Welcome
to
Bhilai Steel Plant
SAIL Vision
“To be a respected world class corporation and the
leader in Indian steel business in quality, productivity,
profitability and customer satisfaction”
SAIL AFTER EXPANSION (MTPA)
Plant
Hot Metal
Crude Steel
Saleable Steel
BSP
7.5
4- 4.90- 7.0
3.15- 4.29- 6.56
DSP
2.45
2.2
2.12
RSP
4.5
4.2
3.99
BSL
5.77
4.61
4.18
ISP
2.91
2.5
2.39
SSP
-
0.18
0.34
ASP
-
0.48
0.43
VISL
0.33
0.23
0.22
Total
23.46
21.40
20.23
BHILAI STEEL PLANT
CONFORMATION TO INTERNATIONAL STANDARDS
Integrated Management System :
• ISO 9001 (Quality Management System) Works, Personnel
deptt. and HRD
• ISO 14001 (Environment Management System) Works, DMM &
Township
• ISO
45001 (Occupational Health and Safety Management
System)
• SA 8000 (Social Accountability Management System)
• ISO 27001 – Information Security Management System (ISMS)
• ISO 50001 – Energy Management System (EnMS)
• ISO 37001 – Anti Bribery Management System (ABMS)
• NABL accreditation for Mechanical and Chemical Testing
BHILAI STEEL PLANT
PRODUCTS
• Long Products:
1. Rails - 45 Kg, 52 Kg & 60 Kg Rails
2. Structurals - Channels & Angles
3. Wire Rods - 5 mm to 12 mm (Plain and TMT)
• Flat Products:
1. Plates - 8 mm to 120 mm thick including
Boiler Quality, High Tensile
BHILAI STEEL PLANT
PRODUCTS
IN
PROJECTS OF NATIONAL
IMPORTANCE
BSP Products in Projects of National Importance
• INS Vikrant - Bhilai Steel Plant has supplied 17,000 T of DMR
249 Grade steel plates out of total 30,000 T used for making
different components of the Aircraft Carrier.
BSP Products in Projects of National Importance
Construction and Engineering Product- Atal Tunnel
Two-thirds of the total
15,000 T of steel used in
the project has been
supplied by SAIL
Out of the 9000T, 6500T was TMT,
1500T structural and 1000T plates for
fabricating beams, besides a small
quantity of GP/GC sheets for
constructing stations and control rooms
BSP Products in Projects of National Importance
Adding More Mettle to the Nation
Kudankulam Nuclear Power
Plant
Central Vista
Sardar Sarovar Dam
Atal Setu (MTHL)
Statue of Unity
Bogibeel Bridge
Auxiliary Buildings of Ram Temple
BHILAI STEEL PLANT
Medical & Health Services
Medical & Health Services
MINES HOSPITAL
(Rajhara, Nandini, Hirri &
Kuteshwar)
BHILAI HOSPITAL SECTOR-1
• 45 Bedded Hospital With
Oncology Speciality
• Main Medical Post – 15 Beds
• Total 78 Bedded
Hospital Facility At
Mines
• Occupational Health
Centre – 2 Beds
JAWAHARLAL NEHRU HOSPITAL & RESEARCH CENTRE
• 860 Bedded prime referral hospital of Durg-Bhilai
region offering tertiary level patient care
• TOTAL 1000 BEDDED MEDICAL FACILITY
BHILAI STEEL PLANT
Corporate Social Responsibility
CSR-Education
• Under CSR, free education is being provided to 50
underprivileged students every year in two English Medium
Middle Schools
• These school are named “Bhilai Ispat Vikas Vidyalaya”
wherein 60% seats are reserved for girl child.
CSR-Skill Development
RPL through CSVTU & IISSSC with HRD
• Recognition of prior learning and certification of contractual workers.
• Major Trades:
✔ Electrician, Crane Operation, Rigger,
✔ Coke oven Battery Operator, Conveyor Operations and
Maintenance,
✔ Refractory Brick Layer, Mobile equipment Operator,
Instrumentation Technician
CSR- Women Empowerment
Training through CG Hastshilp Vikas Board
• Livelihood Generation and Women Empowerment
• Training at village Nandori for Godna Art.
• Training on Bamboo Craft.
CSR- Infrastructure Development
Some activities
• Construction of Community hall at
Village Karsa & Ghughuaa
• Environment Lab at 32 Bungalows,
Bhilai.
• Development of State of Art Sports
Complex
• Renovation of existing stadium.
