Status of the Project

2
2
 Major Projects Commissioned in 2012-13

Sl Major Facilities Comm. Date

1 Coil Packaging Line- CRM III Jun’12

2 Cast House- 6 Oct’12

3 De-Bricking Machine- SMS II Nov’12

4 SPU Bettiah Dec’12

Mar’13
5 Server based telephone exchange (except RLU location in
CRM III)

3
 Major Projects of Phase-I Expansion
To be commissioned in 2013-14

Comm. Date
Sl Major Facilities Likely Comm. Date
As per contract
New Cold Rolling Mill-III
1 Dec’10 Dec’13
(Integrated Commissioning)
SMS II Modernisation
2 Apr’10 Dec’13
Hot Metal Desulphurisation unit
CH-3 : Jul’13
CH -5 : Nov’13
Cast House Slag Granulation
3 Oct’12 CH -4 : Dec’13
System for BF-1,2&3
CH -2 & CH -1 linked
with BF-1 C/R

4
 Major Projects of Phase-I Expansion
To be commissioned in 2013-14

Comm. Date
Sl Major Facilities Likely Comm. Date
As per contract
Dec’13
(Subject to
4 Revamping of Sinter Band No.-1 Dec’12
availability of S/D of
Band-1)
Jan’14
Up gradation of existing HSM
5 Jan’14 (Subject to availability
roughing group
of shutdown)

6 Augmentation of RMHP Jan’14 Jan’14

5
 Summary of Phase-I Expansion of BSL

Rs in Crs.

Approved Capital Cost 6325

Approved Capital Cost (NOC) excl. EDC,IDC & 5325
Contingencies
Value of Order Placed 4892

Cumulative Capital expenditure till Mar’13 3469

2012-13 (RE) 1400

Expenditure Apr’12-Mar’13 837

2013-14 (BE) 1200

6
 CRM-III

7
 NEW CRM-III
Specific Area Time Frame

Integrated Commissioning of CRM-III Dec’13

Total Nos. of Ordered Pkgs/Cost: 25 Pkgs/ 2437 Crs

CRM-III Pkgs Time Frame CRM-III Pkgs Time Frame

CPL Completed Transfer Car Jul’13
ARP Completed Hydrogen Plant Jun’13
SPM Jul’13 Intershop Pipeline Jun’13
PLTCM Aug’13(1st Coil) Nitrogen Vessel Jul’13
Propane Storage Jun’13 ECL Jun’13
EOT Cranes Jun’13 (19/23 Cranes) HDGL Oct’13
Compressed Air May’13 HRCC Oct’13
Roll Shop Jul’13(Combi grinder) TL&IL Dec’13
BAF Jul’13 Effluent Treatment Jul’13
Water Supply Jul’13

8
8
PL-Laser welding

9
PL- Bridle roll no-5

10
TCM-Pulpit with roll changing car

11
SPM- Stand mill housing with walking beam no-2

12
BAF-Furnace with base

13
 NEW CRM-III
Ordered Cost/ Scheduled Likely Completion
Sl Pkgs Expend. Comm.
(Rs. Cr)
CPL-2: Mar’12
Coil Packaging
1 18.98/ 18.62 Jan’10 CPL-1: Jun’12
Lines
(Commissioned)
Acid Regeneration 60.03/ 57.29 Dec’09 To be commissioned with
2 PLTCM
Plant
3 Skin Pass Mill 107.23/ 95.17 Jul’10 Jul’13

4 PLTCM 694.31/ 624.49 Dec’10 Aug’13

5 Propane 7.68/ 4.96 Aug’11 Jun’13

6 EOT cranes 91.3/78.29 Aug’11 Jun’13 (19/23 Cranes)

7 Compressed Air 17.08/ 15.48 Oct’12 May’13

8 Roll shop 107.92/ 67.02 Apr’12 Jul’13 (Combi grinder)

Bell Annealing
9 132.94/ 128.06 Feb’10 Jul’13
Furnace
14
 NEW CRM-III
Ordered Cost/ Scheduled Likely Completion
Sl Pkgs Expend. Comm.
(Rs. Cr)
10.8/ 7.23 Mar’11 Jul’13
10 Transfer car

11 Hydrogen Generation Plant 20.42/ 16.42 Dec’09 Jun’13

43.30/ 30.29 Mar’12 Jun’13
12 Inter Plant & Inshop Pipeline
2.84/ 0.13 Jan’13 Jul’13
13 Nitrogen Vessel

14 ECL Feb’10 Jun’13

486.29/ 367.48
15 HDGL Jul’10 Oct’13
16 HR Coil Conveyor 68.85/ 40.3 Nov’11 Oct’13
Tension leveler & Inspection
17
lines
93.01/ 10.61 Feb’12 Dec’13

