RSP Panorama PDF

PANORAMA
ROURKELA STEEL PLANT

HUMAN RESOURCE DEVELOPMENT CENTRE
Panorama 2017
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
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ROURKELA STEEL PLANT: A RESUME
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.
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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.
Post Expansion Production Capacity (In Million Tonnes per annum):
Pre Expansion Post Expansion

Hot Metal 2 4.5
Crude Steel 1.9 4.2 (*Revised 3.7)
Saleable Steel 1.67 3.9 (*Revised 3.49)
* 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.
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Major Facilities which have come up during Expansion:
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:
Rourkela Steel Plant
the 1st Steel Plant in Asia to adopt LD process of steel making;

the only Plant in SAIL producing large diameter ERW/SW Pipes conforming to most rigid
standards of API;
the 1st Steel Plant in the SAIL family to produce 100% of steel through the cost effective and
quality centred continuous casting route;
the 1st Steel Plant in India to adopt external desulphurisation of hot metal by calcium carbide
injection process;
the only plant in SAIL producing Cold Rolled Non Oriented sheets for use in electrical
industries;
the 1st plant to adopt vacuum degassing metallurgy, primarily for production of Silicon Steel
for the CRNO sheets; and
has the 2nd largest operational Blast Furnace of the country- Durga.
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.
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PROCESS FLOW OF ROURKELA STEEL PLANT
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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.
a) IronOre: Captive Mines at Gua, Bolani, Monoharpur, Barsua,

Kalta, Meghathatuburu, Kiriburu
b) Limestone: BF Grade – Kuteshwar, Jaisalmer and imported from
Dubai
SMS Grade - Jaisalmer and imported from Dubai
c) Dolomite: BF Grade –Bhavanathpur, Biramitrapur and Sonakhan

SMS Grade – Bilha
d) Dolomite Fines Biramitrapur and Sonakhan
e) Ferro Manganese Maharashtra Electrosmelt Limited (MEL)
andSilico
Manganese:
f) Quartzite: Bobli
g) Coal: Prime Coking Coal (PCC) and Medium Coking Coal
(MCC) from Indian Sources
Imported Coking Coal (ICC) – Hard and Soft from
Australia, Canada, USA and Mozambique
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Main Plant Units
a) Ore Bedding and Capacity – 12 MTPA. Receiving, unloading, reclaiming and finally
Blending Plant transporting Iron ore Lump and Fines, limestone, Dolomite,
(OBBP): Quartzite. Base mix preparation for Sintering Plants and
Transportation of crushed fuel and flux for trimming addition to the
new Sinter Unit
b) Sinter Plant I: 2 Sinter machines of 1.5 MT per year (125 Sq.Mtr sintering area
each)
c) Sinter Plant II: 1 Sinter machine of 1.57 MT per year (192 Sq.Mtr sintering area )
d) Sinter Plant III: 1 Sinter machine of 3.70 MT per year (360 Sq.Mtr sintering area )
e) Coke Ovens: 3 Batteries of 70 ovens each (4.5 meters tall), 2 Batteries of 80
ovens each (4.5 meters tall) - all having wet quenching facility and
1 Battery of 67 ovens (7 meters tall) with CDCP facility
f) Blast Furnaces: BF#1 : 1.01 MTPA hot metal capacity with 1491 M3 working
volume & 1710 M3 useful volume
BF#4 : 0.70 MTPA hot metal capacity with 1448 M3 working
volume & 1658 M3 useful volume
BF#5 : 2.8 MTPA hot metal capacity with 3470 M3 working volume
& 4060 M3 useful volume
g) Steel Melting Shop 2 mixers of 1100 Ton each, 2 LDs of 60/66 Tons/ blow and 1 single
I: strand slab caster of 0.5 MT of slabs per year
One LF, One VOR and one VAR
h) Steel Melting Shop 2 mixers of 1300 Ton each, 3 LD Converters of 150 Tons each,
II: 2 single strand slab casters (Caster 1 & 2) of total capacity 1.7 MT
of slabs per year and 1 new single strand caster-3 of 1.5 MT of slabs
per yearone 150 t ARS, three 150 t LF , one RH –OB Unit
i) Hot Strip Mill:  2 Walking beam furnaces of 225 Ton/hr each
 3 Stand Roughing Mill and 4 hi 6 stand Finishing Mill with a
capacity of 1.67 MT HR coils per year.
j) Plate Mill:  1 walking beam furnace of 100 Ton/hr
 3.1 meter wide and 4 hi Reversing Mill of 3,40,000 Tons of
plates per year.
k) Pipe Plants  ERW Pipe Plant of 75,000 Tons per year with high frequency
welding (400 KHz)
 SW Pipe Plant of 55,000 Tons per year with double sub-merged
arc welding.
l) Cold Rolling Mill  2 Pickling lines
 1 Cold Reversing Mill
 1 Five Stand Tandem Mill
 Hood Annealing, Continuous Annealing
 2 Skin Pass Mills
 Sheet Shearing Line
 Continuous Galvanising Line of 1,60,000 Tons per year
m) Silicon Steel Mill  4 Hi Reversing Mill of 73,500 Tons per year of CRNO
n) Captive Power  5 units to produce 125 MW of power
Plant-I
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Product Mix and Application of Products

Products Applications
LPG cylinders, automobile, railway wagon chassis and all types
HR Coils
of high strength needs.
Pressure vessels, ship building and engineering structures,
Plates
space applications
Different defense applications, building of tanks, bullet proof
Special Plates
vehicles etc
Flooring and staircases in the industrial sectors and railway
Chequered Plates
platforms etc.
Steel furniture, white goods like refrigerators, washing
CR Sheets & Coils machines, automobile bodies, railway coach paneling, drums,
barrelsetc.
Roofing, paneling, industrial sheeting, air condition ducting
Galvanised Sheets
and structural.
Small generators, starters for high efficiency rotating equipment
Silicon Steel Sheets &Coils
and relays etc
High-pressure transportation of crude oil, natural gas and
SW Pipes slurry transportation, water supply, sewage disposals, grain
silos, civil engineering pilings etc.
High pressure transportation of oil and water, sewage disposal,
ERW Pipes
tube wells etc.
Plates and Sheets
Coils Pipes
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Major Milestones in Rourkela Steel Plant
 21 December 1953: Agreement signed with Krupp-Demag

for RSP.
 3 December 1958: COB # 1A commissioned.
 5 January 1959: COB # 1B commissioned.
 26 January 1959: CPP-I Boilers-1 & 2 commissioned.
 27 January 1959: Converter-X commissioned in SMS-I.
 18 June 1959: CPP-I Boiler-3 commissioned.
 7 August 1959: CPP-I Boiler-4 commissioned.
 27 December 1959: ASU-1 commissioned in Tonnage Oxygen
Plant-I.
 9 January 1960: Converter-Y commissioned in SMS-I.
 12 January 1960: BF # 2 commissioned.
 31 January 1960: Converter-Z commissioned in SMS-I.
 22 March 1960: COB # 2A commissioned.
 5 April 1960: COB # 2B commissioned.
 6 June 1960: ASU-2 commissioned in Tonnage Oxygen Plant-
I.
 24 June 1960: ASU-3 commissioned in Tonnage Oxygen
Plant-I.
 12 September 1960: Plate Mill commissioned.
 15 October 1960: ERW Pipe Plant commissioned.
 13 June 1961: Pickling Line-1 commissioned in Cold
Rolling Mill.
 28 December 1961: Hot Strip Mill commissioned.
 8 January 1962: BF # 3 commissioned.
 7 November 1962: COB # 3A commissioned.
 21 November 1962: COB # 3B commissioned.
 28 February 1965: Sinter Plant-I commissioned.
 17 August 1966: Converter-P commissioned in SMS-I.
 25 August 1966: CPP-I Boiler-5 commissioned.
 1 October 1966: CPP-I Boiler-6 commissioned.
 30 December 1966: COB # 4A commissioned.
 3 July 1967: BF # 4 commissioned.
 4 October 1967: Pickling Line-2 commissioned in Cold
Rolling Mill.
 20 November 1967: Converter-Q commissioned in SMS-I.
 30 November 1967: ASU-4 commissioned in Tonnage
Oxygen Plant-I.
 17 February 1968: Tandem Mill commissioned in Cold
Rolling Mill.
 15 July 1968: Galvanising Line-2 commissioned in CRM.
 27 July 1968: Galvanised Corrugated Line commissioned in CRM.
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 31 October 1968: Electrolytic Tinning Line commissioned in

CRM.
 6 February 1969: COB # 4B commissioned.
 25 September 1969: Galvanising Line-1 commissioned in CRM.
 21 September 1974: COB # 5A commissioned.
 3 February 1976: 10 MT saleable steel production.
 17 June 1976: Spiral Weld Pipe Plant commissioned.
 1 November 1982: First CCTV network in Asia inaugurated.
 27 December 1983: COB # 5B commissioned.
 24 October 1984: Silicon Steel Mill commissioned.
 12 April 1987: CPP-II Unit-1 commissioned.
 23 March 1988: CPP-II Unit-2 commissioned.
 20 September 1991: 2nd phase of modernisation inaugurated.
 11 March 1993: Units 1 & 2 commissioned in Tonnage Oxygen
Plant-II.
 29 November 1993: Ore Bedding & Blending Plant
commissioned.
 5 August 1996: Continuous Casting Machine-1 commissioned.
 29 September 1996: Sinter Plant-II commissioned.
 7 November 1996: LD-B and Caster-I commissioned in SMS-II.
 7 February 1997: LD-A and Caster-II commissioned in SMS-II.
 15 May 2003: Visit of His Excellency Dr. A. P. J. Abdul Kalam,
the Hon’ble President of India to RSP
 04 January 2008: Foundation Stone laying of the Modernisation
and Expansion programme
 03 February 2009: RSP celebrates Golden Jubilee of its Hot
Metal production
 1 April 2012: Hot trial and Sinter Production commences in the
Sinter Unit#3
 11 August 2012: New Raw Material Handling Plant of OBBP
Complex inaugurated
 1 June 2013: Coke Oven Battery#6 complex inaugurated
 5 August 2013: Commencement of operation of New Blast Furnace #5 ‘Durga’
 10 August 2013: Inauguration of Continuous Slab Caster -3
 17 January 2014: Inauguration of 2 x 700 TPD BOO Oxygen Plant
 4 June 2014: Commencement of operation of New BOF-3
 30 August 2014: Inauguration of New Coal Chemical Plant
 11 November 2014: Inauguration of TGT at BF#5
 11 November 2014: Inauguration of Sinter Plant-3
 1 February 2015: Inauguration of Rolling facilities of 4300 mm
New Plate Mill
 1 April 2015: Dedication of Modernisation and Expansion to the
Nation
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ORE BEDDING AND BLENDING PLANT (OBBP)
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
Raw materials Handled:

OBBP is a centralised unit for unloading and stacking of all major raw materials excluding coal.
Sl. Raw Materials Sources

No.
(i) Iron Ore Lumps (IOL) Barsua, Kalta, Kiriburu, Meghataburu, Bolani,
Chiria( Manoharpur) & Gua
(ii) Iron Ore Fines (IOF) Barsua, Kalta, Kiriburu, Meghataburu, Bolani ,
Gua & Manoharpur.
(iii) BF grade Lime Stone Kuteswar, Jaishalmar & Dubai,
(iv) BF grade Dolomite Bhabnathpur, Birmitrapur & Sonakhan
(v) SMS grade Lime Stone Jaisahalmar & Dubai
(vi) SMS grade Dolomite Belha, Bharaduar
(vii) Dolo Fines Birmitrapur & Sonakhan
(viii) Quartzite Bobbli
(ix) Coke Breeze BSL & ISP
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)
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There are total 20 numbers of Beds for stacking of different materials.

Bed-1 &2 Unscreened Iron Ore Lump
Bed-3 , 5 & 17. BF grade Lime Stone, BF grade Dolomite & Dolomite fines
Bed-4 , 6 & 18 SMS grade Lime Stone & SMS grade Dolomite.
Bed-7 SMS grade Lime Stone , Dolomite Fines & -30mm Lime Stone.
Bed-8 & 9 Screened Iron Ore L.ump ( Sized Ore)
Bed-10, 11 , 12, 15 & 16 Iron Ore Fines.
Bed-13 , 14,19 & 20 Base Mix.
IOL Screening / Washing:

IOL coming from mines contains undersize fraction of -10mm which can affect Blast Furnace
operation. Therefore, this undersize fraction is screened out in IOL Screening Section and then
stacked in Bed No. 8 & 9 from which screened ore is despatched to Blast Furnaces. During monsoon
the efficiency of screening goes down due to stickiness of the material. So the IOL is washed at the
screening plant & the generated -10mm iron ore fines slurry is stacked at designated bed for reuse
after it is dried up.
Base Mix Preparation:

For better and consistent quality of sinter and also for increasing Sinter Plant productivity, Base Mix
is the prime ingredient used in most modern Sinter Plants. Base Mix is a near homogenous mixture
of Iron Ore Fines, Flux, Dolo fines, Crushed Coke breeze, LD slag fines, Mill Scale, Flue Dust etc.
mixed at certain proportion. Major constituents of Base Mix and its percentage are as follows:
Materials Composition Sized ore required
IOF 78 – 79 % 0 – 10 mm
Crushed Flux 9- 11 % -3 mm – 90%
Dolo Fines 1- 3 % -3 mm – 90%
LD Slag Fines 3- 4 % -5 mm – 80%
Crushed Coke breeze 5 – 5.5 % -3 mm – 85%
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.
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Flux Crushing:
PH-II: Flux Crushing at PH-II is carried out in Rod Mills. Lime Stone and Dolomite lump conveyed
to Rod Mill hoppers before crushing at ratio of 40:60 or 30:70 as per the requirement of Sinter Plant.
These are crushed initially in primary crusher known as Swing Hammer Reversible Impactor (SHRI)
to -25 mm and then finally crushed to -3 mm which is around 90% . This flux is used in Base Mix
preparation at PH-II & also supplied to SP- II for trimming addition.
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.
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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
Major Facilities and Equipment.
Equipments / Storage facilities Old OBBP New OBBP Total
No. of Beds 14 06 20
Wagon Tippler 2 01 03
Track Hopper 2 01 03
Plough feeder/ Paddle feeder 2 04 06
Twin boom stacker 4 02 06
Barrel Reclaimer 3 04 07
Bucket wheel Reclaimer 2 01 03
Stacker-cum - Reclaimer 01 01
Rod mill/Hammer crusher 3series

(3R/M & 3SHRI) 4 series (8crusher) 7 series
Coke crusher 2 series 4 series 6 series
Total nos of Belt 156nos 120 nos 276nos

Total Belt length 42 kms 33 kms 75 kms.
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Flow of Materials in OBBP
Incoming Raw Materials
Wagon Tippler Track Hopper
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
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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)
The analysis is usually termed as the proximate analysis, for

the above varieties of Indian coal is as given under:
Proximate Prime Coking Medium Coking

Analysis Coals Coals
Ash 16% - 26% 19% - 29%
Volatile Matter 19% - 26% 20% - 30%
Gross Moisture 6% - 8% 6% - 8%
Fixed Carbon 48% - 65% 41% - 61%
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
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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)]
The proximate analysis of the above-mentioned coal is:
Proximate Imported Coking Imported Coking

Analysis Coals (Hard) Coals (Soft)
Ash 8% - 11% 7% - 11%
Volatile Matter 21% - 23% 26% - 35%
Gross Moisture 6% - 8% 6% - 8%
Fixed Carbon 64% - 71% 54% - 67%
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:
Proximate analysis Analysis of Blended Coal

Ash 12.5 ± 0.5%
Volatile Matter 23% - 24%
Gross Moisture 6% - 8%
Fixed Carbon 63% - 63%
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 Vitrinite % Mean Max Fluidity Crucible

Reflectance swelling index
PCC 45 1.2 200 ddpm 3
MCC 42 .95 100ddpm 1
SCC 55 .95 100ddpm 1
IMP(H) 70 1.15 600ddpm 7
The analysis required for Blast Furnace:
Proximate analysis Analysis of Coke
Ash 16 ± 0.7%
Volatile Matter < 0.7%
Gross Moisture 4.5% ± 0.5%
Fixed Carbon > 80%
Strength of Coke
M40 > 80%
M10 < 8.5%
Coke Reactivity Index (CRI) < 20%
Coke Strength after Reaction (CSR) > 62%
Coke size (25mm - 80mm) > 95%
HRD CENTRE Page:17

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.
At RSP, all coal wagons are unloaded in Tipplers, a device

which can unload at the rate of 12 wagons per hour. There
are two such tipplers for unloading of wagons. The unloaded
coals are stacked in "Piles" in the coal yard. Hence coal piles
of PCC, MCC, ICC(H) & ICC(S) are made in the yard. The
coal yard has a capacity to store more than 60,000 Tons of
coals in piles. Coal from the yard is reclaimed with the help
of scrapper type reclaimer from the piles of stacked coals.
These are then sent to Central crushing station through various conveyor belts. Here the coal is
pulverized below 3.2mm size. The pulverized coal is sent to blending bunkers.
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.
Partial Briquetting Coal Charging (PBCC) Plant:

To improve the coke quality and its yield, part of the coal is transformed to briquettes and blended
with the Charging Car Coal fed to the coal towers. The briquette plant comprises of Binder Tank,
Mixing Kneaders and Briquette Press where crushed coal is mixed with tar & binder and pressed to
form briquettes. This plant was commissioned in 1996.
The Coking Process:

The carbonization of coal is carried out at high temperature in long, narrow silica-brick chambers
called ovens in which coal is coked by the combustion of fuel gas in flues built in the refractory brick
walls which separate the ovens.
The typical dimension of RSP ovens are:
Length 13.59 Meters

Height 4.5 Meters
Width (Pusher Side) 0.37 Meter
Width (Coke Side) 0.43 Meter
Volume 21.60 Cubic Meters
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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.
Nomenclature Size End user

Hard Coke 25 < X < 80 mm Blast Furnace
Nut Coke 15 < X < 25 mm Blast Furnace
Breeze Coke X < 15 mm Sinter Plant
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.
HRD CENTRE Page:19

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.
Coal Handling Plant:

New Coal handling plant caters to the need of Coke-Ovens Battery No-6. Main activities carried out
in New Coal Handling Plant are coal unloading, storage, blending, crushing and conveying it to coal
tower for charging into the ovens. CDI coal for Blast Furnace-5 is also unloaded and stored here.
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Major equipments of New Coal Handling Plant

SL. No. Equipments Function/Capacity
 To unload Coking Coal and CDI Coal from wagons.
 Number : 2 (Identity Tippler 7 and Tippler-8)
1. Wagon Tipplers  Capacity: 20 wagons/hour max.(each)
 Side arm charger for Inhaul and outhaul of wagons.
 1800 rotation.
 To store coking coal and CDI coal and to blend
coking coal.
2. Silos  Total 30 nos each having 2500 ton capacity.
 Weigh feeders are installed at the bottom of silos for
blending of different varities of Coking coal.
 To reduce size and to attain uniformity of blend coal.
3. Crushing.  Installed: 4 nos Hammer crusher.
 Capacity 400t/hr each.
4.  To feed coking coal to charging car.
Coal Tower
 Capacity : 4000 ton.
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.
HRD CENTRE Page:21

Coke Dry Cooling Plant (CDCP)-

Coke dry cooling is a process to bring down the temperature of hot coke coming out from ovens to less
than 2000 C by circulating inert gases. Heat available in the hot coke is recovered during the cooling
process in waste heat boiler to generate steam and power.
Process flow diagram of CDCP.
Basic Data of CDCP

SL. Equipments Capacity
No.
1. Capacity of one cooling chamber. 50 ton/hr
2. Total number of chamber. 04
3. Residence Time 2-2.5 hrs
4. Generation of steam/Boiler 25 ton/hr
5. Steam Yield 0.48 ton/ton of coke
6. Steam pressure 66 ata
7. Incoming coke temperature 10500C
8. Outgoing coke temperature < 2000C
Main equipments of CDCP

Lifter 4 nos, one with each chamber
Mill Fan 4 nos, one with each chamber
Boiler 4 nos, one with each chamber.
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Composition of Circulating Gases

Nitrogen 75%
Carbon Mono-Oxide 13%
Carbon di-oxide 6%
Hydrogen 3%
Oxygen Less than 1%
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.
New Coke Screening Plant-

Screening of Coke is required as Blast Furnace requires coke in particular size range. Coke coming
out from CDCP is in various size. In New Coke Screening Plant, segregation of coke according to its
size range is carried out. Capacity of plant is 200 ton/hr.
Size range of BF coke from COB-6

Centre Coke +60-80mm
Surface Coke +34 to -60mm
Coke breeze -12 mm
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%
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COAL CHEMICALS
Coal is a treasure chest of an innumerable number of chemicals.

The source for all these chemicals is the volatile matter present in
coal, which in our case is from 20-30% of the coal. When coal is
carbonised in the coke ovens, about 320 Nm3/T of gas is generated
which comes from the volatile matter of the coal. The gases
escaping from the coke ovens contain tarry matter, moisture,
vapours of a number of chemical compounds like ammonia,
hydrogen sulphide, naphthalene, benzol etc. These are commonly
known as by-products though they are very useful and valuable
materials. These are rightly called as coal chemicals, which form
the chief raw materials for the manufacture of dye stuffs,
pharmaceuticals, flavours, perfumes, rubber chemicals, plastics
and a thousand of other useful products that are now almost indispensable in our present day
civilization.
The Coal Chemicals Plant at Rourkela serves two purposes:

(i) To recover the primary products like ammonia, crude tar to clean and cool the Coke Oven gas, so
that it can be conveniently used for heating purpose.
(ii) To further process and refine the crude tar to yield a number of marketable products.
On operational basis, the plant can be divided into two parts

(i) Gas cooling and condensation section which includes low pressure cleaning
(ii) Recovery of finished chemicals by further processing the primary products obtained in No. (i).
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
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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:
(a) Gas Holder

(b) Mixing Tank
(c) Under firing Gas Line
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:
Impurities End Gas

1. Naphthalene max 0.12gm/Nm3
2. H2S max 0.8 gm/Nm3
3. Ammonia 0.04 gm/Nm3
4. Tar Fog 0.06 gm/Nm3
HRD CENTRE Page:25

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.
The inlet and outlet composition of BOD Plant is mentioned below:
Inlet to BOD Plant Outlet of BOD Plant

Ammonia 350 ppm 30 ppm
Phenol 150 ppm 1 ppm
Cyanide 100 ppm 0.2 ppm
PH 8.5 6.5 - 7.5
Temperature - 35oC(Max)
Treated effluent is used as quenching medium in Coke Ovens Plant.
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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.
HRD CENTRE Page:27

GAS FLOW DIAGRAM OF NEW CCD OF RSP
Battery-6
PGC-4 NOs
ETP-4 NOs
EXHAUSTER-1 EXHAUSTER-2
BRP Crude Benzole
SATURATOR-1 SATURATOR-2
Enriched solar oil
FGC HRP
CO gas to Battery- 6 and COG grid
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
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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:
1. Capacity of the Plant - 1.5 MT / Annum.

2. Sinter Machine - 2 Nos. (125 T/hr), 125 m2 working area, Mixed
gas fuel, Dwight Lloyd down draft continuous
chain type machine
3. Sinter Breakers - 2 Nos.
4. Primary Mixing Drum - 1 No.
5. Pelletising drum - 2 Nos.
6. Hot Screen - 2 Nos.(separate +6mm & -6mm fractions)
7. Cold Screen - 2 Nos.(separate +25mm,+15mm-25mm,-15mm)
8. Process ESP - 2 Nos.
9. Dedusting ESP - 2 Nos.
10. Exhausters - 2 Nos., 6,60,000Nm3/hr
11. Capacity of Sinter - 1200 T
Storage Bunker
HRD CENTRE Page:29

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:
1. Increase the permeability of the bed.

2. To protect the grate bars from the direct contact with the hot sinter.
-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.
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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 %
The typical physical properties of sinter are:
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%
HRD CENTRE Page:31

Material Flow in Sinter Plant - I
Base Mix, Lime Stone &

Dolo Fines from OBBP
Blast Furnace Returns
Coke Breeze from Coke

Ovens & BFs
Water Primary Return Fines
Mixing Drum Bunker
Pelletising Drum - I Pelletising Drum -II
-5 mm
Sinter Sinter
Machine-I Machine-II
Hearth Layer (-25,+15 mm)
Breaker-I Breaker-II New Cold

Screen
Hot Screen- Hot Screen-

I II
Cooler-I Cooler-II
Ω
Cold Screen
Sinter to Blast Furnace
+25 mm (+25,+5)
size
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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
HRD CENTRE Page:33

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.
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Process Flow Chart of Sinter Plant - II
Coke Breeze from OBBP

Blast Furnace Returns
Base Mix from OBBP
Flux from OBBP

Proportion Bin
PR Fines
Comp. Air
Water
Lime
Sinter mix preparation at Mixing

& Balling Drum
Single Roll Ignition & Sinter ESP STACK

Crusher Making in Sinter
Machine
+50 mm
50mm Double Roll

Hot Screen Sinter Cooling
Screen Crusher
- 5 mm - 50 mm
- 5 mm
+5 mm
25mm
-25 mm
15mm
-15 mm
Sinter Storage 5mm Screen

Screen Screen
Bunker
+15 mm
+25 mm
Blast
Furnaces
HRD CENTRE Page:35

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.
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Circular Sinter Cooler
Hi- intensity Mixer & Granulator

Nodulizer
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.
HRD CENTRE Page:37

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:
Plant capacity 3.706 MTPA

Operating Days/Year 330 days
Production / day 11230 T
Grate area 360 Sq.MTR
Sinter Machine width 4 Meter
Sinter Machine length 90 Meter
Sinter Cooler dia 35 Meter
Max. Stack emission 50mg/Nm3
Productivity, Rated 1.30 T/M2/Hr
Size of finished sinter 5-40 mm
Average temp. Of Cooler sinter 100 Deg.Cent
Sinter pallet size 4 Meter x 1.00 Meter
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Flow Chart
Input Materials:
The input materials & average consumption for making one Ton of Sinter are:
Iron ore Fines (Including BFR) 932 Kg

Lime Stone 55 Kg
Dolomite 105 Kg
Calcined Lime 20 Kg
Coke Breeze 74 Kg
LD Slag 27 Kg
The typical composition of Product Sinter:
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 %
HRD CENTRE Page:39

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.
BF # 1 Commissioning on 27.01.1959, Blown down for

upgradation on 06.08.2013
BF # 2 Commissioning on 12.01.1960, Blown down for phasing out on 27.09.2014
BF # 3 Commissioning on 08.01.1962, Blown down for phasing out on 16.05.2016
BF # 4 Commissioning on 03.07.1967
PCM – 1 Commissioning on 27.01.1959
PCM – 2 Commissioning on 31.12.2012
SGP Commissioning on 23.09.1977
Capacity Modernization BF-IV Up- BF-1

gradation Upgradation &
BF-5
Commission
MT Stage BF # 1, 2 1000 T/Day 1200 T/Day each 1200 T/Day each 2900 T/Day
&3 each
Exp. Stage BF # 4 1500 T/Day 1800 T/Day 97–98 2200 T/day 05-06 2475 T/Day
BF # 5 7924 T/Day
Total 1.8 MT/Yr. 2.0 MT/Yr. 2.2 MT/Yr. 4.5 MT/Yr.
Major modifications during/after modernization:

Sinter screening facilities in all 4 furnaces in 1995 - 96
BF # 4 INBA commissioning on 28.01.1993
BF # 1 INBA commissioning on 30.08.2005
BF # 4 High Top Pressure in Sept’ 2005
BF # 3 Tilting runner in May’ 2007
BF # 5 Commissioning on 5th Aug 2013
PCM – 2 commissioning on 31.12.2012
BF # 1 upgradation started on 22.07.2014
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The main sections supporting the furnaces are:
1. High line Stock House & charging section.
2. Furnace proper and cast house
3. Hot Blast Stoves
4. Gas Cleaning plant
5. Cast House slag Granulation plant / External slag granulation plant
6. Pig Casting machine
7. Fleet of Hot metal ladles (80 T, 140 T & 350 T Torpedo) & slag pots.
8. Ladle repair Shop, Slag dump and clay preparation unit, Torpedo ladle repair shop.
9. Workshop.
10. Pulverized Coal Injection system
11. Top Recovery Turbine
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.
FLOW DIAGRAM OFBLAST FURNACEPROCESS
HRD CENTRE Page:41

FLOW DIAGRAM OFBLAST FURNACE # 5 PROCESS

IRON ORE SINTER COKE
(OBBP) (SINTER PLANT) (COKE OVEN) PCI
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
Raw Material Sources for Blast Furnace
Iron Ore : OBBP (Barsuan / Kalta / Meghataburu / Kiriburu / Gua /Bolani /

Chiria)
Sinter : Sinter Plant – I, II & III
Coke : Coke Ovens (Coals from Dugda, Bhojdih, Kargali,Rajarappa& imported
coal)
Quartzite : Purchased
LD Slag : SMS through MRD
Nut Coke : Through Sinter in BF#1 & 4& Internal generation in BF # 5
Pig Iron Chips : PCM through MRD
PCI Coal : Raw Coal Purchased
Material Balance for 1 Tonne of Iron

INPUT
OUTPUT
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
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The Specifications of the above raw materials are given below:
MATERIAL CHEMICAL (Norms) SPECIFICATION

Iron Ore Lump Fe : 63.5 % min - 10 mm : 5 % max
SiO2 : 2.0 % max + 50 mm : 5 % max
Al2O3 : 2.0 % max Size : 10 to 50 mm
Sinter Fe : 54.0 % min - 5 mm : 5 % max
FeO : 9.5 % + 0.5 % + 40 : Nil
SiO2 : 4 to 5 % Al2O3 / SiO2 : 0.5 to 0.6
Al2O3 : 2.5 % max Size : 5 to 40 mm
CaO : 10.5 % + 0.5 %
MgO : 3.0 % + 0.5 %
Ash : 16 – 18 %
VM : 0.9 %
Coke COB-1-5COB-6 COB-1-5COB-6
Moisture 4 - 5 0.5 Size 25-80 mm 34-80 mm
CRI 20-22 % 23.0% +80mm 4 %
CSR 62 % 66 % +25mm 5 %
M10 8.0 % 6.5 %
M40 80 % 86 %
Quartzite SiO2 : 99 % min Size : 20 – 40 mm
LD Slag CaO : 42 – 44 % Size : 20 – 40 mm
MgO : 8 – 9 %
SiO2 : 12 – 14 %
Mn : 30 % + 1 %
High Line and Stock House ( For BF#1 and BF#4):
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.
HRD CENTRE Page:43

There are two coke service bunkers in each furnace having 525 m3 capacity (300 T of coke) to store
coke coming from coke oven. Each coke bunker is connected to a coke screen to screen out– 25 mm
and discharge + 25 mm size coke to coke weigh hoppers. The + 25 mm size coke from weigh hoppers
is then discharged to skips to be charged into furnaces. The – 25 mm size coke breeze is carried by
fine breeze conveyor belt to fine breeze skip which unloads the breeze in fine breeze bunker. The coke
fine breeze is then dumped from the bunkers to wagons for further transportation to sinter plants
&OBBP.
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.
The charging sequence, selection of charge material, switching of

stock house equipment, weighing of raw materials their subsequent
discharge to skip and movement of skip cars, allare controlled through
a PLC system from charging side control room.
BF#5 Stock House details:
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.
A single batch of stock is discharged into a lock-hopper. A nominal batch size of 27 to 58 m3

willprovide a burden layer thickness of about 38 to 80 cm in the throat of the furnace.
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,
The lock-hoppers alternate being ﬁlled and discharged.
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.
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A median case of four weigh hoppers of ore with miscellaneous and nut coke weigh hopper additions
can make up a typical ore charge of 58 m3.
The weigh hopper-feeders are tuned to discharge a batch in 95 seconds.

