FR (R 0) 3379 For HSM RSP

ROURKELA STEEL PLANT
INSTALLATION OF HOT STRIP MILL

FEASIBILITY REPORT

STEEL AUTHORITY OF INDIA LIMITED
CENTRE FOR ENGINEERING &TECHNOLOGY
RANCHI - 834 002

MARCH 2012 CET/05/RN/3379/FR/RF/01/R-0

RSP CONTENTS CET/05/RN/3379/FR/RF/01/R-0
NEW HOT STRIP MILL Page 1 of 3

CONTENTS - CHAPTERS

Chapter no.

Description

Page no.
1. Summary 1.1-1.3
2. Background 2.1-2.11
3. Selection of Alternatives 3.1-3.3
4. Project Description 4.1-4. 74
5. Project Implementation 5.1-5.1
6. Financial Analysis 6.1-6.5
7. Recommendation 7.1-7.1
Annexures
Drawings

NEW HOT STRIP MILL Page 2 OF 3

CONTENTS - ANNEXURES

ANNEXURE
NO.
DESCRIPTION NO. OF
PAGES
2.6.2-1 Copy of Letter for Assignment From RSP 1
4.2-1 Tentative Product Mix
5.1-1 Implementation Schedule (Pre- Ordering Activities) 1
5.1-2 Implementation Schedule (After Stage-II Approval) 1
6.1.1-1 Capital Cost Estimate Summary 1
6.1.1-2 Detailed Capital Cost Estimate 3
6.1.1-3 Basis Of Capital Cost Estimate 4
6.1.1-4 Volume Of Work for Capital Cost Estimate 1
6.5.1.6-1 Works Cost Of Production 1
6.5.2.2-1 Gross Margin Calculation 1
6.6.1-1 Cash Flow Statement 6
6.6.2-1 Financial Analysis 1


CONTENTS - DRAWINGS

Sl. no. Drawing no. Description
1 CET RN 3379 CEO 00 001 R=0 General Layout of HSM Location
2 CET RN 3379 RF1 00 003 R=0 Layout of Proposed Hot Strip mill
3 CET RN 3379 RF1 00 004 R=0 Layout of sheet shearing Line
4 CET RN 3379 EE1 00 001 R=0 Single Line diagram of Power
distribution Scheme

RSP CET/05/RN/3379/FR/RF/01/R-0
NEW HOT STRIP MILL Page 1.1

1 SUMMARY
1.1 Rourkela Steel Plant (RSP) produces a large variety of steel
products which include Hot Rolled Coils/Sheets, Heavy Plates, Cold
Rolled Products, Pipes and Cold Rolled Non-Oriented Products. RSP
is currently modernizing/expanding their facilities. After completion of
the ongoing modernization, the crude steel production of RSP is
envisaged to be 4.2 Mtpa. The saleable products after completion of
the modernization is envisaged to be 3.99 Mtpa which includes 0.82
Mtpa of slabs.
1.2 The distribution of slabs after the ongoing expansion has been
considered as follows :
Hot Strip Mill : 1.85 Mtpa
Existing Plate Mill : 0.53 Mtpa
New Plate Mill : 1.00 Mtpa
Sales/IPT : 0.82 Mtpa
Total slabs : 4.20 Mtpa
1.3 Hot Strip Mill is the major consuming unit of slabs at RSP which
produces HR coils for sale and also for feed material to downstream
production units of RSP like Pipe Plants, Cold Rolling Mills and
Silicon Steel Mill. The existing Hot Strip Mill of RSP is an old mill
commissioned in mid 1960s. This mill has been modernized three
times in last two and half decades. The rated capacity after the last
modernisation was 1.65 Mtpa. The mill is designed for producing hot
rolled coils with strip thickness range of 1.6-18 mm, strip width of
700-1550 mm and maximum coil weight of 17 t. The average
production for last five years through this mill is around 1.55 Mtpa
(input slabs 1.593 Mtpa) with the best production of 1.61 Mtpa (input
slab 1.648 Mtpa) in the year 2007-08.
1.4 As per the ongoing expansion of RSP, the existing Hot Strip Mill will
have to process 1.85 mt of slabs per year. With ageing of the
equipment that were not modernized earlier and in view of
obsolescence of such equipment, the productivity of Hot strip mill is
low. No modernisation of the existing Hot Strip Mill has been
envisaged in the ongoing modernisation. Hence, with the present
status, the Hot Strip Mill will have difficulty in processing 1.85 Mtpa of
slabs without substantial investment. Even after processing 1.85
Mtpa form the existing Hot Strip Mill, 0.82 Mtpa of slabs remains
which will have to be sold as semis. The quality of the products, viz.,
the thickness tolerance, width tolerance, profile & shape and
metallurgical properties are inferior to those produced from modern

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mills. The mill has been designed for lower strip width (upto 1550
mm) and lower coil weight (upto 17 t). Higher strength of HR coils
cannot be produced through this mill due to limitations in the mill.
The mill will also require regular investment as some sustenance
schemes.
1.5 The quality of products from the existing Hot Strip Mill can be
improved to some extent by extensive modernisation of the mill. The
capacity can also be raised marginally through the modernisation.
This will require investment of around Rs 1200 to 1500 Crore and a
shut down of around 60 days.
1.6 Even after such investment, many of the limitations of the existing
Hot Strip Mill will remain. Around 0.67 Mtpa of slabs from RSP will
remain as semis. Maximum strip width will be upto 1550 mm and
maximum coil weight will be 17 t only. Higher grades like API X-80
cannot be rolled through this mill. The equipment, which will be
retained, will be older and may prove as weaker areas.
1.7 In view of processing the required tonnage of slabs which will be
available after the ongoing modernisation of RSP and to enrich the
product range with wider strip, higher coil weight & excellent product
quality, it is envisaged to install a new Hot Strip Mill 3.0 Mtpa
capacity with state of the art facilities. The existing Hot Strip Mill will
be phased out after stabilisation of the new Hot Strip Mill.
1.8 The envisaged Hot Strip mill will be located near the slag granulation
plant after necessary site development. The Hot Strip Mill will have
following broad parameters :
Strip thickness : 1.2 - 25.4 mm
Strip width : 725 - 2100 mm
Max. Coil weight : 35 t
Specific Coil weight : 20 t/mm (max)
1.9 Major facilities in the Hot Strip Mill will include, two nos. of Walking
Beam type Reheating Furnaces, High pressure desclaing, a 4-high
Reversing Roughing Stand with Edger, Passive covers, Crop Shear,
six nos. of 4-high finishing stands, Laminar cooling system, two nos.
of down coilers, coil conveying system, etc. The mill will have
modern control system including automatic strip width control,
thickness control, profile & shape control, metallurgical properties,
etc. to produce hot rolled coils of excellent quality. A Roll shop will be
provided adjacent to the Mill to cater to the requirements of the new
mill. A Sheet shearing Line of 400,000 tpa capacity will also be
installed for making sheets/plates from the HR coils produced


through the new mill. The existing Dividing Line will also be utilised
for producing hot rolled sheets. Supporting facilities and
infrastructures including power supply, Water & utilities, road & rail
network will also be provided at the proposed Hot Strip Mill area.
1.10 It is estimated that the project will be completed in 42 months from
the date of sanction and 36 months from the date of stage-II
approval. The project will be implemented under four packages, viz.
soil Investigation & survey package, Site development package, Rail
Network package and the Mill package.
1.11 The capital cost estimate for the New Hot Strip Mill, RSP has been
estimated to be Rs. 3879.42 Crore, net of cenvat credit of Rs. 356.03
Crore and inclusive of IDC component of Rs 192.06 crore.
1.12 Techoeconomic parameters of the project areindicated below :
Gross Margin : Rs 931.18 Crore
IRR (Pre tax) : 21.36%
IRR (Post tax) : 18.08%
NPV at 10% discount (pre tax) : Rs 2875.83 Crore
NPV at 10% discount (post tax) : Rs 1782.92 Crore
If only inhouse slabs (2.67 Mtpa) are considered, the IRR (post tax)
works out to be 16.41%.
1.13 A new Hot Strip Mill with modern features is required to roll the
required volume of slabs available after the ongoing modernisation of
RSP and to avoid sales of semis as slabs. Market requirements of
higher coil weight, wider strip, higher strength grades, excellent
product qualities, etc. will be met through the new Hot Strip Mill.
The project is technically feasible and technoeconomically viable and
hence recommended for implementation.


2 BACKGROUND
2.1 Rourkela Steel Plant (RSP) produces variety of saleable products
which include hot rolled coils & sheets, heavy plates, pipes, cold
rolled coated & uncoated coils/sheets and electrical steel (cold rolled
non oriented steel). Rolling & processing facilities at RSP to produce
these products consist of the following complexes :
Hot Strip Mill
Plate Mill
ERW Pipe Plant
SW Pipe Plant
Cold Rolling Mills
Silicon Steel Mill
A new Plate Mill of 1.0 Mtpa capacity is also under installation.
The feed material to the Hot Strip Mill and the Plate Mill are cast
slabs whereas the feed materials to the other mills are hot rolled coils
produced from the Hot Strip Mill.
2.2 Existing Hot Strip Mill
2.2.1 The 1700 mm Hot Strip Mill (HSM) of Rourkela Steel Plant was
installed in mid 1960s for producing 1.15 Mtpa of Hot rolled (HR)
coils mostly of normal carbon steels. This mill has been modernized
three (3) times in last two and half decades. The modernization
activities were carried out with different objectives related to
improvements in productivity and product quality. In the last
modernization, carried out in early 1990s, the production capacity
was enhanced to 1.65 Mtpa.
2.2.2 The existing 1700 mm Semi-Continuous Hot Strip Mill broadly
comprises of the following facilities :
- 225 t/h walking beam type reheating furnaces 2 nos.
- Primary descaler
- 2-Hi reversing rougher (R0) with vertical edger (V0)
- 4-Hi reversing rougher (R1) with attached edger (E1)

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- 4-Hi single pass rougher (R2) with attached edger (E2)
- Coil box
- Rotary crop shear
- Pinch roll scale breaker
- Finishing train comprising of six 4-Hi stands (F1 F6) with hydraulic
AGC in stands F3 F6
- Run-out table with laminar strip cooling system
.- Two downcoilers (C4 & C5)
- Coil conveying system with coil weighing, banding and marking
facilities
- Hot rolled strip shearing line
2.2.3 Main Parameters
The existing Hot strip mill is presently rolling Low carbon steels,
CRNO steels, API grade steels up to X-65. The input slab sizes and
rolled coil parameters, as designed, are as follows:
Slab Dimensions :
Parameters Designed Actual
Thickness : 180 210 mm 180 220 mm
Width : 700 1550 mm 740 1450 mm
Length : 3500 8600 mm 6000 8900 mm
Weight : 17 t max 17 t max
Transfer bar Dimensions :
Thickness : 20 32 mm 20 32 mm
Coils/Strip Dimensions :
Thickness : 1.6 18 mm 1.9 12 mm
Width : 700 1550 mm 740 1450 mm
Inner diameter : 760 mm 760 mm


Outer diameter : 1700 mm max. 1700 mm
Weight : 17 t max. 17 t max
Specific Weight : 13 kg/mm max.
Designed mill capacity : 1,650,000 tpa
Best achieved production in the mill was 1.61 MT in the year 2007-
08. Average of last 5 years production is 1.555 Mtpa of HR coils.
2.2.4 A part of the HR products of the existing HSM is used as input
material in the down stream units, viz, Cold Rolling Mill, Silicon Steel
Mill, Spiral welded pipe plant and ERW pipe plant. Balance is sold as
HR coils or HR sheets.
2.3 Ongoing Expansion/Modernisation of RSP
2.3.1 Rourkela Steel Plant is already under expansion & modernization.
Following facilities are being added/expanded during the ongoing
modernization :
A 67.7 m new Coke Oven battery
A 4060 m
3
new Blast Furnace
A new 150 t BOF at SMS-II
Secondary Refining units (1 Ladle Furnace and 1 RH-OB) at
SMS-II
A single strand Slab Caster at SMS-II
A new Plate mill of 1 Mtpa capacity (expandable upto 1.8
Mtpa in future)
After completion of the ongoing expansion/modernization, the
production level at various processing steps of RSP will be as follows
:
Hot Metal : 4.5 Mtpa
Crude Steel : 4.2 Mtpa
Saleable:
Plates from Existing Plate Mill : 0.4890 Mtpa
Plates from new Plate Mill : 0.9295 Mtpa