• Installation of Solar Water Duel Pump
(SWDP)
CSR-Nurturing Cultural Heritage
▪ Development of Heritage site (Devbaloda)
o Jointly developed by SAIL, Archaeological Survey of India &
Indian Railways
▪ Mallakhamba Academy in Rowghat Mines area (Narayanpur),
in collaboration with State Sports Authorities
CSR- Outreach in Mines
Sl.
Activity
1 Mobile Medical van through RK Mission at Buffer
Zone villages
2 Sports through RK Mission for up-liftment of sports
activity.
3 Drinking Water Through Collector-Kanker
4 Providing E-Rickshaw to Gram Panchayat
5 Providing Mosquito net 1500 families of Narayanpur
Districts and 1200 families of Kanker
6 Distribution of sanitary napkin at Kanker and
Narayanpur District
7 Football tournament at Narayanpur
8 Medical Dispensary at Bhaiyaslebhat in association
with RK Mission Ashram
9 Health center at Khodagaon
Town Services
Area of Clean & Green
Township
8844 Acres
No. of Houses
34350
Stadia/Sports Complex
06
Public Buildings
101
Road Network
535 kms
Water Supply Network
377 kms
Sewerage Network
352 kms
Electrical Network
421 kms
Gardens including Maitry
Bagh
20
EMS ISO-14001 & ISO 9001:2015
Certified Industrial Township
Running 17 Schools with 6000+ students.
▪
Zoo (Recognized by Central Zoo Authority with 300 animals of 38 species
(15 endangered))
▪
INDIGENOUS PRODUCTION OF
DMR-249A STEEL
[For Under-Water applications]
An overview
Presentation Roadmap
• Overview of DMR 249A(Surface applications)
•Objective of Kick off Meeting
•Order Details for BSP
•Currently Valid Reference Documents
•Process Flow at SMS 2
•Secondary Refining
•Process Flow at Plate Mill
•Rolling and Heat Treatment
•Process flow charts for Plate Inspection
•Process flow charts for MTL-2
•Testing scheme for (PAT) at RCL,BSP
•Online Test Reports
•Plate Quality Inspection at BSP
•Comparison of Existing DMR249 A (as per NCD 249 Part 1) and New
requirements of DMR249A for underwater applications.
Overview of DMR 249 A
( Surface Applications)
∙ Bhilai Steel Plant (BSP) was licensed in 2004 by DMRL &
Russian experts, to manufacture & supply of DMR 249A plates
for Indian Navy (surface applications). The scope of this license
is limited to Plate thickness 10 mm to 20 mm for BSP.
∙ The plates are being supplied based on Indian Navy’s
Technical Specification , NCD -0249 (Part -1, Issue -1 , Apr
2011 for NAVAL Ships).
∙ Supply of Plates has commenced from 2004 & a total quantity
of around 40,000 T has been supplied till date.
Objective of Kick-Off Meeting
•
•
•
•
In 2024, Work Order has been placed on BSP to supply DMR
249A(certified Grade) plates for Underwater applications (
submarines).
BSP is geared-up to supply as per Work Order & the
applicable documents – OTI & SQAP issued by DMRL &
approved by Indian Navy. However, this shall be subject to
process review approval by ATVP & DMRL during trial heat
execution.
In-house facility has been developed to perform FAT
(Fracture Appearance Test) which is a new requirement by
DMRL specification.
Volume of sample testing is almost ten-fold & has to be done
as per the Operational Technical Instructions (OTI) of
DMRL.
Order Details for BSP
Out of total order quantity of 900 T as per Rate contract, 550 T has to be supplied by
Bhilai Steel Plant.
S NO.
Thickness(mm)
Weight as per Rate
Contract (in tons)
Approx. Weight as per Present
Work Order (in Tons)
1
10-20mm
550
550
S NO.
Thickness(mm)
Plate Dimension (in mm)
Qty
10-20mm Thickness
1
10
2500*6000
118
2
12
2500*6000
38
3
14
2500*6000
21
4
16
2500*6000
128
5
18
2500*6000
04
6
20
2500*6000
31
Total
340
Order Details for BSP
S NO.
Thickness(in
mm)
Weight( in
Tons)
Rate (in
Rs/Ton)
Amount (in Rs.)
1
10-20
550
93,100
5,12,05,000.00
All deliveries under this Work order are to be completed
by 07 Dec 2024.
Reference Documents available at BSP
References
Date
Reference No.