Furnace Proper:
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:
1. Top Charging Equipments

2. Cooling system
3. Hot Blast Stoves
4. Cast house & cast house Slag Granulation Plant
5. Pulverized coal injection plant
Furnace design parameters are given below:

MAIN UNITS UNIT FACILITIES AT
BF – 1 BF – 4 BF – 5
Blast Furnace No. 3 1 1
Gas Cleaning Plant No. HTP HTP HTP
Scrubber Scrubber Scrubber
Pig Casting Machine No. 1 1 1
Slag Granulation Plant No. CH SGP CH SGP CH SGP
Blast Furnace
Production Capacity / Furnace Tpd. 2900 2475 7924
Working Volume M3 1491 1448 3470
Useful Volume M3 1710 1658 4060
Hearth Diameter M 8.4 9 13.2
Tuyeres No. 20 21 36
Cast House No. 2 1 2
Reactions in the Blast Furnace

Upper Stack Zone
 Reduction of oxides
3 Fe2O3 + CO = 2 Fe2O3 + CO2
Fe3O4 + CO = 2 FeO + CO2
FeO + CO = Fe + CO2
 Decomposition of Hydrates
CO + H2O = CO2 + H2
 Decomposition of Carbonates
Middle Stack Zone

 Direct / Indirect reduction
FeO + CO=Fe + CO2
CO2 + C=2 CO
FeO + C=Fe + CO
HRD CENTRE Page:45

Lower Stack Zone

 Calcination of lime
 Reduction of reduced iron
 Reduction of Silica / MnO2
 Formation / melting of slag
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.
Top Charging Equipment

Charging equipment’s for BF # 1 & 4 : In case of BLT, the skips dump the materials to a receiving
hopper, which is separated from the BLT by upper material gate and upper gas seal valve. After
opening of upper material gate & upper seal valve, material is discharged into BLT material bin
placed over the lower material gate & lower gas seal valve. Then the UMG (Upper Material Gate) &
USV (Upper Seal Valve) are closed to seal the furnace from the atmosphere & the receiving hopper is
ready to receive material from the skips.
Charging equipment’s for BF # 5 :
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.
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Thermal energy from the primary cooling system is transferred to the secondary cooling system with
plate heat exchangers from the secondary cooling water system the heat is transferred tothe
surrounding environment with cooling towers.
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
Hot Blast Stoves & Associated System:

The function of Hot Blast Stoves is to pre heat the air blast before its admission into furnace through
tuyeres. Each furnace is provided with 3 hot blast stoves which are tall cylindrical shell with dome
shaped top for BF # 4 & mushroom dome shape for BF # 1 & 5. Each stove consists of two parts
namely combustion chamber & checker brick work. The combustion chamber is lined with fire clay
brick & checker bricks are Alumina bricks. BF gas is burnt in combustion chamber and the sensible
heat of the flue gases heat up the checker bricks while passing through them from top towards
bottom. The period of heating is called “On Gas” & normally a stove remains on gas for 1 hour 30
minutes at a stretch for BF 1 & 5. After heating, cold blast, supplied from turbo blowers of CPP–I is
passed through the checker works from bottom and the air got heated up by taking sensible heat
from checkers. The period of blast heating is called “On Blast” condition of stove. The blast period is
usually for 1 hour for BF # 5.
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.
Stove design parameters are given below :
MAIN UNIT UNIT FACILITIES AT

BF # 1 BF # 4 BF # 5
Stoves No. 3 3 3
Blast Temperature 0C 1150 1000 1250
Blast Volume Nm3/hr 150,000 140,000 660000
HRD CENTRE Page:47

Process description of BF # 5 Stove:
The hot blast required for the blast furnace operation is

generated in a system of three regenerative heat
exchangers. In this system these heat exchangers are
called stoves. These stoves are operated in a cyclic mode in
order to be able to produce a constant temperature and
volume of hot blast.
With three stoves the system is operated in cyclic manner,

where one stove is "on blast"(producing hot blast) while the
other two are “on gas” (being regenerated/fired). During
the time that the stove changes from “on blast" to “on gas”
and vice versa only one stove is on gas.
During the regeneration phase the heat is accumulated in

refractory material.
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.
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Hydro pneumatic drill machines are used to drill the tap hole up to 2 m – 3 m into the hearth to tap
the metal & slag. Oxygen lancing through mild steel pipes is resorted to, if taping is not possible by
drilling alone. The troughs of BF # 4 are made with special grade refractory mass to handle upto
40,000 T metal before repair. Few iron runners are also made with low cement castables to handle
more then 1 lakh ton metal before repair. Hydraulic powered mud guns are used to close the tap hole
after casting is over with anhydrous tap hole mass which get quickly hardened inside the tap hole.
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.
The design of the cast houses is governed by the following parameters:
Hot metal production

Normal 7294 thm / day
Maximum 8320 thm / day
Slag Production
Normal 2456 T/Day
Maximum 2580 T/Day
Slag rate 290 – 310 Kg/THM
Tap holes 4 Nos.
Tapping per day 10 – 12 Nos
Tapping time per tap 1.5 – 2.5 hours
Duration of slag flow 60 – 100 Minutes
Dry slag pits 4 Nos.
Iron flow rate
Average 5 T/min
Normal range 4 – 6 T/min
Peak (< 3 min) 10 T/min
Iron Temperature 1450 – 1500 0 C
Slag flow rate
Average 5 T/min
Normal range 4 – 6 T/min
Peak (< 3 min) 12 T/min
Slag Temprature 1500 – 1550 0 C
Cast House Slag Granulation Plant:
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.
HRD CENTRE Page:49

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.
BF # 5 Cast House Slag Granulation Plant:
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.
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Gas Cleaning Plant (GCP):

BF – 1& BF – 4 has individual dedicated GCP. The BF gas leaving from top of BF – 1 is having about
20 – 25 gm / Nm3 dust. BF gas is subjected to successive cleaning in dust catcher (by changing the
direction of the flow of the gas), gas washer(washing with water sprays), where by dust content is
reduced to the extent of 4 to 5 mg/Nm3.
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
HOT WATER SUMP COLD WATER SUMP
Flow Diagram of Gas Cleaning Plant
BF # 4 GCP and High Top Pressure:

Due to high top pressure dust content in top gas from BF – 4 is less. The top gas coming from dust
catcher of BF– 4 is allowed to pass through cylindrical scrubber from top where in the gas is cooled &
cleaned by means of several sprays. The semi clean gas is then allowed to pass through a ventury
attached to bottom of the scrubber where in the rest of the dust is cleaned & washed away by the
spray of water in the ventury.
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.
HRD CENTRE Page:51

BF # 5 GCP and High Top Pressure:

The raw gas leaves the blast furnace via the uptakes and is conveyed to the gas cleaning facility via
the down comer and dust catcher. The gas cleaning plant consists of a pre-scrubber, RS-scrubber and
a vertical demister located downstream from the dust catcher.
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.
Pig Casting Machine (PCM-1):

There are two machines. Each machine has two strands of chains fitted with small steel mould
rotating on sprockets. Hot metal is poured into the lime coated moulds & cast as solid pigs.PCM is
provided with 2 EOT cranes for pouring metal, 1 crane for cleaning and material handling and 1
magnet crane for loading / unloading pigs into wagons.PCM handles 80 T capacity hot metal ladles
only. Ladle cleaning, repairing & heating is also done in PCM bay.
Pig Casting Machine (PCM-2):

There is one machine. This machine has two strands of chains fitted with small steel mould rotating
on sprockets. Hot metal is poured into the lime coated moulds & cast as solid pigs. PCM is provided
with 1 crane for cleaning and material handling and 2 magnet crane for loading / unloading pigs into
wagons. PCM handles 350T capacity hot metal ladles only( Torpedo).
Ladle Repair Shops

There are two Ladle Repair Shops, where small and big ladles are repaired, cleaned and relined.
These are used for transportation of Hot Metal.
Torpedo ladle Repair Shop

Torpedo ladles are repaired, cleaned and relined.
Clay Preparation Unit:

Tap hole clay, Mud gun clay and tar mass, which are needed for various jobs like tap hole making,
mud gun filling, spout making and trough / runner making, are prepared in this unit by mixing
ingredients like coke breeze, coal powder, fine clay, plastic clay, refractory grog, coal tar pitch,
sulphite lye and water.
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Slag Granulation Plant:

For every ton Hot Metal produced in our Blast Furnaces, about 400 kg of slag is generated as an
industrial waste. The Slag in granulated form is used as excellent raw material for manufacture of
cement. The granulated slag when used in the manufacture of cement replaces the main ingredient
clinker up to 50-60%. This results in significant cost reduction in cement industry and also results in
marked conservation of lime stone, a basic raw material for both the industries. The project was
commissioned on 31st March, 1977.
Composition of Granulated Slag:

The BF slag has a chemical composition as mentioned below and has about 8-10% moisture. The bulk
density of the granulated slag is in the of the order of 0.8-1.2 Ton per cubic meter &size 0 to 3 mm.
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.
Pulverized Coal Injection (PCI) System for BF#1 & 4:

In order to reduce the amount of coke thatwould normally be consumed in the Blast Furnace process,
and/or to replace Pulverized coal injection is done. BF#1 and BF#4 both are having 100 Kg/thm
injection capacity. Two grinding mills are installed and one common fine coal silo is supplying fine
coal to BF#1 and BF#4.
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Pulverized Coal Injection (PCI) System for BF#5:

The Pulverized Coal Injection System of BF#5 was developed originally and patented by the Armco
Steel Company, LP. and Babcock and Wilcox Company in order to reduce the amount of coke that
would normally be consumed in the Blast Furnace process, and/or to replace other injected fuels. The
Armco/B&W Pulverized Coal Injection system pneumatically conveys Pulverized Coal to each tuyere,
where it is burned using the hot blast.
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.
The Pulverized Coal Injection System (PCI) can be summarized as follows
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
 Pulverized Coal Storage and Injection system

 Pulverized Coal Transport and Distribution system
 Utilities
Top Recovery Turbine (TRT)

The turbine is installed downstream of the demister, and is in parallel with the clean gas main.
During normal operation, the gas passes through the scrubber which cleans the gas, the demister
which removes the mechanical free water, and then the turbine which expands the gas for the
recovery of energy. When the TRT is in operation, almost all of the pressure reduction takes place in
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the turbine and the furnace top pressure is controlled by means of the TRT’s adjustable Turbine
Stator Blades (TSB‘s).
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
Gas Volume (Dry)

Normal 620000 Nm3/Hr
Maximum 700000 Nm3/Hr
Design 620000 Nm3/Hr
Turbine inlet gas pressure 2.15 – 2.65 Kg/cm2 (g)
Turbine outlet gas pressure
Normal 0.14 Kg/cm2 (g)
Design 0.10 Kg/cm2 (g)
Turbine inlet gas temperature 40 – 70 0C
Turbine inlet dust (max) 5 mg/Nm3
Turbine inlet free water (max) 5 g/Nm3
Turbine relative humidity Saturated
Normal Gas Analysis
CO 21 %
CO2 22 %
H2 3%
N2 Balance
Generated power requirements 11 kV, 3 phase, 50Hz
Mechanical design pressure 3.00 kg/cm2
HRD CENTRE Page:55

SLAG GRANULATION PLANT
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.
Input Raw Materials

The input raw material for granulated slag is hot liquid Blast Furnace Slag at temperature around
1250 0 C. This liquid slag is brought from Blast Furnace loaded in slag pots. Input slag analysis is
given bellow:
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
The granulated slag produced has got following properties:

The bulk density is 1 - 1.2 ton/m3.
Size of granulated slag is – 3mm(approx.).
Moisture content is 5 to 10%.
Brief Description of Process

Slag Granulation Plant consists of granulation bay with one open yard EOT crane of 3T capacity and
two storage bays each with one-10T EOT cranes. Granulation bay is located at an elevation of 9
meter and storage bays is located at 0 .00 level. Six nos. of hydro- chutes are provided in the
granulation bay to produce and discharge granulated slag in the storage bays. Hot liquid slag in slag
pots from Blast Furnace comes to Slag Granulation Plant in slag pot cars driven by locomotive
engine. The slag pots are placed on granulation hydro-chutes and connected to the power supply
network through flexible cables from the power plugs located along the columns of the bay. Slag crust
on the top is pierced by means of a conical weight of 1.5 T attached to the 3T EOT crane situated over
the pouring track. After crust is pierced, each slag pot is tilted by electrically driven motor with the
help of ON/OFF push button switch is installed in Control Desk at control tower to discharge the
liquid slag into the receiving bath. The water at 8 kg/cm2 flows through the nozzle box situated
under the receiving bath which cools the liquid slag and thus fuses the liquid slag to granules of
about 3mm size known as granulated slag. The granulated slag produced in this process is thrown to
a distance of 15 to 20 meters away from the chute in the storage bays along with the pressurized
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water. Granulated slag in storage bay is dozed with the help of a dozer within the reach of the 2 nos.
of EOT grab cranes. The grabbing capacity of each bucket of the cranes is 3 m3. The liquid slag
residue, about 30 % left over in the pot is removed at the de-sculling site of Scrap and Salvage
Department.
Electrical Power Supply System:

Electrical power for SGP comes from MSDS-II. 6.6kV power supply through feeder No.4 and feeder
No.15 is stepped down to 415V through 1.6MVA transformers at sub-station. Thus, the power
available at the incomer of the sub-station has 3-phase 415 V A.C. The Electrical power supply to all
the drives and equipments ensured by 3 nos. motor control centers i.e. MCC-1, MCC-2, MCC-3
through dedicated feeders.
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.
Water Recirculation System

In Hydro Chute Method of granulating slag, the main consumable is water. In this process about 40%
water is lost in the form of steam and rest 60% re-circulated as water, which contains some dissolved
impurities. This water is recycled along with required amount of additional water collected from
make up water line. The Water Recirculation System of the SGP mainly consists of:-
1) Recirculation Tanks
2) Pump House
3) Tunnel House.
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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.
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General Layout of Slag Granulation Plant
WAY TO
TARAPUR GATE
LIQUID SLAG FROM B.F

MAKE UP
WATER LINE
WATER RING
MAIN MECHANIC
AL WORK
SHOP
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
HRD CENTRE Page:59

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.
The ladle containing liquid steel is taken to Casting

Shop via Argon Rinsing Station (ARS) /Ladle Heating
Furnace (LHF). During treatment at ARS/LHF, Argon
is purged through liquid steel from bottom, which
causes the liquid steel to homogenize w.r.t chemistry
as well as temperature. Corrective additions for
achieving desired composition are also made at this
stage. From ARS/LHF liquid steel is converted to slabs
in continuous casting machines in SMS-I & II. The
various units like Lime Dolomite Brick Plant (LDBP),
Calcining Plant – II (CP-II), Tonnage Oxygen Plants
(TOPs) and Steel Melting Shops (SMSs) are described in subsequent chapters.
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STEEL MELTING SHOP-I
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:
Flow Sheet of SMS-I
BLAST FURNACE
HOT METAL
MIXER MIXER
CONVERTER CONVERTER
SSM UNITS
VAR VOR
LHF ARS
CASTER
SLABS
PLATE MILL HOT STRIP MILL
HRD CENTRE Page:61

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)
Liquid Caster Steel slab (65 - 66 TCS)

Steel
66 - 70 TCS
Tundish skull (7 - 8 Kg/TCS)
Crop end & Arisings (3 Kg/TCS)
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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.
Keep oxygen lance within recommended height for the converter.

Blowing or working height = Depth indicator reading + bath height.
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.
Working height/ bath height adjustment of oxygen lance position

Total blowing time and reason for long time if applicable
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.
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Ladle preparation bay (Pit side):
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.
Secondary steel making

For most applications, the surface quality, internal quality, micro cleanliness and mechanical
properties of steel produced by conventional route are entirely satisfactory. However quality
requirements of special steels in terms of cleanliness, grain size control, narrow harden ability range
etc. have become quite stringent in recent times. These requirements and compulsions led to the
development of a series of new individual requirements. There are two processes adopted in SSM.
These are:
1. Vacuum Arc Refining (VAR)
2. Vacuum Oxygen Refining (VOR)
Secondary steel making can be defined as the process of making steel suitable for special applications
by final refining and compositional adjustments. In RSP these two processes are adopted which is
mainly based on the vacuum. The basic principle behind this vacuum treatment is that “the amount
of dissolved gases in steel increases with increase in the partial pressure of gases. The other
advantage is that the temperature requirement for the vacuum treatment decreases according to
Sievert’s law.
% Gas dissolved = K×√ (partial pressure of gas at ambient atmosphere)
Benefits of secondary steel refining process

 Improvement in the productivity of primary steel making furnaces such as BOF, EAF etc.
 Better deoxidation practice.
 Decarburizing to attain very low levels of carbon.
 Degassing to attain very low level of hydrogen and nitrogen.
 Desulphurization to attain very low level of sulphur.
 Inclusion shape control.
 Better alloying practice:
 Improved alloy recovery.
 Achieve chemistry in very close range.
 Dephosphorisation.
 Homogeneity with respect to :
 Temperature.
 Chemical analysis.
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VAR/VOR process sequence
1. LD converter steel (1650°C)
2. Teeming ladle (66T &1600°C)
3. Transfer by EOT crane
4. Lowering into VOR/VAR tank.
5. Connection of tank and ladle argon hoses.
6. Argon purging for a minute
7. Initial temperature measurement.
8. Placement of tank cover over the tank
9. Start argon purging at required/specified rate
10. Start steam ejector and attain required vacuum level
11. Start arcing/ oxygen blowing
12. Continue degassing
13. Addition of
 Aluminium
 Fluxes (Lime, etc.)
 Ferro alloys (like Ferro silicon, Silico manganese etc.)
 And calcined pet coke, if required
14. Increase argon flow for thorough mixing
15. Discontinue evacuation
16. Measure temperature
17. Take sample for analysis
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%)
Continuous Casting Shop

Ladle Heating Furnace
The main function of ladle heating furnace in SMS-I is to
dispatch the liquid steel at required temperature for casting
and addition for final aimed chemistry. The specific objective
of heat processing at LHF is as follows:
o Homogenizing the steel bath with respect to temperature
and composition.
o Improved alloy yield and compositional control within
narrow limits.
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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.
Argon Rinsing Station (ARS)

The main function of ARS is to homogenize the liquid steel with respect to temperature and
composition and removal of non-metallic inclusions by formation of slag. The process starts with
placing the steel ladle on the ARS stand. Argon rinsing is started from the bottom. Process chart is
referred for rinsing procedure, additional duration of purging and minimum temperature for lifting
the ladle for casting.
Continuous Casting Machine

The Process
Continuous casting is the process whereby molten metal is solidified into a "semi finished" billet,
bloom, slabs or beam blank. Prior to the introduction of continuous casting in the 1950s, steel was
poured into stationary moulds to form "ingots". Since then, "continuous casting" has evolved to
achieve improved yield, quality, productivity and cost efficiency. Nowadays, continuous casting is the
predominant way by which steel is produced in the world. Continuous casting is used to solidify most
of the 750 million tons of steel, 20 million tons of aluminum, and many tons of other alloys produced
in the world every year.
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''.
Solidification begins in the mould, and continues through

the different zones of cooling while the strand is
continuously withdrawn at the casting speed. Finally, the
solidified strand is straightened, cut, and then discharged
for intermediate storage or hot charged for finished
rolling.
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To start a cast, the dummy bar is inserted from the exit side (lower side) of the copper mould and
then it is sealed at a specified height inside the mould. This
bar (dummy bar) prevents liquid metal (steel) from flowing
out of the mould till a fully solidified strand section is
obtained out of the liquid steel pool. The liquid poured into
the mould is partially' solidified in the mould, producing a
strand with a solid outer shell and a liquid core. In this
primary cooling area, once the steel shell has a sufficient
thickness, the partially solidified strand will be withdrawn
out of the mould along with the dummy bar at the casting
speed. Liquid steel from tundishcontinue to flow into the
mould to replenish the
withdrawn metal at an
equal rate. Upon exiting the
mould, the strand enters a
roller containment section
and secondary cooling
chamber in which the
solidifying strand is sprayed
with water, or a
combination of water and
air (referred to as "air-
mist") to promote
solidification. Once the
strand is fully solidified and has passed through the straightener, the dummy bar is disconnected,
removed and stored for use in the next sequence.
Torch Cutting Machine (TCM)

TCM is used to cut the slabs online to the required length.
The cutting operation is done by oxy-propane gas flame.
Slab Storage and Dispatch Yard

Produced slabs are stacked for proper identification
for dispatching to Hot Strip Mill (HSM) and Plate
Mill (PM) for further processing. As per requirement
some slabs are also despatched to NPM for rolling in
to high quality plates.
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STEEL MELTING SHOP –II

Steel Melting Shop (SMS) - II consists of a Basic Oxygen Furnace (BOF) Shop Complex and a
Continuous Slab Casting Shop (CCM-II) Complex. This Steel Melting Shop was added as a part of
RSP’s modernisation package in late nineties. Hot metal, Oxygen and Fluxes, the main input
materials for steel making are provided by Blast Furnaces (BFs), Tonnage Oxygen Plants (TOP-
I&II), Calcining Plant (CP-II) and Lime Dolomite Brick Plant (LDBP) respectively.
BOF Shop Complex:

BOF Shop Complex can be essentially divided into 3 sections:
a) Mixer & Desulphurisation (DS) Unit
b) Converters
c) Slag Yard and Scrap Yard
Mixer and DS Unit:

Two Hot Metal Mixers are being used for storing Hot Metal (HM) that is received from all the four
Blast Furnaces and to essentially homogenise the HM w.r.t. temperature and composition and to
provide uninterrupted supply of HM as and when required for the converters. The details of the
mixers are:
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.
Details are as follows:

- Heat weight - 150 to 165 tonnes
- Working volume – 165m3
- Metal depth - 1165 mm
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
Details are as follows:

- Heat weight - 150 to 165 tonnes
- Working volume – 165 m3
- Metal depth - 1165 mm
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Two nos. of slag raking machines are provided to remove the slag from the HM ladles before it is
charged in the converter.
- Working member boom with a scrapper

- Boom travel - 5000 mm
- Turning angle - 200 (right or left)
- Boom inclination angle - 100 upward or downward
Converter Shop:
The shop is located at 9.5 m from ground level.

Twonumbers of converters (150 T capacity each) of
topoxygen blown type were installed in this shop.These
converters receive HM and scrap with thehelp of cranes
and other input materials like FerroAlloys, Flux by
mechanised (hopper with weighingfacility) as well as
manual process. The convertersare concentric vessels
manufactured from steelplates and lined with basic
refractories to sustaindesired temperature and corrosion
during therefining process. Oxygen supplied by Tonnage OxygenPlants is blown into it from the top
through a water-cooled lance.
150 TON LD CONVERTER
Slag Yard & Scrap Yard:

The slag produced by the above process is handled by Slag Yard using a remote controlled over head
crane for safety purpose.
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.
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CCM-II Shop Complex:

CCM-II Shop Complex houses
a) Ladle Preparation Bay
b) Tundish Preparation Bay
c) Ladle Heating Furnace (LHF)
d) Argon Rinsing System (ARS)
e) Casters
f) Slab Yard
Ladle Preparation Bay:

The ladles used for handling liquid steel are prepared in this bay.
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
Casting size : 220mm thickness

Width : 900 - 1550 mm
Length : 6000 - 8000 mm
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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.
Other Facilities Available:

There is a Pump House to cater to the exclusive needs of the SMS-II Shop. There is also a
Compressor House for supplying the required compressed air that is required in the Shop. Mould
Segment Repair Shop exists to repair mould, segment and other allied repair activities.
Flow of Materials in SMS-II
Hot Metal (Blast

Furnaces) Ferro
Alloys
Flux (CP- Oxygen Nitrogen Aluminum Flux

Mixer II) (TOP-II) (TOP-II)
LD Converters Ladle (Steel

Car) LHF / ARS
LD Gas
TCM Segments Mould Tundish Turret
Roller Transfer Slab Slab

Table Bed Storage TTCM Disposal
TCM: Torch Cutting Machine, TTCM: Transverse Torch Cutting Machine

HSM & PM
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REFRACTORY ENGINEERING (SERVICES)
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.
The total jobs of the department is carried out in 4 (four ) zones.
1. Blast Furnace Zone a. Blast Furnaces & Stoves

b. Sinter Plants
c. Power Plants
2. SMS-I Zone a. LD Converters
b. Steel Ladles
c. Hot Metal Mixer
d. 80 T H.M Ladles
e. Lime Kilns of CP-I
3. SMS-II Zone a. LD Converters
b. Steel Ladles
c. RH-OB
d. Hot Metal Mixer
e. 140 T H.M Ladles & Torpedo Ladles
f. Lime Kilns of CP-II
4 Rolling Mill Zone a. Foundries
b. Reheating Furnaces of Plate Mill and H.S.M
c. Various furnaces and pickling lines of Cold
Rolling Mills
d. Various furnaces and pickling tanks of Silicon
Steel Mills
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Apart from the above, Refractory Department has a separate planning section, which has functions
like Procurement of various materials, placement of job contracts, allocation & distribution of day to
day required materials to various zones, maintaining stores & preparing Consumption / Cost related
reports etc.
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.
3. Rolling Mill Zone:

Under this zone relining of Reheating Furnaces both of Plate Mills & Hot Strip Mill, Acid Proof
Lining in Cold Rolling Mills (Pickling Line) & Silicon Steel Mills, Various Furnaces in CRM,SPP
& SSM are taken up both during routine repairs and Capital Repair periods.
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LIME DOLOMITE BRICK PLANT (LDBP)
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.
CaCO3 CaO + CO2
Heat input for Kiln # 5 is 850 Kcal per kg of lime
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.
Extra Hard Molten Pitch used is obtained from Coal

ChemicalsDepartment of RSP .Flaky Graphite (96% FC
Min) is obtained from outside sources. Magnesia &
Graphite are mixed uniformly with molten pitch at a
temperature of around 120oC. Hot pressing of this mix is
done in hydraulic press of 1600 T capacity to produce
green (untempered) bricks. These green bricks are then
tempered in Tempering Kiln at a temperature of 300oC to
achieve the desired quality of bricks. The tempered bricks
after cooling are stacked, wrapped, stored and supplied as per requirement of Customers.
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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
CaCO3 + approx. 3180 kJ (760 kcal) = CaO + CO2
CaMg (CO3)2 + approx. 3050 kJ (725 kcal) = CaO. MgO + 2 CO2
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.
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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).
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OXYGEN PLANT
Oxygen Plant(OP) constitutes of Air Separation Units, Propane Storage and Vaporisation Plants,
Compressed Air Stations and Cylinder Filling and Distribution.
AIR SEPARATION UNITS
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.
AIR SEPARATION UNITS( ASU-I &II)
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,
Each unit has got a capacity to produce:

Oxygen : 180 TPD (with provision of 6.2 % in liquid form)
Nitrogen : 310 TPD (with 3.3 % in liquid form)
The units can run in two modes of operation:

i) Gas mode operation: when demand is high
ii) Mixed mode operation: when demand is low
Production rate of gases in respective mode of operation is as follows;
Gas Mode Mixed Mode Purity

Oxygen (Nm3/Hr) 5400 4700 + 327 Nm3/hr 99.5 %
Liquid Oxygen
Nitrogen (Nm3/Hr) 10400 9000 + 340 Nm3/hr 99.999 %

Liquid Nitrogen
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;
Liquid Oxygen Tank : 1000 M3

Liquid Nitrogen Tank : 1000 M3
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Brief process description:

Air compressed to a pressure of 5.2 to 5.7 Kg/cm2 in a four stage centrifugal compressor. Compressed
air is then cooled in air water tower, using chilled water from refrigeration unit to a temperature
below 100C. Pre-cooled air is then sent to air purification unit, where in a twin bed adsorber unit
comprising alumina and molecular sieve, CO2 and moisture are removed from air. CO2 and moisture
free air is then cooled to -1730C in the main exchanger using product gases from the distillation
column. Air then enters the medium pressure column of double distillation column where it is
liquefied. The liquefied air is then sent as reflux to the low pressure column where the process of
separation of oxygen and nitrogen takes places through cryogenic distillation. Product gases from the
distillation column, after cooling air in the main exchanger, is compressed in the product compressors
and sent to Gas Grid of the Plant.
PROCESS OF OXYGEN PRODUCTION:
Product compression by Gas Product

liquid pump and / or Compressor
gas compression
Filtration Cooling
Air
Compression. Purification Expansion

Heat exchange
incoming air with Separation into
CO2+H2O the cold of the oxygen, nitrogen
outgoing product and argon by
distillation
Salient features of ASU-I & II:
Energy efficient medium pressure process with specific power of 0.850 Kwhr/Nm3 of O2 in gas mode
and 0.970 Kwhr/Nm3 in mixed mode.Front end purification unit removing CO2 and H2O from
process air before it enters Main exchangerSophisticated automation with distributed control system
for monitoring and control of the processWide flexibility of operation (80 % to 115 %) both in gas
mode and mixed mode to take care of fluctuating demand.
AIR SEPARATION UNIT (ASU-III)
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.
The production capacity:

 Gaseous Oxygen : 20500 Nm3/h at 18 - 30 kg/cm2 (g) at 99.6% purity
 Gaseous Nitrogen is in three streams with purity level of max. 2 ppm Oxygen
 Low Pressure : 12000 Nm3/h at 0.3 kg/cm2(g)
 Medium Pressure : 5500 Nm3/h at 18 kg/cm2(g)
 High Pressure : 9500 Nm3/h at 35 kg/cm2(g)
 Liquid Oxygen (in Mixed mode) 700 Nm3/h at 99.6% purity
 Liquid Nitrogen (in Mixed mode) 800 Nm3/h with max. 2 ppm Oxygen
 Liquid Argon 650 Nm3/h at 99.9995% purity, with <2 ppm Oxygen &<2 ppm Nitrogen
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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.
BOO OXYGEN PLANT AT RSP
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.
PRODUCTION CAPACITY OF EACH UNIT

Product Flow (per Unit at 100% capacity) Pressure Purity/Impurity
Nm3/hr (Kg/cm2)
HP GOX 20500 30 99.6%
HP GAN 10000 35 2ppm O2
LP GAN 10000 0.3 2ppm O2
ARGON 200 30 5ppm O2
HRD CENTRE Page:79

USES OF OXYGEN, NITROGEN AND ARGON IN STEEL PLANT:
Oxygen ( 16-30 Bar):

 Oxidation of hot metal to steel at SMS-I and SMS-II
 Enrichment of hot blast in Blast furnace
 Oxy-Propane flame for slab cutting in CCM-I and CCM-II
 Oxygen lancing for scrap cutting in SMS-II
 Miscellaneous welding cutting jobs in Rolling Mills / Repair shops
Low pressure nitrogen (2500mmwc)

 Cold Rolling Mill, Silicon Steel Mill for maintaining inert atmosphere in furnaces
 Hot gas generators of BF5 for preventing explosive mixture formation
 Purging in CCD, PM, SPP, Blast Furnace etc.
 Medium pressure nitrogen (18 Bar)
 Instrument Air and De-sulphurisation in SMS-II.
 Coal conveying and pulverization, Instrument purging and Instrument Air in Blast
Furnaces.
 Purging and Instrument Air requirements in CCD, PBS, CDCP etc.
High pressure nitrogen(35 bar)

 Various seals and purges in GCP of SMS-I and SMS-II and gas recovery in
 SMS-II
 Slag Splashing of convertor in SMS-I and SMS-II
Argon (16 bar):

 LHF and ARS of CCM-I and CCM-II and in Secondary Steel Units of SMS-I & II.
 CCM-I and CCM-II for providing inert atmosphere during casting
 On line purging during tapping of Crude Steel in SMS-II
 Bottom purging in Converter -3 of SMS-II
PROPANE STORAGE AND VAPORISATION PLANTS UNDER OXYGEN PLANT

Rourkela Steel Plant (RSP) has three Propane Plants-I, II & III. Propane Plant-I(2x 20t storage) was
installed in 2013 to supply Propane to CCM-II as a replacement of Acetylene Gas for slab cutting.
Propane Plant-II (2x 80t storage) was installed in 2016 to meet the requirement of modernisation i.e.
CCM-III and RHOB in SMS-II and is located near existing Propane Plant-I. Propane Plant-III (2x
60t storage) was installed in 2016 near the Pipe Plant Chowk to meet the propane requirement of
CCM-I, Plate Mill, New Plate Mill,SPP, Fabrication Shop, Repair Shop(E) & HSM.
PROPANE PLANT PROCESS DESCRIPTION:

Liquid propane is stored in Mounded Storage Bullets or Tanks.The liquid propane is brought to the
propane plant by Road Tankers. The liquid is transferred from road tanker to storage tanks with the
help of unloading pump & vapor compressor.Liquid propane is drawn from the bullet outlet line and
fed to vaporizer unit where liquid is heated in hot water bath.The pressure of propane vapor formed
in vaporizer is reduced up to 1.5-2 kg/cm2(g) in pressure reducing station .Vapor at required pressure
is distributed through Propane pipeline to various customers.
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THE MAJOR EQUIPMENT/ FACILITY IN PROPANE PLANT
 Mounded storage vessels.

 Liquid unloading pumps ( capacity 10t/h (max.)) for each unloading point
 Vapour unloading compressors (capacity 29.2 m3/h (max.)) for each unloading point
 SS coil immersed in electrically heated water bath Vaporizers
 Fire Fighting Equipment.
MAJOR USAGES OF PROPANE:-

 Slab cutting in casters(CCM-I, II & III)
 Pilot flame in Flare stacks (SMS-I &II)
 Fuel to enhance Calorific Value of Mixed Gas in Hot Strip Mill
COMPRESSED AIR STATION
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 ).
HRD CENTRE Page:81

DETAILS OF THE COMPRESSORS IN THE AIR GRID
Sl. Location Make Installed Year of Delivery

No Capacity Installation Pressure
( NM3/hr) Kg/cm2(g)
1 Rolling Mill Air Russian- 1 15300 1994 8.0
2 Station Russian- 2 15300 1996 8.0
3 Unit-I of Oxygen GHH (ATC-I) 42000 1958 5.35
4 plant GHH (ATC-II) 42000 1958 5.35
5 GHH (ATC-II) 42000 1958 5.35
6 FS Elliot 13200 2016 8.0
7 FS Elliot 13200 2016 8.0
8 Modernisation Atlas Copco 15300 2013 8.0
9 Area Air Station Atlas Copco 15300 2013 8.0
CYLINDER FILLING AND DISTRIBUTION
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
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HOT STRIP MILL
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.
Walking Beam Furnaces:

Two Walking Beam Reheating Furnaces (5 & 6) of 225 T/Hr. capacities were commissioned during
modernization of HSM. Each Furnace is having 6 zones (Preheating zone top & bottom, heating zone
top & bottom and Soaking zone top & bottom). Preheating and heating zones are having dual firing
system with mixed gas and furnace oil, where as Soaking zones are having only mixed gas firing.
Slabs are put on charging side roller table from depiler with the help of depiler crane with tong / EOT
crane with magnet. Each slab is weighed on ChargingRollerTableWeighBridge. Spotting of slab is
done with laser beam and after spotting, the slab is pushed inside the furnace with the help of
pusher. Movement of slabs inside the furnace takes place by the movement of walking beams called
movable skid pipes (4 nos.), which move in lift, forward, lower and reverse direction in one complete
cycle.
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.
HRD CENTRE Page:83

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.
ROUGHING STAND (R0/V0):

Roughing stand is reversing type 2 High Mill with full
automation. It has twin drives with AC motors (with Cyclo-
Converters) of 3000 kW each.
Heated slabs are given 3 passes maximum and reduced to

desired thickness and sent to R1. V0 is vertical edger for
width control by squeezing slab width up to 100 mm. Slabs
after rolling at R0/V0 are called Intermediate Transfer Bars.
No. of PASS : 3 PASSES
R#0 ROLL DIA. : 1005 – 1100 MM.
BARREL LENGTH: 1800 MM
R#0 DRAFT : 39 MM. (MAX.) IN EACH PASS
V#0 SQUEEZING : 100 MM. (MAX.)
R#0 MOTORS : 3000 kW X 2 A.C SYNCHRONOUS
V#0 MOTORS : 1000 kW X 2 WITH CYCLO- CONVERTER
ROLLING SPEED : 4 M/ Sec.Max.)
ROLL SEPARATING FORCE: 20000 KN (Max) FOR R#0
:4500 KN (Max) FOR V#0
ROUGHING STAND-I (R1):

Roughing stand-I is reversing type 4 high mill with 2 work
rolls and 2 back-up rolls. It has a twin drive with 2 DC
motors of 3800 kW. Intermediate transfer bars coming from
Ro are given 3 to 5 passes and reduced to desired thickness.
There is provision for providing descaling sprays at R1 only
on the forward passes. R1 is equipped with a pair of vertical
edger rolls to control the width of slabs.
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REVERSING MILL : 4 HIGH WITH VERTICAL EDGERS

No. of PASS : 3 – 7 PASSES
R#1 MOTORS : 3800 KW X 2 (D.C THYRIST. CONV.)
R#1 WORK ROLL DIA. : 864 – 911 MM
R#1 BACK UP DIA. : 1185 – 1311 MM.
ROLL FORCE : 25000 KN (Max)
SCREWDOWN DRIVE : 73 kW @ 485 RPM – DC
OUTPUT THICKNESS : 32 TO 45 MM
ROUGHING STAND-II (R2):

Roughing stand-II is 4 high Continuous Mill with 2 work rolls
and 2 back-up rolls. R2 has a single drive of 6250 KWDC
motor. The thickness of the bar from R1 is reduced further at
R2, which is operated from a control post in front of R2 mill
stand. There is provision for providing descaling sprays
before R2 stand. R2 is equipped with a pair of vertical edger
rolls to control the lateral spread of the bar.
NON REVERSING MILL : 4 HIGH WITH VERTICAL EDGERS

R#2 MOTOR : 6250 KW X 1 (DC THYRIST. Conv.)
R#2 WORK ROLL DIA. : 825 – 911 MM
R#2 BACK UP DIA. : 1185 – 1311 MM.
ROLL FORCE : 25000 KN (Max)
ROLLING SPEED : 3.02 M/Sec (Max)
SCREWDOWN DRIVE : 75KW@590/1600RPM–DC,GR-3.16:1
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
TRANSFER BAR THICKNESS: 22 - 38 MM.
HRD CENTRE Page:85

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
ADVANTAGES OF COILBOX TECHNOLOGY:

The coil box enables a remarkable improvement in rolling technology. Operations of a hot strip mill
results in the following advantages
1. Uniform temperature of the transfer bar
By winding the transfer bar to a compact coil the heat loss is only 0.06˚C/Sec. Furthermore, in
the wound coil internal temperature compensation takes place whereby the skid marks are
largely eliminated. This means the soaking zone of the slab heating furnaces can be shortened
with a corresponding reduction in energy consumption.
2. Reduced power rating and lower energy consumption in the finishing train
As rolling in the finishing train takes place exclusively at constant speed, less power rating is
required than in conventional rolling with “speed-up”. Furthermore the possibility of being
able to roll out smaller transfer bar thicknesses without temperature problems in the
finishing train also contributes to reducing power
3. Shorter total length of hot strip mill
The distance between the roughing and finishing train in a conventional mill is determined by
the length of the transfer bar. A coil box can start to coil the transfer bar even when it is
being rolled in the roughing mill.
This means that the length of the roller table between roughing mill and coil box is
determined by the length of rolling stock after the third to last pass.
When rolling with a coil box and at a strip unit weight of 20Kg/mm, the distance between the
roughing and finishing train is reduced by 30-50m, if the final roughing stand is a reversing
stand. In case of non-reversing stand the distance can be reduced by 80m.
4. Smaller number of finishing stands
Due to possibility of rolling transfer bars with smaller thickness and at constant temperature,
the number of finishing stands can be reduced for the same range of strip dimensions.
5. Optimum rolling time adjustment between roughing train and finishing train
Due to straight forward conditions of the coiled transfer bar in coil box operations the transfer
bar thickness can be selected such that the rolling time in the roughing and finishing train is
nearly the same, which means an optimum production level.
6. Extended range of dimensions
Due to the constant transfer bar temperature together with smaller transfer bar thickness
the required deformation energy in the finishing train is lower. This means that the range of
product dimensions can be correspondingly enlarged, that is greater strip width at the same
strip thickness or thinner strip gauge at the same strip width.
7. Improved strip quality
The surface of the transfer bar is not damaged by winding in the coil box. The constant
transfer bar temperature and the consequent rolling in the finishing train at constant speed
and at optimum temperature control, guarantees uniform metallurgical qualities over the
whole strip length. Due to the bending of the transfer bar during coiling, there is an
additional descaling effect.
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8. Improved thickness control

The constant temperature of the transfer bar over the total bar length means lesser demands
on the gauge control in the finishing train and improved thickness uniformity and accuracy of
thickness, improved strip shape and flatness.
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
SIX-STAND 4-HIGH TANDEM MILL: F/M #1 TO F/M#6. FEATURES:

 MAIN DRIVE MOTOR : 3700 KW X 1 IN EACH STAND (D.C.)
 MECHANICAL SCREW DOWN: IN ALL 6 STANDS
 HYDRAULIC SCREW DOWN : IN STAND # 3, 4 ,5 & 6
 AUTOMATIC GAUGE CONTROL THROUGH S-7 PLC
 SPEED CONTROL THROUGH SPEED-MASTER PLC
 QUICK ROLL CHANGE SYSTEM IN ALL SIX STANDS
 ISOTOPE GAUGE FOR THICKNESS MEASUREMENT
 DISTANCE FROM CENTRE TO CENTRE OF ADJACENT STANDS – 5.5 Mtr.
LOOPER: INTERSTAND LOOPERS FOR MAINTAINING CONSTANT STRIP TENSION.