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Hot Rolled Coils/Sheets : 1.2454 Mtpa
Cold rolled products : 0.3017 Mtpa
Pipes : 0.1300 Mtpa
CRNO coils/sheets : 0.075 Mtpa
Total finished products : 3.1706 Mtpa
Semis (Slabs) : 0.8200 Mtpa
Total saleables (including semis) : 3.9906 Mtpa
2.3.2 Distribution of Slabs
The distribution of slabs after the ongoing expansion has been
considered as follows :
Hot Strip Mill : 1.8500 Mtpa
Existing Plate Mill : 0.5300 Mtpa
New Plate Mill : 1.0000 Mtpa
Sales/IPT : 0.8200 Mtpa
2.4 Limitations of Existing Hot Strip Mill
2.4.1 As per the ongoing expansion of RSP, the existing Hot Strip Mill will
have to process 1.85 Mt of slabs per year. With ageing of the
equipment that were not modernized earlier and in view of
obsolescence of such equipment, the productivity of Hot strip mill is
low. It was envisaged to process 1.65 Mtpa of slabs through this mill
during the last modernization in 1992. The best throughput in this mill
was 1.648 MT in the financial year 2007-08. Average throughput for
last five years is 1.593 Mtpa. Hence, with the present status, the Hot
Strip Mill will have difficulty in processing 1.85 Mtpa of slabs without
substantial investment. The quality of the products from this mill is
inferior to those produced from modern mills.
2.4.2 Limitations of the existing Hot Strip Mill of RSP can be summarized
as follows :
Production capability
The capacity of the mill, after last modernization, was rated as
1.65 Mtpa. The cycle time in roughing mill area is high due to
the present layout and limitations in existing roughing mill. The


old roughing stands R1 and R2 have become weaker with time,
resulting in low drafting and speed capabilities. Also, the
drafting and speed capabilities of R1 and R2 are much lower as
compared to present day roughing stands limiting the
possibilities of higher production.
The cycle time of finishing stands is also high because of drive
power limitations. Further, the load on finishing mill is higher
due to less drafting from the roughing mill. Work roll changing
time in this mill is more than 30 minutes whereas modern mill
has work roll change time of around 5 to 7 minutes only. The
combination of these factors restricts higher production from the
existing Hot Strip Mill.
Product sizes
The mill is designed to produce HR coils with maximum width of
1550 mm. Demand for higher width HR coils is increasing
especially for API grades. New mills are coming which can
produce strip upto 2100 mm width and hence will have
advantage on account of this. The Mill is designed to roll strip
with thickness range of 1.6 mm 18 mm. However, a strip
thickness range of 1.9 mm to 12.5 mm is being rolled from this
mill due to constraints in roughing and finishing mills. Modern
Hot Strip Mills can produce HR coils with minimum strip
thickness upto 0.8-1.2 mm which find applications as a
substitute of CR coils at various applications. Also, HR coils of
higher thickness are in demand.
Grades of HR coils
The old roughing stands R1 and R2 have become weaker with
time, resulting in low drafting and speed capabilities. Also, the
drafting and speed capabilities of R1 and R2 are much lower as
compared to present day roughing stands limiting the
possibilities of higher production and rolling of stronger Higher
strength HR coils cannot be produced through existing mill due
to limitations in drive power, poor health of equipment and other
factors. Demand of stronger material upto API X-80 is rising.
Lower Coil weight
The existing Hot Strip Mill is designed for maximum 17 t coil
weight (Specific Coil Weight 13 kg/mm). Higher coil wt. (upto
30-35 t) is preferred and is available from other mills.
Product Quality

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The basic parameters that determine the quality of HR coils are
- Width tolerance : The mill lacks Automatic Width Control
(AWC) system and there are variations in width of the rolled
strip. Width variations of the strip are of the order of +20 to 30
mm, whereas products form competitors are having width
tolerance within 0, +5 mm. Head end fishtails are also
observed in coils produced through the existing mill.
- Thickness tolerance : Thickness tolerance achieved in the
products from this mill is more than 100 m where as a
thickness tolerance of 25 50 microns are achieved at other
modern mill. HAGC was provided in finishing stands from F3
to F6 only. The existing HAGC is of older design, has poor
resolution and repeatability. The controls & automation level
are outdated. Hence the thickness tolerance achieved through
this mill is quite wide.
- Strip Profile: No provision for strip profile control has been
provided with the mill. Strip Profile of all the strip cannot be
measured as there is no profile measuring gauge installed at
the mill. In general, the profile achieved from this mill is of the
level of 100 micron whereas modern mill achieve a level of
Profile 40 60 micron.
- Strip Shape & flatness: No provision has been provided for
measurement and shape control and the shape of the strip
achieved through this mill is poor.
- Strip surface quality: Surface quality of the rolled strip is also
not up the mark as no provision for anti-peeling /oxide
suppression has been provided.
- Metallurgical properties of finished strip: The existing laminar
cooling system is of older open-loop design. The settings are
based on operator experience only and has a poor
repeatability. Hence the required metallurgical properties are
not achieved. Further, for better metallurgical properties, the
finishing mill needs a good temperature regime that can be
achieved with higher transfer bar thickness. With limitations of
drive powers in the finishing stands, the possibilities are
limited.
It can be inferred from the above that the present quality
of HR coils from RSP Hot strip mill falls far below the
present market demand and the HR coils available from
competitors.


Health of equipment
Health of various equipment which has not been modernized
during last modernization, is poor and unpredictable breakdown
occurs. These equipment need to be revamped/replaced for
long time sustenance.
2.5 Necessary Modernisation required in Existing Mill
2.5.1 A part of the mentioned limitations can be overcome by modernizing
the existing Hot Strip Mill. Major areas required of
modernization/revamping will include the following.
Roughing Mill Area
No modernization has been carried out in the existing
roughing stands R1 and R2 and the stand equipment has
inability to roll at designed speeds and drafting capability is
low. The existing roughing stands R1 and R2 need to be
replaced with a new heavy roughing stand alongwith edgers
with higher drafting and speed capabilities and automatic
width control.
The roller tables are inadequately powered w.r.t. the
increased slab weight. The roller tables are prone to frequent
breakdowns. Most of the roller tables, which are old and have
not been modernized earlier, will have to be replaced with new
roller table assemblies along with new individual AC drives.
The existing crop shear will have be modified to facilitate quick
shear blade change and to have provisions for optimization of
crop ends.
Finishing Mill Area
The finishing mill stands are operated at lower speed of rolling
than designed due to its limitations in drive system. There is
no provision for hydraulic AGC in F1 & F2. There is no
provision of profile & flatness control facility. Roll changing
time is high. Load cells have erroneous performance.
Thyristor control systems of existing DC motors are old and
have poor controllability. Existing DC drives of Finishing
stands are not sufficient for higher productivity. Also existing
drive motors are prone to break down and availability of
spares is becoming difficult. Inter-stand loopers have high
inertia, low response and not able to generate tension for
higher thickness strips. Existing inter-stand guides & strippers

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are prone to frequent break downs. Absence of inter-stand
strip cooling, oxide suppression affect strip quality
The finishing mill area need to be up-graded thoroughly for
higher power and modern quality control features so as to
achieve high productivity and better product quality.
Drive system of finishing stands need to be replaced with
higher power AC drives. Existing screw-down system and
hydraulic cylinders need to be replaced with long stroke
cylinders for achieving better thickness tolerance and
reduction in in work roll change time. Replacement of old load
cells with new load cells for better and more accurate roll force
measurement and for facilitating better AGC operations is
required. Roll bending and shifting system alongwith housing
blocks need to be provided at all stands for achieving better
profile and shape of the rolled product. Existing mechanical
mill entry guides have to be replaced with new hydraulic entry
guides and strippers having better operation and easier
maintainability. Replacement of existing roll cooling system
with new roll cooling system is required alongwith inter-stand
strip cooling system and anti-peeling system for better strip
quality and higher roll life. Existing low response electro-
mechanical loppers with high response hydraulic loopers and
tensiometer is required for better control of inter-stand strip
tension and to eliminate width variation (Necking) in the
finishing stands. New state of the art automation system with
mathematical models will have to be implemented for better
quality of the products.
Laminar cooling
Existing laminar cooling system is open-loop and is of older
design with no edge masking. The existing laminar cooling
system will have to be replaced by a new laminar cooling
system of latest design with edge masking facilities to achieve
uniform and better metallurgical properties of strip and to
achieve better coiling temperature control. ROT Roll cooling
facilities will also have be provided. The new laminar cooling
system will be linked with the microstructure control models.
Strip Measuring gauges
A new gauge house will have to be provided at the exit of the
finishing mill train with strip thickness, width, profile and
flatness instrumentation for measurement and control of strip
quality.


Down coilers
Existing entry guides will have to be replaced with new
hydraulic entry guides for better guiding of strip and better
coiling in the down coiler. Replacement of existing down coiler
pinch rolls with new wear resistant pinch rolls is also required
to reduce down time for replacement of pinch rolls and
enabling coiling of higher strength strip. Existing down coiler
wrapper rolls need to be replaced with new wear resistant
wrapper rolls to reduce down time for replacement of wrapper
rolls. Modification of existing automatic jump control system of
wrapper rolls is also needed.
Coil conveying
Augmentation of existing coil conveyors is required for
handling higher production rate and to restore health.
Roll shop
Augmentation of roll shop is required for handling new work
rolls and to match higher production requirements
Electrics
Latest state of art electrical equipment, drives and controls for
all the facilities to match with the technological requirement of
modernization scheme will be required. They broadly include
new AC drive system for the new roughing stand & edger,
finishing stands, roller tables, replacement of existing drive
regulation system with digital drive regulation system.
Automation System
State of Art level II automation and computer facilities
alongwith required instruments & actuators are required in the
Hot Strip Mill for optimizing and controlling the various
parameters for better quality of the products. Modules
required in the mill includes, Mill Tracking, Mill racing,
Rougher & Finishing mill setup, temperature set up model,
laminar cooling model, Microstructure model, Profile &
Flatness control, Slab & coil yard mapping, etc.
Sustenance schemes under AMR
Besides the modernization of the above mentioned areas,
other AMR schemes are also required to restore the overall

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health of the equipment and debottlenecking which are under
process by RSP.
If the above mentioned schemes are implemented, following benefits
are expected :
The product qualities, viz thickness tolerance, profile & shape,
width tolerance and metallurgical properties will improve.
Capacity of the mill will increase marginally.
2.5.2 Limitations to be remained after modernisation
Implementation of the schemes indicated in the preceding
paragraphs will require a capital cost of around 1200 to 1500 crore.
Even after the modernization, following limitations will remain with
the existing Hot Strip Mill.
The mill cannot accommodate the required tonnage of slabs
which will be produced at RSP after the ongoing
modernization. Approximately 0.70 Mtpa of slabs will remain
as semis even after complete modernization of the existing
Hot Strip Mill.
Maximum strip width will remain to be lower (upto 1550 mm)
Coil weight will remain to be lower (17 t max).
Higher grades like API X-80 cannot be rolled in this mill.
The equipment, which will be retained, will be older and may
prove as weaker areas in getting full benefits of the
modernization.
2.6 Plan for New Hot Strip Mill
2.6.1 The existing Hot Strip Mill has limitations in accommodating the
required quantity of slabs which will be available after the ongoing
modernization of RSP. The mill is designed for lower width and lower
coil weight. Higher strength HR coils cannot be produced through
this mill due to limitations in Roughing & Finishing mill. The
equipment condition is not up to the mark due to its age. Many of the
equipment is becoming obsolete and spares availability is getting
difficult. Electrics, control and automation system is outdated.
Products quality w.r.t. dimensional tolerances and metallurgical
properties are inferior to those available from competitors.


A thorough modernisation of the existing Hot Strip Mill will be
required to improve the quality, specially the dimensional tolerances,
of the rolled products and to restore the health of the equipment for
long term sustenance. Productivity of the mill can also be raised
marginally with the modernisation and the mill. The investment
required for this modernisation will be around Rs 1200 to 1500 crore
However, around 0.70 Mtpa of slabs of RSP will remain as semis
even after the massive modernisation. Other basic limitations of the
mill like lower width, thickness limitations, coil weight, limitation of
producing higher strength coils, etc. will remain.
In view of the above, RSP plans to install a new Hot Strip Mill with
wider product range (strip width upto 2100 mm and strip thickness
from 1.2 mm to 25.4 mm) with state of the art facilities. The mill will
have the capacity of 3.0 Mtpa of slabs rolling Out of the total 3.0
Mtpa, 2.67 Mtpa will be inhouse slabs and balance 0.33 Mtpa of
slabs will be purchased/IPT.
The existing Hot Strip Mill will be closed after commissioning
and stabilization of the new Hot Strip Mill. However, the existing
Sheet Shearing Line (Dividing Line) will be retained for
producing the sheets/plates from the HR coils produced
through the proposed Hot Strip Mill.
2.6.2 CET has been assigned vide RSP letter no. AMR-
M&SC/Consulatancy/15/433-37 dated 17.03.2011 (copy enclosed
Annexure 2.6.2-1) for feasibility study of the proposed Hot strip Mill.
Accordingly, draft feasibility report was submitted by CET in August
2011. Subsequently, discussions with RSP on the draft FR was held
in February 2012 and the FR has been finalised accordingly.
2.6.3 The co-operation provided by RSP and other agencies in preparation
of this report is gratefully acknowledged.


3 SELECTION OF ALTERNATIVE
3.1 Approximately 1200 m x 600 m area will be required for installation of
the Hot Strip Mill. Following two alternatives were considered for
location of the proposed facilities :
Alternative-I :Near Hanuman Vati
Under this alternative, the proposed Hot Strip Mill will be located
outside the existing plant boundary near Hanuman Vati.
This site is farther from the existing RSP boundary. All the
infrastructures will have to be created at this site. Longer network of
railways tracks, longer gas and water pipelines, etc. will be required
at this site. There is a water lagoon between the existing boundary of
RSP and this site which has to be taken care for making the
infrastructure. Power corridor is also passing through this site.
Alternative-II: Near Slag Granulation Plant
Under this alternative, the proposed Hot Strip Mill will be installed
near the slag granulation plant. This site was earlier used for
dumping Blast Furnace slag which is not in use at present. This site
is adjacent to the existing plant boundary. The facilities for the
proposed mill will be partly inside and partly outside the existing plant
boundary (major area will be outside the existing plant boundary).
The location is indicated in Drawing no. CET RN 3379 CE0 00 001
R=0.
A road is passing between RSPs existing boundary and this site
which will have to be diverted. Rail network is already existing near
this site which will have to be further extended/strengthened.
Creating infrastructures will be easier at this location.
Selection of alternative
Site under alternative-II is adjacent to the existing plant boundary
and it will be easier to create required infrastructures for the
proposed Hot Strip Mill. Hence, this site is more suitable and is
selected. for the proposed Hot Strip Mill.