OTI
June 2021
OTI-0141-P-CC-20-2017
Version No D
DMRL Draft SQAP
June 2021
HIGH STRENGTH
WELDABLE STEEL IN
THE GRADE OF
DMR-249A WITH THE
YIELD STRENGTH OF
390 MPA FOR PLATES IN
THE THICKNESS RANGE
03.15 – 40 MM Version 1.1
ATVP QAP
2021
HQATVP-DOC-SCMAT-0
002
Rate Contract
08 Dec 2021
1/U/MAT/PDN/249(P)
Work Order No. 1
29 Mar 2022
Amendment No.1
01 Dec 2023
STEEL MAKING (SMS-2)
PROCESS FLOW DIAGRAM OF STEEL
MAKING(SMS-2)
Blast Furnace
Hot Metal
Pouring
Removal of slag / Desulphurization
Ladle furnace
RH Vacuum
degasser
Scrap charging
Argon rinsing
station
Hot metal
charging
Oxygen blowing
converter
Tapping
cast
er
Slab cutting
Slab & Bloom Yard
Storage, Semi Finished
Processing & Dispatch
FACILITIES AT STEEL MELTING SHOP
(SMS-2)
Section
Facilities
Objectives
Converter Shop
Mixer
: 2 Nos. 1300 T each
Converter : 3 Nos. Cap: 130 T each
DS Unit : 2 Nos.
To convert Hot Metal to
Steel
Secondary Steel
Making
Ladle Furnace : 2 Nos.
RH Degasser : 2 Nos.
VAD UNIT
: 1 Nos.
To provide value addition to
the Steel / Produce Clean
Steel
Continuous
Casting Shop
Slab Caster : 4 Nos.
Bloom Caster : 2 Nos.
To provide shape (Blooms /
Slabs) to the Liquid Steel
Slab and Bloom
Storage Yard
To store and dispatch
Blooms and Slabs to RSM
and Plate Mill respectively
HOT METAL
DESULPHURISATION
2 DS UNITS
• 2 SILOS:
•
✔ 1 silo of Fluidized Lime of 120 T
capacity
✔ 1 silo of Mg. REAGENT of 80T
capacity
• Co-injection(Fluidized Lime and
Mg reagent) of reagents with
ceramic lance with the help of
carrier gas Nitrogen.
• After Desulphurization S <0.010
S>0.040 will go through desulphurization
BOF CONVERTER(LD Convertor)
3 x 130 TON CONVERTERS
NOs. OF HEAT/ DAY : 65 Avg.
• Blowing is started by bringing the
lance down to a height of 2.6 m above
the bath level.
• Further the lance is slowly brought to
working height i.e. 1.6 m as per
blowing regime.
• Oxygen blowing is done for about
16-20 mins at a pressure of 16 Kg/Cm2
and a flow rate of 350 - 450 Nm3 /min.
• Fluxes are added in required doses so
that slag formation takes place
properly.
SECONDARY STEEL MAKING
1) Vacuum Arc Degassing Unit (VAD)
2) Two Ladle Furnace (LF) units
3) Two RH Degasser (RHD) units
Purpose of Secondary Refining:
• Homogenization of bath temperature and chemical composition.
• Desulphurization, Arresting NMIs , Dephosphorization
• Hydrogen and oxygen removal
• Achieving prescribed temperature for casting within narrow limits
• Provide sufficient holding time during treatment and casting
• Act as a buffer between convertor and casting unit.
RH DEGASSER
• Basically a circulating degassing unit.
• Helps in achieving low H2 <1.6 ppm content for
rail grades.
• Contains a vessel with inlet and outlet snorkels
both lined with refractory.
• The vessel is immersed into the liquid steel &
subjected to low vacuum.
• The metal inside the RH vessel is exposed to
vacuum level of 1 millibar or less and so
dissolved gasses (H2, N2, O2) in the steel is
reduced.
• The circulation rate of molten steel is as high as
130 T / minute.
CONTINUOUS CASTING SHOP (CCS)
DIAMOLD Tube Mold Design
At SMS 2 casting bay
divided in 2 blocks:• 1st block has 3 old slab
casters and 1 new slab
caster (6, 1, 2, 3).
Hydraulic Oscillator
• 2nd block has 1 combi
caster and 1 bloom
caster.