LOOPER CONTROL THROUGH PLC.
WORK ROLL CHANGE CYCLE: MAX. 2500 Ts. (60-100 Km)
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.
HRD CENTRE Page:87

HYDRAULIC DOWN COILER: 2 NOS. (COILER # 4 & 5) - Commissioned in 1994
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 AREADESPATCH OF COILS TO EXTERNAL CUSTOMERS.
SHIPPING AREA – 2 NOS. OF BAYS (EF & FGBAY)
EF BAY – 2 NOS. OF RAILWAY TRACKS (EF MAIN

TRACK & EF LOOP TRACK).
FG BAY – 2 NOS. OF RAILWAY TRACK (FG BAY MAIN

AND FG BAY LOOP).
(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
UNCOILER, FLATTENER – I, SIDE TRIMMER, DIVIDING SHEAR, FLATTENER – II, PLATE

TURN OVER DEVICE (PTOD), PILER – I & II
HR PLATE DETAILS
THICKNESS : 4.0 – 10 MM.
WIDTH : 1000 – 1550 MM.
LENGTH : 5 – 10 METERS
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HOT STRIP MILL LAYOUT:
Slab Yard Walking Beam Furnaces

5 & 6 (2 x 225 T/Hr)
Pusher Type Furnaces(2 x 225

T/Hr)
Primary Descaler
R1
MATERIAL FLOW INHOT STRIP
R2
Coil Box
Crop Shear
Through Scale Washer
MILL Hot Strip Mill
6 Stand Finishing Mill

Run Out Table
Coilers
HR Coils for
Shipping
Dividing Line Coil Yard
HR Sheets for Shipping
HRD CENTRE Page:89

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
The Input Slab and Finished Plates dimensions are as follows:

Slabs: Width : 900 – 1500 mm
Thickness :210/220 mm
Length :2050 – 2850 mm
Weight : 3.1-7.1 Ton
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Finished Plates: Width : 1500 – 2500 mm

Thickness :8 – 63 mm
Length :4500 – 12500 mm or more as per order
Plate Mill is comprised of following major areas:

1. Slab Yard 9. Dividing Shear
2. Furnace Area 10. Side Piler I & II
3. Mill 11. Normalizing Furnace
4. Hot Crop Shear 12. Hot Leveler III
5. Hot Leveler I & II 13. Cooling Bed III & IV
6. Cooling Bed I & II 14. Piler III & IV
7. Inspection Bed & Marking and 15. Cold Leveler
Punching Section 16. Ultrasonic Testing Section
8. Circular Trimming Shear 17. Flame Cutting Machine
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
i) Charging Roller Table & Pusher

There are four roller tables through which slabs are transported to the furnace door. Pusher, which
is above Roller Table No. 4, pushes the slab inside the furnace. There are total 33 numbers of solid
rolls in all the four tables. All the four roller tables, pusher and charging & discharging doors are
automated and controlled by PLC with the help of photo cells PC02 to 09 for slab centering.
ii) Walking Beam Furnace

Walking beam furnace is used for again heating of cold slab to the desired rolling temperature.
Hearth of furnace has two rows and each row has one pair of fixed beam and one pair of movable
beam. Slab that is pushed by pusher is initially rest on fixed beam. The movable beam transports
slab in such a fashion that slab appears to be walking. Each row in the furnace can have 28 slabs.
The furnace proper can be divided into three heating sections named as Pre Heating Zone, Heating
Zone & Soaking Zone. Group of burners are referred as Zones. There are total 64 burners in different
zones.
HRD CENTRE Page:91

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
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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. The other major mill
equipments are discussed below.
HOT CROP SHEAR

The plates produced in the mill stand have weird front ends. This end is cut in suitable length in hot
condition in hot crop shear so as to facilitate smooth movement of plates in the cooling bed. Hot crop
shear is a Guillotine type shear with movable inclined top blade. It consists of a depressing table and
eight blades 4 on top and 4 at bottom. Up to 20mm thicker plates are cut at head end. Plate crop ends
falls though a chute on a horizontal conveyor belt below where it is further cut into pieces by scrap
shear and loaded in trolley mounted boxes by a inclined conveyor system.
Hot Plate Leveler I & II

Plates from the mill are having wavy edges, or bent and slightly distorted shapes.After hot shear the
plate is passed through the hot plate leveler for making it flat. Leveler consists of number of rolls
arranged in checkered fashion. In principle straightening is achieved by successive bending of plates
in alternative rolls. Up to 20mm plate thickness leveler-I is used and more than 20mm plate
thickness leveler-II is used for leveling purposes.
Cooling Bed I & II

After leaving the levelers, plates are delivered to cooling bed where they are cooled and transported
at the same time. Cooling is natural cooling. To avoid any difference in the mechanical properties
between the top and the bottom surfaces of the plate, minimum possible area of the bottom portion
of the plate is allowed to be in contact with metallic part by grill and skid type design in cooling bed-
I and grill and chain type design in cooling bed-II
Inspection Bed and Marking & Punching Section

After cooling bed I & II the plates are shifted to cooling bed III or generally known as Inspection
Bed. Here the plates are inspected for various defects as well as removal of minor surface defects by
grinding and sorting out. There is a plate turn over device which turns the plate upside down for
bottom surface inspection if required at the entry side of inspection bed. Plate thickness, width and
length are also measured. Plates are earmarked for sampling. Total production recording is also
done.
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.
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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.
Circular Trimming Shear

Rotary trimming shears are normally used for edge trimming of the plates in conjunction with scrap
cutters. The machine is designed for trimming the plates up to maximum thickness of 20 mm at
tensile strength of 80 kg / mm2. It is designed for a width of trimmings 150 mm for plate of thickness
up to 12 mm and trimming width of 100 mm for plates between 12 – 20 mm thicknesses. The
arrangement of equipments at circular trimming shear is as given below:-
1. Roller table in front of rotary trimming shear
2. Plate guiding boggy.
3. 4 nos. plate aligning devices.
4. Cutting line indicator
5. Roller table in delivery side.
6. Rotary scrap shear.
Online UST Machine:

To cater the growing demand of UST tested quality plates with high NSR, the online UST machine in
Plate Mill was installed in 2010. The capacity of new UST is 15,000 MT per month with latest state
of art PLC controlled machine. This machine is capable of testing plates up to 63mm thick, but due to
constraints in roller table, only up to 25mm thicker plate are tested. Thicker plates are tested OFF
line by manual operated trolley type single probe testing machine.
Ultrasonic testing is used for flaw detection/evaluation, dimensional measurements, material

characterization etc. It uses a very high frequency sound energy to penetrate into the entire
thickness of the steel and rebound from bottom thereby detecting any defects in it.
The online UST machine consists of following major equipments:
1. Body inspection system.
2. Edge inspection system.
3. Probes.
4. Follow-up roll.
5. Relative carriage.
6. Odometers.
7. Plate height detection.
8. Water wiper
9. Plate marking.
10. Pre-wetting unit.
11. Roller table for plate movement.
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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.
Side Piler I & II

After cutting at dividing shear to desired length, plates are transported over a roller table to side
pilers I & II. On the side piler I plates up to a maximum length of 15000 mm can be transported.
Longer plates up to a 20,000 mm go over side piler II. A dog type chain transfer serves for dragging
the plates from the roller table to the piler.
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.
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Hot Leveler III

After old normalizing furnace plate is passed through this. The function of hot leveler III is same as
that of hot leveler I & II.
Cooling Bed III & IV

Normalized plates after going through hot leveler are taken to cooling bed III and IV for air-cooling.
Here plates are made to move slowly so that they get enough time to cool. The transfer equipment of
cooling bed III and IV may likewise operate in two groups. For this purpose, chain transfers of each
rolling bed half has individual electric drive.
Piler III & IV

All the plates of 8 to 20 mm up to a length of 5600mm, after passing over the cooling beds are taken
to the side piler III. Plates in the thickness range of 22 to 36 mm go to side piler IV. The plates of
length more than 5600mm but in the thickness range of 8 to 20 mm also deposited in the side piler
IV.
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.
Flame Cutting Machine

Flame cutting is done offline. This machine is used as a
trimmer for plates of thickness more than 20 mm. This is
located in AB bay between B-27 to B-30 along B column.
Oxygen and propane gas is supplied by TOP-1.This machine
is divided into two parts BED-1 and BED-2.Devices used:
Two long cutting (used for side cutting one in each bed) and
Three cross cutting machine (used for end cutting)
Shipping and dispatch
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:
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What are Plates?
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 our plate mill we make plates from slabs which is mainly supplied to us from Continuous Casting
Machine I (CCM I) and Continuous Casting machine II (CCM II).
Our Input Slab and Finished Plates dimensions are as follows:
Slabs Width : 800 – 1500 mm

Thickness : 210 mm
Length : 2200 – 2800 mm
Finished Plates Width : 1500 – 2500 mm

Thickness : 8 – 63 mm
Length : 4500 – 13500 mm
Our Plate Mill is comprised of following areas:

9. Slab Yard 9. Dividing Shear
10. Furnace Area 10. Side Piler I & II
11. Mill 11. Normalizing Furnace
12. Hot Crop Shear 12. Hot Leveler III
13. Hot Leveler I & II 13. Cooling Bed III & IV
14. Cooling Bed I & II 14. Piler III & IV
15. Inspection Bed & Marking and 15. Cold Leveler
Punching Section 16. Ultrasonic Testing Section
16. Circular Trimming Shear 17. Flame Cutting Machine
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
v) Charging Roller Table & Pusher

There are four roller tables through which slabs are transported to the furnace door. Pusher, which
is above Roller Table No. 4, pushes the slab inside the furnace. There are total 33 numbers of solid
rolls in all the four tables. Also all the four roller tables, pusher and charging & discharging doors
are automated and controlled by PLC.
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vi) Walking Beam Furnace

Walking beam furnace is used for again heating of cold slab to the desired rolling temperature.
Hearth of furnace has two rows and each row has one pair of fixed beam and one pair of movable
beam. Slab that is pushed by pusher is initially rest on fixed beam. The movable beam transports
slab in such a fashion that slab appears to be walking. Each row in the furnace can have 28 slabs.
The furnace proper can be divided into three heating sections named as Pre Heating Zone, Heating
Zone & Soaking Zone. Group of burners are referred as Zones. There are total 64 burners in different
zones.
d) 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 number of burners & is called Zone –I. Bottom preheating area has 2 number of
burners & is called Zone –II.
e) 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 ± 200C. 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.
f) 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 number 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.
vii) Slab Extractor & Discharge Roller Table :
Its basic function it 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.
viii) 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. Water is sprayed through nozzle.
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.
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Hot Crop Shear
This is the start of finishing line and is situated in the main mill line. The plates produced in the mill
stand have weird front ends. This end is cut in suitable length in hot condition so as to facilitate
smooth movement of plates in the cooling bed. Hot crop shear is a Guillotine type hot crop shear with
movable inclined top blade. It consists of a depressing table and eight blades 4 on top and 4 at
bottom.
1. Hot Plate Leveler I & II

After hot shear the plate is passed through the hot plate leveller for making it flat. Plates from the
mill are having wavy edges, or bent and slightly distorted shapes. Leveler consists of number of rolls
arranged in checkered fashion. In principle straightening is achieved by successive bending of plates
to and fro.
2. Cooling Bed I & II

After leaving the levelers, plates are delivered to cooling bed where they are cooled and transported
at the same time. Cooling is natural cooling. To avoid any difference in the mechanical properties
between the top and the bottom surfaces of the plate, minimum possible area of the bottom portion
of the plate is allowed to be in contact with metallic part
3. Inspection Bed and Marking & Punching Section

After cooling bed I & II the plates are shifted to cooling bed III or generally known as Inspection
Bed. Here the plates are inspected for various defects as well as removal of minor defects by
grinding and sorting out. The plates after inspection bed is carried for marking the various
information which give details about the plate like its destination, its quality etc which is carried
out with Paint Marking Cum Punching Machine. It was commissioned and put on normal operation
on 01-08-2008.
Features:
9. Dot matrix paint marking head with electro-magnetic activated spray guns and activated
punchers.
10. Trolley for the movement of marking head and punching heads.
11. Overhead structures/guides on which the above item moves.
12. Control panel with PLC for machine control and host communication.
13. Drive panel with driver electronics for the paint spray guns and punch marking heads.
14. Operation terminal –HMI- monitor and keyboard
15. Maintenance/Service panels with manual push buttons for maintenance operation(mounted
over machine)
16. Combined paint/pneumatic supply unit.
The punch head have one punch section with 4 punchers and the paint head have 8 paint sections.
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)
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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.
4. Circular Trimming Shear

Rotary trimming shears are normally used for slitting and edge cutting of the plates. The machine is
designed for trimming the plates up to maximum thickness of 20 mm at tensile strength of 80 kg /
mm2. It is designed for a width of trimmings 150 mm for plate of thickness up to 12 mm and
trimming width of 100 mm for plates between 12 – 20 mm thicknesses.
Online UST Machine:

The objective of the proposal is to install a new online UST machine to cater the growing demand of
UST tested quality plates with high NCR. The capacity of new UST shall have 15,000 MT per month
compared to present capacity of 7,000 TPM with latest art of state computer controlled machine.
I. Existing UST is OFF Line inspection system
II. Manual operated trolley type single type probe testing machine
III. Occupies large floor space.
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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.
6. Side Piler I & II

After cutting the trimmed plates to desired length at the crop end dividing shear they are kept in
side piler I & II. On the side piler I plates up to a maximum length of 15000 mm can be transported.
Longer plates up to a 20,000 mm go over side piler II. A dog type chain transfer serves for dragging
the plates from the roller table to one half of the piler
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.
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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.
8. Hot Leveler III

After normalizing furnace plate is passed through this. The function of hot leveler III is same as that
of hot leveler I & II.
9. Cooling Bed III & IV

Normalized plates after going through hot leveler are taken to cooling bed III and IV for air-cooling.
Here plates are made to move slowly so that they get enough time to cool. The transfer equipment of
cooling bed III and IV may likewise operate in two groups. For this purpose, chain transfers of each
rolling bed half has individual electric drive.
10. Piler III & IV

All the plates of 8 to 20 mm up to a length of 5600mm, after passing over the cooling beds are taken
to the side piler III. Plates in the thickness range of 22 to 36 mm go to side piler IV. The plates of
length more than 5600mm but in the thickness range of 8 to 20 mm also deposited in the side piler
IV.
11. 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.
12. Ultrasonic Testing Section

Ultrasonic test is carried out offline. This is not done for all plates but is carried out on special
request from customers. This machine uses ultrasonic frequency rays for detecting defects inside the
plates as well as on the surface of plates
Flame Cutting Machine

Flame cutting is done offline. This machine is used as a
trimmer for plates of thickness more than 20 mm. This is
located in AB bay between B-27 to B-30 along B column.
Oxygen and acetylene gas is supplied by TOP-1.This machine
is divided into two parts BED-1 and BED-2.Devices used:
Two long cutting (used for side cutting one in each bed) and
Three cross cutting machine (used for side trimming)
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NEW PLATE MILL

Introduction:
New Plate Mill is a 4,300 mm wide plate mill, one of the widest plate mills in the country, with latest
features enabling it to roll plates of very high strength. The new plate mill facility is part of RSP's Rs
12,000 crore expansion project that aims to double the capacity of steel production from 2 MTPA to
4.5 MTPA. This mill is having a Level-2 automated control system which is capable of producing wide
range of plates with close tolerances to meet stringent international standards and maximising yield.
The New Plate Mill has been installed with initial
capacity of 1.0 M T (0.92 MT saleable), which can be
augmented to a capacity of 1.8 MT (1.674 MT saleable).
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 measurement and an automated
accelerated cooling system to produce high strength TMR
rolled plates including for pipe grades up to API XL 100
with lower cost.
The mill is designed with High capacity levelers with hydraulic control and under load positioning
system, high capacity double side trimming and Cross-cut-shears up 50 mm capacity 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 will be equipped with online ultrasonic testing
facility and advanced control systems and material tracking facilities.
Finished Products Grades from New Plate Mill
 IS 2062 E250, E300,E350 A, BR, B0, C WITH OR WITHOUT Cu
 IS 2062 E410, E450 A, BR
 IS 5896-165,205,235,255,325,355,420,490, &560
 ASTM A36
 BOILER & PRESSURE VESSEL STEEL IS 2002(ALL GRADES)
 ASTM 515/516 ALL GRADES, ASTM537 CL-1, ASTM 202
 LLOYDS 360, 410 INCLUDING AR, FG
 API 5L GRADE (UPTO X-70)
 SHIP BUILDING (LL GR A, B)
 Plain Carbon Steel Plate of all international standards (DIN, JIS, EN, ASTM etc)
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Input Slab Output

Width = 1200 to 2400 mm As Rolled Plate Length = 42 mtr maximum
Length = 2200 to 4100 Finished Plate Thickness = 6 to 100 mm
mm
Thickness = 210 to Width = 1500 to 4100 mm
300mm Length = 6000 to 15000 mm
Sheared plate thickness= 6mm-50 mm
Cold leveling of plates = 40mm Max.
Special quality plates: API upto X-100, HSLA, Micro alloy
Structural
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.
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The main dimensions of furnace are as follows:
 Capacity- 225 ton per hour
 Length (wall to wall) 56.000 mm;
 Width 9.300 mm;
Furnace is divided into following control zones:
Zone Location Type Burner

No. Qty.
Zone-1 Top pre-heating zone side burners 8
zone 2 Bottom pre-heating zone side burners 8
zone 3 Top heating zone n°1 side burners 8
zone 4 Bottom heating zone n°1 side burners 8
zone 5 Top heating zone n°2 (with Sequential Firing) side burners 8
zone 6 Bottom heating zone n°2 (with Sequential Firing side burners 8
zone 7 Top soaking zone roof burners 30
zone 8 Bottom soaking zone (with Sequential Firing) side burners 10
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
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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
 Max. Mill speed 7 m/s

 Number of HGC Cylinder 2 (Bottom Mounted)
 HGC Force Cylinders pressure 280 bar
 Maximum hydraulic force 50800kN
 Screw diameter 900 mm
 Screw thread pitch 44 mm
 Work Roll Diameter 1120-1020 mm
 Work Roll naked weight 49300 kg
 Back up Roll Diameter 2200-2000 mm
 Back up naked weight 168000 kg
Roughing mill important constituents:

1. MILL AUXILIARY EQUIPMENTS:
The slabs are descaled before rolling to remove scale, using high pressure water inside the
descaling box and at the mill stand. Onboard descaling system is selected from level-2 setup.
Side guides are arranged before mill to align the slab before entry of the slab inside the mill.
There position is calculated by level-1 according to the width of the slab being rolled. The gap
between the guides is adjusted by a hydraulic system consisting of Proportional valves.
Roll cooling system is also there and cooling water flow is also controlled based on Level-2
setpoints.
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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.
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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.
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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
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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.
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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.
ERW PIPE PLANT

HISTORY:
Originally ERW Pipe plant was designed, supplied, erected and
put into operation in October, 1960 by M/S Mannesmann
MEER of West Germany. Subsequently with the requirement of
API specification, in 1984, new normalizing unit (500KW. 3
KHz) was introduce and roll profiles were changed to increase
the product range from D/T ratio from 50:1 to 80:1. In 1991 the
rotary welding transformer ( Frequency 125 Hz) was replaced
with HF welder - Thermatool make 400 KHz, 600KW for better
welding performance. In 1997 EDDY current m/c for detecting
the welding cracks was replaced by OFF LINE AUTO UST m/c. However in July, 2005 it was
completely modernized by M/S SALZGITTER INTERNATIONAL, GERMANY to produce API pipes
up to grade API-5L-X70 with D/T ratio 100:1
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.
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SECTIONS OF ERWPP AS PER THE MATERIAL FLOW
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.
COIL YARD: The Input HR coils are received from HSM

through internal wagons. After coils are received required
samples are cut and send to Test house for confirmations of its
grade.
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
CROP END SHEAR:

The Crop End Shear which is hydraulically operated is being used for cutting the leading end of the
coil. Provision is there for falling of end shear strap to a collection box via a chute.
SHEAR- END- WELDER:

Function of Shear End Welder is to join the tail end of the coil with the leading end of the subsequent
coil to make it a continuous strip. It is an automatic arc welding process with the principal of MAG
(Metal active gas) welding, where Continuous wire electrode and shielding gas are fed through
welding torch. The main parts of this unit are:
 The main carriage, carrying the hydraulic operated weld- clamp unit and the down cut shear.
 The base frame with mounted hydraulic cylinder for operating the carriage to & fro.
 The welding rectifier sets
 The twin wire welding torch
 The wire feeding units (wire dia -1.2 mm) with motorized travel
 The shielded gas units (CO2 gas)
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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- EDGE MILLING MACHINE:

The primary function of this unit is to give a smooth machine cut edge to the strip required for high
quality weld and to maintain a constant strip width with minimum material loss. It is a very
sophisticated equipment with high precision and successfully substituted the side trimmer as a
better edge finishing equipment. Basically it consists of a four cutter heads with 54 inserts mounted
on each head and each head can cut 6.25 mm maximum. The rotating cutters are driven by motor,
the milling tools are carbide tips located at the circumference of the cutter. Each cutter units are
equipped with width measuring device, clamping devices and surface copying device. The chips are
collected below the milling unit and transported out by a chip conveyor. There is centralized
lubrication unit to lubricate all the parts of the equipment.
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.
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 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
FIN PASS SECTION:

There are three fin pass stands and one pipe guide unit to guide the strip from universal cage to the
weld throat. It is the final stage of forming and helps to give final tubular shape before welding.
There is a fin in the middle of the top roll which helps to prepare the edges and holds the strip edges
firmly to avoid seam wandering and helps to form the required V angle at the weld point. Fin pass 1
is a two roll pass and Fin pass 2 & 3 are four roll pass design. Position of the roll can be adjusted by
motors.
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
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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.
WELD SEAM ANNEALER:

The function of this unit is to normalize the weld zone of pipe for transforming the microstructure of
the weld area to match the mechanical properties of the parent material. There are two units of solid
state seam annealers with the output power of 600 KW each and the frequency of 2.5 KHz. With the
induction heating the heat is is generated directly in the seam by means of the eddy current.
Each seam annealer has two major functional units:
 Frequency converter(FC)
 Annealer work station with output transformer and coil (AWS), positioned close to the line
and before the pull out stand. The unit ahs the facility of automatic seam tracking with quick
lifting facility.
The temperature is recorded through optical pyrometers and has a facility to store the data.
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
HRD CENTRE Page:115

passed the measuring wheel, the PLC submits the start signal and the carriage accelerates with the
preset 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.
PIPE FLUSHING UNIT:

Inside trimming burrs, beveling chips etc. are flushed with water at a high pressure of about 10 bars
in this station for cleaning purpose.
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.
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OFF LINE UST:

The testing system has been designed for the testing of welding seams, Heat affected zone (HAZ) and
both the ends. Weld seam is tested for both Longitudinal & Transverse defects with 450 angle probes
& a pilot line provided at 3 O’clock position on the pipe is tracked by a camera to ensure 12 O’ clock
positioning of the weld seam. There is provision for doing static & dynamic calibrations as required
by applicable Specifications thereby ensuring repeatability. The defect portion is again confirmed by
Manual UST before final confirmation. The system provides the data administration system (DAV)
which administers testing and other 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 disturbances and warning reports of the ultrasound testing electronics (USEL) and
connected computer modules. Coupling of the testing probes is done via guided beam of water.
WORKS / FINAL INSPECTION:

Here the pipes are visually inspected for dimensional accuracy and other surface defects. Finally
accepted pipes are identified with running serial number and color band as per the specified colour
code. Finally passed pipes are shifted to the pipe yard for dispatch.
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.
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Flow of Materials in ERW Pipe Plant
H R Coil
Through Coil Saddle Coil Car, Uncoiler
Leveler and Edge Milling Machine
UST for Strip Testing
Sticker Stand Pre forming Breakdown Stand Edge Bending

Unit
Induction Welder & ID Seam Guide FinPass Universal

Bead Trimmer Stand 1,2,3 Cage
OD Bead Trimmer & Seam Annealer Pull Out Cooling

Scrap Winder & On-Line UST Stand Jacket
Cold Fly Cut Off & Sizing Stand 1,2,3

Straightening Marking Machine
Machine
Pre-Inspection Sample Cutting Machine & Rotary Flame

skid Flattening Press Cutting Machine
Bevelling Machine Flushing Hydro Tester 1 Off-Line

Machine &2 UST
Despatch Pipe Weighing & Works

Final Inspection Inspection
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SPIRAL WELDED PIPE PLANT
To meet the rising demand of handling bulk transportation of

crude oil from shore to Refineries, a Spiral Welded Pipe Plant
(SWPP) was added to Rourkela’s Mills in 1976. SW Pipe Plant
has very modern and sophisticated production and testing
equipment supplied by M/s Hoesch of West Germany.
This mill comprises of fully automatic welding current, voltage

controllers and weld gap control equipment, testing facilities
like X-ray testing, and an Automatic Ultrasonic on line testing
machine. The mill is authorised to produce API pipes. It has
the capacity of producing pipes in the range of 16” to 64” (406.4 mm to 1625.6 mm) outer diameter
with wall thickness of 5.6 to 14.2 mm.
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.
Coil Preparation Stand:

In coil preparation stand the coil, after de-coiling the front end is cut to give a straight edge for
welding to other coil.
Pipe forming and Welding Machine:

There are two numbers of pipe welding machines for pipe forming and welding. After coil preparation
stand, coil is trimmed on both sides to have uniform width. The trimmed coil edges are bevelled and
cleaned on both sides and then passed through drive roll and pre bending roll where the edges are
bent slightly. The complete unit is on a base frame resting on rollers, which can be swivelled within
10 to 50 degrees angle, according to selected run-in angle, depending on the coil width and the pipe
diameter.
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.
Cross Seam Welding Stand:

This unit is used for cross seam welding of pipes to take care of the joining of the two coils.
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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.
Manual Repair Stand:

Pipes identified at visual inspection and other stages of in-process inspection needing repairs, are
repaired in this stand. The defects are removed by grinding. The body or weld seam are re-welded
after removal of defects.
Pipe End Cutting:

On this device, testing rings and defective un-repaired pipe ends are cut off from the pipe.
Hydro-static Pipe Tester:

Here the pipes are subjected to hydro-testing as per grade, diameter and thickness of the pipe.
End Bevelling Machine:

At this station both ends of the pipes are bevelled to produce the machine end, which can be
conveniently welded during laying of pipe lines.
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.
Final Visual Works Inspection:

The inspection station is provided with a rotating device. Each pipe is finally inspected visually to
control the following:
a. Quality and dimensions of the bevelled ends.
b. Surface defects including dents.
c. Geometrical data such as roundness, straightness, off set of weld seam, height of weld
reinforcement, packing.
d. Pipe dimension such as length, thickness and diameter.
Final Customers Inspection:

The Inspector of the customer is provided with one rotating device
and sufficient rack space. The Inspector carries out more or less the
same inspection as is done in works inspection. If pipe orders do
not require customer inspection, this inspection stand is by passed.
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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.
Flow of Material in SWPP
Coil
Preparation
Stand
Forming
Cage
Inside & Outside Visual

Welding (Submerged Pipe Inspection
Arc Welding) CuttingUnit Station
Outside
Repair X-Ray Grinding Welding
Welding Station Station (Skelp Joint)
Hydro Bevelling Ultrasonic End

Testing Machine Testing Radiograph
Station
Electronic
Final Works
Despatch WeighBrid Inspection Inspection
ge
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LASER SEAM TRACKING SYSTEM
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.
1.2 Laser Camera head:

Specification: A laser camera head is one ofthe main devices of Servo-robot’s 3D Laser vision
system. The range sensing of Mini-i /60 3D laser camera is based on an active optical
triangulation principle.Mini – i / 60 technology provides a high range sensing reliability &
a very high lateral resolution.
Characteristics of Mini- i/ 60 3D laser cameras:
Camera Type Mini –i/60

Principle Active optical triangulation using structured laser
beam illumination.
Detector Photo sensitive device
Light source Build–in 50 MW visible laser diode.
Stand off 56. 6 mm
Depth of filed 65 mm.
Field of view :
Close plane 24 mm.
Far plane 35 mm.
Average depth 0.08 mm
resolution
Sample points per 478 or 238
profile
speed 30 / 60 profiles / sec.
Data rate 14340 points per sec
Dimensions 112 mm X 56 mm X 30 mm
Weight 500 g.
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2.1 General introduction:

EZ – TRACK / IT is an ultra fast image processing unit design to co - ordinate laser camera
motion & 3D data acquisition . It also controls processes with the additional intelligence
provided by 3D vision & adaptive feedback control. The EZ-TRACK / ITcontrol unit contains
the high speed SMART BOARD-V3 vision processor to processimage analysis to keep the
camera in the joint by moving the axes.The high resolution laser camera mini – i/60 coupled
with the vision processor EZ-TRACK /IT, extracts the joint profile & the tracking point. It then
sends the signal command to theaxesto adjust the camera position over the part. An option is also
available to allow the userto compute the gap, the mismatch and area of the joint as well as
to adjust differentparameters in real time including the travel speed & wire feed speed.
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.
2.3 Camera Cooling System:

The camera head is cooled by closed loop chilled water. The chiller unit supplies chilled water at
24° C (adjustable) to the camera head continuously.
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.
3.1 Manual Mode:

When power is on, the EZ-TRACK/IT is in manual mode by default. The manual mode allows
the operator to manually jog the axis. This mode allows the operator to manuallyposition the
torch roughly in the joint at the beginning of the seam, prior to calibration of thesystem.
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.
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PIPE COATING PLANT
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.
Pipelines carrying hazardous materials especially oil and

gas need protective coating both on the inside and outside of
the pipelines to combat the corrosive nature of the harsh
outer environment and the derivatives of the load to be
transported. The three layer system uses a copolymer
adhesive to provide excellent shear properties and an epoxy
layer which provides corrosion resistance. 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.
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
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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.
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SPECIAL PLATE PLANT
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)).
MAJOR PRODUCTS & APPLICATIONS:
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
OUR VALUED CUSTOMERS:

 Ordnance Factory, Medak
 Heavy Vehicle Factory, Avadi
 Vehicle Factory, Jabalpur
 Defence Metallurgical Research Laboratory, Hyderabad
 Mazagon Dock Limited, Mumbai
 Garden Reach Shipbuilders & Engineers Ltd., Kolkata
 Mishra Dhatu Nigam Ltd., Hyderabad
 Combat Vehicles Research & Development Establishment, Avadi
 Cochin Shipyard Limited, Cochin
 Terminal Ballistic Test Laboratory, Chandigarh
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)
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MATERIAL FLOW AT SPP
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.
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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.
PLATES PROCESSING AT SPP