4. PROJECT DESCRIPTION
4.1 It is envisaged to install a Hot Strip Mill alongwith a Sheet Shearing
Line at Rourkela Steel Plant. The Hot Strip Mill will be designed for
rolling 3.0 Mtpa of slabs. A new sheet shearing line of 0.40 Mtpa
capacity will also be installed within the proposed Hot Strip Mill
Complex. The existing Sheet Shearing Line (Dividing Line) will also
be retained and will be utilized for production of sheets from the HR
coils produced through he proposed Hot Strip Mill.
The proposed Hot Strip Mill will be located near the Slag Granulation
Plant. Location of the proposed mill is indicated in Drawing no. CET
RN 3379 CE0 00 001 R=0.
4.2 Main Parameters
Broad Parameters of the proposed Hot Strip mill will be as follows:
Slab dimensions
Slab thickness : 200 300 mm carbon steel
Slab width : 725 2100 mm
Slab length : 5000 11000 mm
Slab weight, max : 35 t
Strip dimensions
Strip thickness : 1.2 25.4 mm
Strip width : 725 2 100 mm
Coil weight, max : 35 t
Spec. coil weight : max. 20 kg/mm
Rated Production Capacity : 3.00 Mtpa (Input slabs)
2.94 Mtpa (HR coils)
Main Steel grades
Carbon structural steels
HSLA
Low carbon steels
High strength steels
LPG cylinder steel
Line pipe steels up to API 5L X80
Steels for Automotive applications
Boiler and pressure vessel quality

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DDQ and EDDQ - steels
CQ steels
CRNO
A tentative size wise product mix is indicated at Annexure-4.2-1.
The new Hot Strip Mill will be equipped with advanced control
systems in roughing and finishing mill for rolling of strips with best
tolerances for strip thickness, strip profile, strip flatness, strip width,
final rolling and coiling temperature.
Layout of the Hot Strip Mill is indicated in Drawing no. CET RN 3379
RF1 00 003 R=1.
4.3 TECHNOLOGICAL FACILITIES
4.3.1 SLAB YARD
Slabs coming from the Steel Melting Shops will transported by
railway wagons.to the Hot Strip Mill and will be stored in the slab
storage yards. The slab yards will have storage capacity for
approximately five days. The slabs stacked in the slab yard will be
picked up by overhead crane and placed onto the slab yard roller
table. Slabs will be weighed and measured before transported further
on to the charging roller table in front of the furnaces.
4.3.2 REHEATING FURNACES
Two nos. of reheating furnaces will be provided to heat & soak the
input slabs to the required rolling temperature. The reheat furnaces
will be of walking beam type.
4.3.2.1 Charging & Discharging Equipment
Slabs as received will be perfectly aligned automatically and
positioned in front of furnace and then pushed into the furnace with
the help of pusher. The pushed slab will be carried to discharge side
with the help of walking beam mechanism. From discharge position
the extractor will lift the slab and put down the same on discharge roll
table
4.3.2.2 Reheating Furnace
The envisaged major technological parameters are as mentioned
below :

Type Walking Beam Furnace with two row
charging
Capacity 300 tph based on cold slabs (for reference


size)
Quantity(No. of Furnaces) 2 nos.
Reference slab size Length : 6-10m
Width: 1500 mm
Thickness : 250 mm
Fuel gas Duel Fired Furnace with provision of
firing with Furnace Oil (LCV -9500
kcal/kg) & Mixed Gas (LCV -3600
kcal/Nm3)
Input material
Charging temperature 20
o
C (cold)
Discharge temperature 1280
o
C max.
Temperature difference
(surface and core)
25
0
C max.
Specific fuel consumption 0.3 Gcal/t (on yearly average basis) at
furnace discharge
Skid cooling Water
Charging by pusher
Discharging by extractor
Walking beam furnace skids will of high temperature and wear
resistant steel with high rigidity. The furnace will be packed from
inside with refractory and insulation material to limit the furnace skin
temperature to about 500 C above ambient temperature. The
movement of the walking beams will be hydraulic. A pair of movable
skids walking beam will have central driving mechanism. One cycle
of operation consists of lifting, forward movement, lowering and
reverse movements of walking beams during which slabs will be
advanced by predetermined distances. Hydraulic power pack will be
provided for the movement of the walking beams. Centralised grease
lubrication system will also be provided for the furnaces
Combustion System
The combustion system will include the following:
1) Burners
2) Combustion air piping
3) Mixed Gas & Furnace Oil Piping
4) Combustion air blower
5) Metallic recuperator for air preheating
Three nos. of Combustion Air Blowers (2W+1S) with VVVF drive
have been envisaged for furnace.

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Air Recuperator
A metallic recuperator will be installed in the flue channel to preheat
the combustion air to about 650 oC. The recuperator will be cross-
counter flow type. Dilution air fan & Hot Air Bleed will be provided for
protection of recuperator
Waste Gas Flue Exhaust System
Waste gases from furnace will be taken out through the opening
provided on the charging end, and will be exhausted to atmosphere
through underground tunnel with forced draft fan & chimney of
adequate height. The system will be so designed that waste gas
temperature at the base of the chimney will be kept around 250 deg
C.
Combustion System
The combustion system will include the following:
1) Burners
2) Combustion air piping
3) Synthetic Gas Piping
4) Combustion air blower
5) Metallic recuperator for air preheating
Three nos. of Combustion Air Blowers (2W+1S) with VVVF drive
have been envisaged for furnace.
Air Recuperator
A metallic recuperator will be installed in the flue channel to preheat
the combustion air to about 550
o
C. The recuperator will be cross-
counter flow type. Dilution air fan & Hot Air Bleed will be provided for
protection of recuperator.

Waste Gas Flue Exhaust System
Waste gases from furnace will be taken out through the opening
provided on the charging end, and will be exhausted to atmosphere
through underground tunnel with forced draft fan & chimney of
adequate height.
4.3.3 HIGH-PRESSURE WATER PRIMARY DESCALER
Once the slabs have exited the reheat furnace, they will be
transported via a roller table into a high pressure water descaling
unit. During the reheating process an oxide layer (scale) will form on
the slab, which, if not removed, will be rolled into the surface of the
product causing surface defects and reduced product quality. In


order to ensure optimum product quality, the slabs are descaled to
remove the oxide layer.
The process of scale removal will broadly consist four adjustable
headers (two top, two bottom) with flat-jet nozzles delivering water at
high pressure and suitable flows. Two of the headers will be
operational and two of the headers will be standby. The headers are
enclosed in a descaler hood to collect the water and scale. Chain
curtain will be provided at entry & exit of the descaler. Main
parameters of the primary descaler are indicate below :
Number on top headers : 2
Number of bottom headers : 2
Operating pressure : 240 bar
4.3.4 ROUGHING MILL AREA
The Roughing mill area will consist of a 4-high Reversing Roughing
stand. A vertical edging stand will be provided at the entry side of
each Roughing mill stand.
4.3.4.1 Vertical Edger
The Edger will be capable of taking a maximum draft of up to about
100 mm. It will be equipped with Hydraulic Automatic Width Control
(HAWC) to permit quick width taper adjustments during rolling.
Spindle change device for splined cardan shafts will be provided.
The Edger will improve finished width tolerance, minimize plan view
shape errors and enhance edge quality.
Parameters of edgers
Roll Diameter (grooved rolls) : 1200 / 1100 mm
Maximum roll separating force : 700 t
Maximum width reduction : 100 mm
4.3.4.2 Roughing Stand
The 4-high Roughing mill stand will be situated directly after the
edger and the work rolls are driven by AC drive with two motors with
ski control. Work roll bearings will be four rows tapered bearing. Back
up roll bearings will be keyless type oil film bearings. Top backup roll
will be hydraulically balanced by cylinder located in housing
separator. For work rolls balancing, hydraulic cylinders will be
located in maewest blocks. Back up roll balancing cylinders will be
mounted on the top of the housing. Spindle of cardan shaft design

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with spindle balance and spindle head holding device will be
provided. Mill window liners of duplex material will be provided with
greasing system, The stand will be provided with electro-mechanical
screw down system and hydraulic roll force cylinders and control
system. Two nos. of hydraulic roll force cylinders (one at operator
side and one at drive side) will be mounted on the top of the mill
window. Hydraulic roll force cylinders will be equipped with pressure
and position transducers. The Automatic Gauge Control (AGC) in
conjunction with roll allignment control will be provided to control
thickness, wedge and camber. The roll force hydraulic cylinders will
be fed by high pressure hydraulic system. Other hydraulic cylinders
will be fed by low pressure hydraulic system. Roll cooling headers
The entry and exit side of the stand will be provided with roll cooling
headers. Hydraulically operated Entry guide ledges will be provided
at each side of the stand to centre the slab. Mechanised Quick Work
Change System will be provided for work roll changing. Back-up roll
change is carried out by means of a hydraulic cylinder. The work rolls
and the back-up rolls are placed by crane onto the roll transfer car
which transports the rolls to the roll shop.
Oxide removal headers (top & bottom) will be provided at entry and
delivery guides to direct water to top and bottom of the strip surface
to remove oxide dust. Descaling headers will also be provided at the
roughing stand.
Load cells will be installed between the sledge and the bottom back
up roll chocks.
4-high roughing stand parameters
Mill configuration : 4-high
Work roll diameter : 1250 mm 1130 mm
Work roll barrel length : 2250 mm
Back-up roll diameter : 1600 mm 1440 mm
Roll separating force : 5500 t
4.3.4.3 Delay Table and Passive Cover
After the final roughing pass the transfer bar is transported along the
delay table, which comprises the heat retaining passive cover
system. Passive cover serves for saving temperature of the transfer
bar and for reduced temperature drop between head end and tail
end. Consequently, passive cover helps to achieve a smaller
minimum strip thickness and more consistent final material
properties. The passive cover will consist of a group of insulating


panel located on the delay roller table after the 4-high roughing
stand. Each module of the passive cover can be lifted hydraulically.
Suitable protection will be provided at the entry of the passive cover
to protect it from the curved transfer bar ends.
4.3.4.4 Transfer Bar Reject System
Bar reject device will be provided between the roughing stand and
the finishing stand to reject transfer bar, if required. The system will
mainly consist of suitable nos. of pushing devices actuated by
hydraulic cylinder. Rejected transfer bar, pushed of the rolling line,
will be positioned on skid mounted supports aside the rolling line.
4.3.5 CROP SHEAR
Behind the passive covers, a drum-type crop shear will be provided
to shear and square off the head and tail ends of the transfer bar.
The crop shear will consist of drum housing, drums with shear
knives, knife drums bearings and the drums AC drive system. Knives
will be locked on drums with hydraulic quick unlocking device. The
crop shear is equipped with a crop optimization system to minimize
the yield loss.
The scrap produced will be disposed into scrap buckets via a chute.

Hydraulically adjustable entry guide will be provided at the entry of
crop shear to guide the transfer bar into the crop shear and keep it
centered. Feed rollers will be provided at entry and exit of the crop
shear.
Broad parameters of the crop shear are indicated below :
Shear Type : Start-stop Rotary Drum-type
Maximum bar cross section : 2,100 x 76 mm (API X 80)
4.3.6 FINISHING MILL AREA
4.3.6.1 Secondary Descaler
A secondary descaler alongwith pinch rolls will be provided before
the finishing mill for descaling the transfer bar before entering into
the finishing mill. The pinch rolls will drive the transfer bar through
the water nozzles at uniform speed and will also stop water from
flowing back on the transfer bar and prevent chilling.
The secondary descaler will consist of two nos. of top and two nos.
of bottom headers with flat type nozzles housed in a spray hood,
solenoid operated valves, etc. Descaling system pressure will be 200
bars (indicative). The spray hood will have flaps with replaceable

