Professional Documents
Culture Documents
INTRODUCTION
The internship training in Steel Authority of India Ltd. (SAIL) , Bhilai Steel Plant (BSP), Bhilai,
is a part of the academic curriculum of Bangalore University. It is undertaken for a period of 4
weeks to fulfill the course requirement. The internship training is an eye opener regarding the
actual functioning of different departments in an organization. Also inter departmental
relationships and its significance is thoroughly understood during this tenure.
The main purpose of the internship it to study the organization from different aspects, different
department, and their functioning in detail. It further provides a wider scope to gain an insight
into the practical aspects of the working of the organization.
The study is to prepare the report on the internship training and submit the detailed and
comprehensive report. This will help the company to assess its strength, weakness to take
necessary action to improve the future growth.
The methodology used for the study is through the collection of primary and secondary data.
Primary data is collected from direct observation and discussion with managers and staff
members. Secondary data is collected through annual reports, business journals and existing
records and also from the website of the company.
LIMITATIONS
1) Since it is a very huge organization, time availability to cover the entire organization was
a constraint.
2) Since applying goods to defense, availability of information was also a constraint.
3) Since the organization is to big with too many departments, covering all the departments
in short period was not possible.
4) It is assumed that the information provided by the organization is correct.
5) To Contact with every department head to know about that particular department was
uneasy.
EXECUTIVE SUMMARY
Chapter 2
INDUSTRIAL PROFILE
In 2014, the world crude steel production reached 1665 million tonnes (mt) and showed a
growth of 1% over 2013.
China remained the worlds largest crude steel producer in 2014 (823 mt) followed by
Japan (110.7 mt), the USA (88.2 mt) and India (86.5 mt) at the 4 th position.
WSA has projected Indian steel demand to grow by 6.2% in 2015 and by 7.3% in 2016 as
compared to global steel use growth of 0.5% and 1.4% respectively. Chinese steel use is
projected to decline in both these years by 0.5%.
Per capita finished steel consumption in 2014 is estimated at 217 kg for world and 510 kg
for China by WSA.
Domestic Scenario
The Indian steel industry has entered into a new development stage from 2007-08, riding
high on the resurgent economy and rising demand for steel.
Rapid rise in production has resulted in India becoming the 3 rd largest producer of crude
steel in 2015 and the country continues to be the largest producer of sponge iron or DRI in the
world.
As per the report of the Working Group on Steel for the 12 th Five Year Plan, there exist
many factors which carry the potential of raising the per capita steel consumption in the
country. These include among others, an estimated infrastructure investment of nearly a
trillion dollars, a projected growth of manufacturing from current 8% to 11-12%, increase in
urban population to 600 million by 2030 from the current level of 400 million, emergence of
the rural market for steel currently consuming around 10 kg per annum buoyed by projects
like Bharat Nirman, Pradhan Mantri Gram Sadak Yojana, Rajiv Gandhi Awaas Yojana among
others.
At the time of its release, the National Steel Policy 2005 had envisaged steel production
to reach 110 million tonnes (mt) by 2019-20. However, based on the assessment of the current
ongoing projects, both in greenfield and brownfield, the Working Group on Steel for the 12 th
Five Year Plan has projected that domestic crude steel capacity in the county is likely to be
140 mt by 2016-17 and has the potential to reach 149 mt if all requirements are adequately
met.
The National Steel Policy 2005 is currently being reviewed keeping in mind the rapid
developments in the domestic steel industry (both on the supply and demand sides) as well as
the stable growth of the Indian economy since the release of the Policy in 2005.
Production
Steel industry was de-licensed and de-controlled in 1991 & 1992 respectively.
In 2014-15, production for sale of total finished steel (alloy + non alloy) was 91.46 mt, a
growth of 4.3% over 2013-14.
Production for sale of Pig Iron in 2014-15 was 9.7 mt, a growth of 22% over 2013-14.
India is the largest producer of sponge iron in the world with the coal based route
accounting for 90% of total sponge iron production in the country.
Data on production for sale of pig iron, sponge iron and total finished steel (alloy + nonalloy) are given below for last five years:
Indian steel industry : Production for Sale (in million tonnes)
Category
Pig Iron
5.68
5.371
6.870
7.950
9.694
Sponge Iron
25.08
19.63
14.33
18.20
20.38
68.62
75.70
81.68
87.67
91.46
Demand availability of iron and steel in the country is projected by Ministry of Steel in
its Five Yearly Plan documents.
Gaps in availability are met mostly through imports.
Interface with consumers by way of a Steel Consumers Council exists, which is
conducted on regular basis.
Interface helps in redressing availability problems, complaints related to quality.
Steel Prices
Price regulation of iron & steel was abolished on 16.1.1992. Since then steel prices are
determined by the interplay of market forces.
Domestic steel prices are influenced by trends in raw material prices, demand supply
conditions in the market, international price trends among others.