 As rolled plates received from Plate-mill are strain hardened and grains are elongated in
rolling direction. Machining/grinding of plates in as rolled condition is difficult.
 Soft annealing is done to improve grindeability. However for DMR 249 A & B grade plates
soft annealing and grinding is not required.
 Soft annealing cycle comprises of slow heating up to 7100C in 24hours, soaking for 16 hours
followed by furnace cooling up to 1000C. It relieves stresses, reduces strain hardening and
improves machinability. There are two bogie hearth furnaces,Capacity 100 Tons each, used
for soft annealing; namely S/A furnace and S/R furnace.
 Top surface preparation is done to remove surface scale and minor defects from the plate, so
that ultrasonic test can be carried out on the plate.
 Ultrasonic Testing is done by Research and Control Lab. Ultrasonic testing is done to detect
internal defects (e.g. porosity, gas holes and laminations)in the plates.
 After Ultrasonic testing, Details of the plates (Grade, Heat no., Batch no etc.) are stamped on
the defect free plates and plates are cut to size.
 After Size cutting, plates are sent for primary inspection and bottom surface preparation (if,
required). After bottom surface preparation thickness is measured and plates are sent for
heat treatment/dead annealing as per order requirement.
 Hardness testing follows, after heat treatment of each plate. Samples(Ballistic Test
Piece/Physical Test Piece) are taken from each batch for testing. Mechanical tests of PTPs are
done at R & C Lab. BTPs are sent to PXE, Balasore for ballistic firing. Accepted batch is
processed further
 Accepted plates are then shot blasted in Shot Blasting section with steel shots to remove the
scales produced during heat treatment.
 Final inspection of plates done by Defence inspectors along with R & C lab.
 Accepted plates are then stamped and Painted with rust preventive varnish before dispatch.
HEAT TREATMENT ≈ THE HEART OF SPP
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
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temperature, (which depends on thickness and required hardness) and for a fixed time and slow
cooling.
The line diagram for heat treatment process shown below:
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.
Heat treatment is done through two different lines in SPP.
1. OLD HEAT TREATMENT LINE
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.
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Oil Quenching Unit:-

Oil quenching unit lies near hardening furnace. Oil quenching unit has a capacity of 3.2 tons.
Maximum size of plates that can be quenched is 2 meters X 6.5 meters. The unit comprises of oil
tank, pumps to circulate oil, heat exchanger to cool oil, C hook, and Quette etc.
Apart from oil quenching unit a water quenching tank is also used for quenching thicker
plates(thickness >=80 mm).
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2. ADDITIONAL HEAT TREATMENT LINE (AHTL): COMMISIONED IN DEC-2016
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.
Testing and Quality Control

All the plates, which have undergone heat treatment, have to meet quality parameters
according to the specifications of Indian Defence. Hardness test is carried out for every
plate while other tests(Tensile test, Impact test, fracture etc.) are done for few
representative samples. As per the specifications given for armour plates, representative
plates (BTP/PTP Plates) of every lot has to clear all the required tests. If any BTP/PTP
plate finally fails in tests, entire lot represented by it may be rejected.
Facilities for hardness testing and fracture test are in SPP, while Tensile, Charpy
and microstructure tests are carried out at RCL test house.
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PRODUCT DEVELOPMENTS AT SPP
PRODUCTS APPLICATIONS CUSTOMER YEAR
316 LN,304 NUCLEAR POWER PLANT IGCAR KALPAKKAM 2000-01

LN,9Cr1Mo,A48P2
ASTM 517 Gr F PENSTOCK OF HYDEL PROJECTS & HYDEL PROJECTS, FARIDABAD 2000-01
EXCAVATORS
HARDOX-400 EARTH MOVING EQUIPMENTS CATERPILLAR INDIA LTD., TAMILNADU 2002-03
TARGET STEEL AMMUNITION PROOF TPE,ITARSI 2003-04
SAIL ABHED BULLET PROOF RAIL WAGONS DRDO,PUNE 2008-09
SPADE PLATES T-90 TANKS HVF AVADI 2008-09

130 MM
SAIL RATH BOFORS GUN CARRIAGE GCF,JABALPUR 2009-10
DMR-249 B(WATER NAVAL APPLICATION CSL,COCHIN 2009-10

QUENCHED)
DMR-249 A (Z-QUALITY)WQ NAVAL APPLICATION CSL,COCHIN 2009-10
DMR-249 B NAVAL APPLICATION CSL,COCHIN 2010-11

(OIL QUENCHED)
DMR-292 A GRADE PLATES SUBMARINE APPLICATIONS DMRL,HYDERABAD 2013-14
15CDV6 GRADE PLATES OUTER MOTOR CASING -AGNI MIDHANI,HYDERABAD 2014-15

MISSILE
DMR-249 BK GRADE PLATES SURFACE WARSHIP DMRL,HYDERABAD 2015-16
APPLICATIONS
SAILARM-150 MM TESTING OF AMMUNITIONS ORDNANCE FACTORY, KHAMARIA 2016-17
RHA PLATES
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.
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MATERIAL FLOW
STEEL MAKING AT ASP/BSP
CONCAST SLABS FROM ASP SLAB ROLLING AT BSL FOR INGOT
ROLLING AT PLATE MILL, RSP
TROLLY GRINDING OF TOP SURFACE
ULTRASONIC TESTING
FLAME CUTTING TO SIZE
BOTTOM SURFACE GRINDING & THICKNESS CHECK
HARDENING, OIL/WATER QUENCHING AND TEMPERING
HARDNESS TESTING PTP SAMPLE TESTING BTP SAMPLE
FIRING AT PXE, BALASORE
SHOT BLASTING CAST CLEARANCE
SURFACE &THICKNESS
INSPECTION PAINTING STAMPING DESPATCH
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COLD ROLLING MILL
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).
Material Flow Diagram in Cold Rolling Mill, RSP
HR Coils
PL-2 PL-1
Tandem Mill CR-1
CAL HAL
SP-1 SP-3
Galvanising Tin Mill Black

CPL
Line Plate from BSL
ETL SSL-2
GP / GC CR Coils ETP CR Sheets CR Coils

Sheets
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.
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Pickling Lines:
The first unit of CRM after HSM is Pickling line. During the hot rolling process, a layer of scale
(Iron oxides) is formed on the strip surface, which must be removed prior to further processing. This
removal of scale is performed by physically breaking of scales by mechanical means & then
chemically treating the surface of hot rolled strip with an acid. The process, called ‘Pickling’,
removes the remaining scale by dissolving it in acid. In CRM, RSP HR Coils are treated chemically
by hot dilute Sulphuric acid to remove the oxide scales, so that it can be further rolled to
thinner gauge. There are two Pickling lines in CRM, RSP.
Pickling Line I Pickling Line II
Capacity - 2,80,000 T/Yr. 4,68,000 T/Yr.
Max. Strip width - 1560 mm. 1350 mm
Thickness of Strip - 2-4 mm 1.6 to 4 mm
Pickling Medium - Dilute H 2 SO4 Dilute H 2 SO 4
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:
Tank No. Acid Salt Temperature

Concentration Concentration
1 16-18(%) 400 gm/liter 70 o C
2 18-20(%) 350 gm/litre 75 o C
3 20-22(%) 300 gm/litre 80 o C
4 22-24(%) 250 gm/litre 85 o C
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)
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Cold Reversing Mill-1(CR-1)

This is one, 4-Hi reversing mill which makes 2-5 passes to reduce thickness. It hasa single
stand with reels located on either side of the mill. Steel strip is passed back and forth till the
required thickness is obtained. On the entry side of the mill, means are provided for the coil to be
threaded through the mill to the tension reel on the delivery side. After the first pass, the tail end of
the coil coming from the uncoiler is gripped by the second tension reel on the entry side of the mill. In
each unit, the reel serving as the pay-off unit is operated as a generator, providing back tension to
minimise the rolling friction and feeding of the coil into drive reel motor. In the last pass, the tail end
of the coil is released from the unwinding tension reel.
5-Stand Tandem Mill(TM)

The Five Stand 4 Hi Tandem Mill is one of the most vital
units provided during the 1.8MT Expansion Programme. In
tandem rolling, the material to be rolled undergoes reduction
in all the mills at a time. The Mills usually roll a wide
variety of finished Coils with thickness varying from 0.15 to
1.60mm. Each stand of tandem or reversing mills consists of
a set of independently driven pair of rolls, which come in
direct contact with the strip and create a converging gap for
imparting deformation to the strip. These rolls are called
work rolls. Comparatively larger diameter backup rolls support these work rolls. The maximum
speed of the mill is 1830 m/min. in the fifth stand. The Mill rolls 3 types of finished Coils with
following Specifications:
Parameters Galvanised Sheets CR Sheets Tin Plates

Rated Capacity 1,60,000T/yr 2,50.000 T/yr 85,000T/yr
Max. Strip Width 1220mm 1250 mm 1040mm
Min. Strip Width 560 mm 560mm 560mm
Max. Strip thickness 1.6mm 1.6mm 0.30mm
Min. Strip thickness 0.31mm 0.31mm 0.15mm
Inner Coil diameter 510mm 510mm 450mm
Outer Coil diameter 1600mm 1600mm 1600mm
Max. Coil weight 15 tonnes 15 tonnes 15 tonnes
Production rate 60 T/hr 60 T/hr 30 T/hr
Isotope Gauge after Stand 5 indicates the final thickness.
The material flow of Tandem Mill is:

Coil from PL II  Coil Storage in Tandem Mill bay  Coil Conveyor Coil ramp  Uncoiler
box  3 roller Pinch roll unit(Straightening machine)  Strip guide roller  Lateral Strip
guide  Entry guides  5 Stands  Delivery Guides  Tension Reel Coil Stripper  Belt
Warper  Coil transfer Car  Coil Conveyor
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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.
Hood Annealing process can be divided into the following operations:

(a) Charging of annealing bases
(b) Placing of inner cover
(c) Purging
(d) Placing of furnace
(e) Lighting of furnace and heating of charge
(f) Stopping of heating
(g) Cooling and unloading
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.
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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.
SkinPass Mills (SP-1 & SP-3):

The softened or annealed Steel is then skin passed or Temper rolled with the aim of
imparting a work hardened skin to the steel strip leaving its core soft in the annealed
condition.
Following are the main advantages of Skin Passing.
a. To impart different surface finishes to the strip required for painting, coating enamelling etc.
b. To give a flat surface to the strip.
c. To impart the desired mechanical properties to the strip.
d. To keep the strip free from stretcher strains and luder bands that may develop during the
forming operations.
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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.
Sheet Shearing Line (SSL):

Some Coils are sheared in to different lengths in Sheet Shearing line - 2 and sent to
Customers as CR sheets. SSL consists of one uncoiler & a Harden Shear to cut sheets of
different lengths. On line inspection is done manually.
C.R. Sheets & Coils:

Specifications Sheets Coils
Length 2500 mm
and 3600 mm
Width 1250mm (maximum) 920-1270mm
Thickness 0.5 – 1.6mm 0.35 – 1.6mm
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.
Besides CR coils and sheets CRM, RSP also produces two

different coated products namely Electrolytic Tin Plates
(ETP) and Galvanised plain and corrugated sheets.
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.
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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.
Electrolytic Tinning Line (ETL) Complex:

Here the Coating of tin is done by employing the principles of electrolysis in a acidic medium.
The advantages of ETL are (1) it is faster (2) economical (3) Tin consumption is less (iv)
differential coating can be obtained.
The continuous Electrolytic Tinning Line produces a shining tin coated surface in a variety of coating
thickness. The tin plate shearing lines are equipped with sensitive pin hole detectors and an
automatic off gauge detection system. Description of various processing units and the activities
performed are given as follows:
i) Coil Preparation Line (CPL)
ii) Electrolytic Tinning Line(ETL)
iii) Electrolytic Tin Plate Shearing Lines-1 & 2 (ETSLs)
Coil Preparation Line:

In this line RSP Cold rolled TP Coils, Tin Mill Black Plate (TMBP) Coils (from BSL) are prepared
before they are fed to the Electrolytic Tinning Line. The line is fitted with an Off gauge detector. The
portion of the coils showing off gauge is cut off in this unit. The line has provision to make bigger
coils from smaller ones and a side trimming unit to trim to final width required by the customer.
Anode Cast House:

In Anode Cast House anodes are made from Tin Ingots. These ingots are used in Electro Plating
Tanks of ETL. Tin Ingots are melted in the furnace heated with mixed gas. It has a temperature
measuring instrument. The molten tin from furnace is tapped from tap hole in the mould.
Electrolytic Tinning Line:

The purpose of this unit is electrolytic cleaning, pickling and plating of TMBP Coils with tin,
chemical treatment (passivation) & Electrostatic oiling. The unit consists of Entry Section,
Processing Section & Delivery section.
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.
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Electrolytic Tin Plate Shearing Line:

This unit serves the purpose of shearing the coil to sheet as per requirement of the customer
and classification of ETP. The unit consists of Un coiler , Flying Shear, Pin hole & Off gauge
Detector, Classifier and Pilers.
The specifications of Tinning Line are:
Rated Capacity 25 Tons/hour or 1,50,000T/Yr

Strip size
Width of Strip 560mm – 1040mm
Thickness of Strip 0.15mm – 0.31mm
Maximum speed 370m/min
Coating weight 5.6 gm/m 2
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.
Continuous Galvanising Line:

Galvanising Lines of CRM of RSP were commissioned in July 1968. There are two Senzimer type
Continuous Hot Dip Galvanising facilities with On-line Oxidation Furnace for removing oil, grease,
On-Line Reduction Furnace for annealing in protective atmosphere, Jet Coating for better control
on coating thickness, Chemical Treatment to prevent atmospheric corrosion and Shearing facilities.
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
Plain (GP)  Corrugation Line

There are 2 multi-roller corrugating machines which produce corrugated sheets.
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
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Application:
Galvanizing Sheet is used extensively for roofing, paneling, industrial

sheeting, air conditioning ducts and structural applications.
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.
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SILICON STEEL MILL

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.
Rourkela Steel Plant, a unit of Steel Authority of India

Limited (SAIL) took the lead & achieved the distinction of
being the first in the country to start commercial production
of CRNO. Equipped with the state of the art technology,
Silicon SteelMill with installed capacity to produce 73,500
tpa of CRNO was set up with technical collaboration of M/s
A.K.STEELS (Formerly ARMCO), USA, a pioneer in the field
of electrical steel.
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.
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FLOW SHEET
STEEL MELT SHOP –I
HOT STRIP MILL
BILD UP & SIDE TRIM LINE
ANNEAL & PICKLE
4 Hi COLD REVERSING MILL
TANDEM ANNEAL DECARB
SLITTER
CUT TO LENGTH
PACKING
DISPATCH
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MAIN UNITS:
BUILD UP & SIDE TRIM LINE

Supplier: STAMCO / BLUE-STAR, Electrics. : PLC Drive: ROCKWELL AUTOMATION
This line is used for side trimming & head end / tail end dressing of input Hot rolled coils of
Thickness 2.2 To 2.5 mm, Input width 1055 + 10 / -0 mm & Finish width 1028 / 978 / 928 mm
Line Features:
1. Coil Wt. 15 Mt (max )
2. Coil I.D. 510 & 710 mm, Width 600 To 1150 mm
3. Line speed 15 to 125 mpm.
4. Jog speed 15 mpm
5. Line tension 1.75Kg / mm2
ANNEAL & PICKLE LINE:

Supplier: Main equipments: AETNA STANDARD (USA), Furnace: ELEC. FURNACE CO.,
Electrics: BHEL, PLC: L&T U-84
This line is used for pickling of HR coils after BUST line.

Width - 600 - 1150 mm
Max. Coil wt. 15 Mt
Total Line Length –290 Mts.
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
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ACID TREATMENT PLANT:

This plant is used for neutralization of waste acid from Anneal & Pickle line. Cold reversing mill
rolling emulsion, mill washing & other spill oil of mill is also treated here to remove waste oil. After
neutralization of waste acid effluent is sent to lagoon designed to handle approx. 503 gallons/ min of
influents.
Plant Features:
1. Acid storage tanks FRP - 6 nos.11,000 Gallon each
2. Equalisation Tank - 20,000 Gallons.
3. Aeration tanks
4. Clarifier, floculator
5. Oil skimmer/ reclamation system
COLD REVERSING MILL

Supplier: MECON / WEAN UNITED, Electricals: BHEL, Input: HR coils after Pickling
Coil I.D.: 510 mm, OD: 1750 mm, Width: 600 - 1150 mm
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.
15. Hydraulic Systems:

System A - +ve bending, Back Up balance, Back Up change rig.
Press - 210 Kg/ CM2
System B - Auxilliaries 60 - 70 Kg/ CM2
System C - AGC, 240 Kg/ CM2
Morgoil - 5 Kg/ CM2
Morgoil hydrostatic - 700 Kg/cm 2
Circulating Oil - 5 Kg/cm 2 Drive gear boxes
Roll Coolant System - 4500 Lts/Min 10 Kg/ CM2 2 Tanks 60 M3 each
- Skimmers, CUNO filters, Magnetic filter.
16. Mill modulus - 564 Mt / mm
17. Roll separating force - 2280 Mt (max)
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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
REPAIR & SIDE TRIM LINE

Supplier: Stamco / Blue Star Elec. BHEL PLC Yashikawa
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
TANDEM ANNEAL LINE

Supplier: EPI / ELEC. FURNACE CO., Electrics. BHEL, PLC : Siemens S5
This line is used for Decarburizing annealing of cold reduced coils. Annealed strip is coated with
insulation coating.
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
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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
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CUT TO LENGTH LINE

Supplier: - BLUE STAR/ STAMCO
Electrical – BHEL
PLC – Siemens 155 H
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
MAGNETIC TESTING LAB.

For evaluation & grading of silicon steel.
FACILITIES INSTALLED:
1 Magnetic test console MPG C500, Brockhaus Nesstechnik
2 Fischer Coating thickness gauge
3 Franklin resistivity tester.
4 Sample shear.
AMMONIA CRACKING UNIT

Ammonia cracking unit is producing synthesis gas used
as Protective atmosphere in Tandem annealing line
&Decarburization annealing line of SSM, Galvanizing,
Continuous Anneal & Hood Annealing line of CRM.
CAPACITY:900 NM3 / Hr, 4 furnaces of 300 NM3 / Hr

each, Synthesis gas: 75 % H2 + 25 % N2
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.
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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 consists of following equipments:

a) Lathe- for Turning of R0 and back up rolls of HSM
b) WG1 & WG2- Grinding of back-up rolls of HSM & PM and also work rolls of PM.
c) WG 3, 4, 5-Grinding of Work Rolls of HSM finishing & roughing stands, CTS Blades of PM,
Rubber Rolls and Pipe plant cutter blades.
d) EM1 & EM2- Straight blade grinding of HSM & Plate Mill.
e) CNC-I & CNC-II - Grinding of finishing Mill work rolls of HSM.
Roll Shop - II:

The shop came into existence along with Tandem Mill & Skin Pass Mill-III of CRM in the year 1968.
Following equipments are installed in Roll Shop-II:
a) HG 1- Roll grinding machine for grinding back-up rolls of CRM & SSM.
b) HG 2 & 3 - Roll grinding machine for grinding of work roll of CR-I, SP-I, SP-III and TM.
c) WG 6, 7 & 8 - Roll grinding machine for grinding work rolls of Tandem Mill & SP-III.
d) EM 5 & 6 - Grinding of straight blades of PL1, PL2, SSL & ETL of CRM complex.
e) EM 7-Grinding of circular blades for Pl1, PL2, SSL & ETL lines and SSM.
Roll Shop - III:

The Shop came into existence with commissioning of Silicon Steel Mill in the year 1984. Following
equipments are installed in Roll Shop-III:
a) HG-6 - Roll grinding machine for grinding of SSM work Rolls.
b) Guistina - Roll grinding machine for grinding of SSM work rolls & crop shear blades.
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Roll Shop - IV:
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.
a) Two nos. of WaldrichSiegen make CNC work roll grinding machines.

b) Two nos. of WaldrichSiegen make Combination-CNC roll grinding machines for grinding of
both Back-up rolls as well as work rolls.
c) One auto loader unit.
d) One WaldrichSiegen make CNC knife grinding machine.
e) One conventional Lathe capable of turning of both work rolls as well as Back-up rolls.
f) One antifriction bearing cleaning unit.
g) One Oil film bearing cleaning unit.
h) One each Chock extractor units for Back-up chocks & Work roll chocks.
i) One combination-chock tilting unit.
j) One work roll chock tilting unit.
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MAINTENANCE FUNCTION
Maintenance management is a vital part of industrial management as this is directed towards

optimum utilization of the machineries in an industry, which engulfs highest chunk of investment
made in business. Rourkela Steel Plant has been rightly giving due importance to maintenance,
which is evident from the sound maintenance system that exists in RSP since inception.
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 –
Sl Department Assigned function

1 Engineering Shops Manufacturing / repair of spares, reconditioning of
damaged assemblies, fabrication of structures etc.
2 Crane maintenance Inspection & Maintenance of all EOT cranes of the
plant.
3 Design & modification Preparation/preservation of drawing, redesign /
modification of equipments in the plant etc.
4 Maintenance systems and o Vibration monitoring of rotating equipment.
services Thermography, oil analysis etc.
o Maintenance and modification of CMMS.
Training to users.
o Expert advice on lubrication, hydraulics,
bearings including control function on usage.
o Operation, Maintenance of Compressors and
distribution of Compressed Airto departments
o Allotment/control of Consumption and
procurement Budget.
o Inspection of condition Structures and
reporting.
o Monitoring of maintenance activity in different
departments. Suggestions as per requirement.
5 Repair and construction Centralized man power help for heavy/ specialized
(Mechanical) repair jobs.
6 Civil Engineering services Maintenance and modification of Civil work in the
and structural inspection plant & Inspection of shop floor structures.
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7 Central monitoring group Monitoring of maintenance activity in different
departments. Suggestions as per requirement.
8 Field machinery Maintenance & operation of field machinery
maintenance equipments.
9 Transport Maintenance & operation of vehicles inside the
plant.
Apart from the above maintenance services, utility service of Compressed Air is also under
G.M.(Mechanical).
The various Centralized Electrical Services comprise of –

1 Repair shop (Electrical) Repair/reconditioning of electrical equipments.
2 Air conditioning Maintenance of air conditioning units of the plant
including room a/c
3 Electronics & Electrical Maintenance of electronic systems in the plant.
Technical Services.
4 Heavy Maintenance Man power help to various units of the plant for
(Electrical) heavy electrical jobs.
Apart from the above Maintenance Services, power generation & distribution, steam generation and
blower station is also under G.M.(Electrical).
DEPARTMENTAL MAINTENANCE ORGANISATION

In each production units, under the departmental Head, there is one head of Mechanical
maintenance and one head of Electrical maintenance. In some important units, both mechanical and
electrical maintenance are lead by one Maintenance Head. The maintenance activity of the
department comprises of several functional groups:
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.
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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.
PLANT is divided into different PRODUCTION CENTERS (max.100) - PRODUCTION CENTERS

are divided into many COST CENTERS (max. 100) - COST CENTERS are considered to be
comprising of many GROUPS OF EQUIPMENT (max. 100) - Each GROUP OF EQUIP. is classified
into many SUB-GROUPS OF EQUIP. (max. 10). The mechanical and electrical discipline then list
different ASSEMBLIES under each SUB-GROUP separately (max. 100). Each ASSEMBLY is
considered as comprising of many parts (max.1000), which is the lowest level in the classification
tree. Each level is suitably numbered by which it is possible to assign numeric code to any equipment
at any level.
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.
PREVENTIVE MAINTENANCE SYSTEM

The preventive maintenance system that has been designed by Mr. Kohrn, is in vogue in all
production units. This comprises of time based inspection, regular defect recording, shutdown
planning and execution of planned jobs, breakdown monitoring and analysis etc. The total system is
shown diagrammatically in Fig-1. Different formats with a specific code number (like PM1,
PM2…mentioned in diagram) have been designed for recording/reporting of each activity.
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.
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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.
COMPUTERIZED MAINTENANCE MANAGEMENT SYSTEM (CMMS)

The maintenance system described above is fully computerized at present. The system is popularly
known as CMMS. This was introduced way back in 1987-89, under a UNIDO / Government of India
project. The system has been designed under the guidance of UNIDO experts, by RSP’s internal
manpower only.
The system consists of the following modules:

1. Equipment Classification: This module takes care of the computerization of the equipment
classification as per the style described before. The whole database of equipment of the plant
is at present is available in computer.
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.
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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.
CONDITION BASED MAINTENANCE SYSTEM (CBMS)

Preventive maintenance jobs that are taken up, are not only limited to time based frequencies but
based on condition also. While regular inspection, monitoring of parameters like pressure,
temperature, current etc. detects many job requirements, RSP also has adopted modern methods of
condition monitoring. This service is provided by the central agency MSS (CBMS) department. The
activities include:
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.
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MAINTENANCE
JOB CATALOGUE
PREVENTIVE CORRECTIVE
MAINT. JOBS MAINT. JOBS
TIME BASED CONDITION

JOBS BASED 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
EXECUTION PLAN WEEKLY/

PM3 MONTHLY
PM1 / SHUTDOWN
PM4 PLAN
CAPITAL REPAIR
PM1b PM1a PLAN
EXECUTION PLAN
1Yr. 3Yr.
PM1c
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MAINTENANCE SYSTEM & SERVICES (MSS)
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)
Later on two more departments are added in 2008:

7. Consumption and Expenditure control (CEC)
8. Structural Inspection (SID)
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.
Hydraulics & Pneumatics:

 Trouble shooting in hydraulic systems of plant units and assisting departments in fixing the
problems in case of breakdowns.
 Proper documentation of technical literature and drawings related to hydraulic system
installations.
 Allotment of new stock nos. to standard hydraulic components.
 Working on special problems of hydraulics & pneumatics including development & modification.
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.
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Maintenance Planning & Performance MIS reports:

 Preparation of Annual Capital Repairs Plan & its fulfillment report.
 Preparation of Investigation of Breakdowns & Recommendations Report.
 Preparation of Monthly Department-wise Equipment Availability and utilization Reports.
 Preparation of monthly Maintenance parameter performance report.
 Determination of Maintenance cost of major production units and its reporting
Central Compressor Station:

The compressed air requirement of various units of RSP is met either through individual compressor
station or through Centralized Compressed Air Grid. The individual compressor stations of
department are located in the respective departments & dedicated to meet their particular
requirement which is operated and maintained by the department itself. The Centralized Air Grid
which is operated by MSS department gets air from the two compressor stations located one at I&S
zone (11 compressors of CPT & KG Khosla make) and other at RM Zone (3 compressors of BHEL &
Russian make). Operation & maintenance of the compressors & its auxiliaries are the main activities
of the unit for supply of compressed air with an optimum pressure and flow. The average
generation/consumption of compressed air is approx. 45,000m3/hr which is being fed to the grid round
the clock. The hourly loss of RSP on account of compressed air failure is approx. rupees seventy five
lakhs. In addition to above main activity other activities are as follows:
(a) Maintenance & operation of Circulating Cooling Water system i.e. Pump, Cooling Tower, Sumps,
etc. for the healthy operation of Compressors.
(b) Maintenance & inspection of about 18KM of grid pipe lines with sizes varying between NB200 to
NB600 throughout the Plant starting from SSM to SMS-II.
(c) The inspection of compressed air pipe lines i.e. main grid as well as user points in different shops
to arrest / control the leakages & misuse of compressed air. The generation cost of one M3 of
compressed air is approx. Rs.0.40.
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 Re-refining Plant:

The re-refining plant (ORRP) under MSS department was commissioned in Jan 1982. This oil re-
refining technology was supplied by M/s Indian Institute of Petroleum in consultation with R&C
Laboratory, RSP.
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.
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(a) Used oil collection & storage

(b) Dehydration to remove moisture
(c) Alkaline clay mixing
(d) Clay treatment to neutralize the acid content
(e) Cooling to avoid oxidation of processed oil
(f) Filtration to remove traces of sediment
(g) Storage of base oil in storage tanks according to viscosity gradation.
(h) Blending of oil by transporting
(i) Testing of blended oil
(j) Barreling : Blended hydraulic oil T-3, T-4 & T-5 is issued to various departments like CRM,
HSM, SSM, Pipe Plants, CO, LDBP, OBBP, FMM, SP-I, SP-II, RSM & Blast Furnaces etc.
(k) Production Capacity:
- Collection of used lubricating & hydraulic oil is about 1200 barrels per annum.
- Production of blended hydraulic oil is about 1020 barrels per annum.
Condition Based Maintenance System (CBMS):

Rourkela Steel Plant has a healthy maintenance practice right from its inception in 1959. Condition
Based Monitoring through vibration Analysis has been developed and is in use at RSP, since April
1993, as a key technique for implementation of Predictive Maintenance Program. The coverage has
grown many folds from 45 to 475 nos. of critical equipment in the last 12 years. In addition, for the
first time in SAIL plants, single/double plane in-situ balancing have increased from a mere 9 to 121
(PM) cases, resulting in substantial financial savings.
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.
CBMS Techniques adopted:

- Vibration monitoring / analysis & diagnostic studies
- Oil contaminants analysis through Direct Reading (DR) Ferrography Technique
- HT induction motor monitoring (RDCIS Project)
- Thermo-graphic technique using thermo vision camera for hot spots in switch yards, HT cable
galleries and thyristor control panel.
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.
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- Improvement in availability and reliability of all types of rotating machines.
- At present the reliability of rotating machines is about 96%
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.
Computerised Maintenance Management Systems (CMMS):

Computerised Maintenance Management System (CMMS) is a tool for carrying out maintenance
activities of industrial equipment with the aid of computers. UNIDO/UNDP envisaged the
development and introduction of a modern integrated CMMS first in Rourkela Steel Plant, as it had
a well-established manual maintenance system. Investment on the project was US $1.06 million and
duration of development was from Mar'86 to Dec'89. RSP has extended this technical know-how by
giving support in designing, development and implementation of CMMS activities to Sister Steel
Plants (Bhilai, Bokaro, Durgapur, Alloy Steel Plants, IISCO) in phase II of the project. Other
industries and organisations (NALCO, BALCO, ORIND, etc.) were also assisted.
Need for CMMS:

 Timely maintenance is essential to ensure equipment availability
 In any industry, keeping a track of the large number of equipment, their spare parts and the
huge amount of maintenance jobs is humanly difficult, time consuming and cumbersome.
 Close co-ordination is essential amongst host of related maintenance activities.
 Carrying out routine jobs is time consuming.
 Information needs to be made readily available for facilitating decision support.
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.
Hardware & Software:

In 1996 the CMMS application was re-developed (earlier it was in DSDL/LINC in Burrough’s A3K
machine) in SUN computer system at C&IT department using ORACLE 7.0. Users in the Production
& Services units have access to the SUN from their work place through terminals, connected through
a network (using telephone cables or fiber optics). There are 45 CMMS user departments/ sections.
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.
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 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.
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SHOPS-PLANNING & COORDINATION (SERVICES)
Shop-Planning & Coordination (Services)is a unit of Engineering Shops & is a staff

function created in the year 1970 as a result of the re-organization of Engineering Services wherein
the new concept of having an independent planning department was introduced.
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.
Different Sections of the Department:

 Production Control
 Process Planning
 Inspection
 Off-loading Cell
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
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 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.
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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.
Foundry is equipped with the following facilities:

(i) Material handling.
(ii) Sand moulds & core preparation and drying facilities.
(iii) Melting Units and Pouring accessories.
(iv) Fettling and cleaning of castings.
(v) Inspection.
(vi) Heat treatment.
(vii) Pattern Shop, drilling, planning, milling, grinding machines, circular and band saw etc.
A brief description of the various units under Foundries:
1. Engineering Casting section:

Moulds are prepared for cast iron castings like door frame, flash plate, wharf plate for Coke Ovens
and steel castings for various units of the plant. For preparing moulds the EC section has continuous
sand drying and mixing plant used for preparation of resin sand (Capacity: 5Ton/hr.).
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.
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Non-Ferrous Foundry produces

 Non-Ferrous castings of spares
 Aluminum and copper bars / ingots
 Aluminum nuggets
 Zn Al Pb ternary alloys
4. Heavy Steel Casting section:

For manufacturing of heavy spares (i.e. spares in excess of 5 MT in weight), sand moulds are
prepared at the Heavy Steel Casting section close to the SMS-I pit side. The molten metal for the
purpose of casting is obtained from the Steel Melting Shop. Presently two numbers of steel slag pots
for our sister steel plants are cast every month, on an average. Besides, heavy spares like PMD tyre
for Sinter Plant, LD trunion rings, Intermediate pieces, Dump Boxes and Trays for SMS and Breast
Roll Carrier for Plate Mill are some of the notable castings that have been made in this section. It
may be noted that all heavy steel castings are manufactured as per the definite requirements of other
units of the plant from time to time.
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.
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SHOPS- MECHANICAL SHOP

Mechanical Shop is a manufacturing Shop engaged in manufacturing/ reconditioning of spares for
units of plant on regular basis. Mechanical Shop is the most modern Shop of RSP. This Shop is
equipped with CNC Machine Tools & Higher capacity Horizontal Borer Machine SKODA, CNC
Vertical Boring Machine HOMMA, Fully automated CNC Plano Miller Machine and CNC Lathe
Machine. Mechanical Shop is a machine shop consisting of more than 60 numbers of small & big
machine tools. The entire complex is divided into three bays. “AB” Bay consists of Heavy Machine
tools, “BC” Bay consists of Light Machine tools & the material yard Bay consisting forge rounds and
Saw Cutting &Centring Machine. With the recent inclusion of Band saw machine in the material
yard, Mechanical Shop is now equipped to cut forge round up to 650mm. Depending on the type of
operations, different machines as listed below are used to carry out manufacture/ repair/
reconditioning of spares/ equipment in Mechanical Shop:
1. Lathe 14 Nos. (Max Size 1000mm x12m)

One Fully Automated One meter CNC
Lathe & one 5 Meter Long CNC Lathe
M/c
2. Horizontal Boring Machine 4 Nos. (2 SKODA Machine 200 spindle)
3. Vertical Boring Machine 2 Nos.
OneHOMMA Double Column Vertical
Boring Machine Table dia 6.5 meter
4. Milling Machine 6 Nos.(CNC Milling -2)

5. Slotting Machine 2 Nos.
6. Shaper 3 Nos.
7. Drilling Machine 3 Nos.
8. Planning Machine 2 Nos.
One Fully automated with sub unit
changer & Automatic tool Changer CNC
Plano Milling Machine
9. Gear Hobbing 1 No.
10. Bevel Gear Generator 1 No.
11. Grinding Machine 2 Nos.
12. Saw Cutting Machine 2 Nos.
Semi-Automated Maximum up to 650 dia
cutting Band Saw Machine
13. Centring Machine 1 No.
14. Hydraulic Press 1 No.
15. Cranes(50/15,15/5 &15/5T) 3 Nos
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SHOPS - REPAIR SHOP (MECHANICAL)

Mechanical Shop is a manufacturing Shop engaged in manufacturing/ reconditioning of spares for
units of plant on regular basis. Mechanical Shop is the most modern Shop of RSP. This Shop is
equipped with CNC Machine Tools & Higher capacity Horizontal Borer Machine SKODA, CNC
Vertical Boring Machine HOMMA, Fully automated CNC Plano Miller Machine and CNC Lathe
Machine. Mechanical Shop is a machine shop consisting of more than 60 numbers of small & big
machine tools. The entire complex is divided into three bays. “AB” Bay consists of Heavy Machine
tools, “BC” Bay consists of Light Machine tools & the material yard Bay consisting forge rounds and
Saw Cutting &Centring Machine. With the recent inclusion of Band saw machine in the material
yard, Mechanical Shop is now equipped to cut forge round up to 650mm. Depending on the type of
operations, different machines as listed below are used to carry out manufacture/ repair/
reconditioning of spares/ equipment in Mechanical Shop:
1. Lathe 14 Nos. (Max Size 1000mm x12m)

Two nos. Fully Automated One meter &
Two Meter CNC Lathe &twonos. 5 Meter
Long CNC Lathe M/c
2. Horizontal Boring Machine 4 Nos. (2 SKODA Machine 200 spindle)
3. Vertical Boring Machine 2 Nos.
OneHOMMA Double Column Vertical
Boring Machine Table Dia 6.5 meter
4. Milling Machine 6 Nos.(CNC Milling -2)

5. Slotting Machine 2 Nos.
6. Shaper 3 Nos.
7. Drilling Machine 3 Nos.
8. Planning Machine 2 Nos.
One Fully automated with sub unit
changer & Automatic tool Changer CNC
Plano Milling Machine
9. Gear Hobbing 1 No.
10. Bevel Gear Generator 1 No.
11. Grinding Machine 2 Nos.
12. Saw Cutting Machine 2 Nos.
Semi Automated Maximum up to 650 dia
cutting Band Saw Machine
13. Centring Machine 1 No.
14. Hydraulic Press 1 No.
15. Cranes(50/15,15/5 &10 T) 3 Nos
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SHOPS (STRUCTURAL &FABRICATION )

Structural & Fabrication Shop is another captive shop in the Engineering Shop Complex engaged in
repair and fabrication of various plant equipment of Rourkela Steel Plant. This shop comprises of the
following sections:
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:
1) a) Semi-AutomaticMIG/MAG Welding Machine:
Supply Voltage 415 V, 3 phase, 50 Hz.