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wearing plates driven by pneumatic cylinder to stop high pressure
water from spray backwards.
4.3.6.2 Finishing Mill Train
The finishing mill will consist of six 4-high, fully hydraulic mill stands
(F1F6). Finishing mill train will mainly comprise of the following
facilities :
Guides
Entry and exit guides arranged ahead and at back of the stands
afford guiding action to the strip as it passes the stands
Mill stands
Six nos. of finishing stands will be installed in the finishing mill. Each
stand will be of 4-high configuration.
Mill drive with AC motors, reduction gear box and pinion stands will
be provided. Cardan shaft/ geared spindles with spindle balancing
and head holder will be provided. Work roll bearings will be four
tapered roller bearing. Back up roll bearings will be keyless type oil
film bearings. Top backup roll will be hydraulically balanced by
cylinders mounted at the housing top. Work rolls will also be
hydraulically balanced by cylinders mounted in Maewest blocks. Mill
window liners of duplex material will be provided with greasing
system. Two nos. of long stroke hydraulic roll force cylinders (one at
operator side and one at drive side) will be mounted on the top of the
mill window. Hydraulic roll force cylinders will be equipped with
pressure and position transducers. The initial roll gap setting and
automatic Gauge Control (AGC) is provided via hydraulic gap setting
cylinders The roll force cylinders will be fed by high pressure
hydraulic system. Other hydraulic cylinders will be fed by low
pressure hydraulic system. Load cells will be provided between the
sledge and the bottom back up chocks.
The finishing stands will use shaped work rolls (contoured rolls) with
roll bending and shifting mechanism for control of strip profile and
flatness for the strip. Hydraulic cylinders for positive work roll bending
will be mounted in the Maewest blocks. The positive work roll
bending cylinders will also serve for work roll balancing. Hydraulic
cylinders for negative work roll bending will be mounted in back up
roll chocks. Further, hydraulic cylinders will also be provided at the
maewest blocks for work roll shifting.
Stripper will be provided at entry and exit of each mill stand so as to
guide the transfer bar head and also to prevent the contact between
the cooling water and the strip surface. These strippers will be


adjusted by pneumatic cylinders. The entry and exit side of the stand
will be provided with roll cooling headers.
Quick Work Roll Change system will be provided for work roll
changing in all the stands. Steel sledge for back up roll change will
be located between the bottom back up roll chocks and the mill
housing bed plate.
Work Roll cooling headers will be provided at entry and exit sides of
each rolling stand. Work Roll Cooling header on the entry side will be
located only in top position, while in exit side are located on top and
bottom position. All headers will be mounted on guides. Backup roll
header will be located on entry side on top position. Further, anti-
peeling cooling sprays will be provided at entry side of the stands
which will cool the strip in proximity of the roll bite to avoid damage of
the chromium oxide of the work roll.
Roll bite lubrication will be applied at first four finishing stands to
reduce friction and therefore to reduce separating force and limit roll
wear. The roll bite lubrication system will premix and store a mixture
of lube and water in right proportion to feed a spray system. This oil-
water dispersion will be sprayed at the roll bite through auxiliary
headers & nozzles. One no. of header will be provided at top and
bottom work roll each. Each header will be divided into different
spraying zones so as to optimize oil consumption as per the strip
width.
The mill stands F1 to F4 are equipped with roll gap lubrication
devices.
Parallel neck taper roller bearing alongwith, thrust bearing at the
operator side will be considered. Keeper plate will be swevelling type
mounted on shifting cylinder barrel. Pass line adjustments will be
through shims.
Main parameters (Indicative)
Number of mill stands : 6
Mill configuration : Type 4-high
Work roll diameter (F1-F4) : 850 750 mm
Work roll diameter (F5-F6) : 720 620 mm
Work roll barrel length : 2550 mm
Back-up roll diameter : 1600 1440 mm
Back-up roll barrel length : 2250 mm

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Back-Up roll bearing : Keyless oil-film type
Mill stand force (F1-F4) : 5000 t (max)
Max. mill stand force F5-F6) : 4000 t (max)
Drive Power : 10,000 kW
Work roll bending (each chock) : 200 t max ( F1-F4).
Work roll bending (each chock) : 160 t max (F5-F6).
Work roll shifting stroke : +/- 150 mm (max)
Maximum rolling speed : 20 m/s
Roll force cylinders max stroke : 200 mm
Inter stand loopers
Low-inertia hydraulic looper will be provided between the finishing
mill stands to ensure constant strip tension between two successive
stands and a stable rolling process. Hydraulic actuators will be
directly connected to the loopers arms. Each looper system will
comprise of a looper table assembly , idle roller, hydraulic cylinder &
servo valve for tilting the looper table. Each looper will be equipped
with two load cells, mounted at each side of the idle roll for
measurement of strip tension at drive and operating side for the
control of the strip tension and levelling control.
Oxide blowing system
Top and bottom spraying headers will be provided on mill stands
delivery guides to direct water to top & bottom at strip surface close
to the roll bite in order to avoid mill scale powder formation and
consequently scale fume emissions.
4.3.7 RUN OUT ROLLER TABLE WITH LAMINAR STRIP COOLING
SYSTEM
The run-out table will be provided downstream of the finishing mill
and serves to convey the strip through the laminar cooling line. The
run out roller table will have hollow rollers individually motor driven.
A run out laminar strip cooling system will be provided in the area of
run-out table for cooling the strip down to the required coiling
temperature in order to ensure the required metallurgical properties.
The laminar strip cooling system is equipped with upper and lower
cooling headers for cooling both the top and bottom strip surface.
The run out cooling system will be a U-tubes banks on the top and


blanks of multiple nozzles headers on the bottom. Bottom strip
cooling headers will also be utilized to cool roller table rollers. The
header will be closed/opened by proportional valves according to the
strip thickness, speed and temperature at inlet, so as to assure the
metallurgical properties of the end product. The top headers can be
hydraulically raised in emergency cases.
The laminar cooling section will have different zones so that different
cooling strategies can be applied for various steel grades of the
product mix. Different zones will work in combination with
microstructure control model.
4.3.8 ROLLER TABLES
Roller tables at all locations will consist of roller tables frames, apron
with guides, roll assemblies with individually driven AC drives, roller
cooling system, and automatic bearing lubrication.
4.3.9 DOWN COILER EQUIPMENT
At the end of the run-out roller table, two nos. of down coilers with
the pinch roll units will be provided for coiling the hot rolled strip.
A hydraulically operated side guide will be provided before each
pinch roll unit to position the strip.
The pinch roll unit feeds the strip into the coiler and generates the
strip tension required for the coiling operation. The pinch roll gap is
set by position controlled hydraulic cylinders according to the
relevant incoming strip gage. After threading the strip into the pinch
roll gap, the cylinders are switched to pressure control mode to apply
the necessary force to the strip (depending on strip gauge and
material).
The coiler will be designed as a 3 or 4 hydraulically operated
wrapper rollers with step control.
Pinch roll polisher will be provided for online polishing/grinding of
pinch rolls.
Main parameters of down coilers (Indicative)
Type : 3 or 4 roller type, hydraulically
actuated
Maximum coil weight : 35 t
Specific coil weight : 20 kg/mm

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A strip catcher will be provided downstream of down coiler no. 2 to
stop the strip head end for safety in case of failure of the pinch roll
and down coiler. The strip catcher will consist of a steel curve chute
and carry over apron.
4.3.10 COIL HANDLING AND TRANSPORT SYSTEM
From the coiler the coils will be removed by a coil car and
transported to a coil banding station. One coil car will be provided for
each down coiler. Traverse of the coil car will be through hydraulic
motor. Elevation of the coil cars rollers will be done hydraulically. At
the coil banding station, circumferential strapping of the coil will be
done with the help of banding machine. An automatic coil marking
unit will also be provided.
After this, the coils are transported to walking beam type coil
conveyors. The walking beam coil conveyor will consist of a fixed
supporting frame and a walking beam which through a rectangular
motion, lifts and transfers the coil from one saddle to the next one.
Coil tilters, lifting mechanism, turn table will be provided as
necessary.
Sample collection and inspection station will be located at the
walking beam conveyor. Coil will be picked up by a coil transfer car
and positioned on the coil rotating rig. Sample will be cut with the
help of robotic cutting arm.
Strapping station will also be provided along the walking beam
conveyor. Circumferential and radial strapping of the coils will be
done at the coil strapping station. A strapping machine will be
provided each for circumferential strapping and radial strapping. The
strapping machine will broadly consist of the machine car running on
rails, strap chute, strap dispenser and pneumatic & hydraulic
components. The strap dispenser will be actuated pneumatically.
A coil weighing station will be provided along the coil conveyor
downstream of strapping station..
4.3.11 COIL STORAGE
The coils from the walking beam conveyor will be picked up by
overhead cranes and placed in the coil storage yards. Coil saddles
will be provided to support the coils and allow to dispose them on
multiple rows. The coil storage yards will have the capacity to store
the coils of one week production. Facilities for automated loading and
storage will be provided in the coil yard.


4.3.12 SHEET SHEARING LINE
4.3.12.1 A Sheet Shearing Line of 400,000 tpa capacity will be installed within
the proposed Hot Strip Mill Complex to produce sheets/plates from
the HR coils produced. The sheet Shearing Line will be installed in a
separate bay parallel to the coil storage bays. The sheets/plates
produced through this line will be dispatched from the same bay
(shearing line bay).
4.3.12.2 Main Parameters
Main parameters of the Sheet shearing Line are indicated below :
Inner dia of input coils : 762 mm
Outer dia of input coils : 1,2002,150 mm
Maximum coil weight : 35 t
Hot strip thickness : 5.0 - 25.4 mm
Hot strip width : 1000 - 2100 mm
Max. sheet length : 5000 mm
Maximum : 10 t
Maximum Line speed : 40 m/min
Max threading speed : 15 m/min
4.3.12.3 Description of technological facilities
The technological layout of the Sheet Shearing Line is indicated in
Drawing no. CET RN 3379 RF1 00 004 R=0.The input coils will be
placed onto the coil loading skids by overhead crane. Three skids will
be provided for storing the input coils to be fed to the pay-of reel.
From the skids, a coil car will pick up the coil and will transport to the
payoff reel. The pay-off reel and processor roll are equipped with a
strip centering control system for proper centred strip guiding within
the line. The two pressure rolls will be used for the strip threading as
well as to prevent back-turning of the pressure roll due to back-
pushing of the strip during coil opening procedure. The processor roll
will be used for threading and processing during strip unwinding,
horizontally and vertically adjustable as a function of strip gauge and
material strength A pinch roll unit will transport the strip to the leveler
and also provide the required strip tension. The pinch rolls will be
hydraulically adjusted in accordance with strip thickness, strip width
and material strength. Side guides will be provided before the leveler.

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Two multi roll strip levelers will be provided to improve the flatness of
the strip. The strip leveller will be equipped with multiple levelling
rolls, backed-up by supporting rollers. Top levelling rolls are
adjustable under levelling load by means of hydraulic cylinders.
Hydraulic adjustment of the top levelling rolls is provided with super-
imposed levelling gap control. Compensation of the crossbeam
deflection is provided by means of a pre-bending system for the top
levelling rolls. With the pre-bending system better levelling results of
plates with wavy edges or centre buckles can be achieved.
Individually adjustable bottom rolls are provided in order to allow the
required shape of the levelling gap to be obtained as a function of
strip gauge and material strength.
The strip, after leveler, will be fed to the flying cross cut shear
through pinch rolls. Cutting of strip through the flying shear will be
achieved mechanically by a flywheel. The top blade will be fixed and
bottom blade moves up and cutting method will be downside up Gap
between the blades can be adjusted by motor. Change of blades will
be done by cartridge mode extraction of blade holders. Two
measuring rolls coupled with encoders will be provided for
measurement of length for shearing action. An expandable runout
conveyor will be provided to co-ordinate the motion of the flying
shear with the line. This will be a driven by AC motor belt type
conveyor. The conveyor will automatically adapt its length to the
motion of the flying shear.
A paint marking machine will be provided for marking the finished
plates during transfer on the roller table to the piler.
The piler will comprise of two piling positions and will be arranged for
automatic plate pile changing for plates up to eight meter length.
Another piler will be provided for stacking rejected sheets. The Piler
will be provided with tiltable roller conveyors for providing straight-
sided plate piles in longitudinal direction. The piler will be equipped
with stops for head and tail end of the plates for proper piling. Two
hydraulically operated lifting tables will be located under the piler.
Two separate pile transfers will be used for transport of the plate
piles from the two piling sections to the discharge roller table. Two
lifting tables will hand over the packages from the pile transfers to
the discharge roller table sections. The pile weighing system will be
incorporated in the discharge lifting tables. The weighing system
incorporates a weight card printer and a data memory for data
transfer. Discharge roller tables will be provided for further transfer of
the piles. Mechanised strapping system will be provided to make the
packets.


4.3.13 ROLL SHOP
A Roll Grinding and repair shop will be provided adjacent to the
proposed Hot Strip Mill. The roll shop will be utilized to grind the work
& back up rolls of the new mill, grinding of the shear blades, repair of
the bearings and other associated services. The Roll shop will
comprise of the following main facilities :
- CNC Roll Grinders (5 nos.)
- Roll cooling stands
- Roll handling tackles for handling single/double rolls with
chocks
- Back up and Work rolls chock extractors (2 nos.)
- Roll chock tilter
- Back up roll chock washing station with high pressure hydro
washer
- Work roll chock & bearing cleaning tank
- Roll washing machine
- Set of roll racks
- Rack for grinding disks
- Storage rack for knives
- Jib cranes at required locations.
- Set of instruments including, Portable digital thermometer,
Portable internal & external micrometers, Filler gauges, Depth
gauges, vernier caliper, BUR neck taper measurement gauge-
Bevel measurement, Portable Ultrasonic Crack Tester
Portable Hardness tester Portable Roughness tester
All the roll grinding machines will be CNC controlled. Out of the total
5 grinding machines, three will be designed for grinding finishing
stands work rolls, shear knives and edger rolls. Balance two will be
designed for grinding Finishing mill back up & work rolls and
Roughing stand back up & work rolls. Grinding of work rolls can be
performed with chocks with the rolls.
A workshop will also be provided with adequate numbers of machine
tools.