As a facilitator, the Government monitors the steel market conditions and adopts fiscal
and other policy measures based on its assessment. Currently, basic excise duty for steel is set
at 12.5% and there is no export duty on steel items. The government has also imposed export
duty of 30% on all forms of iron ore except low grades which carry a duty of 10% while iron
ore pellets have a export duty of 5% in order to control ad-hoc exports of the items and
conserve them for long term requirement of the domestic steel industry. It has also raised
import duty on most steel imports by 2.5%, taking the import duty on carbon steel flat
products to 10% and that on long products to 7.5%.
For ensuring quality of steel several items have been brought under a quality control
order issued by the Government.
Further, a Steel Price Monitoring Committee has been constituted by the Government
with the aim to monitor price rationalization, analyze price fluctuations and advise all
concerned regarding any irrational price behaviour of steel commodity.
Imports
Iron & steel are freely importable as per the extant policy.
Data on import of total finished steel (alloy + non alloy) is given below for last five
years:
Indian steel industry : Imports (in million tonnes)
Category
6.66
6.86
7.93
5.45
9.32
Exports
Data on export of total finished steel (alloy + non alloy) is given below for last five years:
Indian steel industry : Exports (in million tonnes)
Category
3.64
4.59
5.37
5.98
5.59
This was a levy started for funding modernisation, expansion and development of steel
sector. The Fund, inter-alia, supports :
Cabinet decided that corpus could be recycled for loans to Main Producers
Interest on loans to Main Producers is set aside for promotion of R&D on steel etc.
An Empowered Committee has been set up to guide the R&D effort in this sector.
EGEAF Was a levy started for reimbursing the price differential cost of inputs used for
engineering exporters. Fund was discontinued on 19.2.96.
(i) Steel : The liberalization of industrial policy and other initiatives taken by the Government
have given a definite impetus for entry, participation and growth of the private sector in the steel
industry. While the existing units are being modernized/expanded, a large number of new steel
plants have also come up in different parts of the country based on modern, cost effective, state
of-the-art technologies. In the last few years, the rapid and stable growth of the demand side has
also prompted domestic entrepreneurs to set up fresh greenfield projects in different states of the
country.
Crude steel capacity was 109.85 mt in 2014-15 and India, which emerged as the 3 rd largest
producer of crude steel in the world in 2015 as per ranking released by the WSA, has to its credit,
the capability to produce a variety of grades and that too, of international quality standards. The
country is expected to become the 2 nd largest producer of crude steel in the world soon,
provided all requirements for creation of fresh capacity are adequately met.
(ii) Pig Iron: India is also an important producer of pig iron. Post-liberalization, with setting up
several units in the private sector, not only imports have drastically reduced but also India has
turned out to be a net exporter of pig iron. The private sector accounted for 91% of total
production for sale of pig iron in the country in 2014-15. The production for sale of pig iron has
increased from 1.6 mt in 1991-92 to 9.7 mt in 2014-15.
(iii) Sponge Iron: India is the worlds largest producer of sponge iron with a host of coal based
units, located in the mineral-rich states of the country. Over the years, the coal based route has
emerged as a key contributor and accounted for 90% of total sponge iron production in the
country. Capacity in sponge iron making too has increased over the years and stood at 46.23 mt
in 2014-15.
Chapter-3
Company profile
TONNES/ANNUMS
533000
750000
500000
420000
950000
3153000
QUALITY POLICY:
Attending market leadership through enhancing customer satisfaction.
Achieving continual improvement in productivity, quality and salability of our products.
Active involvement of all our people in achieving our goals, objectives and target.
PRODUCT PROFILE:
Bhilai Steel Plant (BSP) has mainly three types of products:1.
2.
3.
Semis Product
Long Products
Flat Products
BSP is one of the major producers of long steel products in India. The current product mix of
BSP comprises Plates, Rails, Heavy Structurals, beams, channels, merchant products, bars, rods
and light structurals, wire rods and semis, like blooms and billets. Presently, the long products
constitute about 74% and flat products about 26% of the saleable steel produced at BSP.
(Capacity - 7,50,000 T )
Products
Rails - R52 Kg/m & R60 Kg/m ; UTS 880 N/mm2 rails as per IRST-12/96
specifications , Euronorms and international standards.
Thick web asymmetric rail Zu 1-60
Beams - 600,500,450,400,350,300 & 250.
Channels - 400,300 & 250.
Angles - 200 & 150.
Crossing Sleeper.
Crane Rails - KP80, 100,120 & 140.
Bhilai is the sole supplier of the country's longest rail tracks of 260 metres.
Bhilai Rails
Largest producer and leading rail maker of the world.
Technological Superiority
Steel from LD Converter Ladle furnace - RH Degasser Comcast route; achieving
world best level of degassing/refining to less than 1.5 ppm of hydrogen in liquid steel in
100% of heats.
Capability to produce as rolled lengths of 80 meter and welded panels up to 260 meters
High degree of Straightness due to worlds most advanced and Laser straightness
measurement based end straightening machine.