Welding Wire Size used 1.2 to 1.6 mm
Gas used Carbon Dioxide for MAG, Argon for MIG
Wire Speed 1.5 to 15 m/minute
b) MIG/MAG Column & Boom Welding Machine:
Supply Voltage 415 v +/- 10 %V, 3 phase, 50 Hz.

Welding Wire Size used 1.2 mm to 1.6 mm
Capacity 5T
Drive 4-Roller
Job to be done Dia 150 to 1000 mm
c) MIG/MAG Portable Auto Bore welding Machine
Supply Voltage 230 v ,1 phase, 50 Hz.

Welding Wire Size used 1.2 mm
Drive 4-Rolled
Bore welding size 25 mm to 300 mm
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.
2) a) SAW Machines(I,II,III,IV & V):
Supply Voltage 415 V, 3 phase, 50 Hz.

Machine Type Constant Voltage Type Rectifier
Maximum Welding Current 1200 Amps DC @ 60 % Duty Cycle. 1000 Amps
DC @ 100% Duty Cycle
Wire feed 0.1 to 4.5 m/min.
Wire Size 2 to 5 mm
b) Twin Head SAW Machine:
Supply Voltage 415 V +/-10 %, 3 phase, 50 Hz.

Machine Type Constant Voltage Type Rectifier
Wire feed 0.1 to 4.5 m/min.
Wire Size 2.5 to 5 mm
capacity 5T
3. Air plasma cutting machine:
Supply Voltage 400 V +/-10 %, 3 phase, 50 Hz

Power rating 10 KVA to 30 KVA
Cutting material Stainless steel
Plate cutting capacity 20 mm maximum
Air flow 175 lt/min at 5.0-5.5 kg/cm2
Other Machines available for processing jobs are as follows:
4. Shearing Machine (Flywheel Type):

Shearing capacity : 6 mm MS (max.), Shearing width - 2 meters.
5. 3-Roll Bending Machine:

Bending Capacity : 12mm max. (50% width)
Bending Width : 4meters.
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.
ii) Rolling Stock:

This section repairs and overhauls all types of cars like 140 T Hot Metal (HM) Car, 80 T HM Car,
Slag Cars of Blast Furnaces and SMS-I, Flat wagons and Acid Cars of CRM for transportation of hot
metal, steel & slag inside the plant. New frames are also fabricated and assembled as and when
required as per the need of plant. Major and massive repair of completely damaged Slag Cars, HM
Cars and Flat wagons have been undertaken many times.
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iii) Structural Shop:

Repair and fabrication of all types of fabricated items of the plant like Hot Metal Ladles, Crane
Girders, LD Converter, Zinc Pots, Hot Air Socket, Skid Pipes and Recuperators for reheating
furnaces of HSM& PM,INBA Dewatering drum, etc. are taken up in this shop. LD cones, BF shell
plates etc. are also fabricated for sister units of SAIL. Most of the monuments seen today inside the
Plant and Steel Township are all fabricated in this shop for beautification of Steel Township.
Following Machines are available for facilitating fabrication:
1) a) CNC Profile Cutting Machine (1&2):
Supply Voltage 450 V +/-10 %, 3 phase, 50 Hz +/- 5 %

Effective cutting length 8m
Effective cutting width 3.0 m
Effective cutting thickness 6mm to 200 mm
b) Profile Cutting Machine:

(Max. cutting thickness = 100mm)
2) Hydraulic Press:
(Capacity: 600 Tons)
3) a) Plate Bending Machine:

(Capacity: Max. MS plate width 2500mm, 50mm thick)
b) Heavy duty Hydraulic Plate Bending Machine:
(Capacity: MS plate width 3100mm & 80mm thick)
4. Radial Drilling Machine:

(Capacity: Max. drilling 50mm)
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REPAIR & CONSTRUCTION (MECHANICAL)
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:
Sl. No. Zone Responsibilities / Areas covered
1. BF BFs , COs, Battery#5,CCD & OB&BP
2. SMS-I SMS-I, SMS-II, CP-1,CP-2, TOP
3. SP-I SP-I, SP-II, SP-III
4. Rolling Mills PM, HSM, Pipes Plant
5. CRM CRM Units like PL-I, PL-II, ETL etc.
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
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Sl. No. Zone Responsibilities / Areas covered
1. Repair and maintenance of 60 nos portable

Dewatering Pumps.
9. Pump Section 2. Need based deployment of dewatering pumps
during monsoon, capital repairs, major
repairs
1. Mechanical maintenance of 54 nos of

commercial road/rail weigh bridges, weighing
platforms and weighing machines in RSP.
2. Liasioning with legal metrology Department,
Weigh Bridge and
Government of Odisha for Calibration and
10. Pressure Vessels
stamping of all the weigh bridges in a
Section
frequency of one year (statutory obligation)
3. Testing and certification of 249 nos of
unfired pressure Vessel (statutory
obligation)
1. Repair and maintenance of 25 nos of portable
Electric Winch of 1.5T to 10T capacity.
2. Need based deployment of Electric Winches
11. Winch Section
during, capital repairs, major repairs ,project
activities
1. Repair and maintenance of Hydraulic Jacks

(85nos) of maximum capacity upto 500T.
2. Need based deployment of hydraulic jacks
12. Hydraulics Section
and pumps during breakdowns, capital
repairs and major repairs
3. Repair of Eldros.
RC(M) maintains flexibility among all the zones to increase productivity of workforce.
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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 main functions of the department are:

 Regular inspection of Cranes and making inspection reports based on which all repair activities
are planned and carried out.
 Prompt attending of breakdowns on Cranes so that there is no production loss.
 Coordinating Major and Capital repairs of Cranes done through outside agencies.
 Procurement of spare parts required for Cranes.
 Revamping of Cranes. This includes lowering of complete crane, repair, modifications and re-
erection.
 Relocation of surplus Cranes after required modification in the drives.
 Thorough inspection of Cranes by competent persons as required vide Factory Acts and ensuring
compliance to all statutory requirements of EOT Cranes.
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.
The main activities of the zones are:

1) Regular inspection, Preventive maintenance & House-keeping of cranes based on shutdown
schedule.
2) Attending to breakdowns.
3) Arrange spares / assemblies through Crane Workshop or Shops and maintain records of the
assemblies, subassemblies & parts.
4) Load testing of Cranes as per schedule / after replacement of any major component or after
capital repair.
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.
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The main functions of Crane Capital Repair Group are:

1) Maintenance of Lifts(inside Plant Premises & outside the plant premises like IGH & Rourkela
house) through AMC, Minor & Major Repairs.
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.
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FIELD MACHINERY (MAINTENANCE)
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.
Maintenance Activities Zone-wise:

1. Modernization Zone looks after Equipments of SMS-II, SP-II, SP-III, OBBP, BF-5 & Refractory.
2. RMD Zone looks after equipments of T&RM (All Chain Dozers).
3. SMS-I Zone looks after equipments of CO, BF, SMS-I, LDBP, Shops and Refractory.
4. MRD Zone looks after Equipments of Pipe Plants and all Crawler Cranes of MRD and Dumping.
5. CRM Zone looks after all Forklifts of CRM, HSM and SSM.
6. Pool Zone looks after all Heavy Dumpers including Haulpak (35T) Dumpers, all Tyre mounted
Hydraulic Cranes & Compressors.
7. Truck Pool looks after all TATA Trucks and Mini Trucks.
8. Base Workshops looks after all Tractors, Excavators, Tyre Dozers, forklifts and Capital Repair.
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.
Some of the Activities of FM (M):

1. Removing of wastages from SMS-I , PCM and CCM-I
2. Removable & shifting of sludge from SMS-I, BF Filter House and sludge ponds of SMS-II to
OBBP bed for its gainful utilization.
3. Removable of wastages and arising from Blast Furnaces.
4. Removable and loading of slags from INBA.
5. Deployment of Mobile cranes for erection/ shutdown purposes.
6. Deployment of Haulpak Dumpers for Housekeeping.
7. Shifting of Structural , heavy jobs, transformers etc by Trailers
8. Shifting of pug from pug mill to all Blast Furnaces.
9. Maintenance of all Mobile heavy equipments of the Plant.
10. Procurement/ Reconditioning of heavy equipments.
11. Tyre puncture repairs of heavy tyre mounted vehicles.
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12. Capital repair of mobile earth moving equipments.
13. Dispensing of diesel to all crawler equipments at site.
14. Housekeeping of different production areas.
15. One time cleaning jobs as per requirement.
16. Monument installation
17. Township requirement of mobile equipments and maintenance of heavy mobile equipments.
18. Organizing Training for operators and technicians of heavy Mobile equipments.
19. Shifting of tundish in SMS-I & SSD scrap Yard.
20. Maintenance of de-bricking machines and dumping cranes.
21. AMR schemes related to Heavy mobile equipments.
Mobile equipments in FM(M) Fleet:

FLEET
SN TYPE OF VEHICLE MAKE
SIZE
1 Haulpak Dumpers BEML 10
2 Tippers Ashok Leyland 38
3 Tyre Pay-loaders JCB, TATA, ESCORT, HM 22
4 Chain Pay-loaders CAT, KOMATSU 5
5 Excavators JCB, L&T, TATA 17
6 Tyre Dozers CAT 1
7 Chain Dozers BEML, CAT 9
8 De-Bricking machine TML, Gradall, Weiger 6
9 Hydraulic Cranes 8T/12T Escort 27
10 Crawler crane TATA 4
11 Hydraulic crane 20T/55T TIL 4
12 Forklift 1.5T/2T Godrej/Voltas 27
13 Forklift 16T/20T Godrej 4
14 Side Loaders Baumann, Fantuzzi 3
15 Compressors ELGI 4
16 Road Rollers L&T Case 2
17 Vacuum Loaders TPS 3
18 Road sweeping TPS 1
19 Garbage compactor TPS 3
20 Lime Tankers TATA, Ashok Leyland 6
21 Trucks and mini Trucks TATA 41
22 Mini Trucks Swaraj Mazda 13
23 Trailor Ashok Leyland 1
24 Tractor Mahindra 10
25 Diesel Dispensener TATA 1
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.
FM(M) is an ISO and OHSAS certified department.
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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.
C) IGH Pool at IGH Campus :-

1. Provides Ambulance services to patients of Steel Township round the clock throughout
the year.
2. Provides ambulance service to peripheral villages and Family Welfare section.
D) Repair & Maintenance Centre at Central Pool :-

Repair centre undertakes the maintenance and repair of vehicles & is sub-divided into
following sub centers to carry out different repair activities.
1. Servicing Section
2. Electrical repair section
3. Tyre section
4. Body & chassis repair section
5. Painting section
6. Engine section
7. Battery section
8. Planning & procurement section
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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.
F) Record keeping cell (Fuel issue record):-

Fuel is issued to all the tyre-mounted vehicles of RSP, RMD, NSPCL, Quality Assurance
Estate (Metal). New Log books are issued and old Log books are kept in record room.
G) Store & Fuel Dispensing Unit

Store section of Transport Department is meant for storing spare parts & consumables being
used for different maintenance & operation activities and the fuel (Petrol & Diesel)
dispensing unit, a sub-unit.
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.
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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.
To overcome the constraints of manual retrieval of documents, On-line availability of drawings

through RSP LAN system was conceived. The Digitization and CAD centre of Design Department
boasts of state of the art technologies and new age machines like Printers and Scanners. There are
two LASER printers (XEROX 510 WIDE FORMAT), each used for printing upto A0 size printouts.
Similarly two OPTICAL scanners (XEROX 36” WIDE) are used for scanning drawings and
documents of upto A0 size.
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
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utility of work study standards etc. The section also coordinates with Inter Plant Steel Standards
(IPSS) Secretariat for distribution of IPSS copies in the plant units and other related
correspondences.
RSN (ROURKELA STEEL NORMS)

RSP follows a set of standards known as Rourkela Steel Norms. Initially when the plant was set up
in collaboration with Germany, a separate standard was formed which followed the DIN (German)
standards as all the major equipments were of German origin. These standards closely follow the
IS(Indian Standards). Around 1547 nos of Standards have been incorporated into 9 volumes,
classified by their types. RSP is the only Steel plant distinct in the respect that it has its own set of
standards. No other steel plant in India can boast of such a facility. They comprise of the following
volumes:
1) Volume 1 General Fundamentals and Drawing Practices

2) Volume 1A Gears and Gear Boxes
3) Volume 2 Engineering Materials
4) Volume 3 Tools
5) Volume 4 Machine Elements and Mechanisms
6) Volume 5 Fasteners and misc. machine elements
7) Volume 6 Pipes, Flanges, Hoses and Accessories
8) Volume 7 Cranes and Lifting Tackles
9) Volume 7A Material Handling
10) Volume 8 Lubrication, Hydraulics and Pneumatics
11) Volume 9 Electrical
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.
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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.
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CAPTIVE POWER PLANT-I

An integrated Steel Plant cannot depend on a single source of power for its requirement. Any power
failure will result into huge loss running into crores of Rupees. So as a rule, all the integrated Steel
Plants should have its own Power generation plant,called
captive power plantapart from purchasing power from local
utility services. The present average power requirement for
our plant is 240MW, which reaches to a peak level of 280 MW
for a short duration of 15 minutes. We are having a contract
with GRIDCO to draw power from the Orissa grid
system.With the expansion of RSP to produce 4.5 MT of hot
metal,new power & blowing facilities have been added. Now
our captive power source comprises of CPP-1,CPP-2 & CPP-
3.CPP-2 is under the control of NSPSCPL(NTPC SAIL
POWER SUPPLY CORPORATION PRIVATE
LIMITED)which is ajoint venture company of SAIL & NTPC
having 50 % each equity partnership. Time and again, CPPs have proved to be the most reliable
source of power in the steel plant.
Captive Power Plant is having following main functions to perform:

 To supply cold blast to all four Blast Furnaces.
 To supply process steam to the whole Plant.
 To take care of critical loads of the Steel Plant.
 To utilize the by-product gases arising out of the process of Steel making.
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.
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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.
Medium Pressure Boilers:

In order to supply process steam to the whole plant, two MP boilers were installed &commissioned in
1978 each having a capacity of producing 60 T/hr of supersaturated steam at 18 kg/cm2 & 350 deg. C.
The feed water that is being used in Main Power Plant requires to be de-mineralised water whereas
MP boilers do not require that level of purity. In November’ 2006 & 2007, BHEL make ESPs were
installed in MP Boilers # 1 & 2respectively.
 Make: M/s. ISGEC John Thompson.

 Type: Water Tube Boilers.
 Firing System: Spreader Stoker.
 Fuel: Coal of size minus 25 mm.
 Maximum Continuous Rating: 60 T/hr.
 Pressure of Steam: 18 Kg/Cm2.
 Outlet Temperature: 350 ± 500C.
 Required CV of Coal: 5000 to 5500 K Cal/Kg. (UHV)
 Coal is supplied from Old Coal Handling Plant.
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.
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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:
 Power & Blowing Station:

 It is having 3 Nos. of Turbo Blowers supplied by MANNTURBO(GERMANY)
 Specification of Turbo Blower and accessories :
 # 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
- Speed : 4782 U/Min

 Critical Speed : 2526 U/Min
 Critical Speed : 6783 U/Min
- Power Requirement : 14519 Kw

- Volume Flow Rate : 165000 Nm3
- inlet pressure : 0.9959 kg/cm2
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)
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2. Output: Rated output: 18,000 KW(at generator’s terminal)
3. Operating conditions:
 Speed (turbine/generator) : 4887/1500 rpm
 Inlet steam pressure : 58 kg/cm2.A
 Inlet steam temperature : 480+/-5 0C
 Exhaust steam pressure : 0.1 kg/cm2.A
 Max. 1st extraction pressure : 11.58 kg/cm2.A
 (Controlled extraction) : (At turbine nozzle)
 Max. Inlet flow : 113,400 kg/hr at 5% VWO
 1st extraction flow : 0&18400 to 62000 kg/hr
 Max. Exhaust steam flow : 67,000 kg/hr at 0.1 kg/cm2
CDCP Boilers &BPTG:

CDCP– Coke Dry Cooling Plant:
Application - Heat recovery by Quenching of Hot coke Process Description: The waste heat boiler
recovers heat from the exhaust gases of coke dry cooling plant.DM Water comes from the DM plant
goes to De-aerator. In the De-aerator the dissolved gases like O2, CO2 are removed. From the De-
aerator water goes to feed pumps and from the Feed pumps water fed to the boilers through feed
unit. The feed water first enters into the economizer-1 and then economizer-2 to receive sensible heat
from circulating gases and then enters to the drum the water from the drum, through down comers
goes to bottom Ring header as well as circulation water pumps. Water from Ring Header goes to
water wall and water from circulation water pumps goes to Evaporators coil bundles. Water
Evaporation takes place in water wall and Evaporators. In the evaporators and water wall, the water
at saturation temperature receives latent heat from circulating gases passing over the tubes. The
water in water wall rises to top due to density difference and reaches to top Ring header and then to
Drum (Natural circulation). The water from circulation water pumps after passing through
Evaporators reaches to Drum (Forced circulation). The separation of saturated steam takes place in
the steam drum. The saturated steam further heated to final temperature (440°C) by passing
through primary and final super heater. The Desuper heater controls the final super heater steam
temperature. The super-heated steam comes from the super heater goes to PRDS and Turbine
Station through Common headers.
Coke Dry Cooling Plant Design Technological Parameters

1 Number of blocks 4 4
2 Capacity of one chamber in terms of cooled coke 50 TPH
3 Temperature of coke charged into the oven 1000 ± 50°С
4 Temperature of cooled coke ≤ 200°С
5 Temperature of circulating gases before the boiler 750 - 800°С
6 Temperature of circulating gases in blowing device 160-180°С
7 Time of coke holding in the chamber ≤ 2 hrs
8 Specific blowing rate 1450-1500 m3/T of coke
9 Steam capacity of a boiler Upto 25 TPH
10 Superheated steam temperature 500 0C
11 Superheated steam pressure 66 Kg/cm2
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BPTG Design Parameters for 6.5 MW Generation
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
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.
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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.
Power Distribution System

Presently RSP Power system is 220kV as we receive power from Tarkera Grid s/s to MSDS-IV s/s by
means of 2 Nos. of 220kV Transmission lines. This is stepped down to 132kV by three Nos. of 160
MVA Auto Transformers feeding power to MSDS-III s/s. In turn MSDS-III s/s is connected to MSDS-
II & CPP-II by means of 2 nos. Transmission lines each. Also, CPP-II & MSDS-II are connected to
MSDS-V s/s by means of 2 nos. Transmission lines each. Thus, a double ring of 132kV is formed by
CPP-II >>>> MSDS-III >>>> MSDS-II >>>> MSDS-V s/s. These all are outdoor Double Bus
switchyards. In recent RSP expansion to 4.5 MT, PD Department added MSDS-IV, MSDS-V, MSDS-
VI switchyard and many other 33kV & 6.6kV substations.
At CPP-2, power is generated at 11 kV and stepped up to 132 kV. Power from CPP-2 is received at
MSDS-III & MSDS-V through 2 nos. 132 kV feeders each. Grid power from Tarkera Grid sub-station
is received at 220 kV at MSDS-IV through 2 nos. 220 kV feeders. There is another 132kV switchyard
MSDS-VI, which is connected to MSDS-III & MSDS-II by means of one line each at 132kV. At all
these switchyards (MSDS-II, MSDS-III, MSDS-V, MSDS-VI) power is stepped down from 132 kV to
33 kV.
At CPP-1, power is generated at 6.6 kV and stepped up to 33 kV. CPP-1, CPP-3 & MSDS-III are
interconnected to form a 33 kV network. All the 33 kV sub-stations are fed from MSDS-II, MSDS-III,
MSDS-V & MSDS-VI or CPP-1. AT different 33 kV sub-stations, power is again stepped down to 6.6
kV and fed to no. of 6.6 kV sub-stations distributed throughout the plant. HT motors are directly
connected at 6.6 kV boards. For other loads, power is again stepped down to 430 V level for direct
consumption in different plant units. Large loads like Ladle Furnaces, Sinter Pant Exhausters and
main rolling mill motors are directly fed at 33 kV through dedicated unit transformers.
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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.
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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.
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SCADA / SLCC
The SCADA (supervisory control & data acquisition) of RSP power system consists of RTU (Remote
Telemetry Units) located at different sub-stations. These RTUs collect digital data (status of CB,
isolators, earth switches etc.) and analogue data (voltage, current, power etc.) of all feeders of that
sub-station and Transmit to the Server installed in the Main control room. Communication between
the RTU and the Server is through dedicated Fiber optic network. Other functions of the system are
maximum Demand Control, Energy Calculation, Data logging, Trend Display and Report generation,
Islanding & Load-shedding etc.
Power Factor Improvement
Grid Import power factor (PF) attracts penalty if it is lower than 0.92. Thus, PF improvement is an
important activity for power system operation. For PF improvement, we have a 25 MVAr Capacitor
bank at MSDS-III switchyard, 2 Nos. 18.5 MVAr Capacitor Banks at MSDS-V, smaller capacitor
banks at LHF-I, LHF-IIA and 1 MVAr capacitor banks (about 20 nos.) connected to various 6.6kV
substations. As per recommendation of M/s PRDC, we have to install three SVC systems to
dynamically compensate reactive power through Thyristor controlled Reactors.
1 MW Solar PV Plant
PD Department operates & maintains 1 MW Photo Voltaic Solar Plant which is the first MW level
such plant in SAIL. Apart from this, we have 2 Nos. rooftop Solar plants of 5 kW each. This had come
in existence since Feb, 2016. This was constructed to address our Renewable Power Obligation
(RPO). As of now, RPO stands at 3% (Solar) & 4.5% (Non-Solar) of our captive generation.
Maintenance Practices
Preventive Maintenance as well as Predictive Maintenance practice is followed in Power distribution
department. For routine preventive maintenance, all major equipments are enlisted in the SAP
Maintenance Module. Maintenance of equipment is carried out every day based on the schedule,
generated by the system. In addition, comprehensive inspection is carried out and defect report is
generated. The defect report is included in the system for job scheduling.
Advanced testing equipment and methods are used to carry out insulation diagnostic tests on all
major equipments. These tests are used to assess insulation health of equipment and to predict likely
failures. Based on the test results, remedial actions are taken to ensure no surprise failure of
equipment. Condition based maintenance tools like Thermo- vision camera are also used to detect
defects and likely failures.
Energy Billing and payment for import power; Unit wise energy accountings, co-ordination with
utility grid, dealing with Authorities for fulfillment of statutory obligations etc., are other
responsibilities of PD Department PD is an ISO certified department. All the documentations are
meticulously maintained as per laid down practices. SOP and SMP are strictly followed in day-to-day
work. Compliances are regularly reviewed internally and corrective actions taken. Major power
related infrastructures added in this expansion (RSP 4.5 MTPA) are as follows:
 Installation of one 220 kV GIS (MSDS-IV) along with three no. of 160 MVA, 220/132 kV Auto-
Transformers
 Addition of Three 62.5 MVA transformer at MSDS-III and one 63 MVA transformer at MSDS-II
 New 132/33 kV MSDS-V & MSDS-VI s/s
 A 33 kV Double Bus GIS indoor switchboard for RM-1 ( HRM loads)
 New 33 kV (4 nos. ) and many 6.6 kV sub-stations for power supply to all additional loads
 Interplant cabling at 33 kV & 6.6 kV and new cable tunnels
 Provision of Emergency power to modernization area loads
 Plant SCADA & Islanding system up-gradation
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ELECTRONICS & ELECTRICAL SERVICES

This department mainly consists of two sections i.e. Electronics Section & Electrical Services (Electro
Technical Services) section.
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.
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 Testing of High Tension breakers at sites.
 Insulation resistance, Polarization Index measurement of HT motors, transformer cables ,HT
Bus bar etc.
 Motor failure Analysis and necessary suggestions.
 Hi-pot testing of HT cables as per requirement of Power distribution and other department.
 CT – Ratio/Scheme testing as per Power distributions requirement.
 Checking of Earth Pit Resistance of all Electrical installations in the plant.
 Making of PCB as per requirement of all production departments of Rourkela steel plant.
 Testing of Electrical drives, motors, panels, bus bars and Electrical protection system of
NSPCL and other units of SAIL as per requirement.
 Calibration of Megger of consumer departments as per ISO requirement.
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COMMUNICATION ENGINEERING DEPARTMENT

Communication Engineering Department (CED) maintains the following communication equipment
in the Plant and Township.
Server Based IP Exchanges for Plant and Township:

The Steel Plant has Server based Telephone Exchange and telephone cable network to take care of
voice communication inside Plant and Township. The present capacity of the Exchange is 10560 lines
distributed throughout Plant & Township. It is a single system with distributed architecture
ensuring 100% feature transparency for both Plant and Township Subscribers. There are 4 main
Communication Servers , 18 remote Gateways distributed throughout Plant & Township in which
15 nos of Gateways are connected over optical fiber network & 3 nos of Remote Gateways (TPH,
SSSY &SGP) are connected over wireless media. Apart from normal features like automatic call
back, wake up call, accessing local/STD landline & mobile dialing, the system supports enhanced
features like Calling Line Identification (CLI) , DID( Direct Inward Dialing) Facility, Fixed
mobile convergence facility , IP Telephony , Centralised Network Monitoring System to have fast
fault diagnosis of the total system from a single location , Voice Guided Complaints Handling
System and integration with state of art audio conference server system . Distributed architecture
has saved copper cable and its laying over long distances to take care of expansion units. The system
will also take care of future expansion of RSP at NHSM etc. System supports both fibre optic &
wireless media connectivity Gateways connected in ring topology to ensure 100% redundancy during
cable cut. It has five digit dialing numbering scheme and intercom numbers can be accessed from
BSNL/other service providers by dialing 0661-24XXXXX where XXXXX is RSP Intercom number.
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.
Despatcher Communication System:

These are 24/56/200 line small Digital Exchanges catering to the internal communication needs of
the shop floors like OBBP, BF, SMS-II, EMD CPP-I & SP-I . Extensions of these exchanges can
access to the main Plant exchange also.
Central Internet facility:

Central Internet facility has been made available to RSP’s LAN users ensuring the transparency and
fairness in internet transaction to enhance the efficiency of various departments. The scheme
envisages the integration of 20 Mbps bandwidth connectivity through FO (Fibre Optic) cable from
BSNL and 16 Mbps bandwidth connectivity through wireless from Aircel using internet gateway
security system (UTM). The security system installed in hot standby mode comprises of Firewall,
intrusion, protection and detection system, gateway antivirus, web filtering etc. With faster
performance and standby mode of operation the leased line internet system is highly secured &
reliable.
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Audio Conference System at Plant Control
This is a 200 lines Audio Conferencing System with latest state of art technology dedicated for
communication/audio conference of Plant Control with Senior Officers at Plant & Residences with
many features of conferencing . It comprises of two servers (Meeting exchange) one in active mode
and other in standby mode . Both the servers are integrated with the main communication server
CM-Server through SIP trunks. During emergency, we can send pre-recorded emergency
announcements through blast dial to all the senior executives of the plant. Conference can be
extended through special Plant Control Numbers /Intercom numbers/Mobile Numbers.
Press To Talk (PTT) Communication System:

These systems are used for loud and clear communication between one spot to another, when
engaged in the production process and has been installed at various shop-floors like HSM, Plate Mill,
NPM, CRM, CCM-I, SSM,BF-V, Sintering Plants, CP-II, CHP. The individual units are called
stations. There are approx. 500 such stations distributed inside Plant. The features included are
duplex or simplex communication with selective calling, group calling, paging, one key dialing etc.
VHF/Radio Communication System:
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.
Miscellaneous Systems under CED:

In addition to the above CED also looks after the installation / maintenance of Road Safety Blinkers
and Audio Alarm systems at Rail –Road Crossings inside the Plant, Airport VHF/NDB
Communication System, High speed Internet with broadband for 50 nos for senior executives at
Residences and online Telephone Directory system . CED also maintains Video Conference system at
RSP for video conferences with all SAIL units . 10 nos of GPS Clocks are also maintained by CED to
keep synchronized time in all the pivotal spots in the Plant like Main Buildings and Gates.
Mobile Services from BSNL:

RSP has entered into the integrated GSM technology based mobile communication in closed user
group(CUG) configuration for SAIL employees on all India basis. This has been implemented by M/s
Bharat Sanchar Nigam Limited (BSNL). The scheme envisages:
1. Toll free unlimited talk time within RSP SAIL CUG Cell.
2. Local/STD/National call/National Roaming for users of CUG phone.
3. International roaming, sending & receiving SMS, call conferencing and other value added
services like GPRS, 3G, ISD etc. on demand.
4. Toll free with unlimited talk time between RSP SAIL CUG and RSP intercom landline
telephones.
This has become the fastest and reliable communication amongst the SAIL employees of various
plant units.
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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.
Role of Instrumentation in CO-CCD

 Measurement and Control of different process signals through Client-Server based DCS in
Battery-1.
 Measurement and Control of different process parameters through SLCs (30 Nos.) and PC
based SCADA systems in Battery-2, Battery-3 and Battery-5.
 Measurement and Control of concentration of H2SO4 acid in acid plant of CCD.
 Measurement and Control of Suction Pressure in MT and Expansion Exhauster.
 Monitoring of machine and process parameters in MT, Exhauster and Booster through PC
based systems.
Role of Instrumentation in Blast Furnaces

 Maintenance of DCS (4 Nos.) for Monitoring and Control of Process parameters in BF-1 to BF-
4.
 Maintenance of Critical Process Parameters through Stand-alone micro-processor based
Controllers (40 Nos.)
 Maintenance of on-line gas analyzers for analyzing of CO, CO2 and H2 in BF Top gas.
Role of Instrumentation in SMS-I/SMS-II

 Measurement of Temperature at each stage of Steel making and determination of Cast-able
steel through measurement of oxygen ppm at LHF/ARF.
 Maintenance of HMIs (7 Nos.) for Start-up, Running and Shutdown of all systems in SMS-II
(for BOF, GCP, Mixer, LHF, ARF, Caster & Gas Recovery).
 Maintenance of PLCs (14 Nos.) for critical interlocks for Plant and equipment safety in SMS-
II.
 Maintenance of SLCs (90 Nos.) for Process communication with PLC for different critical
control through Modbus Network in SMS-II.
 Maintenance of Gas analyzers (10 Nos.) for selection and recovery of LD gas.
Role of Instrumentation in SP-II/TOP-II
 Maintenance of Process Control including Interlocking and Protection for SP-II.
 All operating parameters including on-line production reports are generated through DCS in
SP-II.
 All the weighing system operators for all the bunkers are also monitored and controlled
through DCS in SP-II.
 Maintenance of PLCs (19 Nos.) for starting, interlocking and monitoring functions of critical
equipments like Compressors, Expansion Turbines, Nitrogen and Argon compressors of TOP-
II.
 Control and Monitoring of Process Parameters through DCS in TOP-II.
 Quality parameters like Purity of different products are monitored by 19 nos. Analyzers in
TOP-II.
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Role of Instrumentation in CPP-I

 Maintenance of C&I systems related to 6 Nos. of HP Boilers, 3 Nos. of MP Boilers, 5 Nos. of
Turbo-Alternators and 5 Nos. of Turbo-Blowers.
 Maintenance of Process Control including Interlocking and Protection for Boilers and
Turbines through DCS (3 Nos.).
 Maintenance of Process Control including Interlocking and Protection for Boilers and
Turbines through PLCs (3 Nos.)
 Maintenance of Electronic Turbine Governing Systems (8 Nos.) for Turbo-Alternators and
Turbo-Blowers.
 Maintenance of Vibration Monitoring Systems (8 Nos.) for Turbo-Alternators and Turbo-
Blowers.
Role of Instrumentation in Rolling Mills

 Thickness Measurement Systems (15 Nos.) in HSM, PM, CRM and SSM.
 Roll Force Measurement Systems (18 Nos.) in HSM, CRM and SSM.
 Re-heating Furnace Temperature Control through DCS (3 Nos.) in HSM and PM.
 DCS based Computerized Batch Annealing System at HAL of CRM.
 Maintenance of X-ray & Ultrasonic Testing machines at ERWPP/SWPP.
 Maintenance of Stand-alone Controllers (150 Nos.) for different Process parameters at HSM,
PM, SPP, CRM and SSM.
 PLC based Temperature Monitoring Systems at RM Compressor Station.
Role of Instrumentation in IRS

 Calibration of Master Instruments for ISO-9001/ISO-14001.
 Central agency responsible for repair and calibration of Site Instruments for the whole plant.
 Centralized maintenance of CMMS systems for Instrumentation Department
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REPAIR SHOP (ELECTRICAL)

Repair Shop (Electrical), the Central Captive Electrical Repair Shop of RSP caters to the need of
repair and periodical overhauling of around 15000 electrical equipments which are there in the plant.
It handles around 3000 work orders annually.
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.
Work Shop Features:

Main sections of the Work Shop are:
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
All windings are done with Class F insulation.
To carry out all these activities it is equipped with

 Coil winding machines of various sizes.
 Stainless Steel / Resiglass binding facility
 HT coil moulding facility
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TRANSFORMER REPAIR SECTION:

In this area repair of transformers from as small as control transformers to repair / recondition of
33KV large power transformers are carried out.
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.
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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
Shop Maintenance (Electrical):

One section of Repair Shop (Electrical) takes care of electrical maintenance of all equipments i.e.
EOT cranes, Machine tools which includes sophisticated CNC machines, installed in Engineering
Shop Complex [Repair Shop (Mechanical), Fabrication Shop, Structural Shop, Mechanical shop],
Acetylene Plant, Crane Capital Repair & Crane Maintenance Workshops & RCL . Apart from routine
& preventive maintenance, repair and modification work are also done on a regular basis by this
group to upgrade the drive /control of all major machines in line with technological advances. A no. of
units have since been replaced with new drives / VVVF controllers / PLCs etc. Import substitution is
given thrust while conceiving the modification / replacement projects.
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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:
(a) Package AC Unit 253 Nos.