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4.3.14 EOT CRANES AND MATERIAL HANDLING
Overhead EOT cranes will be provided at different locations of the
Hot Strip Mill as indicated below :
Slabs Yards : 4 nos. (2 in each bay)
Furnace Charging : 2 no.
Furnace bay : 1 no.
Mill bay : 3 nos.
Roughing stand motor bay : 1 no.
Finishing stands motor bay: 1 no.
Coil storage & dispatch bays: 6 nos. (3 nos. in each bay)
Sheet Shearing Line & dispatch: 3 nos.
Roll shop : 3 nos.
Scale Pit : 2 no.
Suitable handling facilities will be provided at other auxiliary areas
including pump house, compressor, etc.
Two transfer cars will be provided between the mill bay and the roll
shop for inter bay transfer of rolls. A transfer car will also be provided
between mill bay to motor house.
4.3.15 HYDRAULICS & LUBRICATION
4.3.15.1 Oil-Hydraulic System
Broad details oil hydraulic system will be as below:
i) The flow and pressure for the systems will be selected by the
Bidder, based on the system requirement.
ii) Filters used will be duplex type with electrical clogging
indicators. rating of the filters will be as per system
requirement. ratio will be 200. Flow capacity of pressure
line filters will be 2 times the maximum flow rate of pumps
and flow capacity of return line filters will be 3 times the total
flow rate of pumps.
iii) Mineral oil will be used.
iv) The tank capacity will be minimum 5 times the capacity of
main pump.


v) The different velocities to be considered for the system will
be as below:-
For suction lines 1.0 m/s (maximum)
For pressure lines 5.0 m/s (maximum)
For return lines 3.5 m/s (maximum)
vi) For the pipelines, size up to DN 30, inside diameter will be as
per DIN 2391/C. Connection will be by welding cone screw
coupling with O-ring seals according to DIN 2353. For sizes
above DN 30, inside diameter will be as per DIN 2448 and
will be connected by flanges. Pipelines and fittings will be as
per system requirement.
vii) The air breathers will be desiccant type.
viii) The system will be designed with oil level monitoring in the
tank, pressure monitoring in the system, temperature
monitoring etc.
ix) The Power Pack will be provided with tray at the bottom for
taking care of leakage of oil.
x) Off-line filtering-cum-cooling system will be provided. Capacity
of pump (lpm) will be 1/10
th
of tank capacity
xi) The number of standby pumps will be as below:
Number of normally
operating pumps
Number of standby pumps
1 - 4 1
5 - 8 2

4.3.15.2 Grease Lubrication System
Broad details for Grease Lubrication System will be as below:
i) Centralised motorised dual line grease lubrication system
ii) The system will be 1 No. working and 1 No. standby for main
pumps with reservoirs, filters, relief valves, change over
valves etc.
iii) Refilling pump, main pumps, change over valves will be
electric motor operated.
iv) Pipe sizing will be carried out based on actual pressure drop
calculations. However, minimum pipe sizes will be as below:
Pipe Zone Pipe OD (mm) x
pipe thickness
(mm)
Material of pipe

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Pipe Zone Pipe OD (mm) x
pipe thickness
(mm)
Material of pipe
Main header 30 x 3 DIN 2391 C
Branch lines from main
header up to inlet of
distributors
20 x 2 DIN 2391 C
Feed lines from
distributors up to inlet of
bearing points
10 x 2 DIN 2391 C
v) The system will be operated based on end pressure relays as
well as timers.
vi) Reservoirs for main pumps will have minimum capacity of 100
litres.
vii) 1 No. grease refilling pump with provision of easy taking out or
putting in of the refilling pump inside the barrel, like provision
of a hand operated winch, will be provided.
viii) Operating period will be considered as 24 hours per day.
4.4 UTILITY FACILITIES
4.4.1 Compressed Air System:
Compressed Air will be required for pneumatic valve actuation,
camera cooling etc for furnace and mills as well as for furnace oil
atomization in the furnace. The approximate requirement for the
same will be
Mill including Reheating Furnaces - 1000 Nm3/h
Furnace Oil atomization - 5000 Nm3/h
The compressed air for oil atomization will be utilized occasionally
when furnace will be fired by furnace oil. Above mentioned
requirement for Compressed Air will be tapped from the grid near the
old HSM. The compressed air system will be complete with driers
and compressed air piping to different consumers
4.4.2 Fuel Oil System
For normal operation Furnace will be fired by Mixed Gas. However in
case of occasional gas shortage the Reheating Furnace will also be


capable of firing through Furnace Oil. Furnace oil for the purpose will
be brought from old HSM through pumping. For this purpose a
furnace oil pump house will be installed at old HSM. To maintain the
flow ability of furnace oil electric tracing of oil pipelines have been
envisaged. A day tank of 100 kl capacity will be installed in the new
HSM along with oil supply system to the Reheating Furnace.
4.4.3 Other Utilities
Nitrogen for purging of gas line will be tapped from existing DN600
header near column no. B-71. Oxygen required for general purpose
cutting etc at a pressure of 18-20 bar will also be tapped near
column B-71. All the utility pipelines will be laid on new trestles as
there are no existing utility pipe supporting system available between
old HSM & new HSM.
4.5 WATER SYSTEM
4.5.1 The water system envisaged for various requirements of proposed
Hot Strip Mill (HSM) will be re-circulating type and will be designed
with zero discharge concepts. Only make-up water will be taken from
the existing Lagoon of RSP with adequate treatment and pumping
facilities.
The proposed water system for the Mill will consist of following types
of water systems:
1. Reheating Furnace Cooling Water System
2. De-scaling Water System
3. Mill Equipment Cooling Water System
4. Laminar Cooling Water System
5. Strip Cooling Water System
6. Mill Auxiliaries & Motor Cooling Water System
7. Make-up water system
8. Cable tunnel dewatering facilities
All critical equipments and equipments related to contaminated scale
water will have 100% standby. Other equipments like cooling tower,
heat exchanger, filters, settling tanks, water softeners will have
minimum one standby.
All underground pipes will be routed through ventilated and
illuminated pipe cellars with adequate space for inspection and future
pipe replacement.
All pumping stations and equipment buildings will have pendant
operated handling facilities like cranes/ hoists.

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All cooling towers will be of RCC structure, over-ground basin, FRP
fan and covered hot water basin. Cooling towers of each circuit will
have 10% side stream filtration facilities.
All auto control valves will be electrically operated gate valves and all
manual valves more than DN300 size will be gear operated.
There will be common maintenance workshop with adequate working
space and a small manufacturing area with basic machines like
centre lathe, drilling machine, power saw, bench grinding, welding
etc.
At present, the makeup water pipe line of size DN250 is going
underground to SGP through the proposed HSM area. This line is to
be suitably rerouted without affecting production of SGP.
Each water circuit will have flow, pressure, temperature
measurements and also have indication in the main control room.
All water tanks/sumps will have adequate manual cleaning facilities.
Wherever applicable, the on-line type quality monitoring instruments
like pH meter, Turbidity meter, TDS, Hardness etc. to be provided.
4.5.1.1 Reheating Furnace Cooling Water System
Soft water is envisaged for skid cooling of the Reheating Furnaces.
The envisaged flow rate is 1600m3/h at a pressure of 40mWC at the
consumer end. It is proposed to install a dedicated Soft water
generation & re-circulation system for the proposed Reheating
furnace with all its associated facilities like Soft Water Plant, Soft
water sump, Emergency overhead soft water tank, Chemical dosing
unit, Pumps, filters, heat exchangers, pipes, valves, fittings,
instruments etc. However, 100% standby soft water plant and soft
water pumps are envisaged.
A Pipeline will be laid from the Pump delivery header, installed in the
Mill Pump House upto the Reheating furnace header with all valves
and fittings. After cooling the skids, the hot water will be returned to
the heat exchangers for cooling. A water filter will be provided in the
supply line to ensure that no foreign material enters the water-cooling
elements. Makeup to this re-circulating system will be taken from the
proposed Soft Water Plant. The industrial water required for Soft
Water Plant will be tapped from the proposed makeup water
network.
To take care the emergency situation arising out of pump failure or
power failure, an Emergency Overhead Water Tank is envisaged to
supply cooling water for half an hour. Provision of emergency power
supply will also be there.


Industrial water is envisaged as secondary water for heat
exchangers. A separate water system (industrial quality) is to be
installed for the purpose with all its associated facilities like Pumps,
Cooling tower, filters, valves, pipes, fittings etc. A Pipeline will be laid
from the Pump delivery header, installed in the Mill Pump House up
to heat exchangers and from heat exchangers to top of the cooling
tower to carry hot water from Heat exchanger with all valves, fittings,
instruments etc. The makeup water required for re-circulation cooling
water system will be tapped from the proposed makeup water
network.
Filtered water is envisaged as cooling water for direct cooling system
of reheating furnace. The water will be tapped from delivery header
of filtered water pumps.
4.5.1.2 De-scaling Water System
Filtered water is envisaged to be used for de-scaling purpose. De-
scaling system for roughing mill and finishing mill will be at different
pressure. The envisaged flow rate for roughing mill is 700m3/h at a
pressure of 2400mWC and for finishing mill is 120m3/h at a pressure
of 3800mWC. A Common Filtered Water system is to be installed for
the purpose with all its associated facilities like Settling tank, Settled
water sump, Settled water pumps, Pressure filters, Filtered water
sump, Filtered water pumps, Cooling towers, Duplex water filter,
valves, pipes, fittings, instruments etc. Two groups of pumps will be
installed, one group will consists of settled water pumps to supply
water to Pressure filters and other group will consist of filtered water
pumps to supply water to De-scaling system through filters. Return
water from de-scaling system will go directly to the settling tank
through scale channel. Arrangement for removal and transportation
of mill scale and oil from scale pit and settling tanks will be there. The
makeup water required for re-circulation water system will be tapped
from the proposed makeup water network.
Air blowers and filter backwash pumps are envisaged for
backwashing of pressure filters.
4.5.1.3 Mill Equipment Cooling Water System
Mill Equipment consists of two parts, one is high pressure (HP) roll
cooling and other is low pressure (LP) roll cooling. Filtered water is
envisaged as cooling water for Mill Equipment. The envisaged flow
rate at the consumer end is 2070m3/h at a pressure of 120mWC for
HP Roll Cooling and 1730m3/h at a pressure of 60mWC for LP Roll
Cooling system. For HP roll cooling filtered water will be pumped
from the common filtered water sump by a group of pumps with
associated piping, instruments etc. For LP roll cooling, water will be
tapped from de-scaling water circuit. Return water from Roll Cooling
will go directly to scale channel for scale flushing.

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Two groups of pumps will be installed for scale flushing, one group
will consist of flushing water pumps to supply water for scale flushing
and other group will consist of scale water pumps to transfer water
from scale pit to settling tank. MOC of scale water pumps will be of
abrasive resistant material of minimum hardness 600 BHN and MOC
of valves, fittings will be of wear resistant material. Scale water
pumps will have two parallel headers up to settling tanks each having
100% capacity to facilitate repair. Scale water channels, pipes will
have inside coated with abrasive resistant basalt/ ceramic linings.
The envisaged flow rate at the consumer end is 100m3/h at a
pressure of 45mWC for scale flushing.
The makeup water required for re-circulation water system will be
tapped from the proposed makeup water network.
4.5.1.4 Laminar Cooling Water System
Filtered water is envisaged to be used for Laminar Cooling. The
envisaged flow rate is 6760m3/h at a pressure of 5mWC at the
consumer end. Filtered water will be tapped from the common
filtered water sump. The system will consist with all its associated
facilities like pumps, filters, valves, pipes, fittings, instruments etc.
Return water from the system will go directly to a common sump
through suitable water channel. The common sump will collect return
water from both laminar cooling & strip cooling system. From the
sump water will be pumped to settled water sump through solid
separator. The makeup water required for re-circulation water
system will be tapped from the proposed makeup water network.
4.5.1.5 Strip Cooling Water System
Filtered water is envisaged to be used for Strip Cooling. The
envisaged flow rate is 1150m3/h at a pressure of 150mWC. Filtered
water will be tapped from the common filtered water sump. The
system will consist with all its associated facilities like pumps, filters,
valves, pipes, fittings, instruments etc. Return water from the system
will go directly to a the common sump through suitable water channel
and from the sump water will be pumped to settled water sump
through solid separator. The makeup water required for re-circulation
water system will be tapped from the proposed makeup water
network.
4.5.1.6 Mill Auxiliaries & Motor Cooling Water System
Industrial water is envisaged as cooling water for Mill Auxiliaries and
Motor cooling. The envisaged flow rate is 500m3/h at a pressure of
35mWC. For this Cooling Water System water will be tapped from
cooling tower of secondary water circuit of heat exchanger cooling.
Only one group of pumps is to be installed for the purpose with all its
associated facilities and piping. A Pipeline will be laid from the Pump
delivery header, installed in the Mill Pump House up to the consumer
points with all valves, fittings, instruments etc. Return water lines will


be laid from consumer points to top of the cooling tower to carry hot
water.
4.5.1.7 Make-up Water System
Make-up water is required for all re-circulating water systems.
Estimated make up water requirement for the proposed mill will be to
the tune of 1000m
3
/h.
The required makeup water will be available from the existing
Lagoon of RSP. Lagoon water will be treated to industrial makeup
water quality and pumped to an overhead makeup water tank at
proposed Mill area. Adequate treatment facilities have been
envisaged. All industrial makeup water consumers will avail water
from the proposed makeup water tank through a suitable piping
network. The water treatment plant will be installed on the space
available in between the Lagoon and National Highway. Area
requirement will be to the tune of 100x200m, which will be developed
accordingly. The electric power requirement will be to the tune of
1000kW maximum demand & 1750kW connected load.
The quality and other parameters of Lagoon water is as specified
below:
pH 6.98 7.8
TSS 108 - 794 ppm
Oil & grease 2 4 ppm
Iron 2.5 4.2 ppm
Ammonical nitrogen (NH
3
-N) 4.8 15.5 ppm
Phenol 0.05 0.09 ppm
Cyanide 0.05 0.2 ppm
BOD 10 18 ppm
COD 44 92 ppm
Water temperature 32
o
C
Tapping point Near discharging point from
Lagoon.
Distance between Tapping
point and proposed Mill
1500m. approx.
Proposed make up water pipe
routing
Underground along the existing
and proposed road
Make up to soft water system will be provided by a new soft water
plant through a soft water storage tank. For soft water plant,
industrial water will be tapped from the proposed makeup water line