World class tested rails passing through state of art online NDT equipment; Laser
straightness measurement, Ultrasonic and eddy current testing machines
Computer controlled automatic rail handling system and automatic yard mapping for rail
storage.
Computerized Rail Tracking system for collection and storage of all process and testing
related data of each rail.
NEW PRODUCTS:
To meet the customers requirements, increase the market share and widen the product
range, several new products have been developed.
BS-1501-224 Grade 490A for mounded pressure vessels.
API 5L X-52/X-65 Plates for Line Pipe Applications.
High Tensile Plates BSEN-100025, S-355 K2G3 and BS4360 50 DD Specifications for
export with sub-zero impact toughness, thicker plates in boiler quality grade.
SAILMA 300 HI plates in 75 & 80 mm thickness were developed for DLW, Varanasi, for
application in locomotive base plate.
MANAGING DIRECTOR
GM(F&A)
ED (PROJECTS)
ED (WORKS)
Organization
structure of BSP
GM (IT)
GM (PROJECTS)
GM (M&SP)
ED (P&A)
GM (TS)
GM (PERS)
GM (PP&E & BEDB)
GM (HRD)
GM (IA)
GM I/C (SERVICES)
GM (SAFETY)
GM (MS)
GM I/C (MINES)
GM I/C (M&U) (REFR)
DIR (M&HS)
ACVO
COC
DGM (L & A)
ED (MM)
GM (MM)
CHAPTER-4
FUNCTIONAL
DEPARTMENTAL
1.MARKETING DEPARTMENT
CENTRAL MARKETING ORGANIZATION(CMO)
The ISO: 9001:2000 certified Central Marketing Organization (CMO) is Indias largest industrial
marketing set-up that markets carbon steel Produced by the four integrated steel plants of SAIL.
Headquartered in Kolkata, it transacts business through its network of 34 Branch Sales Offices spread
across the four regions, 25 warehouses equipped with mechanized handling systems, 11 Customer
Contact Offices and 16 Consignment Agents. CMOs domestic marketing effort is supplemented by its
ever-widening network of authorized and rural dealers who meet the demands of the smallest customers
in the remotest corners of the country. A strong IT support system enables real-time network connectivity
within the entire CMO network. Extensive customer contact, product and segment specialization, close
monitoring of order servicing and feedback analysis through the Customer Satisfaction Index are
established norms at CMO. The customer-friendly approach of CMO is backed by practical after- sales
services. Through the process of Key Account Management, CMO provides single window service to key
customer across the country for every business transaction from enquiry to order booking, order tracking
to delivery, and even consultancy and after-sales services.
Central marketing organization is the marketing unit of SAIL. The Central Marketing Organization
(CMO) of SAIL was formed in 1963 when the public sector steel plants were managed by Hindustan
Steel Private Limited. It caters to the domestic market and is responsible for marketing of all the products
manufactured by all the steel plants of SAIL in a coordinated manner. The CMO undertakes marketing of
materials produced by SAILs plant through a distribution network of 43 Branch Sales Offices (BSO),
stockyards, dockyards, consignment agents and extension counters spread all over the country. Central
Marketing Organization (CMO) and most of its divisions have their Headquarters at Kolkata and they
reports to the Director headquartered at Delhi. However, departments like transport and shipping, export
and etc. report to exchange to Executive Director located at Delhi.
Marketing Strategy
a)
b)
c)
d)
e)
f)
Trading of steel by sourcing from international sources, to enable packaging for key customers
g)
h)
Major Function
Market research, Demand Assessment, segment prioritization, product planning, sales and after sales
services etc. CMO has a network of sales offices and stockyards within the country for purpose of
distribution of materials outlets. The other aspects controlled by CMO are planning, customer services,
transport and shipping data information system etc.The distribution of iron & Steel products is done by
the CMO through 45 branches and stockyards located in all important steel consuming centers in the
country. For administration purposes, the branches are grouped under 6 regions. The distribution through
the stockyard is of the order of 69% and through direct dispatches by the plant 31%. They operate various
schemes of the products is fast and the customer are satisfied.
Eastern Region
Western Region
Southern Region
Northern Region
CMO has got transport and shopping determinants to handle the export and import consignments at
different ports. These offices are at following places.
Calcutta
Chennai
Paradip
Haldia
Visakhapatanam
To coordinate about production and dispatches in different steel plants, CMO has got SRM offices at
following places :
Bhilai
Durgapur
Roukela
To take care of the exports, CMO has got office at New Delhi, there is separate fertilizers and chemical
division to sell fertilizers and chemicals produced by the plants.
There are three executives called as product executives for BSP they take care of separate division in BSP
the main divisions being:
Plate Mill
Heavy Structure
Structures
The movement plans are generated by BSO only. The main purpose of the movement plan is to give the
commercial as well as the quality information of any particular transaction. This information is then sent
to the M & SP department of BSP.