(b) Crane AC Unit 29 Nos.
(c) Central Air-conditioning Plant 29 Nos.
(d) Chilled Water Plant 23 Nos.
(e) Room AC 806 Nos.
(f) Water Coolers 263 Nos.
(g) Split AC 124 Nos.
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.
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HEAVY MAINTENANCE (ELECTRICAL)

This is a centralized department catering to the need of the whole plant in the areas of maintenance
of mechanical aspects of heavy electrical machines and electrical aspects of EOT cranes and ground
equipment. This department has two sections, i.e. Machine Section and Electrical Section.
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.
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PRODUCTION, PLANNING & CONTROL
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.
PP&C department has the following sections:

 Long Term Planning& Strategy
 Product Planning sections
 Rail despatches
 Sales Co-ordination (Road despatches)
 Exports
 Statistical Section
 Weigh Bridges
 Plant Control
Long Term Planning& Strategy:

The main function of the section is to prepare the Annual Business Plan (ABP) of the company for
each financial year. The section coordinates with the Corporate office, CMO, RMD and all the unitsof
the plant to chalk out the plan.
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.
Product Planning Sections:

Each product is having a product planning section. The different sections are SMS planning, HSM
planning, Plate mill planning and CRM & PET planning. The major function of the Product Planning
section is to ensure proper & timely execution of various customer orders.The process involves from
receipt of order (Acceptance of movement Plan) to its execution, the entire planning, coordination,
follow up etc. as indicated below:
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- 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.
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TRAFFIC & RAW MATERIALS

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
 Dispatching finished products to outside parties. At 4.5 MT stage of production a total of
about 17 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:
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.
B) Carriage & Wagon (C&W) Section:

This section has a fleet of 438 rolling stocks of different types such as HB, BOBS, PLATEFORM
CAR, BOX, BOI, STC, Gondola & Link car. It has one Rail cranes (829). RAIL CRANE help will be
provided to other departments against their requisition as and when required. Detail of rolling stocks
is as follows:
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.
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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
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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.
1. Planning & procurement of all major raw materials.

2. Accounting & record keeping of all receipt and dispatches of raw materials in SAP including GRN.
3. Co-ordination between various agencies such as CCSO,BTSO,RMD,O/Dir. ,RMC, Indian Rlys,
NSPCL for planning, procurement & logistics of various major raw materials.
4. Day to day data entry of Raw materials in website of Department of Mines, Government of Odisha
& IBM(Government of India website). These are statutory requirements.
5. Manual unloading of raw materials at track hopper-I,II,III, breeze coke bunker, LD fines bunker,
CPP-I bunkers, H/Line, slot bunker etc. are being done on day to day basis by Raw Materials
section of Traffic & RM.
E) Loco Repair Shop:

Loco Repair shop section of Traffic & Raw Material Department has two sub- sections for repair of a
fleet of 40 numbers of locomotives.
(i) Loco Light Repair Shop: Light repair jobs such as

servicing (R1 schedule) of all locomotives and
preventive maintenance (R2 schedule& R3
schedule) of GE &BHEL locomotives are done at
this shop
(ii) Loco Heavy Repair Shop for maintenance: Major

schedule of all WDS6 & WDS6 AD locomotives
such as R2 schedule,R3 schedule & R4 schedule
are done at this shop.
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Detail of Loco fleet is given as below:

SL.NO. Fleet Type Detail Qty. in Remarks
Nos.
01. General Weight-90T,Twin Power Loco Call
Electric Locos Pack Of 370 HP Each Or No.601,602,603,607,609611&612
07
Double Unit Of 370 HP Capacity-600HP
Each,600 Series
02. BHEL Locos weight-90t,single power Loco Call No.701, 702, 703 &704
04
pack of 700hp or 700 series capacity-700hp
03. WDS6 Locos Weight-126t,Single Power DC-DC, Traction generator
pack of 1350 bhp,1400 series supplies dc voltages to dc series
motors , BHP-1350,Power losses
20 in driving auxiliary
assembly/sub-assemblies-150 HP.
Actual HP (1350-150)=1200(max.)
04. WDS6AD Weight-126t,Single Power AC-DC, Traction Alternator

Locos pack of 1350 bhp,1400 series produces ac current which is
converted into dc by power
09 rectifier installed above traction
alternator and supplies to dc
series motors , Actual HP (1350-
150) =1200(max.)
TOTAL NO.OF LOCOMOTIVES 40
This shop is responsible for maintaining and up keeping of these locomotives. There were two rail
cranes out of which 01 number (call no.828) written-off & disposed off. Presently, It is responsible for
maintaining 01 number of Rail Crane (call no 829) for its use in different department of RSP.
Details of shop equipment:

1) LOCO HEAVY REPAIR SHOP:
a) EOT crane -01 no. Capacity-30T (main hoist and 5T auxiliary hoist)
b) Water load box: for testing HP of WDS6/WDS6AD Locomotives
c) Jib Crane -03 nos.
d) Pressure Time Pump test bench (for GE Locomotives) -01 no.
e) Fuel pump and Atomizer test bench of WDS6/WDS6AD Locomotives -01 no. each
2) LOCO LIGHT REPAIR SHOP :

a) Under slung crane -03 nos. Capacity-3T each
b) Under slung crane -01no. Capacity-5T
c) Drill machine -01 no.
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.
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MATERIALS RECOVERY DEPARTMENT
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.
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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.
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CIVIL ENGINEERING (SERVICES)
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:
Sl. No. Equipment Quantity

1. Pay Loader - 2.5m3 capacity One
2. Dumper - 5.5m3 capacity One
3. Road Roller - 8/10 Ton capacity One
4. Truck mounted sewer cleaning machine One
5. Total station computerized survey Two
equipment
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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 functions of Structural Inspection Department 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.
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CONTRACT CELL (WORKS)
The Contract Cell(Works ) was formed in the year 1998. It processes and awards all types of
contracts of the Works area.
Its broad functions are as follows:

 Scrutiny and clearance of indents for various types of contracts in Indent Screening
committee.
 Floating of tenders after preparation of tender documents.
 Uploading the tenders in the web-site / publishing the tender in press.
 Opening of tenders, techno-commercial scrutiny, opening of price bids.
 Negotiation with the firms to obtain reasonable rates.
 Award of contracts.
 Identify the areas for rate contracts & enter into long term rate contracts for repetitive jobs.
 Regular co-ordination with different departments like indenting department, Integrated
Contract Labour Cell (ICLC), Finance, Internal Audit, Law, Vigilance etc.
 Interaction with Contractors.
 Building up data bank.
 Preparing MIS.
 Taking appropriate action in case of failure by the contractor to execute the Job.
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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.
Brief description of major Sections:

Tarkera Pump House:
Tarkera Water Works is constructed on the left bank of the river Brahmani by Rourkela Steel Plant
and named after the village Tarkera. It comprises a pick-up weir, treatment units, raw water and
make-up water pumping facility. The pick-up weir has been constructed across the river in order to
raise the up–stream river level for pumping raw water. Brief data of pick-up weir is given below.
i) Total Length of Weir 1,268 feet

ii) Crest level of Weir 641.5 feet
iii) River bed level 630.0 feet
iv) No. of Sluice Gates 8 numbers (10’ X 40’)
v) No. of Falling Shutters 51 numbers (10’ X 3.5’)
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.
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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 System:

All the storage tank outlets are connected to a common pipe network to which suction of make-up
water pumps are connected. There are two make-up water pump houses, one constructed at 1 MT
stage of the plant and other constructed under modernization scheme. Seven pumps in old pump
house and three in new make-up water pump house have been installed. There are 2 types of make-
up water pumps of capacity 3500 cbm/hr, head 45 mtr (6 nos.) and 2100 cbm/hr, head 45 mtr (4 nos.).
All the make-up water pumps are centrifugal, dry pit, vertical installation type. With all above
facilities at Tarkera Pump House, the water requirement of Rourkela Steel Plant and a part
requirement of Township is met.
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.
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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:
i) Catchment Area 2,366 sq. miles (6,057 sq. Km)

ii) Full Reservoir Capacity 2,57,000 Acre-feet (317 Million m3 )
iii) Length of Reservoir 17 miles (27.2 Km)
iv) Max Reservoir Level 690 feet
v) No of Sluice Gates 2 numbers, 8 feet X 8 feet
vi) No of Radial Gates 11 numbers, 51 feet X 22 feet
Plant Drinking Water System:

A filter house consisting of 8 nos. of rapid gravity sand filter beds is provided within the plant
premises. Make-up water is tapped from the make-up water ring main and filtered through the rapid
gravity filter beds. Alum solution is added to the make-up water in the influent channel before
filtration. For the purpose of disinfection, bleaching powder in solution form is added to the water
after filtration. Hydrated lime is dosed in the underground storage tank for maintaining the pH level.
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The filtered water is collected in the storage tanks from where it is lifted to the high level tank by
means of pumps for further distribution in the plant. The high level tank is staged at RL: 874.3 feet
in order to facilitate smooth flow of drinking water by gravity.
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.
Rolling Mill Pump House:

This pump house comprises of main pump house, scale pit-I (SP-I) pump house and cooling water
return station. The pump house supplies service water for the direct & indirect cooling of equipments
of HSM & CRM and is a recirculation water system.
The service water recirculation system consists of following major equipments:
a. Supply pumps for supplying treated service water to HSM & CRM at a minimum pressure of
2.8 kg/cm2. No. of supply pumps: 11, capacity: 1500m3/hr,45 mtr head.
b. Collection Pit with bucket type EOT crane for mill scale removal near SP-I. Contaminated
return water (contaminated with mill scale and oil) from HSM is collected in Collection pits
where mill scale is removed by a bucket EOT crane and water is further sent to settling tanks
through scale pumps situated at Scale Pit-I pump house. There are 6 nos. of scale pumps of
capacity 1440 cbm/hr at 45 mtr head.
c. 4 Nos. of Settling tanks each of capacity 1550 m3/hr, size: 55 mtr long x 8 mtr width x 3.5 mtr
depth, where mill scale and oil is separated with the help of scrapers and oil skimmers
respectively. Overflow water from these tanks is passed to filter beds for further purification
to remove oil traces and finer size mill scale. The mill scale from settling tank entry point is
removed by one EOT crane for subsequent use at OBBP.
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.
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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
STORAGE TANK SCALE PIT-I PUMP

HOUSE
SETTLING TANKS
FILTER BEDS
SUPPLY PUMPS
Plate Mill Pump House:

This unit has following sections and the functions are as mentioned under:
a. Indirect Cooling Water system: This is a recirculation system for providing clean water for cooling
of equipments of Plate Mill. The system consists of supply pumps(2 nos., discharge 315 CMH,
head 55 MWC), cooling towers, storage sump.
b. Direct Cooling Water system: This is also a recirculation water system for spray cooling of Rolls,
De-scaling of slabs etc. The return water is contaminated with scale and oil. For making this
water reusable, it is passed through collection pit (scale removal), scale pumps (3 nos. discharge
960CMH, head 30MWC), settling tanks (max. flow 1150 CMH), scrapper & oil skimmer for
removal of scale and oil, return pumps (2 nos. discharge 1025 CMH, head 30 MWC), pressure
filters, cooling towers, sumps and supply pumps (2 nos., discharge 960 MWC, head 60 MWC). Mill
scale is removed with an over-head bucket type EOT crane and oil is removed from settling tan
wit oil skimmers.
c. Soft Water System: This system provides soft water to Reheating Furnaces of Plate Mill and Hot
Strip Mill. Soft water is pumped to reheating furnaces (HSM: 4 pumps: discharge 650 CMH,
head 55 MWC, Plate Mill: 3 pumps, discharge 550 CMH, head 55 MWC): and the return water is
passed through plate type heat exchangers for cooling. For cooling of hot return soft water in the
heat exchangers, industrial cooling water is circulated. This industrial cooling water system is a
recirculation system with pumps (HSM: 3 pumps: discharge 930 CMH, head 30 MWC, Plate Mill:
2 pumps, discharge 655 CMH, head 30 MWC) and cooling towers. A Soft water treatment plant
has been provided to supply soft water to make up the losses in the soft water circuit. The soft
water treatment plant consists of aerator, iron removal filters, pressure filters, base exchangers.
An overhead emergency tank is provided for supply of soft water to reheating furnaces in case of
power failure up to 20 minutes. In case of extended power failure beyond this provision is also
there to supply make-up water to the furnaces. Two pumps of discharge capacity 555 CMH and
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head 45 MWC take water from the common sump of recirculation water are installed to supply
water for cooling of compressor of HSM.
SMS Pump House

The purpose of this system is to supply cooling water to LD converters and to Oxygen Plant (TOP-I).
Water is supplied to consumer points in SMS-I & TOP-I through a set of pumps. Return water from
the consumers are collected in the hot water sump. From this sump hot water is pumped to cooling
towers for cooling. From cooling towers the cold water is collected in cold water sump for further
supply. Make-up water is added through a set of pressure filters to the cold sump.
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.
Major Water Conservation Measures taken:

1. Recovery of water from ash ponds for use as water for ash handling in Power Plants
(NSPCL).
2. Recovery of waste contaminated water from Gas Cleaning Plant of SMS-II (highly alkaline in
nature) for use in BOD Plant of Coal Chemical Department.
3. Utilization of BOD Plant over-flow water in Coke-Ovens for quenching purpose.
4. Regular inspection of water pipe lines, water systems for leakages/wastages and rectification
on immediate basis.
5. Regular maintenance of cooling towers to maintain cooling water temperature as per design
norms to avoid excess usage of water. The drift losses and loss due to over-flow from Cooling
Tower sumps have also been controlled.
6. Conversion of once-through system to re-circulation system in pipe plants.
7. Use of water treatment chemicals in major recirculation systems to maintain water quality
and reduce water wastage due to blow down.
8. Introduction of localized booster stations at Coke oven and power plant to reduce running of
higher capacity pumps at Tarkera Pump House.
Future Strategy for water conservation

Ensuring recirculation water system in all the new units coming under 4.2 Mt expansion plan.
Introduction of rain water harvesting and zero discharge concepts in the new pump houses exploring
the possible re-use of drain water from different outfalls.
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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.
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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.
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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.
Rourkela Steel Plant thus is committed to:

a. Ensure the safety of its employees and the people associated with it including those
living in its neighbourhood.
b. Pursue the safety efforts in a sustained and consistent way by establishing safety
goals, demanding accountability for safety performance and providing the resources to
make safety programme work.
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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,
 Air  Water  Land &  Social & Cultural Environment

In a way to protect Environment, Rourkela Steel Plant is working on various fronts to minimize
consumption of various natural resources –
 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
RSP adopted a three-pronged strategy to abate pollution. They are;

 By developing a very strong monitoring/analysis and inspection setup.
 Augmentation of existing pollution control systems through retrofitting jobs.
 Installation of new state of art pollution control equipment.
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  Water Pollution  Land Pollution
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,
 Electro Static Precipitators (ESP)

 Bag Houses
 Wet Scrubbers
 Multi Cyclones
 Dry Fog Dust Suppression Systems
 Wet Fog Dust Suppression Systems &
 Water Spray systems
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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,
 Oil separators, Dissolved air floatation units

 Sedimentation tanks & clarifiers
 Rapid Sand filters, Pressure Filters
 Activated carbon filter
 Neutralisation units
 Belt press system, Belt filter systems
 Sludge ponds & Oxidation Pond (Lagoon)
 Biological Treatment (BOD Plant)
-- Equalization Units
-- Dissolved Air Floatation Unit
-- Activated sludge treatment
-- Trickling Filter
-- Sludge Digestion
-- Sludge Drying beds
Land Pollution Control / Waste Management -- Different types of waste

products are generated from different processes while making steel at different stages. RSP
has taken up a massive drive in Inventorisation and characterization of these wastes.
Based on a detailed study on the composition, proper alternate uses of these wastes are
identified. These wastes are utilized within the plant for steel making and given to
outsiders for making other by products. The major Wastes utilized are;
 Blast Furnace Slag – for cement manufacturing

 BOF slag – for sinter making & pavement making
 Lime Fines – for sinter making & water treatment
 BFc Flue Dust & SMS Sludge – for Pellet making
 Mill Scale – for Base Mix preparation for Sinter
 Fly ash – Fly ash brick making & land reclamation &
Filling of low lying areas
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.
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Environmental Laboratory is certified with ISO-14001. The Environment personnel carry

out monitoring of
Air Pollution levels -- Stack Emissions

-- Work-zone emissions
-- Fugitive Emissions
-- Ambient air quality at 6 locations
-- Noise
Water Pollution levels at– Sources of generation (at different departments)

-- Outfalls (10 nos)
-- Lagoon inlet & outlet
-- River Koel, Brahmani up stream & downstream
For monitoring the pollutant levels, Environmental Laboratory is equipped with various
latest monitoring and analytical instruments viz,
 Stack Monitoring Kits  Spectrophotometers (HACH & MERCK)

 High volume samplers  BOD incubator & apparatus
 Respirable dust samplers (PM10 & PM2.5)  COD reactor
 Noise meters  pH, Conductivity & DO meters
 Flue gas analysers  Turbidity meter
 Atomic Absorption Spectrophotometer Distillation Sets
 Orion – Ion Analyser
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Environmental Engineering Department has installed various online monitoring systems

for continuously monitoring the Stack Emissions, Ambient Air Quality and Effluent Quality.
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
PM, SO2 & NOX - Oxides of Captive Power Plant#1

Nitrogen
pH Tarkera Pump House
Total Suspended Solids Lagoon outlet
Continuous Effluent
BOD3days BOD Plant
4. Quality Monitoring
Chemical Oxygen Demand (COD) CRM Neutralisation Unit
Systems
SSM Acid Treatment Plant
Rolling Mill Pump House
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.
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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.
Motto: - We Serve To Save
Aim: - Zero Fire Incidents
Objective:
1. Prevention of Fire
2. Prevent Loss of Life & Property
3. Extinction of Fire.
Different Section / Wings:
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.
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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:
SN. Description Nos.

1. Foam Tender 06
2. Foam-cum-DCP (Combined Tender) 01
3. Air Field Crash Fire Tender 01
4. Water Tender 01
5. High Capacity Water Bowser (14 KL Capacity) 01
6. High Landing Hydraulic platform (Simon Snorkel) 01
7. Emergency Tender 01
8. Towing Tender 02
9. Jeeps 03
10. Portable Pumps (Petrol- 6, Diesel – 2) 08
11. Submersible Pumps (Electrical) 05
12. Trolley mounted Long Range Foam-Water Monitor 01
13. Trailer Pump 01
14. Portable fire Extinguishers 7500
15. BA sets (Oxygen type-19 & Air Type-22) 41
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.
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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
Call Us to Help You

Fire Control Room: Inter-Com -47700, 47000 &47796,
BSNL-0661-2510142.
HRD CENTRE Page:229

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.
Srujani Creativity Award Scheme:

A Creativity Award Scheme under the name “Srujani” is in vogue in RSP. Under the
scheme, employees are encouraged to implement their creative ideas for any improvement
pertaining to their own area of work. The scheme is decentralized for effective and quick
implementation of ideas and speedier recognition of employees. The suggestions are
evaluated and awarded by multi-tier review committees. Departmental Rolling Trophies,
Best Suggestor award and Second Best Suggestor awards are awarded each year on the
basis of employees’ contribution to SRUJANI Scheme during the preceding financial year.
These awards are given by our respected CEO on 15th of August every year.
.
Delegation of Powers:
Formulation and Compilation of delegation of powers for the executives of RSP pertaining to
various items like Statutory, Capital, Establishment matters, Revenue powers, etc. Fixing of
financial Powers for Executives of various areas, approval and issuance of the same.
Modification and Amendments of Delegation of powers as and when required.
Scrutinizing & Clearing of Indents
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
Form Design and Control:

Designing of new forms as per the requirement of the departments, modification of
existingforms, allotment of O & M number, coordination with official language cell for
making trilingual forms.
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Administrative Items:
The requirement of various items under administrative category are studied and
recommended for procurement for different departments.
Annual Maintenance Contract

Operation of Annual Maintenance Contract as a centralized agency for all the photocopier
machines at RSP to facilitate smooth performance
IED is also functioning as member of different Committees

 Outsourcing Committee
 Empanelment of Contractors for Electrical, Mechanical and Structural Jobs
 Contract Review Committee
 Central Survey Committee for AMR Cases.
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RESEARCH & CONTROL LABORATORY
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.
The broad outline of its activities includes:

a) Chemical analysis of all Raw Material inputs like Coal, Iron ore, Manganese ore, Lime
stone, all Ferroalloys, Petroleum coke etc. and samples collected from vendors and sent
by inspection wing of Materials Management Department spread across four Metros),
b) Chemical analysis of in process materials like hot-metal, slag, sinter, steel, emulsion,
water, acid, salt etc. and output materials and products.
c) Process Control and process parameter auditing
d) Inspection of in process and finished products
e) Mechanical & Non Destructive testing
f) Refractory testing
g) Statistical Quality Control (SQC) & process capability studies
h) Certification of finished products & issue of Test certificate to customers.
i) Test support & guidance for maintenance departments for material selection
j) Failure Investigation
k) Product development and special steel making
l) Maintaining and operating product licenses
m) Coordinating with customers & their inspection agencies for plates & pipes
n) Technical information and documentation.
o) Nodal agency for R&D projects undertaken by RDCIS
p) Nodal agency for Quality Circles
q) Supporting Agency for generation of Patents from RSP where RDCIS is the Nodal
Agency.
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:
Iron & Steel Area:

 Sequential and Simultaneous X-ray Fluorescence Spectrometers
 Computer Controlled Optical Emission Spectrometers
 Container Lab in SMS-II
 Leco Analyzers for analysis of Carbon and Sulphur measurement
 Mechanized Sample Preparation for Ferro Alloys
 Machine for measuring Cold Crushing Strength (CCS) of Refractories
 Pulverizers and Pelletizers
 Geisler Plastometer
 Bomb Calorimeter
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 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
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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.
No other strategy can be predictive of success in today’s competitive environment. We

have been able to realize the “customer first” approach and percolate it down to the
workmen level with associated changes in our attitude towards quality of our processes
in general and quality of product in particular. Our first endeavor was to implement ISO
9002 Quality Assurance System (QAS) in both the Pipe Plants which were certified to
ISO 9002 QAS in December 1993. Subsequently Plate Mill was certified to ISO 9002
QAS in December 1994. ERW & SWPP have been certified to API Q1 (American
Petroleum Institute Q1) since inception.
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.
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ADDITION MODIFICATION REPLACEMENT

PROJECT MONITORING & SPECIAL CELL
(AMRPM&SC)
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).
The activities involved in processing AMR schemes in a nutshell are as follows:
 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.
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 For corporate schemes, after scrutiny at AMR-M & SC department it is processed

through IPSC and discussed in plant level PAG(Project Appraisal Group). The case
cleared in PAG is then processed for in-principle approval of CEO after which it is
sent to SAIL Board for Stage-I approval.
 After sanction, each project is monitored by AMR-M & SC department starting from
rising of purchase requisitions, issue of tender enquiry, placement of purchase
order/job contract, material delivery, execution & commissioning.
 A data base is maintained by the AMR-M & SC department for all the proposals
starting from receipt of the proposal till closure of the project.
 All sanctioned schemes are monitored and status is updated in MIS report which is
published in once in every two months.
 Project Completion Report (PCR) for all completed schemes are obtained from the
user department.
2) Write-off of assets under AMR category:

AMR-M & SC department is also the nodal agency for processing for write-off of
AMR category of assets. Following are the activities for processing for write-off.
 Departments send write-off proposals along with relevant information/documents to

AMR-M & SC department with a request to form the Survey Committee.
 AMR-M & SC department constitutes the Survey Committee & communicates to the
concerned department for carrying out the survey of the equipment.
 Departments send Survey Committee Reports to AMR-M & SC department for
placing the proposal before CSC (Central Survey Committee).
 Head of AMR-M & SC department is the convener of CSC. AMR-M & SC
department conducts CSC once a month depending on the number of survey reports.
 Recommendations of CSC are sent to the concerned departments.
3) Award of consultancy to M/S CET:
 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.
4) Dumping permission for zero-value materials:
 Applications are received from various departments for permission of dumping of

zero-value arising at the designated places.
 After scrutiny of the documents, approval is obtained from the competent authority
for permission. GM I/C(Services) is the approving authority for dumping permission.
5) Other Dumping activities: AMR-M & SC also co-ordinates activities likeensuring

availability of dumping space for zero-value items. Co-ordinates with FM-M for regular
dozing for creating space in the dumping area. Explores new area for dumping for
future.
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6) Boundary Wall Inspection:
 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.
7) (Intelligence Buro) Team inspection:
 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.
8) Security meeting of GM I/C(Services):
 Head of AMR-M & SC department attends the security meeting taken by GM

I/C(Services) which is held once in a month.
 Necessary follow up is done with the concerned agencies for compliance of security
related points.
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.
HRD CENTRE Page:237

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:
Item 2006-07 After Expansion

Hot Metal 2.12 MTPA 4.5 MTPA
Crude Steel 1.99 MTPA 4.2 MTPA
Saleable Steel 1.94 MTPA 3.99 MTPA
Techno-economic parameters:
Item 2006-07 After Expansion

Coke/ Fuel Rate (kg/thm) 577 392
BF Productivity (t/m3/d) 1.37 2.14
Specific energy (Gcal/tcs) 7.98 5.80
Manpower Productivity
148 262
(tcs/man/year)
The implementation of following packages has been deferred:
 New CRNO Complex

 New Facilities in CRM Complex
The above facilities are proposed to be taken-up after the New Plate Mill has been
stabilized.
Page:238 HRD CENTRE

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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:
AUGMENTATION OF OBBP AND BLENDING FACILITIES
Executing Agency: M/s Heavy Engineering Corporation Ltd., Ranchi, India &
M/s Shapoorji Pallonji & Company Ltd., Mumbai, India
Commissioned : Feb, 2014 / March, 2015 (commissioned in phases)
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.
HRD CENTRE Page:239

Raw Materials transferred by OBBP:
4 Nos.: 3 x 1139 cu m useful volume, 1 x 1658 cu m

Blast Furnace useful volume
Raw material: Iron Ore Lump
SP-I: 2 x 125 sq m grating area
Raw material: Base Mix
Sintering Plant SP-II: 1 x 192 sq m grating area
Raw material: Base Mix, trimming addition Coke &
Flux
1 no. Kiln of 150 tpd capacity
Lime Calcining Plant-I
Raw material: Lime stone & Dolomite
4 nos. Kilns of 250 tpd capacity
Lime Calcining Plant-II
Raw material: Limestone& Dolomite
This turnkey package consists of the following:
 Receiving, unloading, stacking, reclaiming and finally transporting of raw materials

required for Blast Furnace-V, Lime Calcining Plant (new as well as existing), Flux
Crushing Unit and new Proportioning Bins for base mix facilities.
 Base Mix Preparation Plant for SP-II & SP-III including flux and fuel (coke) crushing
units for receipt of plant arisings, base mix preparation, stacking & reclaiming to Sinter
Plant-II and Sinter Plant-III.
 Transportation of flue dust, mill scale, etc. from ground hopper / junction house to new
proportion unit.
 Transportation of crushed fuel and flux for trimming addition to Sinter Plant-II and
Sinter Plant-III.
 New conveyer line for transportation of limestone and dolomite to consuming units.
 Automatic Sampling System, 2 nos. with sample cutter, collection, sizing, crushing and
grinding facility.
Facilities / equipments:
 Unloading :
 Wagon Tippler: 1 no.

 Track hopper: 1 no.
 Stacking & Reclaiming :
 4 nos. of beds to stack the incoming raw materials.

 Equipments in 4 nos. beds
 Twin Boom Stacker : 1 no.
 Stacker cum Reclaimer : 1 no.
 Barrel Reclaimer : 2 nos.
 Bucket Wheel Reclaimer : 1 no.
 Flux & Fuel Crushing Unit:
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 Flux Crushing Unit:

There are 4 nos. parallel closed loop crushing and screening streams to provide (-3)
mm fines of SP grade limestone & dolomite.
 Fuel Crushing Unit:
To crush the coke to (-3) mm with the help of double roll crushers there are two
primary crushers and 4 nos. secondary crushers.
 Base Mix Preparation, Stacking and Dispatch:
 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.
Sl. No. MATERIAL SIZE DISTRIBUTION (mm)

1. IronOre fines 0 to –10 mm
2. Limestone / Dolomite (crushed) -5 mm (having 90% -3 mm)
3. Coke breeze (crushed) -5 mm (having 90% -3 mm)
4. Mill scale 0 to –10 mm
5. BF sinter return fines 0 to – 5 mm
6. LD slag 0 to – 10 mm with 20% higher size
 The base mix is stacked in 2 nos. base mix beds and reclaimed. The following
equipments are in base mix beds:
 Twin Boom Stacker : 1 no.

 Barrel Reclaimer : 2 nos.
 Transfer Car : 1 no.
 Auto Sampling System:
Two separate Auto Sampling Systems complete with sample cutter & provisions for
collection, sizing, crushing and grinding are provided.
INTRA PLANT TRANSPORTATION OF MATERIALS
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.
HRD CENTRE Page:241

 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.
COKE & COAL CHEMICALS
NEW 7 M TALL COKE OVEN BATTERY-VI
Executing Agency: M/s MECON Ltd., Ranchi, India

Commissioned : April, 2013
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.
To achieve air pollution norms the following are provided:

 Leak Proof Doors
 Water Sealed AP Covers
 HPLA (High Pressure Ammoniac Liquor Aspiration)
 Door & Frame Cleaner
 High Pressure Water Jet Door Cleaner
 Land Based Pushing Emission Control (PEC) System
 Effluent Disposal
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 Coke Dry Cooling Plant (CDCP)
The technical data for the battery are given below:

No. of Ovens 67
Total Height of Battery 7m
Useful Height 6.7 m
Useful Volume 41.6 m3
Production of run – of – oven Coke (Dry) 0.768 MT/yr
Total length (between buck stays) 16,000 mm
Total useful length 15,160 mm
Width at pusher side 385 mm
Width at coke side 435 mm
Average width 410 mm
Useful volume of oven 41.6 m3
Axial distance between ovens 1.400 mm
No. of flues in heating wall 32
Distance between the flues 480 mm
The Pollution Control Stipulations applicable to New Coke Oven Battery as per MOEF are
as following:
 Leakage from Doors – 5 %

 Leakage from Charging Lids – 1 %
 Leakage from AP Caps – 4 %
 Charging Emissions – 16 seconds / charge (with HPLA)
NEW OVEN MACHINES FOR 7 M TALL COKE OVEN BATTERY-VI
Executing Agency: M/s Bhilai Engineering Corporation Ltd., Bhilai, India

Commissioned : December, 2014
Oven machines for COB-6:
Machines Nos.
Coke Pusher Car (PC) 2
Coal Charging Car (CC) 2
Coke Transfer Car (TC) 2
HRD CENTRE Page:243

Coke Pusher Car:

The Coke Pusher Car comprises of four distinct and independent units viz. Leveler, Pusher,
Door Extractor cum Door & Door frame cleaner and Long Travel along with other auxiliary
facilities mounted on a structural frame with air conditioned operator’s cabin. The track rail
size is CR-100 with leveled gradient and nil curvature. The machine has PLC based
automation.
Coal Charging Car:

The Coal Charging Car is of screw feeder type having VVVF drive for precision control of
screw feeder’s speed. It has 3 bunkers with adequate capacity for charging an oven having
three charge holes and a min. chamber volume of 41.6 m3. The coal blend is collected from
new coal tower (No. 5). The car completes the charging operation within 120 seconds
(simultaneous charging). Coal Charging Car ensures emission free charging of ovens (as per
statutory stipulations) with HPALA system in operation for on-main charging. All
actuations of this equipment are hydraulic, except long travel and some of the motions of AP
and Gooseneck cleaner. The operator’s cabin is provided with air- conditioner.
Coke Transfer Car:

The Coke Transfer Car performs all the required functions on coke side such as to remove
the door, clean the door & door frame, fix the door, clean the oven sole, transfer the hot coke
into hot coke bucket, and control the pushing emission. The cycle time for car is less than or
equal to 11 minutes. The equipment moves on two rails (size 60 kg/m) mounted on the coke
side of the battery. One of the rails can also be mounted on the service platform on the coke
side of the battery. The operator’s cabin is equipped with air-conditioning facility.
The Coke Transfer Car is supplied along with a land based Pushing Emission Control (PEC)
System.
NEW COKE DRY COOLING PLANT FOR 7 M TALL COKE OVEN

BATTERY-VI
Executing Agency: M/s Bhilai Engineering Corporation Ltd., Bhilai, India, M/s SE
GIPROKOKS, Ukraine & M/s UKRINDUSTRY (CUI), Ukraine
Commissioned : June, 2014
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.
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Technological Parameters / Features of CDCP:
Description Unit Value
Temperature of coke charged in the chamber 0C 1050

Temperature of coke after cooling 0C < 200
Temperature of circulating gas before entering cooling chamber 0C 170-180
Temperature of circulating gas before waste heat boiler 0C 750-800
Thermal efficiency % 80-85
Pressure of steam generated Ata 66
Temperature of steam generated 0C 500
Generation of steam / boiler T/hr 25
Capacity of one cooling chamber T/hr 52-56
Time of coke cooling in chamber hr 2-2.5
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.
NEW COAL CHEMICALS DEPARTMENT FOR 7 M TALL COKE OVEN

BATTERY-VI
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.
New CCD consists of the following technological units:

 Gas Condensation Plant.
 H2S removal unit & recovery of sulphur.
 Sulphuric acid spray system for ammonia removal from gas & recovery and processing of
concentrated mother liquor solution in the existing salt handling & bagging unit of COB
# 1 to 5.
 Final gas cooling and naphthalene removal & recovery unit.
 Chilled water plant.
 Cooling water system.
 Benzol Recovery Plant.
 Storage facilities for Benzol &Sulphuric acid.
HRD CENTRE Page:245

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.
UPGRADATION OF EXISTING CCD

Executing Agency: M/s Shriram EPC Ltd., Chennai, India & others
Commissioned : From February, 2010 to July, 2015 (commissioned in phases)
The up gradation of existing CCD (both 1.0 MT & 1.8 MT units) involves:
i) Replacement of existing equipments with new equipments on existing foundations and

also at new locations on new foundations.
ii) Installation of new equipments and new units.
iii) Installation of new schemes to remove operating problems encountered in CCD.
The entire work has been executed through 11 different packages.
NEW COAL HANDLING PLANT
Executing Agency: M/s McNally Bharat Engineering Company Ltd., Kolkata, India
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:
 Installation of 2 nos. wagon tipplers.