18 Effluent Treatment Plant 7.59/ 5.11 Sept’11 Jul’13

19 Water Supply System 68.40/ 42.79 Oct’11 Jul’13
15
 Major Hurdles & Reasons for delay- CRM III

Initial Delay:
 Delay in ordering of civil & structural packages.
 Segregation of civil and structural packages has caused delay due to
lack of co-ordination.
 Delay in ordering of utility Pkgs like water supply, effluent treatment,
Compressed air (re-tendered) & Hydrogen generation and related
technological packages like HRCC, tension levelling & RGBS. There
was no order placement between 2008 to 2010.
 Non sequential ordering of Pkgs i.e, ARP, CPL were ordered in the
beginning, whereas Tension levelling and RGBS & Utilities were
ordered late. Due to the absence of the load data progress of Civil & Strl
job got delayed related to cranes & other technological pkgs.
 Civil work was further delayed on account of delayed design & engg. of
sublevel jobs related to transfer car, connectivity of HT/LT cable to
MSDS-9, foundation of coil conveyor.
16
 Major Hurdles & Reasons for delay- CRM III

Delay during execution

 Delay in approval of the drawings by the consultant and supply of
equipment by the main contractor
 Initial delay by the structural contractor to hand over the fronts for
erection of equipment.
 Interface issues between the Principal Contractors and the erection
contractors
 Diversion of drainage system in RGBS, HDGL, BAF & PLTCM areas
& supply line for steam & Nitrogen
 Poor performance by water supply contractor
 Design capacity of valley Gutters & down comers are not matching with
the requirement & is still under modification.

17
 Major Hurdles & Reasons for delay- CRM III

Delay due to availability of utilities:

 Non availability of required utilities viz. Steam, Hydrogen, Mixed gas,

Propane & Nitrogen, water & Compressed air.

 Non-availability of steam is 35 Tons/hr @ 6 bar for CRM-III before

commissioning of Boiler 9 of TPP of BPSCL.

 Nitrogen vessels ordered on structural shop.

18
 Preparations for Integrated Trial of CRM III

 PLTCM: Integrated Trial run with CR Coil completed on 31-01-13

from Pickling line to Tandem Mill.
 Coil packaging line-1&2: Already commissioned.
 Skin Pass Mill: Integrated Trial run of the 1st coil done on 31-12-12.
 Bell Annealing Furnace: Integrated Trial run:
 BAF 1 & 2: from 15-05-13 to 15-06-13
 BAF 3 & 4: from 01-07-13 to 31-07-13
 Roll Shop: Major eqpt. supplied. Combi-grinder will be ready by Jul’13.
 ECL: Commissioning by Jun’13.
Erection almost completed: 696/704 MT. Piping & ACVS system is
expected to complete by May’13.
 EOT Cranes: 19/23 Cranes will be commissioned by Jun’13. 10 nos.
Crane commissioned. 8 nos. Cranes under commissioning. 3nos. Crane
under erection. Change order for 04 nos. cranes under process of
19 approval (02 nos. already commissioned).
 CRM-I

20
 CRM-I
Specific Area Time Frame
Conversion of Sulphuric Acid Jan’14
Pickling to HCL PL-1 of CRM-I

SN Pkgs Ord Cost/ Schedule/ Status

Expend. Likely
(Rs. Cr) Compln.
1 Conversion of 40.89/ Jan’13/ • Design & Engg- 170/228
Sulphuric Acid Jan’14 nos.
Pickling to HCL
PL-1 of CRM-I • Eqpt. supply - not
started. (Billing schedule
under approval).

21
 Hot Rolling Mill

22
HSM K-Bldg

23
HSM-E Bldg

24
HSM- Extractor Bldg of RHF

25
 Hot Strip Mill
Specific Area Time Frame
Roughing Mill Upgradation Jan’14

SN Pkgs Ord Cost/ Schedule/ Status

Expend. Likely
(Rs. Cr) Compln.
1 Roughing Mill 498.97/ Jan’14/ • Design & Engg.- 90% completed.
Upgradation 51.12 Jan’14 • K-bldg. (Pump, Transformer ,
Panel & Hydraulic room)- Raft
casting completed. Wall casting
in progress.
• E-bldg. (Transformer bldg)- Strl
Fabn & Ercn in progress.
• D-bldg. (Drive Panel house)- Strl
Fabn in progress.
• Ordering for major eqpts.
Completed. Supply likely to start
from May’13
26
 Hot Strip Mill
Specific Area Time Frame
Reheating Furnace-1 Jul’14

