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
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