 Transportation of coal unloaded by wagon tipplers to RCC silos for storing of both coking
coal and CDI coal.
 Reclamation of coking coal from RCC silos by belt weigh feeders and further
transportation to crushing station by belt conveyor.
 4 nos. crushers in crusher building.
 Transportation of crushed coking coal from crushing station to coal towers by belt
conveyor.
 Weigh feeders below coking coal silos are provided with automatic proportioning device
and digital system for accuracy. These feeders are VVVF controlled with AC drives.
 Reclamation of CDI coal from RCC silos by vibro feeders and further transportation to
junction house by belt conveyor.
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Panorama 2017
NEW SINTER PLANT -III
Executing Agency: M/s Larsen & Toubro Ltd., Kolkata, India & M/s Outotec
GmbH,Germany
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.
Technical Details of SP-III:
Sintering area 360 sq m Spec. Productivity 1.3 T/m2/hr

Size of finished sinter 5- 40 mm Annual working 330 days
regime
Under grate suction 1650 mm WC Bed Height 700 mm max.
Circular annular dip rail deep bed type sinter cooler 396 sq m
Tumbler index +6.3 mm 75% RDI 30% max.
min.
Reducibility index 65% min. Gas consumption 15000 kcal/T
Make up water 0.18 m3/ T Sp 41 kWh /T
Powerconsumption
Avg. temp of cooled 100 ºC Stack emission <50 mg/NM3
sinter
Rated capacityfor 1500 tph Belt width 1400 mm at
incoming raw 2.0 m/s
material
Rated capacityfor 550 tph Belt width 1200 mm at
outgoing product 1.5 m/s
sinter
HRD CENTRE Page:247

NEW BLAST FURNACE-V & AUXILIARIES
NEW BLAST FURNACE-V
Executing Agency: M/s TATA Projects Ltd., Secunderabad, India & M/s Danieli
CorusBV, Netherlands
Commissioned : October, 2014
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:
Hearth Diameter 13.2 m

Number of tuyeres 36
Furnace working volume 3470 m3 (approx)
Furnace useful volume 4060 m3 (approx.)
Daily hot metal production 7924 tpd (avg.) 8320 tpd (max.)
Annual hot metal production 2.8 MT / yr
Campaign life 20 years (with minor intermediate
repairs)
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.)
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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
Oxygen enrichment % 4-6 %

BF top gas characteristics
(net & dry)
Pressure (max. operating) kg/cm2(g) 2.5
Volume Nm3/THM 1500 – 1550
Temperature oC 100-200 oC
13.
CO % 25.2-25.7
CO2 % 21.7-21.9
N2 % 46.4-47.6
CO/CO2
Calorific value kcal/Nm3 875 (approx.)
Hot metal characteristics
Si % 0.6 (max.)
14. S % 0.050
P % 0.15
Desired hot metal temperature oC 1450-1500
Slag characteristics
15. Slag rate kg/THM 290-310
Slag temperature oC 1500-1550
HRD CENTRE Page:249

NEW TURBO BLOWER STATION

Executing Agency: M/s Bharat Heavy Electricals Ltd., New Delhi, India
Commissioned : January, 2015
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.
The parameters of each blower are as following:
Discharge flow : 2550 to 3500 Nm3 /min at 9 to 1 duty point

Discharge pressure : 4.0 to 5.2 kg/cm2 at 9 to 1 duty point
Normal flow requirement of new BF#5 is 5500 Nm3 /min
BOILER, STG, BPTG & BLOWING STATION
Executing Agency: M/s Thermax Ltd., Prune, India

Commissioned : March, 2014
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.
TORPEDO LADLES & REPAIR SHOP
Executing Agency: M/s Simplex Castings Ltd., Kolkata, India & M/s Hyundai Heavy
Industries Co. Ltd., South Korea
Commissioned : March, 2015
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.
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NEW PIG CASTING MACHINE
Executing Agency: M/s Metal Engineering & Treatment Company Pvt. Ltd.,
Kolkata, India
Commissioned : May, 2014
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
3RD BOF CONVERTER (1X150 T)
Executing Agency: M/s SMS SIEMAG AG, Germany & M/s SMS India Pvt. Ltd.,
Gurgaon, India
Commissioned : July, 2015
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:
Nominal heat size 150 T

Maximum heat size 165 T
Working volume with new lining 165 m3
Wear lining Magnesia-carbon bricks
h/d ratio with new lining approx. 1.4
Converter shell Lined with bricks with high conductivity magnesia-
carbon bricks
Converter bottom Integral bottom type with provision for practicing
combined blowing (inert gas stirring) process
Trunions Hollow trunions with bore size suitable for laying
pipe lines required for practicing combined blowing
(inert gas stirring) process.
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AUGMENTATION OF UTILITY FOR SIMULTANEOUS BLOWING AT

SMS-II
Executing Agency: M/s BOC India Ltd., Kolkata, India
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.
CONVENTIONAL (1 X 1 STRAND) SLAB CASTER-3
Executing Agency: M/s SMS SIEMAG Aktiengesellschaft, Germany & M/s SMS
India Pvt. Ltd., Gurgaon, India
Commissioned : October, 2013
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.
Technological parameters of new Conventional Slab Caster:
 Annual production of liquid steel (SMS-II) : 3,772,000 T/yr

 Quantity of cast slabs: 1,500,000 T/yr
 Heat size: 150 T (nominal), 165 T (max.)
 Heat delivery cycle: 50 min
 No. of strands :1
 Type of machine: Vertical mould with progressive bending/unbending
 Base radius: 9.0 m approx.
Design Features:
 Design range: 220 - 300 x 1200 – 2500 mm x mm

 Machine equipped to cast: 220, 250, 300 x 1200 – 2400 mm x mm
 Slab length: 6000 – 10000 mm
 Type of unbending : Continuous straightening
 Casting time: ~ 50 min
 Casting speed for different sizes & grades: (1.5 – 2.0) m/min
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 Machine speed: 0.6 – 6.0 m/min

 Preparation time: ~ 45 min (max.)
 No. of heats per sequence with one tundish: 12 - 15
 Avg. no. of heats/day : 26 - 30
 Caster availability: 330 days/yr approx.
 Design production capacity of CCM: 1,534,500 T/yr
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
RUHRSTAHL HERAEUS DEGASSER (RHOB)
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.
HRD CENTRE Page:253

The following are available:
 RH vessel complete with

o Vacuum vessels (1 + 2)
o Hot off takes (1+1)
o Hot off take jacking cylinders (4)
o Walking pipe ( 1 set)
o Gas cooler (1)
 Snorkel tube 3 pairs
 Vessel bottom part heat shields & cooling pipes 3 sets
 Vessel top part
 Vessel cover
 CCTV camera
 Clamping screw
 Seals
 Vessel refractory
 Vessel handling (lifting & lowering) system, moving platforms and rocker system.
 2 hydraulic power pack comprising of vacuum pump system
 Steam system comprising valves, pipe work, nozzles, ejectors, condensate traps, etc.
 Water ring pump complete with motor, water separator, instruments, condensers
 Booster 1 set
 Spraying condenser 1 set
 Seal tank 1 set
 Gas cooler 1 set
 Snorkel car including drives, lifting platform, hydraulic system, etc.
 Snorkel & vessel deskulling machine 1 set
 Exchange frame with hydraulic cylinders 1 set
 Vessel bottom and top part repair facility 1 set
 Drier for vessel top & bottom part 1 set
 Condenser water system 1 set
 Machine cooling water system 1 set
 Auto ejector cleaning device 1 set
 Snorkel jam breaking machine 1 set
 Off-gas stack 1 set
 Utility system comprising O2, fuel gas for preheater & oven
 Electrics, instrumentation, automation level-1, level-2 and telecommunication,
CCTV system
 Ventilation and air-conditioning
 Fire detection and alarm system
 Fire protection system
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LIME & DOLO KILN COMPLEX FOR SMS-II & SP-III
Executing Agency: M/s FLSmidth, Pvt. Ltd., Chennai, India & M/s Cimprogetti,
S.p.A.,Italy
Commissioned : January, 2015 / September, 2015 (commissioned in phases)
 One Lime kiln (1x 350 TPD]

 One Dolo kiln (1x 350 TPD]
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.
The major equipments / facilities are as given below:
 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.
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AUGMENTATION OF POWER SUPPLY FACILITIES
AUGMENTATION OF EXISTING MSDS & INSTALLATION OF NEW

MSDS IV, V & VI
Executing Agency: M/s Siemens Ltd., Kolkata, India

Commissioned : December, 2014 / March, 2015 (commissioned in phases)
(i) CPP-II (EXISTING)
 Addition of 2 nos. 132 kV bays for feeding power to MSDS-V.
(ii) MSDS-II (EXISTING)
 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.
(iii) MSDS-III (EXISTING)
 Addition of one 62.5 MVA transformer at MSDS-III.

 Addition of one 132 kV bay.
 Addition of one 33 kV bay.
(iv) MSDS-IV (NEW)
 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.
(v) MSDS-V (NEW)
 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.
(vi) MSDS-VI (NEW)
 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).
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(vii) RM - 1 (NEW)
 A 33 kV double bus GIS indoor switchboard for RM-1 & PM for stable power supply to
existing HRM loads.
MEDIUM VOLTAGE POWER DISTRIBUTION SYSTEM WITH INTRA-

PLANT CABLING & SCADA
Executing Agency: M/s Larsen & Toubro Ltd., Chennai, India
Commissioned : From October, 2014 to November, 2016 (commissioned in

phases)
 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.
UTILITY PACKAGES-PROPANE / LPG STORAGE & HANDLING

FACILITIES
Executing Agency: M/s Globe Gas Equipments India Pvt. Ltd., Mumbai, India
Reasons for installation of Propane Plant:
 Cost of propane is one third that of acetylene.

 Storage for propane is safer than acetylene which is unstable.
 Transportation of propane is safer than that of acetylene.
 Calcium carbide is required for acetylene plant which is scarce nowadays and also after
use of carbide lot of lime is generated, disposal of which is a problem.
Brief description of the unit:

Propane is received in road tankers and unloaded from the tankers by means of liquid
unloading pumps and vapor compressors and filled in the storage vessels. Unloading is done
first by liquid unloading pumps and after the complete withdrawal of liquid from the tanker,
which is indicated on the sight glass indicator, the propane vapor is transferred by vapor
compressor to storage tanks. Propane is drawn from the storage vessels through the
discharge liquid line and vaporized in the vaporizers. Thereafter, pressure of propane vapor
is regulated to a pressure of 1.5 – 2.5 kg/cm2 and supplied to consumers through headers.
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
HRD CENTRE Page:257

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
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%.
2 X 700 TPD OXYGEN PLANT (BOO BASIS)
Executing Agency: M/s Linde AG, Germany & M/s BOC India Ltd., Kolkata,
India
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.
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COAL DUST INJECTION IN EXISTING BLAST FURNACE-IV
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.
NEW 4.3 M WIDE PLATE MILL
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.
Commissioned : December, 2016 / March, 2017 / April, 2017 (commissioned in

phases)
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.
HRD CENTRE Page:259

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.
RAILWAY INFRASTRUCTURE & LOGISTICS
Executing Agency: M/s ARSS Infrastructure Projects Ltd., Bhubaneswar, India,

M/s Simplex Engineering & Foundry Works Pvt. Ltd., Bhilai,
India, M/s Bhilai Engineering Corporation Ltd., Bhilai, India
& others
Commissioned : from May, 2015 to August, 2016 (partly)
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.
New Coal Complex Yard (NCCY):
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.
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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.
Marshaling Yard (MY):
Major augmentation in rail infrastructure proposed in MY include full electrification of 5

lines, top wiring of 6 lines, providing full rake length link lines between facing point of the
Marshaling Yard and RSP gate so that the train can be received up to Marshaling Yard,
facing point clearing the non-security area outside the RSP gate.
New Plate Mill (NPM) Area:
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.
Signal & Telecommunication:
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
HRD CENTRE Page:261

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.
UTILITIES PACKAGES FOR AUGMENTATION OF INDUSTRIAL,

DRINKING & FIRE FIGHTING WATER
Executing Agency: M/s Jamshedpur Utilities & Services Company Ltd.,

Jamshedpur, India
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.
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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.
NEW COMPRESSED AIR STATION
Executing Agency: M/s Blue Star Ltd., Kolkata, India & M/s CICB-Chemicon Pvt.
Ltd., Bangalore, India
Commissioned : January, 2017
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.
SPECIAL PLATE PLANT
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
Commissioned : December, 2016
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.
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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.
3.0 MTPA NEW HOT STRIP MILL
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.
Need for New HSM:
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.
Salient Features of New Hot Strip Mill:

Production capacity of the Mill will be 2.94 Million Tons Hot Rolled coils per year and sheet
shearing line capacity will be 0.4 Million Ton per year.
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Major Facilities:
 Reheating Furnaces - 300 Ton/hr×2+1( Future)

 4Hi Roughing Strands
 Heat Shield
 Slab Sizing Press (future)
 7 Stand Finishing mills
 Laminar Cooling
 Down Coilers – 2nos. + 1no. (future)
 Pallet Conveyor
 Sheet Shearing Line
 Water Recirculation & Waste Water Treatment Plant
 Compressed Air Plant
 Power Distribution
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
Key features of products from New Hot Strip Mill:
Sl. Dimension / Slab Size Product Size

No. Weight
1 Thickness 200-300mm (max.) 1.2 – 25.4 mm
2 Width 725-2150mm 725-2150mm
3 Length 5.0 – 11 m In coil form
4 Weight 35.0 MT (max.) 35.0 MT (max.)
5 Specific Weight 22.5 kg/mm 22.5 kg/mm
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.
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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.
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COMPUTER & INFORMATION TECHNOLOGY
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.
IT Resources at Primary Data Centre (PDC)

 SUN M9000 servers (2 nos)
 SUN T5440 servers (15 nos)
 X86 servers (17 nos)
 Hitachi USP-V Enterprise Storage (36 TB)
 SUN SL3000 Tape Library
 CISCO MDS 9509 SAN Switch (2 nos)
 ATEN KN2124v KVM Switch (2 nos)
 CISCO 2960S-48TD-L Server Farm Switch (4 nos)
 UTM
 Network Core switch
 NetVault Backup Management Software
 Sanovi Disaster Management Software
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 CA Enterprise Management Software

IT Resources at Secondary Data Centre(SDC)
 SUN M9000 server (1 nos)
 SUN T5440 servers (3 nos)
 X86 servers (7 nos)
 Hitachi USP-V Enterprise Storage (22 TB)
 SUN SL500 Tape Library
 CISCO MDS 9509 SAN Switch (2 nos)
 ATEN KN2116A KVM Switch (2 nos)
 CISCO 2960S-48TD-L Server Farm Switch (4 nos)
 UTM
 Network Core Switch
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.
Data Centre at C & IT:

 SUN Hyper Sparc 712
 SUN Blade 2000
 SUN Fire 280R (2 nos)
 SUN Fire 480R (2 nos)
 SUN 3510 Fiber Storage
 SUN Fire V440 (2 nos)
 UTM (4 nos)
 Xeon Servers for RSP Mail, Network Security & Anti-Virus (5 nos)
 Enterasys N-7 Core Switch for RSP LAN
 4 MBPS MPLS connection for SAILNET
 Windows 2000 Server for e-Procurement Data Exchange
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Following are some computer application areas in RSP:
 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.
Information pertaining to company profile, management, achievements, milestones,

certifications, policy, procedures, products, facilities, annual business plan, production
highlights and financials is currently available on the site.
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
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provision for functional departments to publish useful information which will be accessed by
employees across the organization.
Data Communication Network & Security:

Data Communication Network of Rourkela Steel Plant encompasses more than 140 km of
Optical Fiber Cable including Plant premises and Steel Township. Data packet switching is
done at three levels, Core Level (HP 7510 Core Switches), Distribution Level (HP 7506
Distribution Switches) and Access Level (various managed HP / Enterasys / Cisco Switches).
For remote location connectivity wireless equipments catering to Point to Point (PTP) and
Point to Multi Point (PMP) functionality of make Motorola / Cambium are used. The entire
network is monitored through network management software (HP IMC 7.2). Rourkela Steel
Plant is also connected to SAIL MPLS VPN for interconnectivity among different units of
SAIL.
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.
Process Control Computer Systems in RSP:

A general process control computer system consists of the following levels of distribution of
responsibility, with two-way communication among peer-level as well as with higher levels:
 Level-1 - direct digital control of process using PLC, DCS (Digital Control System)
and Operator HMI (Human Machine Interface)
 Level-2 - supervisory control level, for process tracking and optimization using a
server type of computer and terminals
 Level-3 - intra-level coordination computers for production, planning and control
functions
 Level-4 - scheduling, decision making, management information level
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:
Sl. Location Computer System Modules

No.
1 SP-II L1: Yokogawa,  Online connection to L1-DCS
for data acquisition
 Parameter display and
transfer to Plant-status
database
2 BOF-II Shop L1: ABB, Siemens  New heat preparation

L2: VAX/VMS  Process aim calculation
 Hot-metal, scrap ordering
 Reblow Calculation
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No.
 Main blow advice
 Ladle alloy calculation
 End of blow & Feedback
calculation
3 Casters L1: ABB, L&T, ABIL, Siemens  Material Tracking

(SMS-I& II) L2: VAX/ALPHA/ VMS  Cut-length optimisation
including advice
LHF & Argon  Laboratory Management
rinsing  Dynamic secondary cooling
control
 Machine status tracking
 Heat/slab tracking
4 Reheating L1: Siemens PLC, Yokogawa  Slab arrival

Furnace DCS, L2: VAX/VMS  Slab line-up
(HSM)  Process tracking
 Thermal tracking
 Zone-wise set point
downloading
 Rolling programme
 Pacing control
 In-process weighing
5 HSM: L1: Siemens Simadyn- D,  Automatic mill pass-R0

Roughing, Siemens 6R80, Rockwell PLC,  Process tracking
Coil box, ABB XA Automation, ABB  Looper Control
AGC, Speed Drive DCS 800, Siemens PLC-  Gauge Control
Control, 400, Technology Card-458,  Speed Control
ROT, Master & Hitachi Digital Drive,  Communication among L1
Coiler Parker Drive, ABB Automation  Coil shape control
Controls, XA,  Process synchronisation
Coiler HMI: Win CC
Conveyor
6 ERWPP L1: ABIL PLC,  Planning
L2: Windows 2000  Pipe tracking
 Product analysis
 Pipe testing & inspection
 Dispatches
7 Energy L1: ADAM signal I/O  Data acquisition

Management L2: Windows-2000, FIX  Analysis Management
 Alarm Management
 Online Mixed Gas CV
 Gas balancing
 Mimics and trend graph
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No.
8 Supervisory L1: ECIL-RTU  Data acquisition
Load Control L2: Windows-NT, SCOUnix  Alarm Management
Centre  Area-wise energy balancing
 Mimics and trend graph
 Connectivity with Eastern
Grid
9 Environment  Online data acquisition from

Functions field instruments
 User interface system for
parameter monitoring
 Periodic area-wise reporting
to Management & Statutory
bodies
10 Weigh L1: Digital weight indicators:  Online communication with

Bridges Philips, Avery, Sanmar, Digital-Weight Indicator for
Ashbee, Weitex weighment
L2: Windows-XP, Windows-7  Communication with central
database server
 Communication with SAP
 Logic for net weight calculation
and screens for operator
interface
11 BF5 L1: ABB  Process Tracking
L2: HP/Windows 2008, Oracle  Burden Calculation and
11g Tracking
 Stove Optimisation
 Heat Flux Monitoring
 Hearth Monitoring System
 Tapping Information System
12 New Plate Furnace:  Improve product quality
Mill L1:Siemens  Reduce Specific Fuel
L2:HP/Windows 2008, Consumption
Oracle 11g  Generate correct set point
(Mill-Setup)
Mill  Communication with Level1,
L1: GE, Daniele peer L2 Applications and SAP
L2:HP/Windows 2008, Oracle  Product Tracking Slab/
11g Mother/ daughter plates
 Managing product flow
Finishing  Set Point Calculation for
L1: ABB shearing lines, HPL and CPL
L2:HP/Windows 2008, Oracle  Data logging and Reports
11g generation for Production &
quality
13 CCM-III L1: Siemens  Material Tracking
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No.
L2: HP /Windows 2003, Oracle  Cut-length optimization
11g advice
 Breakout Prediction System
 Dynamic secondary cooling
control
 Machine status tracking
 Heat/slab tracking
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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:
Peripheral Industries & Vendor Development (PIVD):

1. This is a dedicated section for development of vendors and industries near RSP.
2. Acts as an interface between Local Industries, Government of Orissa, District Industries
Centre & RSP for resolving issues related to the local industries.
3. It provides help to the peripheral industries to orient their manufacturing process & end
products to meet RSP’s requirement, thereby helping in their development & growth.
4. Important functions include maximization of reservation of items for Local Small Scale
Industries (SSI) and facilitating increase in the order booking value on Local SSI, for
development of SSI in Orissa.
5. Other functions include Creation of adequate vendor base for items for which sufficient
vendors are not available, and timely registration and renewal of registration of
suppliers
Standardization& Rationalization Group (SRG):

1. This is RSP's central spare and consumables catalogue specification clearance agency.
All transactions of this section are on-line in Integrated Materials Management System
(IMMS) and SRG operates on paperless office concept.
2. SRG is responsible for specification standardization in order to reduce the total number
of catalogue numbers of RSP by reducing duplicate catalogue generation.
3. SRG plays an important part in the clearance of indents.
Stores & Stock Control:

The activities of the Stores section can be broadly classified as dealing with collection,
receipt, handling, inspection (at stores), stock charging, preservation and issue of materials.
These are important flow control activities in the Supply Chain. Regardless of the efficiency
with which all preceding activities have been conducted, to a significant extent Stores
activities determine to a great degree the satisfactory supply index to the production units.
Receiving and Storage play a more important role in supporting and facilitating production
operations. Receiving is responsible for expeditious receipt and general inspection of
materials, as well as for a thorough review and comparison of all relevant documentation
with the materials. Stores is responsible for identification and safe, efficient physical
handling and storage of materials. The receiving operation is animportant control point in a
materials system. This is the only point at which the purchasing control documents actually
meet the materials themselves. Subsequently, stores assume responsibility for the physical
care and control of the inventory. Since this material represents a major portion of the
organizations total invested capital, this responsibility is a significant one. In Rourkela Steel
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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.
Other activities of the Stores at RSP are:

1. Handling of affairs related to transporters. This is done by the Consignment Section
of Stores
2. Store is also the custodian of materials not drawn by indenting department. Items
which are not drawn for a long period are classified as Deemed Non-moving (items
not moved for more than 4 years and less than 5 years), Non-moving (items not
moved for more than 5 years), Obsolete / Surplus (items unusable and approved by
MD). Materials declared as obsolete / Surplus are disposed off by marketing
department.
3. All activities of Stores, starting from entry of material at RSP gate till issue to
departments has been computerized. Payment copy of GARN (Goods Acceptance/
Rejection Note) is being electronically transferred to Finance and also to the
suppliers through EPS system. All outside despatches through Stores is also
computerized.
4. Another important function of Stores is to lodge insurance claims and realise the
same through F&A (Claims & Freights Section).
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:
HRD CENTRE Page:275

1. Quality of purchased materials and services.

2. Reducing the total cost of acquiring of the materials or services.
3. Reducing the time to acquire the materials or services.
4. Technology: Firms supply base should provide the appropriate technology in a
timely manner.
5. Maintaining continuity of supply.
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.
The various sections in Purchase are as mentioned below:

1. General Purchase- Looks after the procurement of consumables
2. Spares- Handles the spares procurement of various departments.
3. Refractories-Caters to the refractory needs of the plant
4. Rolls-Involved in the procurement of Rolls
5. Minor Raw Material (MRM)- Procures Raw Materials
6. Import-Involved in procurement of materials of imported nature.
7. Repair Job Contract (RJC)- Only Non-Works RJC cases are processed
8. Ispat General Hospital (IGH) Purchase-Involved in medical Purchases.
The salient features of Purchase functioning are as follows:

1. The Purchase/ Contract Procedure 2009 govern the entire gamut of operations.
2. Extensive IT tools are in use in Purchase Operations. The Integrated Materials
Management System (IMMS), which is a network linking the Indentors, MM, and
Finance and facilitates Purchase functioning. The procurement activities have been
web enabled through the E-Procurement system (EPS). RSP is the pioneer and
leading plant in SAIL regarding use of EPS. All activities from issue of enquiry,
submission of offers by parties, opening of offers, generation of comparative
statement, receipt of orders by parties, receipt details of materials, payment
information and submission of inspection request and issue of inspectioncertificate is
carried out over internet. Today even issue of open/ global tender and procurement
through Reverse Auction route is possible through the EPS. More than 90% of the
cases are processed through EPS.
3. Emphasis is being placed for maximization of long-term rate contracts with price
variation clause, open/ global tendering & price bid through reverse auction route.
Inspection:
1. The broad function of the Department is to ensure that the material being supplied
meets the desired specification as per the quality requirement of the user.
2. Inspection is carried out at Stores Receipt and in the premises of vendors.
3. Inspection department develops the Quality Assurance Plan for items in consultation
with user departments.
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4. Inspection also undertakes Capacity Assessment of vendors in the Vendor

Registration Process.
5. The inspection activities are carried out by the RSP Inspection Wing located at
Rourkela as well as by RSP Unit Offices located in Delhi, Kolkata, Mumbai and
Chennai.
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.
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FINANCE & ACCOUNTS

The major functions of Finance & Accounts department are as under:
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.
Preparation of annual Budget and budgetary control reports:

Operation budget is prepared as per guidelines of the corporate office. Department wise
budget is fixed for each expenditure head for controlling expenses bringing about cost
efficiency in the operation of the plant. Quarterly budget reports are made available to
different departments for their information and necessary action. Capital budgets are
prepared by Project finance in consultation with head of works and project department.
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.
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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.
Preparation of pay roll and complying with the provisions of Provident

Fund Act, Income Tax Act, and Payment of Final settlement:
Monthly payrolls are prepared on the basis of master data in the computer duly updated
from time to time on issue of relevant office orders by Personnel Department and Plant
departments. Attendance of all the employees is collected and fed into the computer by the
Finance department. Finance department is also responsible for disbursement and recovery
of loans, deduction and deposit of income tax at source. Employee wise accounts are
maintained for the Provident Fund deducted every month from the salaries of the
employees. Final Settlement such as Payment of Gratuity, Leave encashment, Terminal
transportation expenses are calculated and paid.
Scrutinizing purchase/contract/expenditure proposals and giving

concurrence:
Proposals involving funds and requiring approval of MD are routed through ED (F&A).
Other proposals are checked by finance department as per delegation of power. The
representative of Finance department is nominated in various tender/negotiation
committees for obtaining the best price and commercial terms.
Examining the financial viability of investment proposals:

Various investment proposals are thoroughly examined from financial point view.
Payment of Suppliers/Contractors Bills:

Bills of suppliers/contractors are received, checked and paid as per the terms of contract
with them.
 OB&A
This section deals with Payment and accounting of contractors/small value purchase
order bill, telephone and mobile bills, stipend and honorarium bills, CISF bills,
electricity bills of NSPCL, GRIDCO/WESCO, advertisement, journal & newspaper bills,
transport and taxi bills, land rent and water cess, picnic subsidy bills, funeral expenses
bills, entertainment and function expenses bills, recovery from contractors towards
demand from PF and ESI, sales tax authorities etc. Accounting of materials received
from sister plant for further processing.
 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.
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 Claims and Freight

This section deals with Payment of railway freight, railway staff bills, demurrage bills
and accounting thereof, Insuring the assets of RSP, taking marine, transit and
contingency insurance policy. Lodgment and settlement of claims with railway and
insurance companies toward wrong/ overcharge of freight, transit loss of material and
loss of assets of RSP.
 Stores Bills and Accounts

Stores bills section deals with payment to supplier of stores & spares, Refractories, Rolls
and Minor Raw Materials and accounting thereof. All stores and spares (indigenous as
well as imported) purchased for revenue consumption are paid by stores bills section. In
addition to these stores bills section make payment of freight bill to authorized and
unauthorized transporters, handling bills, testing charges, Accounting of payment made
by BTSO toward custom duty, port rent, ocean and airfreight. Accounting of material
received from and despatch to sister plant. Form ‘C’ and Form ‘F’ are issued to suppliers
and sister concern respectively against supply of stores and spares.
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.
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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.
Grievance Redressal System:

Effective and quick redressal of grievances of employees is a vital Personnel function
especially in a Labour intensive industry like Rourkela Steel Plant. There is an effective
system of informal grievance handling through Employee Assistance Register (EAR) to
settle employees’ grievances at the shortest possible time. The EARs are available in all the
Personnel Unit Offices and in Control Rooms of some major departments. The aggrieved
employees can record their grievances/ difficulties relating to a number of areas attendance,
pay, house allotment/ maintenance, promotion, seniority, etc. The Unit Personnel Officers
take appropriate follow-up actions to sort out the grievances at the earliest and also keep
the employee concerned informed by making appropriate entries in the EAR. In addition to
the above, there are also formal grievance redressal mechanism called Grievance Redressal
Committee (GRC) and Executive Grievance Board (EGB) for redressal of the employees’
grievance on a time bound basis.
Employees’ Welfare and Social Security:

Employees welfare is of utmost priority among various Personnel commitments in any
organization. Personnel department takes utmost care for ensuring & up keeping of vast
array of welfare facilities both statutory and non-statutory. Some of the main Welfare
facilities include canteens, rest rooms, drinking water, public convenience buildings, first
HRD CENTRE Page:281

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.
Performance Management System(PMS) and growth of employees:

For an objective assessment of the performance and potential of the employees and to
distinguish between different levels of performance, the Personnel department implements
the Performance Management System in vogue in the company. A comprehensive appraisal
system for the employees has been developed to ensure an objective assessment of
performance and potential of the employees and to integrate company's and individual
goals. Transparency and objectivity being the two pillars of effective performance
management, the systems for assessment of performance have been made online. Besides to
motivate the employees for their better performance, Personnel department takes care of
the aspiration of the employees by effecting promotion, career planning and succession
planning. There are also systematic Promotion Policies for promotion within executives,
within non-executive employees and also for promotion from non-executive to executive
cadre.
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:
 MD’s Mass Contact Exercise: With an aim to synergize employees towards

organizational goals, a unique and unprecedented programme started on 19-04-2002.
It is held once in a week, where around 500 employees participate and contribute their
constructive idea/suggestions for growth of the organization and interact with the
Managing Director. A presentation highlighting the areas of concern and good
performance is also made to aware the important issues affecting the plant and the
employees.
 General Manager’s Communication Meeting: Every General Manager holds a
monthly meeting of groups of employees of his area of control and major departmental
issues, action plans, performance highlights, etc. are discussed.
 HOD’s Communication Meeting: Heads of departments hold weekly/ fortnightly
meetings with employees where departmental issues, safety aspects, improvement
plans etc. are discussed.
 Sectional In-charge’s Communication Meeting: Sectional In-charges of major
units hold weekly meetings of employees to discuss day-to-day shop-floor issues.
 Issue Based Workshops: It is held whenever required and all agencies concerned
with the issue are encouraged to evolve improvement plans.
 Special focused communication: Depending upon the need of the hour special
focused communication programs relating to turnaround, cost-effectiveness, better co-
ordination etc. are organized.
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Besides these Unit Personnel Executives also communicate various plant related issues to
the employees at shop floor.
Building a Responsive Work-force:

Discipline plays an important role in an Industry. It is a bare minimum necessity for
sustaining the Production & Productivity. While emphasizing positive discipline like quick
grievance redressal, ensuring proper welfare facilities, improving quality of work life etc.
Prompt and consistent disciplinary action is taken against the employees concerned under
the disciplinary rules & procedures of the company. In order to ensure the employees
availability on the shop floor in time, the Direct Reporting System (DRS) is in vogue
whereby employees report at their place of work directly and put their signature in the
attendance register both at the beginning and end of the shift. The Unit Personnel
Executives undertake periodic surveillance on DRS to make the system more effective.
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.
Besides the above some key Personnel functions in RSP are:

 Formulation and ratification of human resources policies, in line with the business
strategies.
 Designing and redesigning of organization and work systems.
 Designing and regulating compensation systems.
 Ensuring compliance to statutory requirements.
 Functioning as convener of all job contracts in the works departments.
 Ensuring compliance of all statutory matters in respect of final bills of contractors.
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.
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HUMAN RESOURCE DEVELOPMENT CENTRE
The Human Resource Development

Centre of Rourkela Steel Plant was set
up during 1959 and was then called
“Technical Institute” imparting technical
knowledge and skill to all new entrants
to the then Hindustan Steel Limited.
Over the years, the institute was
entrusted with the responsibility of
training not only new entrants, but also
of developing the skill and competence of
the existing employees. In line with the
changing focus of the organization, the
activities of the Centre also grew to
encompass a wide spectrum of developmental activities and the centre was rechristened as
“Training and Development Centre” and subsequently “Human Resource Development
Centre”. It is the first HRD Centre among SAIL steel plants to have been certified under
ISO 9001 Quality Management System during November 2003.
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.
Over the past years the HRD Centre has

redefined its horizon and has become a center
stage for the transformational process of
Rourkela Steel Plant and, has played a vital role
in the turnaround initiatives of Rourkela Steel
Plant. Apart from carrying out activities
towards the competence development of
employees, the HRD Centre has also become the
venue for several professional development
activities by playing host to several national and
international workshops, seminars and
conferences.
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Focus of HRD Centre

While making efforts towards bringing about continuous improvements and fostering a
culture of learning and innovation, the focus of HRDC has been on linking training events
and outcomes to the business needs and strategic goals of the company. Our major activities
include:
 Organizing HR interventions to bridge the gaps
in competence and skill.
 Development of competence of employees
 Addressing specific needs of the various
departments for enhancing performance.
 Building capability of employees for multi-
skilling and multitasking.
 Enhancing Managerial Skills of executives.
 Designing and conducting specific interventions
to enhance managerial effectiveness.
 Evaluating the effectiveness of training
programmes in all In-house technical training
programmes.
 Continuously improving the quality of training.
 Creating and maintaining a learning
environment
The process of Training & Development at HRDC & CPTI

The process of training and development of employees is represented in the diagram below:
Training Need Competence Organizational

Assessment Mapping Requirement
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
HRD CENTRE Page:285

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.
Infrastructure Facilities at HRD Centre:

Located inside the works premises and close to the Main Gate, the HRD Centre has
sprawling green lawns bordered with seasonal flowerbeds and encircled by lush green trees.
The Centre is well equipped with modern facilities and infrastructure required for
conducting different types of training programmes. Some of them are:
 Classrooms/Syndicate Discussion Rooms
 Workshop Facilities: All skill development/ multi-skill technical training
programmes are carried out in the following workshops:
 Machine shop
 Welding Shop
 Fitting Shop
 Electrical Shop
 Hydraulics & Pneumatics
Laboratory
 Electro-Hydraulics Laboratory
 Electronics Laboratory
 Computer Hall
 Gopabandhu Auditorium-
Having
a capacity for sitting 500 persons.
 Library
 Model Room
 Trade Testing Centre
 Customer Care Cell
 Documentation Cell
 Trainees’ Hostel Complex
 3 Trainees’ Hostels with
 Training Hall
 Dining Room
 Recreation Room
 Indoor Badminton Court
 Basket Ball and Volley Ball Court
 Play ground (for Football, Cricket etc.)
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CENTRAL POWER TRAINING INSTITUTE