Central Planning & Products Division: The main function of the division is to bring about coordination
between the market demand and production of the steel plants. The four Resident Sales Mangers of the
CMO located in four tonnage plants report to this divisions in respect of matters relating to marketing viz.
movement, dispatches etc.
Alloy Steel Divisions: This division looks after marketing of alloy and special steel products
manufactured by alloy Steel Plant, Durgapur and also coordinates sales efforts with Visvesvaraya Iron &
Steel Co. Ltd (VISL), SSP and MEL.
Pipes, Electrical Steel Sheets & Tin Plates Division: Headquarters of this set up is located at Mumbai
where majority of the customers for these materials are situated. These materials have to be marketed
under highly competitive conditions. This division works out marketing strategies such as pricing,
distribution system, storage and delivery facilities etc. This division has a field set up at each of the
regional headquarters.
Market Management Group: This group is headed by group market manager. This group cosistes of
market managers. Market managers are responsible for market strategy & planning in terms of sales,
market share & profitability in a specific market segment.
Salem Steel Products Divisions: This division headquartered at Chennai by Salem Steel plant. They
have field office at each of the regional headquarters as well as major consumption center.
Marketing Services Divisions(MSD): This division looks after the management of this divisions is
supported by a computer center where data on marketing operations throughout the country are processed
on a regular basis to bring out periodical MIS reports. The responsibility of designing & implementing
road movement, handling contract systems etc. is also with them.
Commercial Division: This division deals with formulation of polices on distribution. This division also
deals with parliament question on behalf of Central Marketing Organization.
Application Engineering Group: This division deals with application about selection of best suited raw
materials, development of new products required by the market etc. It also undertakes technical
inspection on behalf of the CMO wherever needed. The A.E. personal are posed at each regional
headquarters.
Fertilizers and Chemicals Divisions: This division is headquartered at Kolkata and looks after
distribution of Ammonium Nitrate products by Roukela Steel Plant and Ammonium sulphate produced by
all the steel plants. This division has got offices at field location where the demand for fertilizers is
substantial.
Market Research Group: This division undertakes assessment of demand for Pig Iron & steel products
for long term perspective & advice management about the market. This division brings out periodic
reports covering various aspects of consumption, market condition, competitors activates etc. They have
field representatives for collecting & forwarding market intelligence to the headquarters.
Transport & Shipping Department: The department is headquartered at Kolkata and has branch offices
at major port areas. This division is responsible for handling imports & exports on behalf of SAIL. These
divisions clear the coals imported of SAIL, at the ports and forward the same to various steel plants.
Finance & Accounts Department: This department renders financial advice to the line managers as well
as CMO headquarters and maintains the accounts of the Organization covering Home sales, Transport and
shipping exports, internal audit, etc.
Computerization Division: This division is headquartered at Delhi and reports to General Manager, This
division is in change of the on going project for total Computerization of CMO at headquarters field
offices and SRM in the plant location. At present this division is responsible for hardware and software
maintenance also. Software Development Center at Hyderabad is engaged in developing and updating
software required for CMO marketing.
Legal Cell: This cell deals with all legal matters of CMO like court cases, arbitration, examination of
different documents for giving loans to employees for house building & renders legal advice on various
transactions. This is headed by GM (Law) who reports to Director (commercial)
Special Project Division: This division is headquartered at Delhi and reports to Director (commercials).
This division deals with modernization of stockyards giving technical help and assistance to the stockyard
in maintenance of handling equipment etc. This department also deals with construction of office building
of CMO and acquisition / construction of residential accommodation etc.
It is a part of CMO various BSO offices are located all over India which performs the job of marketing of
SAIL products throughout the India. It receives the order from various customers, does market research,
analyze competitive position, demand pattern etc.
The prices for all products at BSP are done by the government of India. These prices are fixed and are
quite economical for the customers as it is quite low as compared to the competitors.
Selling Methods
There are two methods for BSP:
1. Tender Pricing
2. E-auction
Types Of Customers
There are two types of customers:
End user customers: These customers basically use products in factory, plants for power projects of
other purposes like fabrication.
Traders: These customers buy products from us and again sell them to the end users.
SAIL plants is performed by CMOs Transport & Shipping Division (T & S) headquartered at Kolkata,
T&S has branch offices at Haldia, Paradip and Vizag ports.
Products
Bhilai offers a rich and varied product mix to the domestic and international markets by different ways.
The are divided into two categories, which is:
Prime Product
Secondary Product
Prime Product
Rails (KG/Mtr)
Angle (MM)
: 45,52,60
80,100,120
50x50x5/6,65x65x5/6,8/10,75x75x6/8/10,80x0x6/8/10, 90x90x6/8/10,50x150x16/20,
200x200x16/20
Secondary Product
Coke fraction
Slab
Steel Scrap
Secondary Products
Coal Chemicals
Merchant Mill (MM)/Wire Rod Mill (WRM)/ Rail and Structural Mill (RSM).