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and supply water to soft water plant through adequate pipe size for
smooth operation of the soft water system.
For industrial water system make-up water will be tapped from
existing makeup water ring main and supply water to Cooling Tower
basin. The water flow will be controlled by the level of cooling tower
basin.
For direct water (filtered water) system make-up water will be
supplied to Filtered water sump. The water flow will be controlled by
the level of the sump.
Each makeup water consumer will have a venturi/ orifice type flow
transmitter in the line with flow indication in the main control room.
4.5.1.8. Cable tunnel dewatering facilities
For dewatering the underground cable/pipe tunnel 12 no pits will be
provided with 12nos sump pump sets alongwith pipes, hoses etc.
The water from cable/ pipe tunnel will go to the recovery water tank.
4.5.2. Control Philosophy
The cooling water system will be fully automatic with PLC. However,
facility for local start/stop will also be provided for each individual
drive. All electrically operated valves will have position indicator.
There will be one main control room for all water systems with all
operational parameters, warning signals, instrument readings etc. will
be displayed. There will be local operation stations also. MMI with
display monitors will be installed in main control room for continuous
display, monitoring and recording of all the important parameters of
water systems.
4.6 AIR CONDITIONING & VENTILATION SYSTEM
Following types of Air Conditioning & Ventilation System are
envisaged for proposed Mill:
4.6.1 Chilled water based Central Air Conditioning system will be installed
in a central AC plant building for various Control Rooms, PLC rooms,
MCC rooms housing intelligent MCCs, digital drive rooms, weighing
electronic rooms, Office Spaces, etc.
The proposed Chilled water system will consist of the following major
equipment:
1) Water cooled chiller units with accessories
2) FRP cooling towers for closed circuit condenser cooling
system


3) Necessary chilled water pumps (with 100% stand by),
Condenser cooling pumps (with 100% stand by), piping,
valves, etc.
4.6.2 Dry pressurized ventilation system will be installed for switch gear
rooms and MCC rooms having non-intelligent MCCs.
4.6.3 Push-pull type ventilation system will be provided for cable
tunnel/cellar and cable basements.
4.6.4 Exhaust ventilation system will be provided for compressor house,
battery rooms, chiller plant room, transformer rooms, pump houses,
store, toilets, etc.
4.7 FIRE FIGHTING SYSTEM
4.7.1 A comprehensive fire fighting System has been envisaged for entire
area of the Hot Strip mill. It consists of the following:
Portable Fire Extinguishers as first aid Fire Fighting System
Water based Fire Fighting System
Automatic Fire Extinguishing System
i) High Velocity Water Spray System(HVWSS)/ Medium Velocity
Water Spray System (MVWSS)
ii) Gas based Fire Fighting System
Passive Fire Protection
4.7.2 Portable Fire Extinguishers
Portable fire extinguishers will be provided as per TAC norms to all
the covered area in the HSM. This includes but not limited to new
buildings, shops, electrical rooms, cable vaults, ventilation shafts,
junction houses.
4.7.3 Water based fire Fighting System
1) A pump house will be provided to accommodate the envisaged
for fire fighting equipments, like electrically operated main fire
pumps, diesel driven 100% standby diesel engine driven pumps,
two jockey pumps i.e. working as well as standby, envisaged in
this package. The minimum pumping capacity of the main fire
water pump has been envisaged as 546m3/h. These pumps are
complete with all accessories as per TAC norm. The facilities for
automatic starting, stoppage and interlocks of the pumps will be
provided depending upon the line pressure. A material handling
facility like under slung crane will be provided. An electrical
control room will be provided to accommodate the control panel
along with electrics. A covered tank with a partition wall will be
provided for storage of fire water for two hours of pumping

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capacity. The line pressure should be kept as per TAC norm
however it should not less than 8.8 Kg/cm
2
. Water will be tapped
(DN150) from the proposed makeup water line. The facilities will
be provided for refilling of fire water to both the compartments of
the tank with the level switches and motorized valves. The
tapping point will also be provided with gate valve for isolation.
2) Ring main based pipe header (DN300) to be provided to entire
HSM area along the road to cater the fire water requirement.
External hydrant will be provided for ever 45m spacing whereas
internal hydrants will be provided at every 30m spacing. Every
landing platform will be provided with landing valves. Each
internal hydrant will be provided with hose box complete with two
numbers of fifteen meter hose, coupling, nozzles. The
underground pipeline will be provided with wrapping and coating
as per IS to protect it from corrosion..
3) Manual type water spray system will be provided in the entire
length of conveyor galleries. Each conveyor gallery will be divided
not more than 50m segment for water spray. Each segment will
be fed water from the riser connected to the Fire water header. A
gate valve will be provided to each riser for isolation.
4.7.4 Automatic Fire Extinguishing System
1) High Velocity Water Spray System (HVWSS)/ Medium Velocity
Water Spray System (MVWSS):
High velocity water spray system(HVWS) for transformers (above 10
MVA or having oil more than 2000 lt.) and Medium velocity water
spray system (MVWS) for cable tunnels/cable galleries/ cable
cellar/ cable vaults etc in the HSM complex. These system will be
automatic and controlled by delude valve.
2) For protection of Computer rooms/ PLC rooms/ important Critical
Control rooms including false floor and false ceiling, automatic
clean agent fixed fire extinguishing system (IG-541) will be
provided. The system will be designed according to NFPA 2001.
100% reserve cylinders filled with gas and accessories will be
provided for all systems. There will be provision for switch over
from main to reserve cylinders automatically from the panel as
well as through toggle button.
4.7.5 Passive Fire Protection
Fire Retardant Compound and Fire Barriers will be provided in
electrical cable runs as passive fire protection. The
compartmentalization of cable tunnels will be done as per IS:12459-
1988. Fire check doors will be provided at each compartment.
4.8 INSTRUMENTATION, PROCESS CONTROL & AUTOMATION
The Control and Automation systems are envisaged to provide
complete control and monitoring of the following proposed areas.


The areas to be covered will be broadly consist of Slab Yard,
Reheating Furnaces, Roughing Mills, Passive Heat Shield, Crop
Optimization System, Finishing Mills, Cooling, Coilers & Coil
Conveying Systems, Coil yard, Roll Shop, Hydraulic Systems, Drive
Systems etc. Various process of Hot Strip Mill will be controlled by
the operator from the respective Control Pulpits housing Control
Desks, HMIs, CCTV monitor, Display and Alarm devices, etc. In
order to monitor and control the complete process of Hot Strip Mill in
an integrated way all process control equipment at Level-0, Level-1 &
Level-2 will be fully integrated to form a unified control system
transparent to the operators. The system will be reliable, efficient,
less maintenance oriented, and easy to operate. Level-3
Manufacturing Execution System (MES) will be executed at HSM to
manage manufacturing information. The MES will integrate all the
functions and services, customers need for sustained maximization
of the plant performance.
4.8.1 Level of Automation
The proposed system will be based on micro-processor based
network compatible field instruments with hierarchical control
philosophy consisting of field instruments, field sensors, electro-
pneumatic control valves, electrics, final control elements, gauges
etc. at Level-0 , Process Control Systems consisting of multi-
processor based Technological Control Systems (TCS) with Data
Acquisition System (DAS) at Level-1. Material tracking from Slab
yard to Coil yard will be part of automation system. Process
Optimization Servers for Slab yard, Furnace, Roughing Mill, Finishing
Mill, Cooling & Coiler, Roll Shop etc. along with process
mathematical models will be provided for process optimization
functions at Level-2. Fuzzy logic/Neural network will be used for
optimization functions. The proposed automation system will be
interfaced with the existing plant wide network for receipt of slab PDI
(primary data inputs- width, weight, thickness, length, steel grade
etc.). There will be interfacing between servers of various areas for
exchange of input and output data. The automation system will be
ERP compatible. Besides process optimization; process & plant
simulation during installation & commissioning, computerized
maintenance management system, roll shop management system,
etc. will be considered. Storage Area Network (SAN) will be provided
for archival data management like slab data. coil data, quality data
etc. Level-3 Manufacturing Execution System (MES) will be executed
at HSM to manage manufacturing information like management of
product, resources, scheduling, dispatching, execution of production
orders, collection of production data, production tracking, production
performance analysis etc. and interfacing with Level-4 system like
production planning control, plant ERP system etc. The software
modules of MES will be based on ISA S95 to optimize all horizontal
production processes from slab to strip; vertically integrate the

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information flow from end to end for better decision making, assured
maintenance and further development over the entire life cycle of the
plant.
4.8.2 Slab Yard Management
Slabs coming from the continuous casting machines will either be fed
into the slab yard ROT or stored in slab yard. There will be slab
marking and slab reading system. The reader will send the slab id
data wireless to the automation system. The slabs intermediately
stored in the slab yard will be picked up by overhead crane and
placed onto the slab yard roller table. Automatic positioning of EOT
cranes will be part of the slab yard management system. Slabs will
be weighed at ROT. Also, length measurements of the slab will be
done at ROT through a photo array system. Slab thickness/width will
be measured through a laser based system at ROT. These data will
be sent to the automation system for validation of slab data. There
will be a control pulpit with Operator Console/ HMI at slab yard for
data entry of slab storage in the yard. Level-2 system with a
dedicated Server will be provided for keeping slab PDI, slab yard
management and slab archival functions. Slab Yard mapping in all
the three axis will be done to show the location of desired slab in the
console/HMI. Storage Area Network (SAN) will be provided for
archival data management like slab data.
4.8.3 Reheating Furnace Management
Walking-beam furnaces with sufficient capacity for cold charging will
be provided for heating up the slabs. The slabs will be charged
through the furnace in one row. Slab mapping inside the furnace with
time stamping will be made and will be displayed at Operator
consoles. Reheating will have separate charging pulpit and will have
Furnace Control Pulpit for controlling and monitoring of furnace
parameters. Slab discharge from furnace will be carried out from
Furnace Control Pulpit. There will be provision of taking into account
discarded slabs in automation system.
4.8.3.1 Basic functions of Furnace Automation
1) Automation of Level-0
The functions of level-0 automation system will be:
To send all data coming from the field like pressure,
temperature, flow etc.
To actuate various drives like valves, motors etc.
Control & automation system of level-1 will monitor operational
conditions of the furnace, analyses the information and control the
heating as well as other technological parameters and will be
performed in a PLC system.


The basic functions of the complete system will be:
Digital control of burners/ Fuel-air ratio control
Supervision of process variable: Monitoring and control of
process parameters as per technological requirement.
Combustion control: Adjustment of heating rate in each zone of
the furnace in response to change in the production rate, quality,
process parameters, operational irregularities, etc.
Heat balance calculation.
Graphical display of process information
Diagnostic and alarm generation
Events and report generation for MIS
Gas mixing and Booster control and monitoring
Pump house for cooling water system
Level-2 system with a dedicated server for furnace process
optimization will be provided for two nos. of reheating furnaces.
Furnace mapping will be done to show the location of slabs inside
furnace with time stamp in the console/HMI. The purpose of the
level-2 system will be to fix the temperature set points in the various
zones of the furnace using mathematical models so that each
product can be discharged from the furnace with its required
discharge temperature in a precise and repetitive manner. This will
be done over the whole operating range of the furnace and during
delays and for wide range of steel grades, discharge temperatures,
product sizes etc. The objective of the optimization system will be as
follows:
Predictive thermal modeling: Predicting slab discharge
temperature and making automatic corrections for zonal
temperature set-points by actual slab temperature
measurements.
Real time thermal modeling :Thermal behavior of slab in any
zone of the reheating furnace
Slab temperature gradient calculation
Automatic zonal temperature set-point calculation for level-1
control
Calculation of heating and soaking time
Self adaptive and self tuning features based on historical data.
Fuel optimization and automatic handling of temperature set-
points during scheduled and un-scheduled delays.

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Historical logging of Level-2 information/data
4.8.4 Mill Management
4.8.4.1 Mill Automation (Roughing, Finishing, Cooling & Coiler)
1) L2 process control server systems will be provided for Roughing mill,
Finishing mill, Cooling & Coiler operation. There will be minimum
three number servers for process optimization, model calculation and
cooling. Also, there will be warm backup server with both servers
sharing raid disk arrays configured on the SAN (Storage area
network). Server system will be complete with hardware, software
and mathematical models to carry out process control and
optimization functions.
2) Server will carry out process optimization functions for pass schedule
calculation, automatic thickness control, Automatic width control etc.
for stand R2 of roughing mill. Optimization functions for pass
schedule calculation, profile control, flatness control etc. for stand F1
to F6 of finishing mill to be carried out. Process server will also carry
out optimization functions for laminar cooling and two nos. coilers.
Inheritance and adaptive control will also be part of the function.
There will be short term and long term adaptation with predictive
controls. Following control & optimization functions will be carried out
in Level-2 process server:
Strip temperature
Strip rolling
Width calculation & control
Pass schedule calculation for RM & FM
Profile & flatness control
Laminar cooling etc.
Coiler functions
3) Following artificial Neural Network based mathematical models will
be considered for the mill.
Roll thermal & crown model
Pass to pass adoption
Temperature model over lengthy & thickness
Rolling model
Mechanical, Yield stress & Friction models
Strip thickness model
Model of elastic mill stand & roll stack deformation
Ferritic rolling
Microstructure cooling
Adoption of the models etc.