In 1985, the Government of India had constituted a
high level committee to look into the various aspects
of training in the Power Sector. Recognizing the
importance of specialized training for power plant
personnel, the SAIL board in April 1990 approved
the setting up of the Central Power Training
Institute(CPTI) at Rourkela under the
administrative control of Management Training
institute, Ranchi. CPTI was accordingly established
in October 1993 to provide specialized training to
power plant personnel not only of SAIL but also of all major power plants in India.
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.
Infrastructure Facilities at CPTI:

Located inside the Project and modernization Complex, close to the Traffic Gate of Rourkela
Steel Plant, the Central Power Training Institute is centrally air-conditioned and reflects an
ambience befitting a learning centre. Equipped with state of art infrastructure facilities and
HRD CENTRE Page:287

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.
 Operator Training Simulator:

It has a replica operator training
simulator of 60 MW Coal fired
Captive Power Plant of Rourkela Steel
Plant (Presently M/s. NSPCL). It is
the first of its kind in India with
indigenous technology and the only
one in non-utility sector. The
application software ensures high
degree of fidelity in reproducing the
exact response of the actual power
plant to various operator actions. It
consists of simulator computer station, control panels; Microprocessor based input /
output system, field device terminals to simulate local operations, Instructor station and
data acquisition system (DAS). The total plant is functionally divided into process
simulation, interlock simulation and control simulation for boiler, turbine, generator and
electrical system. As on date, it is in the process of being upgraded functionally.
 Lecture Halls and Simulator
Hall:
The Institute is centrally air-
conditioned. Main sessions are
conducted in the three Lecture halls
and one screening room well
equipped with audio-visual aids.
Hands on sessions are conducted at
site.
 Information Centre :
The information centre has a large collection of books, handbooks, journals and
courseware from Indian / foreign publishers on all areas of power engineering and
management. Documentation and drawings related to all SAIL power plants, video
cassettes on power plant operation and control are also available. It has a collection of
more than 850 books and 49 manuals on power plant engineering and allied subjects. It
also subscribes to 5 journals / magazines, 5 newspapers and 10 house magazines.
 Syndicate Rooms :
Syndicate discussion is a regular feature in problem solving workshops and other action
plan oriented programmes, particularly for executives. CPTI has three well designed
syndicate rooms for smooth conduct of workshops.
 Facility for Corporate programme:
CPTI organizes corporate programmes in an auditorium having a seating capacity for 82
persons. The compact auditorium is equipped with a captive public address system and
attached projection facility. An additional Conference Room capable of accommodating
30 -35 participants is also available.
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 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.
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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 concentrates for achieving organizational goal by:-

 Cost effective management of litigation through qualitative and quantitative
disposal.
 Developing In-house legal expertise to advise Management and draft legal
documents without assistance of outside Advocate.
 Organizing seminar/training program for line manager on current legal issues and
apprise higher Executive on its implication on business/strategy related decision
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.
The department deals with matters/cases pending before different courts/fora/authorities of

different jurisdiction (Civil Courts, Criminal Courts, Tribunals, Labour Courts, Consumer
Fora, different High Courts and Supreme Court). The statistics of the last 10 years reveals
that the success rate achieved by Law Department is always maintained above 90%. It is
motto of the Law Department to promote settlement, encourage mediation/conciliation and
implement all order/judgment as far as possible.
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.
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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.
Town Engineering – Civil:

The Civil Wing of Town Engineering Department takes care of the repair and maintenance
work of the residential quarters in the township. Apart from this, regular maintenance is
carried out in Socio-Cultural Centers including Civic Centre, Bhanja Bhawan Complex,
Utkalmani Gopabandhu Ispat Library, Adarsha Pathagar, Deepika Mahila Sanghati and
Social Homes/Community Centers spread over the townships.
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.
As a part of environment up-gradation, beautification and road safety campaign, various

important chowks and roads are continuously modified with re-carpeting and widening,
providing adequate parking space and installation of monuments and fountains.
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
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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.
Town Engineering- Electrical:

Town Engineering (Electrical) Department caters power to nearly 24, 000 houses in addition
to the public utility service like Water Supply system, Hospital, Clubs, Office premises etc.
In the process, a vast network of HT, LT and Street Lighting are to be maintained round the
clock. This network consists of the following:
 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.
 440 Volts Distribution System:

 154 numbers of 11 kV/440 V distributions Sub-Station scattered over the entire Steel
Township have to be maintained round the clock for supplying electricity. The total
length of 33KV overhead lines nearly 40KM, underground cable is 17KM, 11KV
overhead line nearly 210KM &underground cable 80KM, 440 V overhead line and
underground cable covers a distance of nearly 1500 KM.
 Water Supply Installations:

 Power supply to Intake Wells, Hill Top Pump houses and Booster Pump Houses are
maintained round the clock within availability of dual source. 110 numbers LT
Motors and 6 numbers EOT Cranes are maintained by the Department.
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.
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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.
 Water Supply – Town:

Water Supply (Town) meets the potable water requirement of Steel Township, Rourkela. It
supply potable water as per IS : 10500 – 1993 Quality norms to approx. 24000 residential
quarters apart from hospitals, schools, market places, State & Central government
organisations and public utilities. It also provides drinking water to some of the designated
slums/ Bastis inside the Steel Township. Apart from this, raw water also been supplied to
parks, nursery and gardens. It maintain water tankers (2 No's.) to supply potable water to
ceremonies and functions organised inside Steel Township including functions organised by
employees on daily basis. Basic objectives of the Water Supply (Town) is,"To supply potable
water 1500 litres/day/Quarter (as per norm) conveniently, economically & uninterruptedly,
in a sustainable manner, twice a day."
Source of Raw Water a. River Koel

b. River Brahmani
Intake Wells a. Jhirpani Intake Well – located on the bank of
river Koel in Jhirpani. 3 no. of Intake wells of
total pumping capacity 36 MGD.
b. Tarkera Intake Well – Located on the bank of
river Brahmani for Township area. 2 X 6.4
MGD capacity.
Water Treatment Plants a. Water Purification Plant, Hill Top, Sector-2
with filtration Capacity : 18 MGD.
b. Brahmani Water Works, Sector-8 Capacity : 9
MGD filtration capacity.
Chemicals used for a. Ferric Alum as a coagulant.
Water Treatment b. Poly Aluminum Chloride (PAC) as a coagulant.
c. Lime as pH neutraliser.
d. Disinfectant (Bleaching Power).
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Production Process (Flow Diagram):

Raw water comes from intake well pump house of Koel river and passes through the
bubbling tank in the Water Purification Plant. Here the speed of water is reduced and heavy
particles present in the raw water settle down to the bottom of the tank, which is finally
disposed off. Chemicals are added (coagulant) for vigorous mixing.
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.
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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.
The efforts of the department aiming at ecological restoration by massive afforestation

programmes in and around Rourkela has been widely acclaimed as RSP won the prestigious
Indira Priyadarshini Vriksh Mitra Award for the year 2003 from Ministry of Environment
and Forest, Government of India. Horticulture Department is participating at the All India
Rose Shows organized in various parts of the country with a collection of cut roses from
Rourkela Township and have bagged a number of Prizes. In 2016, at Agri-Horticulture
Society in Kolkata, 23 nos. of prizes was credited to Horticulture Department of Rourkela
Steel Plant
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
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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.
Apart from this Horticulture Department is creating awareness among Rourkelaites

regarding environment and its protection. The department is regularly organizing Annual
Horticulture show, Rose and Chrysanthemum show and garden lay out competition with
huge participation. The Department is also organizing essay, quiz and elocution competition
and sit & draw competition among school children on the various topics related to our
environment. Regular Zoo Education programs are being conducted at Indira Gandhi Park
Zoo for the conservation of wildlife and its importance. Training programmes are also being
conducted at Ispat Herbal Garden on herbal plants and its beneficial effects to create
awareness among participants. Horticulture Department has also undertaken activities for
distribution of saplings free of cost to the villagers adjacent to Rourkela Steel Plant.
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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,
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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.
To maintain a clean and green environment about Ac

4000 of land have been covered under plantation with
more than 45 lakhs of trees. There are 3 major parks
viz. Indira Gandhi Park equipped with boating
facilities, Toy Train & Musical Fountain facilities
along with a Zoo , Ispat Nehru Park having a fantastic
XD theatre, boating facility, Fitness path & children
play ground etc. and Jubilee Park in the heart of
Township.
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.
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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.
Rourkela Steel Plant has not only taken the

initiative of providing infrastructure but has also
taken initiative in providing scientific coaching
through reputed trained coaches and Senior Players
of national and international repute. While initiative
is taken for imparting training in 12 disciplines, a
special thrust has been given in the area of
Athletics, Hockey, Chess, Cricket, and Table Tennis.
For tapping the hidden potential of the young and
budding talents, Day Scholar Scheme is being operated in Hockey and Athletics where the
selected players - 25 in Hockey and 20 in Athletics are being provided free kits for their
practice. As a special initiative a Chess learning Centre is being run by Rourkela Steel Plant
for the last five years. These centres had groomed a number of players of regional/ national/
international level under the watchful eyes of Coaches.
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.
Rourkela Steel Plant has also taken several

initiatives in organizing tournaments and
Championships at different level like local, State
and National level. The presence of the Indian
Hockey stalwarts at Rourkela for a period of 2
months before their participation in Doha Asiad
was a great pleasure and honor for the
Rourkelities. Similarly, the Federation Cup
Basketball tournament organized by Rourkela
Steel Plant at its Ispat Basketball Complex saw all the Indian Internationals in action. The
Public Sector Hockey tournament and the Sub Junior Girls National Hockey are the other
major events organized at Rourkela.
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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.
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CORPORATE SOCIAL RESPONSIBILITY (CSR)

DEPARTMENT
CREATING POSITIVE FOOTPRINTS IN SOCIETY

Rourkela Steel Plant (Rourkela Steel Plant) which is a unit of Maha Ratna CPSU Steel
Authority of India Limited (SAIL), is a forerunner in the field of Corporate Social
Responsibility. Giving back to the society – the core philosophy of Corporate Social
Responsibility is enshrined in the management ideology and style of Rourkela Steel Plant,
the first public sector Steel Plant in India, right from its formative days. A harmonious
relationship with the local community and inclusive growth of the organization has been
possible with Rourkela Steel Plant’s consistent endeavors in the field of social responsibility.
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.
Evolution of CSR Process inRourkela Steel Plant
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.
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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.
Institutions for the differently abled, such as Home

& Hope & Asha (both institutions for the mentally
challenged), Rourkela School for Deaf,
Radhakrishna Dristihina Vidyalaya, Lathikata etc.
are patronized by Rourkela Steel Plant from time to
time.
The following Scholarship Schemes have been

formulated to promote education in peripheral
areas, by way of providing financial support to the
needy students:
 Merit based cash award, i.e. Rs.5000/-, Rs.4000/-, Rs.3000/-, Rs.2000/- and Rs.1000/-
respectively for 1st, 2nd, 3rd, 4th and 5th position holders among boys and girls
separately for students of High Schools and
M E Schools.
 Financial Assistance (upto Rs.1.50 Lakhs)
for Professional Studies is a scheme
primarily for poor ST / SC students and
poor general category students, for
pursuing Engineering, Medical,
Agriculture, Management etc.
 Under the Scholarship Scheme for
underprivileged students, 200 students
from peripheral areas are awarded
scholarships @ Rs.10800/- for students in
classes upto V and Rs.12000/- for students in classes VI-XII.
Learn to Read (L2R) Program is a customized program to promote primary education

through innovative learning techniques such as singing, dancing, games and other
activities, adopted in 100 schools.
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.
Akshaya Patra Project:
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.
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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, upgradation 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.
HEALTH (INCLUDING SUPPORT FOR

PHYSICALLY/MENTALLY
CHALLENGED):
Three free medical center with facilities for

pathological investigations for the under
privileged are operating 6 days a week at Ispat
Sanjeevani, Sector-6, Chikatmati Model Steel
Village & Jalda Resettlement colony.
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.)
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 Sneha (leprosy care)

 Chetna (Thalassemia & Sickle Cell)
 Akshay (tuberculosis)
 Charaka (general surgery).
RCH & Family Welfarecamps are also conducted at IGH, in association with Govt.
Income Generation & Livelihood:

Different Projects were undertaken to supplement the household incomes of the peripheral
populace.
Under Project Parswanchal Vikas (Integrated Tribal Development

Program),Community Focused & Family focused interventions were made.
Family focused interventions promoted programs like

 Agro-Horti-Forestry (Wadi): Intercropping of seasonal vegetables, horticultural
plants like lemon, litchi, mango etc. and forest trees.
 Live-stock (Poultry, Goatery, Duckery)
 Improved agriculture.
 Providing smokeless chullah.
Community focused programs included:

 Water resources / watershed development
 Creating and developing SHGs & Village Level Organization etc.
 Skill development on different trades.
Employability enhancement programs in the health sector are being conducted

atIspat General Hospital as follows:
i. Medical Attendants training.
ii. Advanced nursing training.
iii. Specialized training on physiotherapy.
Left Wing Extremist (LWE) Training: A prevention/rehabilitation program to address

the left wing extremist problem, has been taken up in association with the State Govt. for
unemployed youth under which 110 such persons have been imparted ITI training at ITC,
Bargaon.
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),
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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)
WATER SUPPLY & SANITATION:

Water facility created through tube wells, dug wells, renovation of ponds etc. and piped
water supply system in the adopted villages &
re-settlement colonies/ reclamation camps.
Comprehensive water supply and

sanitation project:
Water & Sanitation are two basic issues. In the
peripheral areas of Rourkela, sources of water
are the usual hand pumps, dug wells, ponds,
nearby stream etc. In a few villages, piped
water supply is there through stand points.
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.
With the above backdrop, it was contemplated to have a

project for comprehensive water & sanitation in the
adopted villages. The concept is to have a sanitation unit
(bathroom & toilet) in all the households and to have
piped water supply to all the households through three
tap connections. The important dimensions addressed in
the system are to mobilize the villagers for their direct
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participation – firstly by participation in the scheme,

owning the project by contribution and for
sustenance of day to day operation.
The project involves a water supply system with a

source and overhead tank, along with pipe network.
Cost of the water system is borne by Rourkela Steel
Plant, whereas cost of the sanitation unit is shared
by Rourkela Steel Plant & the villager concerned.
The villagers are also contributing Rs.50-100/- per month towards routine
operation/maintenance.
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.
SWACHH VIDYALAYA ABHIYAN
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.
Solar Powered Drinking Water Supply System:

In order to enable availability of safe drinking water to the villagers who do not have
electricity or have erratic electricity supply, a solar powered drinking water supply system
has been installed at Jaidega village. The project will be expanded to other areas in future.
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.
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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
The Women Resource Centres have become a

catalyst for the overall empowerment of
adolescent girls & village women through a
holistic approach. In the advancing stage WRCs
are moving ahead to form/join the consortium to
strengthen their linkages, address the
technological gap for social and income
generating activities and converge with different
schemes.
In a gist, the broad benefits of the project have been as

follows –
 Change of mindset
 Improvement in articulation of ideas/thoughts
 Better quality of living
 Improved sense of health and hygiene
 Development of entrepreneurial skills.
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Hasta Kargha (Handloom Centre):

A new chapter has been opened on the auspicious
occasion of Gandhi Jayanti 2012, by opening of a
Handloom Weaving Centre providing skill on
handloom weaving to supplement household
income and promote handloom. 45 girls in three
different batches are getting trained. The centre
houses state of the art equipments such as pit
looms, frame looms, various pre-looming
instruments, calendaring machine, cabinet dyeing
machine etc.
The products of WRCs and handloom centre were put up for exhibition-cum-sale by the
SHGs in Pallishree Melas-2016 at Puri , Rourkela and Koraput.
Sanitary Napkin Making Project

A low-cost sanitary napkin project has been launched in
April 2015 where 6 girls from peripheral areas have
been trained to make quality sanitary napkins at a very
low cost. The centre has a daily production capacity of
1000 sanitary napkins.
White Phenyl Making Unit

A unit for white phenyl production has been established
recently, in which 2 girls from peripheral areas have
been trained and engaged for production of 100 litres of
white phenyl per day.
Shree Shakti Scheme
In order to recognize and motivate the outstanding
Self Help Groups of Women in the peripheral
blocks of Bisra, Nuagaon, Kumarmunda,
Lathikata& Rajgangpur as well as in the
resettlement colonies, a scheme has been launched
in 2014-15. Under this scheme, 7such SHGs were
awarded on the occasion of Women’s Day on 8th
March, 2015. The Sri Sai SHG of Jabaghat won the
First Prize of Rs.50,000/-.
PROMOTING SPORTS & CULTURE:
“Samvardhan – Rural Sports”programs have been taken up since 2012-13, by conducting

tournaments in rural locations in popular games such as football, kabaddi through the
villagers groups/institutions.
“Synergy – The Lok Samskrutik

Mahotsav”programs have been launched since
2012-13 to promote rich tribal culture of the
peripheral areas, under which programs are
conducted in the peripheral areas involving
hundreds of village teams.
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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.
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PUBLIC RELATIONS
Defining PR:
Public Relations is the deliberate, planned and sustained effort to create mutual
understanding between an organization and its stakeholders.
The cornerstone of every PR initiative is effective communication. A pre-requisite of effective

communication is a thorough understanding of the Company, the nature of its stakeholders
and the dynamics of the environment (business, political, social et al) in which it is
operating.
Functions & Areas of Responsibility

 Image building of the Company
 Dissemination of information regarding the organization through print and
electronic media
 Reaching out to a global audience through effectual use of social media.
 Media relations
 Advertising and Publicity
 Event Management
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
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Units of Public Relations

 Communications
 Rourkela Steel Television Centre
 A/V Unit
 Documentation Centre
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
Rourkela Steel Television Centre

 Daily News in Odia, Hindi & English
 Updation of the RSTV news on Youtube and providing link in Facebook
 Yearly Round Up
 Health File
 Documentaries, reports
 Recording/Telecast of important programmes
 Interviews & Panel Discussions
 Cultural Programmes, Quiz and other special programmes etc.
 Messages of important dignitaries
 Operating and regulating contracts for videography
 Providing footage to TV channels
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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
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PROTOCOL & HOSPITALITY SERVICES

Liaison Cell:
The prime responsibility of the Liaison Cell is to assimilate, analyze and synthesize internal
and external intelligence on the plant affairs. It monitors important internal and external
developments of relevance to Rourkela Steel Plant and sensitizes the Higher Management
on the ensuing as well as forthcoming developments/issues in the fields of political, social
and trade unionism etc. Besides it coordinates with the appropriate authorities and agencies
as per requirement from time to time.
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.
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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.
Vigilance Set Up in Rourkela Steel Plant:

At Rourkela Steel Plant, Vigilance set up is headed by Addl. Chief Vigilance Officer (ACVO)
and assisted by a number of executives and Vigilance Inspectors who are in the rank of non-
executives. All postings in Vigilance are for a tenure of 3 years extendable up to 5 years.
Vigilance Department reports directly to Chief Executive of RSP & CVO, SAIL.
Responsibility & Functions of Vigilance Department:

Prime responsibilities of Vigilance are
 to plug loopholes in the system and procedure
 to protect the honest employees
 to ensure deterrent punishment to wrong doers
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
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and Conduct Discipline & Appeal Rule 1977 provide a non-exhaustive list of misconducts for
which an employee can be punished.
Direct punitive vigilance functions involve the following:

 Carrying out prompt investigation into the complaints, which are not
pseudonymous/anonymous and are having clear vigilance angle. Besides
complaints, surprise checks also reveal discrepancies that are taken up for
detailed investigation.
 Guiding Disciplinary Authority in preparation of charge memoranda/Charge
sheets
 Presenting cases of vigilance before Inquiry Committee
 Recommending type of punishment (whether Major or Minor) for errant
employees of E3 level and below
 Taking advice of Chief Vigilance Officer (CVO) on the type of inquiry (First
Stage Advice) and type of punishment (Second Stage Advice) to be awarded to
errant employees of E4 grade and above.
 Refer vigilance cases involving employees of E8 and above to CVC through CVO
for advice on quantum of punishment to be awarded.
 Ensuring inquiry is completed within 6 months from the appointment of Inquiry
Officer and punishment order passed promptly.
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.
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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.
It examines, evaluates and provides professional opinion on its systems of financial,

operational and management controls. It is an effective management tool to ensure that
management controls are working effectively and operations are being carried out in
consonance with the overall organizational objectives. One of its major functions is to check
the compliance with established and statutory accounting system and procedures to ensure
that the final accounts represent a true and fair financial position of the company.
Internal Audit Areas:

 Audit of sanction
 Proprietary Audit
 Audit of expenditure
 Audit of conformity with generally accepted accounting principles/standards,
accounting policies of the company and statutory provisions of Companies Act,
Income Tax Act (Security Exchange Board of India) etc.
Scope & Functions:

 Reviewing the reliability and integrity of financial and operating information and
means used to identify, measure, classify and report such information.
 Reviewing the means of safeguarding the assets.
 Appraising the economy, efficiency and effectiveness with which resources are
deployed. In particular to ensure that:
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.
 Reviewing operations, activities or programmes to ascertain whether results are

consistent with set objectives and goals and whether they are being carried out as
planned.
 Conducting special/management audits and other special assignments so directed by
the Chief Executives/ Chairman/ACB.
 Coordinating the replies to the Government Audit Queries, Inspection Reports, Draft
Audit Paras, Comprehensive Appraisals and COPU Questionnaires.
 Maintaining liaison with the Statutory Auditors and to provide all assistance to
them as may be required.
 Assisting Audit Committee in ensuring transparency in the management functions
to make it an effective tool of Corporate Governance.
The exact scope of an audit, nevertheless is decided on the basis of risk analysis, previous
reports, resource availability, time and cost constraints prior to commencing an audit.
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Follow up/ Review of Audit activities:

On completion of Audit of a particular area/department a Preliminary Report (PR) is issued
to the Auditee department for compliance/ further comments. On receipt of Auditee’s
comment, the Final Report (FR) is issued to the Principal HoD incorporating the Auditee’s
comments and further comments of Audit. A copy of FR is also sent to Corporate Internal
Audit for perusal and further actions, if required. The Action Taken Report (ATR) is
subsequently issued by the Auditee. Regular follow up is done with Auditee Department to
ensure implementation of various audit suggestions. Special emphasis is given for
identification of Significant Audit Findings (SAF). The same is regularly followed up for due
compliance and the same is monitored by the Corporate Internal Audit on a regular basis
till implementation.
 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.
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MEDICAL & HEALTH SERVICES

Rourkela Steel Plant's concern for a healthy environment is symbolized by it's Medical and
Health Services. This concern has led RSP to establish a modern, multidisciplinary,
comprehensive and premier medical centre in the eastern region which has been functioning
since 1959 to provide quality medical & health
services to the employees of RSP, members of their
family, supporting population and inhabitants of the
neighboring areas of Orissa and it's adjoining states.
Equipped with state of art diagnostic facilities,
equipment and a committed task force of competent
professionals, the hospital is a centre for curative,
preventive, promotive and rehabilitative functions.
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
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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.
Post Graduate Training:

Post-graduation training (DNB): Nine Departments of IGH, namely, General Medicines,
General Surgery, Paediatrics, O&G, Anaesthesia, Pulmonary Medicine, Ophthalmology,
and Pathology have been accredited by National Board of Examinations for DNB training.
Efforts are on to have DNB training in other disciplines as well. The training imparted to
the candidates is nowhere less than any postgraduate institute and the pass percentage of
our candidates is very high.
The various units of IGH-

Surgery:
The Surgery unit includes General Surgery, Neurosurgery, Burns & Plastic Surgery,
Orthopedics and Trauma Surgery. The unit is accredited for post graduate teaching. It runs
three operation theatres and a round the clock emergency operation theatre. It carries out
microsurgery, sophisticated orthopedic and neurosurgery in addition to urological
procedures. Laparoscopic surgery for Gall Bladder is carried out for the last 15 years. So far
more than 1000 patients have received the benefit of this button hole surgery. Many critical
cases are also successfully operated by the doctors of this unit.
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.
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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.
Paediatrics and Neonatology Unit:

It has a well-equipped Neonatology Unit and Pediatric Intensive Care Unit. It is the first
hospital in the Public Sector Undertakings to establish collaboration with University of
Maryland, USA through a Global Network Funding.
UMB NICHD Research Network

Ispat General Hospital is proud to find a prominent place in the international medical
research map, by way of association in this multi-centric medical research project. This was
started in the year 2002 under the banner of Global Network Project, in association with
University of Maryland (USA), National Institute of Health (USA), ICMR and Govt. of
Orissa. In September-2008 the banner was renamed as UMB NICHD Research Network
with the project titled “Prevention of Neo-Natal Infection in the Indian setting using
Probiotics”. Under this project, currently field intervention is going on in 131 Anganwadi
centres in the operational area, where there has been significant reduction in the infant and
neo-natal mortality
Obstetrics &Gynecology Unit and Family Welfare Unit:
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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.
Chest & TB, Dermatology and Mental Health Units:

These units engaged in both preventive and curative aspects of the employees and the
general population. With the help of SAIL-National AIDs Control Organization (NACO)
initiative, it has established a voluntary consultation unit for suspected HIV-AIDs patients.
It conducts regular awareness programmes for the employees, general public, students etc.
DOTS treatment is provided free of cost to TB patients under RNTCP.
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.
Eye, ENT and Dental Units:

The Ophthalmology unit is well equipped with modern gadgets for phaco-emulsion, micro-
surgery etc. The ENT unit is recognized as the centre of excellence for removal of foreign
bodies from the respiratory tract in the infants and children. Many endoscopic procedures
and surgeries have been started for the benefit of patients.
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.
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DBT Sickle Cell Project

Ispat General Hospital along with Dept. of Biotechnology, Govt. of India, Ministry of Science
& Technology has undertaken a project “Study of morbidity patterns in sickle cell disease in
western Orissa and its correlation with different genetic factors, fetal haemoglobin
concentration and epistatic factors like malaria.
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.
Emergency and Trauma Unit:

A new emergency and trauma unit was constructed above the casualty wing. It was
inaugurated in August 2014. Equipped with dedicated OT, ventilators, monitors and life
support system, it caters to various critical and injury cases from in and around Rourkela.
New Nehru OPD:

It was inaugurated in September 2015 by CEO. The main motto of this OPD is to establish
super specialty clinic, facilitate central blood collection unit and other OPDs.
Super Specialty Clinic:

In line with the declaration by Hon’ble PM of India to develop a super specialty hospital at
IGH a Super-Specialty Clinic was inaugurated in April 2016 where Consultants in various
specialization like Nephrology, Oncology, Neurology, Cardiology etc. from Apollo Hospitals
Hyderabad shall provide consultations to patients of IGH.
Special Features of IGH:

 Established first Dialysis unit in Eastern India
 Established first Intensive Care Unit in SAIL
 Established first Burns Care Centre in Public Sector Undertakings
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 First Industrial Hospital in India to start implantation of Pace-Makers

 First Industrial Establishment in India to implant the Pace-Maker in the youngest
person (8 years old boy)
 Organised first All India Steel Doctors Conference
 PHACO Surgery for cataract started at IGH for the first time in SAIL hospitals
 First Industrial Hospital to establish collaboration with University of Maryland,
USA in Pediatrics & Neonatology
 WHO recognized the training centre of IGH for Severe Malaria.
 For the first time the Bio Chemistry Laboratory achieved the recognition of Zero
variance index score under the external quality assurance scheme conducted by
Christian Medical College, Vellore.
 A RAMP was inaugurated on 16.12.2016.
 Cash deposit machine in front of registration counter as a support for cashless
transactions.
HRD CENTRE Page:323

CENTRAL INDUSTRIAL SECURITY FORCE
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,
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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.
INDUCTION OF CISF IN RSP, ROURKELA:

In order to provide effective security coverage in RSP Rourkela including Barsua Iron
Mines, Barsua/Tensa CISF was inducted on 08.11.1971 with the strength of 1275 headed by
Deputy Inspector General. In the intervening period there was increasing/decreasing of
strength of CISF. The strength of CISF posted at Barsua Iron Mines, Barsua/Tensa that
was placed under Raw Material Department of SAIL, Kolkata, was separated in Dec 2008
and it was declared a separate Unit headed by an Assistant Commandant under the
administrative control of DIG CISF Unit RSP Rourkela. Due to such declaration, the
strength of CISF at RSP Rourkela comes to 1177. In the year 2004 there was a need of
increasing of strength of CISF because of creation of some new duty posts in Modernization
Plant, Power Gate and few of the location in Township area of SAIL RSP Rourkela.
Accordingly re-survey was conducted and the strength of CISF was increased. Now the
strength of CISF in RSP Rourkela is 1277 to 1247 headed by Deputy Inspector General.
Beside the above, various Mines Units such as MIOM/KIOM Meghahataburu, BOM Bolani,
GOMGua,BIM Barsua/Tensa and NSPCL Rourkela have been placed under the
administrative/operational control of DIG CISF Unit RSP Rourkela.
PHYSICAL SECURITY MEASURES AVAILABLE IN RSP ROURKELA:

RSP Rourkela has total 33.89 Sq. KM covered by 25 Kms long perimeter wall with proper
overhang and gates for entry/exit of men and materials. There are about 19 watchtowers in
the plant. Inside patrolling road along with the perimeter wall is also available. Adequate
lighting arrangements with Tower lights are also available. Communication facilities are
also available with sensitive duty posts. Modern Gadgetry equipments like VHF sets (GM)
Motorola , Handheld wireless Sets, Dragon Lights, HHMD, DFMD, Trolley Mirror, Pericopic
Mirror, Bomb Suppression Blanket, Bullet Proof Jackets, Night vision devices, Binacular,
CCTV Camera etc. are available with CISF. Keeping in view the present security scenario
and increasing of naxalite/terrorists activities, morchas have been placed at various gates as
well as road blockers have also been provided at the gates. Quick Reaction Team has been
introduced who are carrying out patrolling in the plant area round the clock. Crime prone
areas are identified where ambush teams are being deployed to curb crime. The unit has a
well-trained dog squad team of sniffer and tracker dogs which are being utilized for area as
well as vehicle checking at gates ,stores, parking area and all other area of plant. Major
threat to the plant has also been assessed on regular basis. Beside the above Pass system is
also available in RSP Rourkela. Passes are issued by CISF on the authentic
recommendations of authorized signatories. Various types of passes are available for making
entry/exit in RSP Rourkela. Photo Passes are issued to all RSP Employees. Separate passes
are issued to Contractor Laborers and Supervisors only on proper recommendations of RSP
Management. Laser System Identity cards for the plant’s employees are issued from CISF
Pass Section on submission of filled up applications in a prescribed proforma duly forwarded
by the HODs. Visitors are also issued with passes on submission of applications duly
recommended by CLC Department to CISF Pass Section. To make the system foolproof,
passes of all the employees, contract laborers and visitors are being strictly checked at all
the gates to avoid entry through duplicate pass.
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ACCESS CONTROL AND ADMINISTRATION:

Security of RSP Rourkela including various sensitive posts located in Township area as well
as located at a distant place such as Mandira Dam, Air Strip, Tarkera Pump House, Slag
Granulation Plant,33 KV Station etc. is effectively looked after by CISF. As per the re-
survey report, 21 gates are operating in RSP Rourkela, which is being guarded by CISF
round the clock besides 28 vital installations situated inside/ outside the plant. The security
system in the plant for countering criminal activities, are being up dated from time to time
according to threat perception and round the clock guarding around the vital installations,
important stores, all gates, escorting of railway wagons, patrolling inside and outside the
plant premises etc. is being ensured by CISF.
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: -
a. Computerized inventories in the Stores are maintained

b. Thorough verification of material movements is maintained
c. Combing operations/ambush is conducted at regular intervals
d. Strict checking of passes of employees, contractor labourers, visitors at the
gates ensured
e. Thorough checking of vehicles are made at the gates
f. Random checking is being conducted at Contractor’s stores, loading points
g. and canteens.
h. Patrolling has been intensified
i. Surprise re-weighment of loaded vehicle is being conducted
j. Dogs are being utilized during ambush/patrolling
k. Existing modern gadgetry equipment are utilized at gates
l. Scrap materials have been stored in a safer place
m. Character and antecedents of employees are verified
n. Control Room has been established at Main Gate to receive/pass over of various
information to concerned authorities.
o. Checking/surprise checking of various posts and activities are conducted frequently.
p. All the movements through the gates are being monitored by Control Room through
CCTV Cameras.
q. Flow of traffic, movement of vehicles and safety within the plant is also being
regulated/controlled in normal course.
r. Stores, Mandira Dam, Air Strip, TPH, SGP and Cash counters are guarded
effectively round the clock by the deployed static duty.
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.
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Panorama 2017
HRD CENTRE Date: 05th August 2017

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PANORAMA

ROURKELA STEEL PLANT

HRD CENTRE Page:1

ROURKELA STEEL PLANT: A RESUME

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Post Expansion Production Capacity (In Million Tonnes per annum):

Pre Expansion Post Expansion

HRD CENTRE Page:3

Major Facilities which have come up during Expansion:

Rourkela Steel Plant

the 1st Steel Plant in Asia to adopt LD process of steel making;

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PROCESS FLOW OF ROURKELA STEEL PLANT

HRD CENTRE Page:5

a) IronOre: Captive Mines at Gua, Bolani, Monoharpur, Barsua,

c) Dolomite: BF Grade –Bhavanathpur, Biramitrapur and Sonakhan

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Product Mix and Application of Products

Plates and Sheets

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Major Milestones in Rourkela Steel Plant

 21 December 1953: Agreement signed with Krupp-Demag

HRD CENTRE Page:9

 31 October 1968: Electrolytic Tinning Line commissioned in

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ORE BEDDING AND BLENDING PLANT (OBBP)

Raw materials Handled:

Sl. Raw Materials Sources

HRD CENTRE Page:11

There are total 20 numbers of Beds for stacking of different materials.

IOL Screening / Washing:

Base Mix Preparation:

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HRD CENTRE Page:13

Major Facilities and Equipment.

Equipments / Storage facilities Old OBBP New OBBP Total

Plough feeder/ Paddle feeder 2 04 06

Twin boom stacker 4 02 06

Bucket wheel Reclaimer 2 01 03

Rod mill/Hammer crusher 3series

Coke crusher 2 series 4 series 6 series

Total nos of Belt 156nos 120 nos 276nos

Page:14 HRD CENTRE

Incoming Raw Materials

Wagon Tippler Track Hopper

HRD CENTRE Page:15

The analysis is usually termed as the proximate analysis, for

Proximate Prime Coking Medium Coking

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The proximate analysis of the above-mentioned coal is:

Proximate Imported Coking Imported Coking

Proximate analysis Analysis of Blended Coal

Coal Vitrinite % Mean Max Fluidity Crucible

HRD CENTRE Page:17

At RSP, all coal wagons are unloaded in Tipplers, a device

Partial Briquetting Coal Charging (PBCC) Plant:

The Coking Process:

The typical dimension of RSP ovens are:

Length 13.59 Meters

Page:18 HRD CENTRE

Nomenclature Size End user