Exports
Plate Mill
Marketing and Strategic Planning section of BSP are segmented into two main parts, namely
These two zones are divided into different sub zones. Primary Product Zone is divided into
a) 2.5 Million Tonne (long products- rail and structural, wire rods, TMT bars, channels,angles, rolled
blooms and billets of different sizes and specifications, Pig Iron )
b) 4.0 Million Tonne (flat products- Plates of different Sizes and specifications, continuously casted Slabs
and Blooms in SMS-II)
c) Exports of primary products.
b) Miscellaneous Section: This section is sub divided into i) Secondary steel products (cast iron, steel,
mild steel secondary etc.) and ii) Secondary non-steel products (Blast Furnace slag, BF flue dust, lime
sludge, different refractory waste, cinder from soaking pits etc.).
1.1.
The following flow charts depict the role of marketing department in the dispatch of the material.
1.1.1.
Road Transfer
1.1.2.
Rail transfer
1.1.3.
Inter-plant transfer
Exports
An Overview:
For any organization, the Finance & Accounts function plays a key role in guiding the organization to
meet its ultimate goals and objectives. While Finance function embarks upon regulating the inflow
and outflow of funds, the Accounts function basically supports the finance function by way of
analyzing the transaction in a most befitting manner. Finance & Accounts function is like a mirror
through which one can peep into the health of an organization.
Finance & Accounts Department of BSP has to execute several activities. The Department has been
divided into several sections based on organizational needs and functional expertise required by
grouping activities of similar nature as a section. The objective of Department is always to meet the
requirements of Line Departments, customers, suppliers, stakeholders and Government Departments
while discharging its own functions such as accounting, budgetary control, rendering advice on
financial matters and meeting the statutory requirements. To back up all above functions, the
Department has a vast and dedicated team of professional accountants and experts.
Finance also discharges special functions such as taxation like Central Excise, Sales Tax, VAT, CST, Entry
Tax, and Terminal Tax.
Bhilai steel plant has implemented SAP in 2009-10 under the ERP system, by which the functions of
Finance are linked online to various technical functionality and processes. Which has lead to availability
of online information and database for various finance work, analysis, etc. This has lead to a sea change
in the working and environment of Finance Department.
3.PRODUCTION DEPARTMENT
Products
Shop
Rail
Products
& Rails
Structural
Mill
Annual
Product
Width
Capacity
Dimension range
range
Length
(Tonnes)
(mm)/ Profile
(mm)
(metre)
750000
13,
Rails
Heavy
Beam
260
Structurals
600x210,500x180
Infrastructure Projects
450x150,
400,350,300x140
250x125
Channel
Crane Rails
400x100,
Crossing
250x82
sleepers
Angle
300x90
150x150, 200x200
Cranes
Broad gauge sleepers
Shop
Products
Annual
Product
Width
Capacity
Dimension range
range
Length
(Tonnes)
(mm)/ Profile
(mm)
(metre)
Lt. Structurals
Merchant
Mill
65x65
70x70,
75x75
80x80,
90x90
Channel
5,00,000
TMT
50x50,
Round
75x40,
100x50
Engineering
TMT
and
Infrastructure Projects
(Plain)
Mill
4,00,000
5.5,
6,
7,
Electordes
8, 10, 12
Manufacture
Infrastructure Projects
Boilers,
Plate Mill
Plates
9,50,000
1500
8 160
4.5 - 15.0
3300
Defence
Bloom,
Slab
Semis
&
NWS
Billets
from BBM
HC Bloom from
CCS
Billets
5,53,000
Re-rollers
Blooms
1502 , 3202
Foundry
Ammonium Sulphate (Fertiliser)- Brand Name -RAJA
Coal Chemicals
Tar
(Pitch,
By
products,
Napthalene,
Creosote
Oil
Road
Tar,
Products
Benzol
Processed Slag
products
(NG
Benzene,
Toulene,
Xylene,
Long Products
RAILS
Product
Application
Railway Tracks all over the country & also for export customers.
Rail
RAILS
Product
Application
Crane rails in CR-80/CR-100/CR-120 sections, used for tracks of
Crane Rail
prone areas
HCR TMT Bar & Wire Rod (8, 10, 12, 25, 28,
Flat Products
PLATES
Product
Application
industry
S235/S275, etc.)
High Tensile plates (SAIL MA 300/350/410/450, IS 2062
E300/E350/E410/E450, EN 10025 S355, JIS G 3106
SM490 A/B, ASTM A572 GR.42/50, etc.)
690AR, etc.)
Gr.55/60/65/70
High strength Pressure Vessel Quality plates for use at
PLATES
Product
Application
1, EN 10028 P275
high pressure
Gr.16Mo3
resistance property
A number of Indicator points to the need for extensive use of careful manpower planning if optimal use of
human resource is to make.
Labour productivities in steel plants is only a fraction of those prevailing in most other countries.