SN Pkgs Ord Cost/ Schedule/ Status

Expend. Likely
(Rs. Cr) Compln.
1 Civil work for 10.15/ Sep’12/ • Civil Dismantling of existing furnace
RHF-1 0.90 Jun’13 completed.
• 15/18 nos. Column casting in
extractor bldg completed.
• Civil const. work to start from 25-04-
13.
2 Repl. of Pusher 65.04/ Sep’13/ • Basic engg. drgs- 86% completed.
type RHF-1 by 6.67 Jul’14 • Detail engg. drgs- 68% completed.
Walking beam • Ordering for major eqpts. completed.
type furnace • Eqpt supply likely to start from
May’13.

27
 Blast Furnace

28
 CHSGP of CH-6, BF-3

CHSGP of CH-6 commissioned

29
 CHSGP of CH-6, BF-3

CHSGP of CH-6 commissioned

30
CH3, DWD - Conveyor Gallery

31
CH3 Pump cellar

32
 CHSGP for BF-1,2&3
Specific Area Time Frame

CHSGP for BF-1,2&3 Dec’13

Total Nos. of Ordered Pkgs/Cost: 3 Pkgs/ 208 Crs

CHSGP Time Frame

CH-6 Commissioned
CH-3 Jul’13
CH-5 Nov’13
CH-4 Dec’13
CH-2 Dependent on BF-1 C/R
CH-1 Dependent on BF-1 C/R

Reasons for Delay:

• Initial delay in finalizing layout, design & engg.
• Change in the scope and design by CET.
• Conveyor gallery passing through the existing coal yard is having interference
with enabling pkgs under Mecon’s consultancy.

33
 CHSGP for BF-1,2&3
Ordered Scheduled Likely Status
Cost/ Comm. Completion
Sl Pkgs
Expend. , Date
Rs. Crs.
1 Cast House 207.78/ Oct’12 CH-3 : Jul’13 CH-6 –Production started
Slag 128.17 CH -5 : Nov’13 from 15.10.12.
Granulation CH -4 : Dec’13 CH-3 – T/run of individual
System for BF- eqpt. in progress. Conv.
1,2&3 (6 units) CH-1&2: gallery eqpt. under erection.
(Dependent on CH-5 and CH-2: Erection of
BF-1 C/R) utility pipe line completed.
Modified drg. of Conv. Gallery
Disposal System under approval by CET.
(Pkg-3)- Dec’14* CH-1: Ercn of RC conveyor &
Utility pipelines in progress.
CH-4: Ercn of Chimney
completed.
*Separate route from JH-25 to
JH-27 finalised with CET
Mecon & BF. Deviation
quantity being worked out by
34 the party & CET.
 CHSGP for BF-1,2&3

Ordered Scheduled Likely Status

Cost/ Comm. Date Completion
Sl Pkgs
Expend. ,
Rs. Crs.
2 Augmn/Upgdn 52.37/ Apr’13 Jun’14 • Design & Engg done-
of BF High 4.86 247/284 nos.
line conveying • Civil fdn completed-
system 11/11 nos.
• Mech eqpt supplied-
43/149 types.

35
 SMS-II

36
 SMS-II
Specific Area Time Frame
Integrated Commissioning of HMDS Unit Dec’13

Total Nos. of Ordered Pkgs/Cost: 14 Pkgs/ 336.87 Crs

SMS-II Pkgs Time Frame SMS-II Pkgs Time Frame

Civil & Strl work Dec’13 HMDS Dec’13
Power Distribution May’13 Torpedo Ladle Car Sep’13
Extn. of trollyline in DS bldg. Dec’13 EOT Cranes (GR I ) Dec’13
Nitrogen vessel Aug’13 EOT Cranes (GR II ) Dec’13
Building extn of CCD Mar’14 Slag Pot car Sep’13
Electrics for HM supply Aug’13 Torpedo Ladle Heating, Aug’13
Ladle, L- Stand & Transfer Car Dec’13 Drying, Cooling System
Steel ladle drier & cooler Dec’13