4) Laminar cooling based control will be used for microstructural target
cooling in the rolled strip. Physical modeling of the steel
transformation will be used to compute temperature and phase
fractions along the entire cooling section in real time. The cooling will
enable changes in the microstructure properties of the strip. The
models will be suitable for all types of steel including modern grades
such as dual phase and complex phase. The advance control will
provide flexible selection of targets and strategies based on temporal
cooling courses. Precise control of temporal cooling along the entire
cooling section as well as selection of coiling temperature will be
provided.
5) Data like mechanical properties such as tensile strength and
elongation will be available in Microstructure monitor at FM control
pulpit. System will be flexible to provide wide range of cooling power.
6) The proposed automation system will be continuously sharing data of
primary slab, transfer bar parameters after Furnace and overall strip
tracking in the mill through other computer systems like slab yard,
furnace computer systems etc.
7) The above system supply will also include necessary system
software, programming software, application software, mathematical
models and development of necessary protocol for interfacing to
different systems.
8) All functionality of the mill except plant safety will be carried out
through Technological Control Systems (TCS). The TCS used for mill
function will be same make and of same family. Each mill stand of
the mill will be controlled through minimum on number TCS system.
Technological Control Systems (TCS) will be proposed to carry out
technological functions for roughing mill (RM) R2, finishing mill (FM)
F1 to F6, media, laminar cooling, two number coilers etc. . Each TCS
system will have requisite number of multitasking controllers and
process I/Os with suitable interfaces to PLC and Drive systems of
the mill. These controllers will be equipped with CPUs, memory
modules, communication system, process I/Os, power supplies,
racks, panels & interface modules along with requisite application
software which will be used for carrying out the process control
functions such as HAGC control in all stands, speed control, AWC,
ATC, camber control, centerline control, roll force control, skew
control, cobble protection control, profile control, flatness control, roll
bending, roll shifting/CVC, laminar cooling, coiler control etc. TCS
also will be used for carrying out sequential, interlocking and alarm
functions of mill & auxiliaries, hydraulics, emulsion, descaler, mill
entry & exit, mill readiness, etc. All TCS will be connected through
high speed dedicated control bus for exchange of data between
controllers.

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9) Passive heat shield temperature sensors will be monitored. Passive
heat shield will be operated through TCS system from finishing mill
pulpit.
10) PC based necessary development tools; engineering stations,
programming unit etc. and other accessories for computer system &
TCS will be considered in the scope of work.
11) New Local Control Stations (LCS) will be installed at the mill stands
consisting of selector switches, push buttons, indicating lamps; digital
display, soft-key & LCD monitor etc. with necessary protections for
localized mill functions like roll changing, screw down operation etc.
LCS with soft-key and touch screen type monitors will be provided for
new hydraulics & lubrication system of the mill. The LCS will be
interfacing with the PLC system.
12) Process Data Acquisition (PDA)
This will be used for high-speed acquisition of process data, on line
display of analog and digital variables, other discreet analog and
binary signals from the plant. PDA system is a powerful tool for
maintenance personnel for commissioning, mill setup,
troubleshooting, data and failure analysis. PDA's will be hooked up
directly to the real time reflective memory of the controllers. There
will be minimum two licenses for the PDA system for the mill and will
be housed at TCS rooms.
PDA system will record all system variables online and save in user-
defined files. The on line display of the selected channels will occur
at user defines time base. For acquisition of data, required selection
of data (say tension, control, speed, drive parameters etc.), range
clock rate etc. will be entered by the user. Measurement session will
be saved in a user defines file. The representation function is off line
display and it will contain an overview function for fast review of all
the channels in various modes. It will be possible to print or convert
the selected curves for further analysis. It will be possible for integral
/ differential calculations, log conversions etc. System will permit fast
Fourier transformation and auto / cross correlation. The PDA will
perform the following minimum functions:
Synchronous monitoring & recording of all system variables
Powerful on line monitoring
Quick & easy configuration within integrated I/O Manager
Mass storage
Off line display and analysis
Export of data to Microsoft office (Excel)
4.8.4.2 Mill Instrumentation


1) Roll force measurement system will use strain gauge type load cells
for each mill stand. Slab type/ washer type load cells (2 nos. for each
mechanism) will be used for measuring roll force. Each load will be
hermetically sealed to prevent any internal damage due to the
presence of water and other solvents used in the mill. Load cells are
compression force transducers for measuring force or weight.
Pressure transducers of hydraulic circuit will be used as back up of
roll force measurement.
2) Pressure Transducers will be used for static and dynamic pressure
measurement and remote pressure control. This will be used for roll
force and roll bending pressure measurement. In the present
application strain gauge type pressure transducers are envisaged.
Quantity and rated pressure of pressure transducers will be as per
control & design parameter.
3) Multi point gauge for thickness, profile, width & flatness will be
provided at the exit of F6. Profibus DP/ Ethernet interface and fiber
optics signal transmission to the automation for display will be done.
4) Non-contact type two number line scan CCD camera based width
gauge will be provided at the exit of R2. Profibus DP/ Ethernet
interface and fiber optics signal transmission to the regulation system
and for display will be done.
5) Lasser Doppler Velocimeter (LDV) based Length Measurement
system
LDV based length measurement system of strip length will be
installed at the exit of R2 for Crop Optimization system. The LDV will
be installed before the hot crop shear. Necessary terminal display
will be made available at FM main control pulpit and crop pulpit. The
signals will interface with automation system and crop regulation
system.
6) Magnetostrictive Position Sensors (Temposonic type) or Installation
of absolute/ incremental encoders based position transducers with
Profibus DP/ Ethernet/Modbus interface and fiber optics signal
transmission for Hyd AGC in R1 & R2 mill stands.
7) Position Sensors (Sony magnescale type) based position
transducers with Profibus DP/ Ethernet/Modbus interface and fiber
optics signal transmission for Hyd AGC in R2 and F1 to F6 mill
stands.
8) Installation of position transducers for the QWRC system work roll
pull out arrangement & QWRC system side shifter unit will be
provided.

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9) Installation of position transducers for the proposed CVC system side
shifter unit work roll shifting arrangement
10) HMD with hot standby arrangement will be considered for the mill at
various locations like entry to mill stands, ROT, passive heat shield,
crop shear etc. for material tracking. Photo-relays will be used as
HMDs to detect presence of hot material.
11) Ratio Pyrometer/ Dual temperature measuring instruments (2 color
infra-red ratio type Pyrometers with complete system) will be
considered at important locations. Five number spot measuring
pyrometer will be provided at Furnace exit, RM exit, FM entry, exit &
before coiling. Two number scanning pyrometer (across the strip
width) at FM exit and before coiling will be provided.
12) Differential tension measurement device between last loopers of FM
will be provided for tension control between FM mill stands.
13) Load cell based Tensiometer Looper will be provide at the FM last
mill stand for tension measurement for flatness control.
14) Sensing devices such as angle transducers, opto-digital encoders,
combination tachometers, photoelectric switches, loop sensors,
programmable limit switches, proximity switches, strip speed
measurement devices, light barriers, etc. will be in the scope of work.
15) Interfacing of electrics & automation with Passive heat shield &
Hydraulic AGC in F1 to F6 Mill Stands will be considered.
16) Single frame Jumbo 7-segment displays (250mm) will be provided
for display of input and output gauges of the strip thickness,
thickness deviation, etc., at appropriate places in the mill proper.
17) Field mounted devices, sensors, transducers etc. including mounting
brackets, socket outlets, couplers & utility connections will also be
considered.
18) Strip Surface Inspection System
Online non-contact Strip Surface Inspection will be carried out for
both sides of the rolled strip through camera based measurement.
The system will be based on white LED illumination and 12 bit
resolution cameras four numbers per each surface with highly
elaborate techniques and algorithms through image processing. The
system will include state of the art image based classification builder,
follow up indicators and image enhancing capability. The
measurement system will be located near down coiler.
The system will have software capability to verify that the product
meets the specification in terms of surface quality. The system will


work as a watchdog warning the operator about processing problems
in a strip. HMI will be provided for viewing surface faults as well as
surface inspection report in a continuous manner. The archival data
will be stored in SAN. Adaptive control and inheritance will build a
strong database to help in better understanding the product surface
quality.
19) Utility: Industrial water and instrument air will be provided at take
over points for various sensors for cooling, purging, cleaning etc.
4.8.4.3 Mill Visualization System
1) There will be Client server based Visualization system. Hot standby
Database HMI Server for Process Supervision and Monitoring
System will be considered. HMIs for Visualization System,
Engineering Station, Developmental Consoles, Programming station,
Plant simulation station etc. will be considered for the mill. There will
be plant wide data communication network based on OFC on TCP/IP
protocol with common global database. Visualization system will be
connected to suitable communication network (LAN) linking various
mill locations like Control room, Computer Room, Centralized Control
Pulpits, Local control stations etc. for integrated control.
2) Consumption of utilities and power will be considered in the Data
Acquisition System (DAS) package.
3) File server, Web server etc. will be provided for mail massaging and
remote monitoring of data and CCTV images. Firewall, password
protection, antivirus software will also be considered.
4) The scope will also include supply of Operator stations/ Human-
Machine Interfaces (HMIs) with 21 TFT colour monitor for down-
loading of rolling schedules and set-points, process supervisory
functions, visualization of process parameters & process trends,
reports and status, fault logging, trending, etc. There will be common
HMIs for L1 and L2 client preferably.
5) The control desks will be ergonomically designed and will be
provided with control elements such as selector switches, push
buttons, indicating lamps; digital display, analogue meters etc. LCS
will be positioned near mill stand for local control and visualization.
4.8.4.4 Mill Networking
1) There will be a common bus based on FOC with TCP/IP protocol to
which HMIs and servers will be connected. All TCS systems along
with PDA system will be connected through a dedicated fast bus for
exchange of critical data between controllers. There will be industrial
Ethernet bus connecting to TCS systems for transmission of critical
field data of hydraulic servo valves, pressure transducers, roll force
data etc. R I/O, Drive systems etc. will be connected through

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Profibus DP. Network switches will be provided at Server room, TCS
room, ECR, Instrumentation room, Control rooms/pulpits etc.
Ethernet network will be designed with a fibre optic, Gigabit bus
based type backbone with ring/star/mesh topology. Redundancy in
Switches and FOC will be provided as per requirements, allowing
communication to take place in case of fault at one switch. All the
core switches will be manageable type. Client HMIs, HMI database
server and software development station will be equipped with
double LAN adapters and will be connected to both the redundant
network.
2) Communication with Plant ERP system
The Level-2 automation system and Level-3 MES system will
establish communication with TCP/IP based plant network.
Production data and any other necessary information will be
transmitted to the proposed Level-4 ERP system. The L2 & L3
system hardware, OS & RDBMS will be compatible with ERP.
3) Twisted pair cable will be laid inside the control room and FO cable
will be laid for outside premise for communication. FO cable will also
be laid between each remote I/O unit and the main processor.
4) Interface (both hardware and software) with internal systems, like
power distribution system, automation system, Passive Heat Shield
controller, Auxiliaries (hydraulic, grease, compressor etc.) systems,
Furnace, Gas boosting stations, Water systems, Fire alarm systems,
communication systems, Slab yard, Roll shop management system
etc. will be considered. CCTV system, communication system, fire
alarm system will have separate network.
5) Interface (both hardware and software) with external systems, PPC
Level-3 system, CCD computer system, SMS, Laboratory and
connection with Plant network will be included.
6) Network management software will be provided for diagnostic and
network management.
4.8.4.5 Mill Tracking
T.O.P. for material tracking will start from the Slab charging roller
table at slab yard upto coil dispatch at coil yard. Interfacing of mill
sensors signals like HMDs, mill gauges, roll bites etc. will be done
with automation system for material tracking.
1) The material tracking function will maintain a queue of the materials
in the HSM.
2) Material tracking system in the mill from slab yard and up to the coil
conveying system of HSM exit, so that process control & monitoring