The cost of Indian steel, which at one time used to be among cheapest in the world is now above the
international level.
RECRUITEMENT
In bhilai steel plant recruitment is done through the divisional employment exchange, whenever the
number of vacancies exceed, the divisional employment exchange of Durg district distribute 50% of the
vacancies to the exchange of the region like Raipur, bilaspur, korba districts etc.
5. ENGINEERING DEPARTMENT
2.1.1 INTRODUCTION
The first step in the production of steel is to produce iron, and iron production involves
separating iron from iron ore. There are mainly three basic methods of producing iron: Direct
Reduction, Iron Smelting and the Blast Furnace method. Direct Reduction method includes both
gas and coal based processes. The product coming out of these processes (Sponge Iron or Direct
Reduced Iron) is in the solid state. Electric Arc Furnace follows DRI process for the production
of crude steel. In Iron smelting process coal and iron ore fines are used as charge materials and
liquid product will come out of the furnace, example Corex process. EAF or BOF route is
followed for steel making. For achieving high production rates with great degree of heat
utilization Blast Furnace (BF) route is the most economical way till date. So Bhilai Steel Plant,
which is an ore based Integrated Steel Plant had chosen Coke ovens Blast Furnace BOF /
THF route for the production of crude steel.
the denser iron. The iron can then be separated from the slag in the cast house. 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.
The shaft or stack, where the ores are heated and reduction starts.
The bosh, where the reduction is completed and the ores are melted down.
The hearth, where the molten material is collected and is cast via the tap hole.
Iron Ore: Iron bearing materials; provides iron to the Hot Metal
Sinter: Iron bearing material. Fines that are generated in the plant are effectively utilized
by converting them to sinter. Provides the extra lime required for the iron ore that is
charged in the blast furnace.
Coke: Acts as a reductant and fuel, supports the burden and helps in maintaining
permeable bed.
Limestone: Acts as Flux. Helps in reducing the melting point of gangue present in the
iron bearing material
Manganese Ore: Acts as additive for the supply of Mn in the Hot Metal
Pellets: Iron bearing materials. Although not in use right now, there is a proposal to
utilize the fines below the sinter grade for pellet manufacturing and the pellets formed are
going to be charged in the BF.
The very hot gas ascends through the furnace, carrying out a number of vital functions.
Upon melting, the iron ore produces hot metal and slag, which drips down
through the coke.
Zone to the hearth, from which it is removed by casting through the taphole. In the dripping zone
the hot metal and slag consume coke, creating void age. Additional coke is consumed for final
reduction of iron oxide and carbon dissolves in the hot metal, which is called carburization.
Thus the liquid products Hot Metal and Slag settle in the Hearth. These two products are
removed periodically from the blast furnace. The process is called tapping the blast furnace. The
other gaseous product, which is going to the top of the furnace, contains dust in it. It is cleaned in
the Primary (dust catcher); Secondary (ventury and scrubber) and Tertiary (electro static
precipitator) gas cleaning system and the cleaned gas is used as a fuel all over the plant.
It will take minimum 6-8 hours for the solid raw materials that are charged from the top to reach
the bottom, whereas gaseous products that are sent through the tuyeres will go out in 2-8
seconds.
2.2.1
INTRODUCTION
FlowChart2. SMS I
Steel Melting Sop - 1 (SMS-1) follows the conventional route of steel making in which steel is
produced through Twin Hearth furnaces and cast into ingot moulds.
Initially SMS-I was set up to produce 1 MT steel annually, from 6 Open-Hearth furnaces of 250
T capacity each. First tapping was done on 12th October 1959. Sixth Open-hearth furnace was
commissioned on 22nd February 1961. Later on it was decided by the corporate management to
increase the capacity of the shop to 2.5 MT, by installing 4 more open hearth furnaces of 500 T
capacity and converting OH no. 6 from 250 T to 500 T capacity, which was completed on 14th
April 1967. Steel production through Open-hearth furnaces had the following drawbacks :
1. Low productivity.
2. Cumbersome operation of the furnaces.
3. Higher fuel & refractory consumption.
To overcome the above drawbacks it was decided by the management to replace open hearth
furnaces by Twin Hearth furnaces (Both hearths having capacity of 250 T each). The following
table shows the commissioning of different twin-hearth furnaces (by replacing different openhearth furnaces)
2.2.2
PROCESS DETAILS
CHART1. Commissioning of different THF by OHF
Sl. No.
TH Furnace
Date of Commissioning
10
12/09/86
Remaining
1,2,3
01/01/90
two
4,5,6
29/06/92
hearth
21/01/98
open-
furnaces,
i.e. No. 7 &
9 have been scrapped, and presently SMS-I has four twin hearth furnaces only. The production
capacity of the Shop is 2.5 MT by running 3 Twin-hearth furnaces at a time.