37
HMDS Bldg

38
HMDS, combi car Fdn

39
HMDS, Pit 1 bolting

40
HMDS- ESP with ID Fan

41
 SMS-II-HMDS Pkgs
Sl Pkgs Cost/ Completion Likely
No Expenditure schedule completion
1 Civil, Structural, piping, Rs. 173 crs 31.08.2010 Dec’13
Dismantling and Re- Rs. 110.93 Crs
Routing Works.
2 Power Distribution Rs 18.00 Crs 30.09.2009 May’13
Rs 15.92 Crs
3 Electrics for extension of Rs 0.26 Crs 15.12.2011 Dec’13
trolley line system in Nil
Desulphurisation building
4 4 nos. of Nitrogen Vessel Rs 5.03 Crs 22-02-09 Aug’13
Rs 3.75 Crs
5 Building extn of CCD Rs 5.53 Crs 14-04-13 Mar’14
Rs 0.553 Crs
6 Electrics For Augmentaion of Rs 2.7 Crs 05.05.2011 Aug’13
hot Metal Supply Rs 2.13 Crore
7 Ladle, ladle stand and Rs 27.84 Crs 30.11.2009 Jul’13
transfer car Rs. 21.60 Crs
8 Ladle Drier & Cooler for Rs 2.14 Crs 05.02.2011 Dec’13
42 SMS-II Rs 0.214 Crs
 SMS-II-HMDS Pkgs
Sl Pkgs Cost/ Completion Likely
No Expenditure schedule completion
9 Hot Metal Desulphurization Euro 16,96,979 15.04.2010 Dec’13
+ Rs 51.20 Crs
Euro 13,13,212 +
Rs 45.53 Crs
10 08 nos. Torpedo ladle car for USD 47,04,800+ 31.08.2010 Sep’13
augmentation of hot metal Rs 21.27 Crs.
supply USD 36,05,987 +
Rs 4.26 Crs
(22.41 Crs)
11 Double Girder & Four Girder Rs 75.00 Crs 28.02.2010 Dec’13
EOT Cranes. Rs. 61.43 Crs
12 Double Girder and Under Slung Rs 25.00 Crs 02.02.2010 Dec’13
Cranes for SMS-II & CCS. Rs. 21.13 Crs
13 Slag Pot Car Rs 0.79 Crs 25-07-11 Sep’13
Nil
14 Torpedo ladle heating drying Rs 2.63 Crs 30.06.2009 Aug’13
and cooling system Rs 2.04 Crs
43
 Major Hurdles & Reasons for delay- SMS II
 Total failure of consultant causing increase in Civil & Strl work by 75%.
 Unexpected diversion of railway tracks- 4 times for site clearance.
 Strengthening of Rly track going to SSD for site clearance of new
Torpedo bay.
 Diversion of 8 nos. HT cables which were fauling with the foundation of
new torpedo bay.
 Non- availability of CR-140 Rail (for 450MT Crane) in India.
 Diversion of Underground drainage pipeline
 Diversion of gas pipeline
 Construction of -18M pits at a distance of only 3M from the Rly track
carrying hot metal ladle.
 Construction of another pits -18M at a distance of only 5M from existing
SMS-II auxiliaries bldg.
 Shifting of 4 nos. of Nitrogen vessels.
 Dismantling & reconstruction of Faecal pump house.
 An existing cable tunnel passing through HMDS area was encountered at
shallow depth which necessitated the use of pile foundations. 44
44
 Raw Material Handling

System in RMHP

45
 RMHS & Sinter Plant
Ordered Schedl./ Status
Cost/ Likely
Sl Pkgs
Expend. Comm.
(Rs. Cr)
75.16/ Dec’12/ • Dismantling of duct and
7.88 Dec’13 Strs of partial cooling
(dependent zone completed.
on the • Fabn Drgs for wind box
availability released. Material
Revamping of Sinter of S/D) procured & Fabn work in
1
Band No.-1 progress.
• 1st lot of Imported eqpt.
expected to reach Kolkata
by 30-04-13.
• 2nd lot of Imported eqpt.
dispatch from Russia.

46
 RMHS & Sinter Plant
Ordered Cost/ Schedl./ Status
Sl Pkgs Expend. Likely
(Rs. Cr) Comm.
Raw Material 107.85/ Jan’14/ • Civil & Strl work in Area
Handling system 28.58 Jan’14 Repair Shop & electrical sub-
store completed.
• Controlled blasting in
Wagon tippler-5 area (new)
in progress. Rock breaking
upto -14M out of -18M level
completed.
2
• One side RCC wall
completed from -12M to
-6M level.
• Strl Ercn in JNA1 in
progress.
• Civil work for Trestle of
conveyor P1C1 & JNA8A
under progress.
47
 CO&BPP

48
 CO&BPP
Specific Area Time Frame
Ammonium Sulphate Plant Jul’14

SN Pkgs Ord Cost/ Schedule/ Status

Expend. Likely
(Rs. Cr) Compln.
1 Ammonium 88.25/ Dec’13/ • Basic Engg drgs- 75%
Sulphate Plant - Jul’14 completed. Detail engg- 25%
completed.
• Dismantling of existing shed –
25% completed. Likely to
completed by May’13.