Slab
SLAB YARD(SBS)
SBS YARD
Slabs- Stored / Dispatched to Plate Mill
Blooms- Stores / Dispatched to RSM
Rolling of slabs into Plates at
Bhilai Steel Plant
Process flow at Plate Mill
ROLLING & HEAT TREATMENT
•Reheating
Temp:
• Descaling
at furnace
160 kg/cm2
•Pre
heating
zone: 1100-11900
•Salt
spray
for effective
0
•
Heating
zone
temp:
1220
–
1280
C
descaling
0
•Soaking zone temp: 1200-1240 C
•Descaling
•Entry Temp:1125 – 11500C
•Exit Temp:1020-10600C
•Rolling at Roughing stand
•Rolling at Finishing stand
• Entry Temp:950-975 C
• Exit Temp:800-875C
•Furnace Normalising
• Zone 1-2: 880±30
• Zone 3-5 : 920 ±20
• Zone 6-9: 910 ± 20
Process flow charts for Plate Inspection
•Inspection Bed 1
•Top surface Inspection
•Visual Inspection
•Thicknesss Measurement
•Inspection Bed 2
•Bottom surface visual Inspection
•Transfer bed 1 and 2
•Sample Marking
•Transfer bed 3 and 4
•Identification and final dimension check
•Normalising
Normalised
plates
Third Party
Inspection
Sampling for Mechanical tests
1.
2.
3.
4.
5.
Sample Scheme: 1/Plate
Sample Marking at TB1/2 as per
sample plan SRTP 155
Sample Location: Front end, Back
end for each plate(taken from the
middle third of plate width across
Rolling direction) and 1 sample from
each corner of plate (min 3 plates of
each thickness).
Marking on Sample for PAT: Plate
no, FEC/REC, Rolling direction,
sample size :550*450 mm.
Marking on sample for Uniformity
test: Plate no, FL/FR/RL/RR,
Rolling direction, samples
size:400*300 mm
Process Flow at MTL-2
Normalising area
Test Coupons & Test Advice from Plate Mill
Spreading, MTL No. Marking, Loading the
test coupons on Gas Cutting Table.
Test House receives test
advice for test coupons &
receives in MES SQM 041,
allots MTL no. on test
coupons.
Gas Cutting According to Test
Advice
Tensile
sample
Impact
sample
Fracture
Appearance test
(FAT)
CA
sample
GS and
IR
Testing scheme for (PAT) at RCL,BSP
1. Tensile Test
• As per ASTM E8
• 1 sample from each end of plate.
• Specimens to be cut across the plate rolling direction(in Transverse
direction).
• Flat Tensile specimens
2. Impact Test
• As per ASTM E23
• 1 sample from each end of plate
• Specimens to be taken in (in Longitudinal direction)
• 3 samples shall be extracted from end of the plates.
• Test temperature ~ -60°C
Testing scheme for (PAT) at RCL,BSP
3. Fracture Appearance Test(FAT):
At Room
Temp
-10⁰C
• 2 samples from both ends of plate.
• Samples to be cut across the plate
rolling direction.
• 3 Point bend tested to fracture and
examination of fracture surface
• In house facility modification has
been done in Bend machine for this
test.
4. Grain size and Inclusion Rating
Uniformity Test
• For plates with length >6m to be used for
underwater applications mechanical uniformity
needs to be checked by carrying out the following
tests(minimum 3 plates of each thickness or to be
continued until such time that uniformity is
established)
• Tensile(T) and Impact test(L).
• Chemical Analysis (CA) samples
Comparison of Existing DMR249 A and New
requirements of DMR249A certified
Existing DMR
New Requirements of DMR 249A
Underwater application
Order Size : 10-20mm x1600-2500mm
x6300-12500mm
Order Size : 10-20mm x1500-2500mm
x6000-12500mm
Sample Scheme:
(Spec- 3/Heat/Thickness)
Sample Scheme:
(Spec- 1/Plate ) from both ends.
Sample Size: 400*300 mm
Sample Size: 550*450 mm for PAT &
400*300 mm for corner test
Testing Scheme: Tensile, Bend, Impact,
Chemical Analysis(CA), Grain size
(GS),Inclusion rating (IR)
PAT: Tensile (Transverse),
Impact(Longitudinal), FAT at Room
Temp, FAT at -10°C, Chemical
Analysis(CA), Grain size (GS),Inclusion
rating (IR)
Uniformity Test from 4 corners: Tensile
, Impact, CA
-
Sample Preparation time for FAT-1.5
Hour
On line PTR Fracture Appearance Test
(FAT)
Plate Quality Inspection at BSP
Final checks
✔ Presence of marking on plate
✔ Surface quality
✔ Status of edges
✔ Flatness deviation
✔ Test value reports
✔ Test Certificates
Thank You