1983. The original charter of CISF was to provide protection and security to the
property of Public Sector Undertakings. It was amended in 1989 by Act No.20, which
entrusted the responsibility for providing protection to the employees of Public Sector
Undertakings within their premises to CISF. CISF Act was again amended by Act No.40 of
1999 which enlarged the charter of -
(i) Providing Technical Consultancy Services related to security of any private Sector
industrial establishments
(ii) To protect and safeguard the organizations owned or funded by the Government and
the employees of such organizations as may be entrusted by Central Government and
(iii) Any other duties which may be entrusted by Central Government from time to time.
CISF Act was further amended in 2009 which broadened the scope of CISF Protection for
Joint ventures undertaken by the Government and Private sector as well as also to Private
Industrial Undertaking along with public sector undertaking. CISF, which made a
beginning with a sanctioned strength of 3192 in 1969, has grown to strength of more than
one lakh forty thousand. CISF is the only Para Military Force to have a Fire Fighting Wing.
Now a day the functioning of CISF is not only existed within the periphery of Industrial
Undertakings but CISF is also being deployed for Election Duties, Internal Security Duties,
VIP security ,National monuments security duty, Government Building Security, Metro Rail
Security, Rescue Operation duties through the CISF NDRF Battalions, private sector
establishment security ,UN Mission duties etc.
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: -
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 and social awareness
programmes are also being organized by CISF in Bisra Camp Complex, CISF Auditorium
and in nearby area. 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.