49
 Pkgs Under Tendering

50
 Upcoming Projects
SN Pkg. Name Budget NIT TOD Status
& Pkg No. Cr.
1. Recovery BOO 15-09-12 30-10-12 Against EOI, response of 14 bidders
type stamp 30-11-12 received on 24-04-12.
charged 01-02-13 Pre Bid meeting held on
08&09.11.12. 8 bidders participated.
battery 12-02-13
Single offer recieved upto 14-03-13.
22-02-13 ILFS New Delhi sought extension by
14-03-13 6 weeks.
Case referred to high level
committee for appropriate decision.
High level committee recommended
for dropping the idea of getting the
stamp charge battery on BOO basis
due to single offer from bidder.
However CET has been asked to
compare the Stamp charge battery
Vs 7MT Tall conventional battery
option so that BSL can move forward
for own battery.
51
51
 Upcoming Projects

SN Pkg. Name Budget NIT TOD Status

& Pkg No. Cr.
2. Rebuilding 251.58 06-11-12 08-01-13 6 offers received.
of Coke 22-01-13 1. Gillander, 2. HEC 3. L&T,
Oven 4. BEC 5. SREPC, 6. Mecon
Battery -7 TER received from CET on 18-04-
13. Under reveiew by TEC & CEC.
(Pkg-1)
3 New 883.43 28-02-13 19-04-13 7 offers received. Under evaluation
Sintering by CET.
Plant – II 1 Mecon+ SDM China
2 POSCO+NCC
(Pkg-1)
3 NHI China+Essar Project
4 Tecpro+Uralmash +Trafalgar
5 MBE+HTC China
6 L&T +Outotech
7 TPL+ Sino Steel

52
52
 Upcoming Projects

SN Pkg. Name Budget NIT TOD Name of Status

& Pkg No. Cr. Bidders
4. 450 TPD 50.00 Meeting with TC, TEC
Lime Shaft and CET held on
Kiln (Pkg- 21.03.13.
Recommended for
2)
retender the case
with revised TS &
revised eligibility
criteria.
Revised TS &
eligibility criteria
awaited from CET.

53
53
 Upcoming Projects
S Pkg. Name & Proposal Status
N Pkg No.
5 Modn & FR for Stage-I submitted by PAG meeting held on 20-
03-13. Reply to the PAG
Upgradation CET. Under study. queries sent to CO on 05-
of SMS-I Stage I: 1.306 MT (1*130 BOF, 1 04-13.
slab caster, 1 LF & Gas holder) Additional PAG queries
Est. LCNC Rs 1365 Crs received from Corporate
Benefit: Ingot casting will be Project and were replied.
stopped. Waiting for Board Sub
Net increase in crude steel Committee meeting.
production by 4 lakhs per ton.
Stage-II: 1.85 MT, (2*130T DS, 2*
130 BOF , 1 Thin slab caster, 2 LF
& 1 RHOB (Overall Crude Steel
capacity of BSL will be 6.5 MT by
2017-18)
54
54
 Upcoming Projects

SN Pkg. Name Budget NIT TOD Name of Status

& Pkg No. Cr. Bidders
6 Up- 131.6 Board Sub
Committee meeting
gradation scheduled on 30-04-
of Stoves 13.
of BF # 1

55
55
 SMS-II-HMDS Pkgs
HMDS- Present Status
Fabrication & Erection of Building Strs of HMDS & Silos (490/519 MT) Completed.
Erection of Technological Structurs of ESP (819/1370 MT) Completed.
Erection of Equipment (250/796 MT) Completed.
Erecn of plate work in HMDS bldg (Environmental enclosure & Hood) in progress.
Front Not available: a) Old Steel Ladles for Lip modification work, b) Combi Car
Tracks, c) Duct supporting trestle foundations, d) Dust Conveying System, e)
Hydraulic, PLC and Computer rooms etc.
BALANCE WORK: Equipment erection of HMDS Stations, 2 nos. of Combi Car,
duct and duct supporting trestle, Dust Conveying System, laying of LT and Control
cables, erection of instmn and automation eqpts etc, PRS for Nitrogen, Insulation
of ESP.

HELP REQUIRED: 4 nos. of HM Ladles are to be handed over to M/s TPL for Lip-
Modification work, 4 nos. of Take-Over Points (TOP) are to handed over to M/s
TPL for tapping of Utility.
Services from existing network of BSL, which are dependent of Shutdowns.
a) Compressed air, b) Nitrogen, c) Oxygen and d) Industrial cooling water
57