For maintaining temperature of the hot metal. Two mixers have been installed in SMS-I, one at
each end of the main building. Both the mixers are drum-type, inactive mixers, lined with
magnesite bricks, having a capacity of 1300T each. An average temperature of 1300C is
maintained with burners using coke oven gas as fuel. The hot metal in mixer contains following
(averagely):
- 3.5 to 4.0%
Mn
- 0.6%,
- 0.045%,
- 0.18% to 0.22%
Si
- 0.6% to 1.2%
SMS-I comprises of various sections for melting, casting & stripping of 2.5 MT ingots annually
The main sections are :
1.
2.
3.
4.
5.
Mixer
Stock Yard
Furnace
Pit side
Mould Yard
necessity for additional source of water was felt and this additional water requirement of BSP
was assured from Mahanadi Reservoir complex.
Raw water is conveyed to BSP by open unlined Tandula Main Canal which is 69 kms. from
Tandula Head Works. Tandula canal is connected to Kharkhara and MRP by respective feeder
canals. Water released from irrigation reservoirs (Tandula & MRP complex) is received and
stored in a site storage reservoir, having a capacity of 36 million cubic meters, and is called
Maroda-II.
2.3.1 The storage capacities of Reservoirs:
A. State Government Irrigation Department :
1. Kharkhara - 144.95 Million Cubic Meters.
2. Tandula - 302.27 Million Cubic Meters.
3. Gondli - 96.56 Million Cubic Meters.
4. Ravi Shankar - 767.00 Million Cubic Meters.
5. Dudhawa - 284.00 Million Cubic Meters.
6. Murrom Silli - 162.00 Million Cubic Meters.
B. Bhilai Steel Plant :
1. Maroda-I - 9.09 Million Cubic Meters.
2. Maroda-II - 35.90 Million Cubic Meters
2.3.2 The major units of water supply department are :
1. Pump Houses - 70 Nos.
2. Cooling towers - 85 Nos.
3. Radial Settling Tanks - 22 Nos.
4. Horizontal Settling tanks - 96 Nos.
5. Filter Houses - 02 Nos.
6. Oxidation Ponds - 04 Nos.
7. Water Chemical Treatment Plant - 02 Nos.
8. Chlorine Stations - 03 Nos.
9. Over Head Tanks - 12 Nos.
: 1 No
: 1 No
3 HMT Lathe
: 8 Nos
: 1 No
: 1 No
: 1 No
: 1 No
: 1 No
9 Slotting Machine
: 2 Nos
10 Shaping Machine
: 1 No
: 1 No
: 1 No
: 2 Nos
: 1 No
: 1 No
: 1 No
: 1 No each
: 1 No each
19 Heating Furnace
: 1 No
: 2 Nos
: 1 No
: 1 No
: 2 Nos
The main jobs involved are revisioning/replacing of the bearings, reclamation and
replacement of various rollers, alignments of rollers and frames, checking of hydraulic cylinders
of pinch rolls and replacement of oil seals etc. and alignment of various sets.
Apart from this mechanical spares required for Capital & Regular repairs of various departments
are manufactured as per schedule plan by Central Planning Department. Some of important
manufactured items are, hollow shaft of SMS-I Stripper crane, Cinder Notched Monkey used in
Blast Furnace, different sizes of Slide Blocks etc.
2.4.3 OTHER IMPORTANT ASSEMBLIES MADE/REPAIRED ARE:
Blooming & Billet Mill popularly known as Mother Mill, is a primary mill designed to roll 2.5
MT/Annum of ingots into semies in the form of blooms & billets. A two high reversing blooming
mill and 12stands Continuous Billet Mill are part of this department. The 1150mm two high
reversing Blooming Millis designed to roll steel ingots into blooms for Continuous Billet Mill
and Rail & Structural Mill. Average weight of steel ingots which are used for rolling is 8 to 9
Ton. Major sections are described below:
2.5.2 SOAKING PITS
Heating of the ingots and soaking at a particular temperature is done in the soaking pits. There
are 14groups of recuperative type soaking pits. Each group consists of 2 pits. Each pit is heated
by two burners situated diagonally opposite in the upper part of the lateral wall of the pit. The
fuel burnt is mixture of coke oven gas and blast furnace gas with a calorific value of 1450 - 1500
KCal./Cu.M. Air is preheated inceramic recuperators and the gas in the metallic recuperators.
The ingots are placed in the pits in such away so that proper circulation of the flame around the
ingot is ensured. Generally 16 ingots are placed in one chamber at a time. Strict records are
maintained to avoid mix-up.
After 4th to 5th round of rolling, cleaning of the pit is done by scrapper bar held by the tongs
crane and bottom is made with two buckets of Coke Breeze. Out of the 28 pits (14x2), 22 to 26
pits are under operation depending on requirement and the balance is under repair/reserve.
Operational data of Soaking Pits
Dimensions of the pit
Length : 6.7m, Width : 4.2m , Depth : 4.5m
Soaking temp. : 1280 to 1320 deg.C
Pit pressure : + 0.2/0.3mm w.c.
2.5.3 Blooming Mill Blooming mill is a 2-High horizontal stand, equipped with individually
driven rolls. Each roll of the Blooming Mill is driven by 930 V, 8000 KW, 0-20-80 rpm motor.
Length of Roll - 2800 mm, Dia. of Roll - 1150 mm (Min.1100mm & Max.1180mm)Rolls are
used in pairs. Each roll set is ground with the required pass design (4 including the shaped beam
pass). After rolling of about 1 lakh ton, the rolls are charged. The used rolls are sent for
redressing in Roll Turning Shop. After redressing they are assembled and reused. The Top Roll is
balanced by counter weights. It is moved up and down by screw down mechanism driven by two
motors mounted on the top of the stand. There are manipulator side guards on both sides of the
Roll stand.
i) 320 x 320 mm
ii) 265 x 340 mm
iii) 260 x 300 mm
iv) Shaped blooms for Beam-450mm & Beam-600mm
v) Narrow Width Slab 200 x 320 mm
vi) Narrow Width Slab 200 x 420 mm
2.5.4 BLOOM STORAGE : Blooms assigned for Rolling in the Rail & Structural Mill and
requiring inspection and conditioning are transported hot, by 15 ton over-head cranes and
stacked in specified areas depending on quality of steel. IS/ISO-14001: 2004
2.5.5 BILLET MILL: The Billet Mill has been designed to roll billets from blooms of cross
section 325x325 sq.mm in 6 to 12passes depending on cross section of billets to be produced in
the Mill. The capacity of the Mill is15,01,000 Tonns/Year.The Mill consists of 12 working stands
arranged in three groups.
a. The First group contains Two 2-High Horizontal stands with a 90 deg. tilter in between. These
stands are equipped with rolls of diameter 1000mm and length 1200mm.
b. The Second group called the roughing group contains 4 stand - 2 each of Horizontal and
Vertical stands arranged alternately. These stands are equipped with rolls of diameter 700mm.
c. The Third group called the finishing group located after the transfer table contains 6 stands 3horizontal and 3 vertical stands arranged alternately. These stands are equipped with rolls of
diameter 500mm.
Rolled billets after the roughing group of stands which are not to be rolled further are transported
by transfer table and by pass roll table to the stationary 800T shear where they are cut into
required length. The billets are gathered and transported to cooling bed by roll tables.
Billets from roughing group intended for further rolling in finishing group are transferred to the
last group of stands. If necessary, the front end of billet can be cropped off by 250 T shears
installed in front of the group. After rolling in the finishing group, the billets are cut by flying
shears into billets of length 5 to 12m.After cutting, the billets are transported to cooling beds by
roll tables and transfer skids.
SECTION OF BILLETS ROLLED ARE
CHAPTER- 5
SWOT ANALYSIS
SWOT Analysis
The primary function of Bhilai Steel Plant are derived from the functions of the mother
organization SAIL. As a production unit of SAIL, BSP carries out the specific functions and task
assign to it from time to time, both with regards to production and execution of other functions of
SAIL, such as design consultancy, training and development etc. The primary analysis of any
organization begins with the SWOT Analysis. It gives a complete picture so as to where an
organization stands with respect to its competitors
And areas where its lags behind. It also gives a bird eye view f the possible opportunity that
exists which can be capitalize upon the threats that may affect its operations at present or in the
future.
SWOT
Strengths:
Capacity of plant
Product Mix
Quality of Products
Human Resource & Management
Weakness:
Supply of Raw Materials
Demurrages
Rigidity of Labor Law compared to other countries
Opportunities:
Upsurge in Indian Economy
Technological Edge
Human Resource Management
Threats:
CHAPTER-6
FINDING, SUGGESTION
AND
CONCLUSION
SUGGESTION
CHAPTER-7
BIBLIOGRAPHY
REFERENCES
My plant work visit book , A Release of Training & Management Development
Department, BSP
http://www.itclearning.com/blog/?p=1565
http://www.sail.co.in/
https://www.sail-bhilaisteel.com/
http://en.wikipedia.org/wiki/Bhilai_Steel_Plant
http://www.icai-bhilai.org/contents/about-bhilai.php
http://articles.economictimes.indiatimes.com/keyword/bhilai-steel-plant
http://www.firstpost.com/tag/bhilai-steel-plant
http://www.business-standard.com/article/companies/record-production-of-
saleable-steel-in-bhilai-steel-plant-114011000806_1.html
http://www.mapsofindia.com/chhattisgarh/economy/bhilai-steel-plant-bhilai.html
http://www.fieldtofactory.lse.ac.uk/SteelPlantHistory.htm
Notes provide by Mr. K.V. RAJU ,SR MANAGER (FINANCE AND
ACCOUNTS DPT.) and Mr. ABHISHEK KOCHAR (Jr. MANAGER) EXCISE
DEPT.