of the coil is carried out, as desired, in different sections for the mill
process line. Material tracking data will be displays at HMIs as per
process requirements.
3) Segment Tracking
Segment tracking will be carried out for finished coil for thickness,
temperature, hardness etc. at regular intervals and the data will be
stored for archival. For the current rolled material a segment tracking
will be performed, which will be based on the actual process data
transmitted from the basic automation system. External storage for
data archival of 5000 rolled coils measured parameters with 8 traces
stored at approx. 3m interval will be provided.
4) Roll Tracking
Roll tracking between mill and roll shop will be provided for
identification of rolls and for information like tonnage rolled, roll
machine history and for roll inventory management. The last used roll
diameters for 1000 rolls will be maintained in the Level 2 system,
thus allowing complete roll histories (diameter, crown) to be tracked.
This data will be used as a verification check on operator entered roll
diameters for a particular ID of a roll. The proposed system will have
provision that once a roll is changed in the particular stand, date and
time when roll has been inserted/ removed and the rolled tonnage
and length will be stored in the database.
4.8.4.6 Crop Optimization System
The use of latest state of the art technology in the area of crop shear
operation will be proposed, which will make a substantial
improvement in reduction of quantity of crop ends. It will have
calculations done in real time basis for individual tasks and to down
load the calculated set values so as to co-ordinate the drive level
functions and technological functions being performed by the
controllers.
1) Crop Visualization System
The optimization system will receive sets of information like the crop
cutting strategy, the bar identification and the bar thickness etc. for
each transfer bar from the host computer as the bar approaches the
last roughing stand. Upon receipt of the signal of last pass, the vision
system will capture head and tail end images.
Two number solid state line scan area array CCD camera of high
resolution will be mounted above the transfer table at the exit of R2.
High-speed pattern recognition software will intelligently analyses the
image and precisely determines the complete profile of the head and
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An optimal cut point will be determined in accordance with the unique
shape of the head end. The image of the head end of the strip, with
the cut line superimposed will be displayed for the operator in a
operator station at FM control pulpit monitor. The system will transmit
the information about optimal or desired crop cut and other relevant
data to crop shear controller (TCS).
2) Crop Communication System
Crop optimization system will be hooked to LAN, for communication
to the host computer system. The strip numbers, thickness, strip
width, temperature etc. associated with the next strip to pass through
the last rougher will be input to the crop optimization system through
this link. Crop cut length, weight, width (optional), length of the bar
(optional) etc., information and alarm messages will be transmitted to
host computer over the same link. Following MIS functions will be
carried out:
Crop Statistics Display
Crop Statistics
Camber Statistics
Strip Width
3) Strip Tracking
This vision system will follow the strip as it moves from the last
rougher to the crop shear. The camera will capture the image of the
head and tail end of the strip. The material will be tracked and the
speed of the strip will be measured through encoders, hot metal
detectors, laser velocimeter positioned in strategic places.
4.8.5 Plant Emergency System
Emergency functions for complete mill will be designed according to
the international norms, standards and regulations and will have the
following features.
1) Fail safe PLC under certification will be provided for carrying out
Plant Emergency System.
2) Emergency Stop (E-Stop Category-1): Emergency stop (E-Stop)
is a safety operation, required for dangerous situations or as a
designed safety reaction to equipment failure or malfunction.
3) Quick Stop (Stop Category 2): Quick-stop-mode will require all
drives in the associated Quick-Stop-Area to be stopped
synchronously as quickly as possible.
4.8.6 Condition Monitoring System
The condition monitoring system with Diagnostic server will include
following:


1) Temperature monitoring complete with PT100 sensors, Local
cabinet with necessary multiplexer and intermediate amplifier,
signal conversion and signal processing module etc. will be
offered for the following drives. Also, LAN interface will be
provided to super co-ordinate Diagnostic server for necessary
data storage/ analysis.
Main drive motors (R2 & V2) with air to water heat exchanger
if any.
Bearings of main drives and Large aux. drive motors, pinion
stand of main stands / TMB/FFB, HT motors
Water-cooled main drive converters if used.
2) Vibration monitoring of gearboxes for motors greater than
1000 KW rating will be provided. This will include necessary
Industrial universal-axial vibration / acceleration sensors with
its pre-processing units, IP55 local cabinet, Analysis and
diagnostic software package for defect detection system, Data
& signal management, condition evaluation and monitoring,
Maintenance and service interface, with its PC, 19 inch
monitor, software etc. Also, LAN interface will be provided to
super co-ordinate Diagnostic server for configuration of
individual vibration channel, data storage and frequency
analysis. The measuring devices complete with its protective
housing will be suitable for rolling mill environment.
3) Torque condition monitoring of R2 main drive spindles etc.
complete with heavily protected strain gauges, telemetry (non
contact power supply & signal transmission), signal evaluation
(Analog/digital signal conversion), IP55 cabinet, Stator
electronics, bending compensation, pre-processing unit, data
& signal management, condition evaluation & monitoring,
maintenance & service interface, Interface with other systems
etc. Also, LAN interface will be provided to super co-ordinate
Diagnostic server for necessary data storage / analysis.
Two nos. sensor system for top & bottom spindle of R2 each
with individual torque analyzing system, required nos. of
preprocessing units and local cabinets, spare channels and
necessary interface with other systems (like main drive speed,
current and load cells etc.).
4) Complete CMS including server & PC's, networking
components, software along with intelligent local data
capturing devices & interface with Level-1 system, on-line
monitoring, of/off line analysis of acquired parameters with
generation of necessary screens and reports.
4.8.7 Coil Yard Management
Coils coming from the mill will be brought to the coil yard through coil
conveying systems. Weighment of coil and Eye strapping of the coil
will be carried out in the coil yard. There will be coil marking and coil
reading system. The reader will send the coil id data wireless to the

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automation system. There will be a control pulpit with Operator
Console/ HMI at coil yard for data entry of coil storage in the yard.
Automatic crane positioning system will be considered for coil yard
management. Level-2 system with Server will be provided for
keeping coil PDI, coil yard management and coil archival functions.
Coil Yard mapping in all the three axis will be done to show the
location of desired coil in the console/HMI. Storage Area Network
(SAN) will be provided for archival data management like coil data,
quality data etc. The Coil yard management system will provide
following benefits:
Better yard utilization
Faster coil retrieval & feeding
Real time display of inventory & order progress
Minimum coil handling
Optimum crane utilization
Avoid of wrong dispatch of coils to customer
Mix up coils can be identified
4.8.8 Roll Shop Management System
Roll shop management will be part of the scope of work. Roll shop
management will minimize number of rolls in production; optimize
production, optimized shop logistic etc. Roll data management will
contain roll history. Information exchange with roll shop must be
comprehensive and suitable for both way communications. Roll
shop management will usher following advantages:
High quality assemblies
Optimizing roll machining process
Dimension information on chocks
Optimum use of bearings
Transparency of the system
The RSMS is a server based software system to manage roll shop
equipment such as grinders, rolls, chocks, bearings etc. RSMS
will also provide historical data, inventory, tracking and
maintenance information. A client server based complete
Information system comprising of server, required number of PC
workstations, networking as well as standard and application
software, as needed, will be supplied. The functions to be
performed by RSMS will include but not be limited to the following:
Maintain a database containing all information related to rolls,
chocks, bearings, roll/bearing/chock assembly
Tracking of rolls, chocks, bearings
Display status of rolls, chocks, bearings
Generation of grinding schedules based on production schedule
for roll change and mill setup
Storage of grinding profiles for all rolls to be used in the mill line
Data gathering from linked grinding processes


Input screens for data entry for de-chocking and re-chocking
process
Generation of reports for all possible combination of stored data
Generation of purchase orders and requisitions to track costing
information on the inventory
Establishment of link with mill Level 2 system for necessary data
exchange related to tonnage rolled, rolls status etc.
Establishment of link to higher level systems via mill Level 2
system, as required
4.8.9 Computerized Maintenance Management System
The Computerized Maintenance management System will be
suitable for any level of user and will be customized for the mill.
The activities handled by CMMS will be the following:
Equipment & Facilities Management
Planning, Scheduling, Preventive Maintenance operation
Job plan & work order management
Resource management
Inventory management
Report & Analysis
CMMS will store/ find equipment/ asset information, i.e. technical
specifications, work outstanding, cost of ownership etc. It will build
comprehensive and detailed library of jobs for each planned and
unplanned jobs/routines. It will have plans for jobs forthcoming week,
month, year or any other time interval. It will quickly and easily
provide complete history of each equipment and their depreciation
value. Necessary hardware and software will be provided for CMMS.
4.8.10 Process & Plant Simulation System
Safe & quick commissioning and the quick attainment of full
production capacity is of prime importance. The commissioning of
the mill takes much of the time because set up, testing and
implementation of the electrical & automation system starts after
mechanical components had been installed on the site. Long
commissioning time happens due to technical interfaces between
individual modules of the electrical & automation system
(technological control system, L2 automation system etc.) as well
as integrated system for the plant. These will show kinematic &
dynamic behavior of the mill. Also, it will help in reliable quick start
up and secure take over reducing mill commissioning time and
quickly realizing full potential of the mill. To commission the
system quickly the following methodologies will be used:
Plug & Work Test Process: The core of the process is testing
against a virtual production sequence. By means of simulations,
the automation system will be tested under practical production

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conditions. This will help in deriving fault free pre optimized plant
solution. These will allow the testing of the actual hardware &
software under almost real plant condition.
Virtual production test: The customer specific construction models
are used as a basis and the relevant geometrical data, the
kinematic and dynamic behavior of the plant unit in question as
well as function of the field instrument located on the unit are
transferred to the simulation model in a more or less automated
layout process.
Test facilities: The entire software and hardware of the scope of
supply is installed to judge the completeness and workability of
the system as a result commissioning is significantly accelerated.
Process and plant simulation will be conducted at the mill
automation supplier premises in presence of the Purchaser.
Mill operators will be given training in near mill operating
conditions for all the steel grades enabling training in real time
environment.
4.8.11 Manufacturing Execution System (MES)
MES will integrate all the functions and services of customer need for
sustained maximization of plant performances. MES of HSM will
ensure a seamless and transparent flow of data vertically from the
process to the management level and horizontally from the delivery
of raw materials to the finished product. The software modules of
MES will optimize all horizontal production processes, from slab to
strip and vertically integrate the plants information flow end-to-end,
helping the management to make better-founded decisions; and
assure maintenance and further development over the entire life
cycle of the HSM plant.
All necessary hardware of server systems, networking hardware and
software like OS, Application development software, application
software modules for MES will be considered for MES. Interfacing to
plant server and HSM server will also be considered for exchange of
MES information. Various modules for HSM MES are given below.
1) Production management
MES production management module will provide the relevant key
information on the status of production, the status and location of
every material unit and of all relevant resources for the entire plant
HSM. The software module of Production Modeling will accurately
describe the entire production process including production rules in
each production step. Material and order tracking will continuously be
updated and checked using production rules.
2) Information management
This module will provide reliable information on the current status of
the production operation and its metrics. From predefined structures


in a database and a data warehouse, all information is extracted,
processed, and made available in a format that can easily be
evaluated. In addition to predefined standard reports by powerful
Web Reporting Tools, the system delivers up-to-date graphically
enhanced Key Performance Indicators for the key matrices of the
production.
3) Material management
The coil yard management system is a solution that unifies material
and information flow across the entire system from the sensor to
control room. The module will have innovative tools such as material
and order scheduling, web connection and service support.
4) Production planning
The module will provide optimum capacity and production path
planning based on technological plant limits, plant conditions and
scheduled availability. These will also maximize production across
the entire process- with the global optimum taking precedence over
the local optimum. The optimized production sequences created by
Production Planning also minimize set-up efforts thus improving
product quality resulting faster and more reliable planning even in the
event of fault conditions. There will be different scheduling solutions
or the plant. Also overall planning functions will be available to create
production orders based on new customer orders.
5) Quality management
Quality management module will assess quality and develop
appropriate strategies to overcome quality defects without infringing
production process in any way. Here, early detection of fault will
allow the plant to act quickly and securely to limit damage, avoiding
costly returns and loss of reputation. Quality control functions will be
available based on flexible specification management of all
production steps. Online production rules will be checked
continuously to check if production is running properly in specified
limits. There will be a seamless integration between the modules of
quality control, production order management and production
scheduling to ensure the best balance between plant utilization,
product quality and customer order due dates.
6) Logistics management
Storing and retrieving raw materials, intermediate goods or final
products take up a significant amount of the production and delivery
time. Optimized slab yard and coil yard logistics will provide
significant advantage by reducing costs and increasing the
competitive edge. The module will efficiently support stock keeping,
quality planning and product dispatching.
7) Laboratory management
The module will collect and manage all quality data in a central

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database and configure quality workflows and analysis in the lab and
on production line. This will include automatic validation and alarm
handling for management.
8) Maintenance & Equipment management
The performance of the plant greatly depends on the effectiveness of
its maintenance system. The maintenance module will help to
increase availability while supporting the competitiveness of the
production. The functionality of the module ranges from maintenance
planning using standardized work schedules to the initiation of
maintenance orders based on defined criteria and the collection and
archiving of all incurred costs to fulfill the technological and process
needs of the plant.
9) Energy management
Total cost of energy for HSM is very large of the total production
costs. The energy module will show transparency for revealing actual
energy consumption. The module functions in recording consumption
data, allocating energy charges, planning, energy forecasting,
generating energy balances etc. The module will be configurable and
scalable for the different automation levels and production units.
4.8.12 Modes of Operation
The proposed mill will have three modes of operation for RM & FM.
1) Manual mode
There will be no rolling in this mode. The operator through HMI/
switches provided in main control pulpit will have facility of manual
and auto calibration of hydraulic screw downs. The individual system
will be tested during maintenance using manual mode.
2) Automatic mode with process computer
In this mode, the process computer will send the set points
calculated from the pass schedule to the Level-1 system. All rolling
parameters except tension will be dynamically calculated and down
loaded to Level-1 system based on the actual feed of rolling
parameters from Level-1 system. Any change in entry thickness
during threading will cause new preset value down loading to the
Level-1 system.
4.8.13 UPS Systems
New UPS systems will be used for the proposed automation system
consisting of Severs, Networking hardware, TCS, PLC and process
supervision & monitoring system, process instrumentation,
telecommunication, fire detection & alarm system, etc. Each UPS
systems will be in parallel redundant configuration with 50% load
sharing. The Rectifier and Inverter of UPS system will be IGBT
based. The UPS system will have battery back up time of minimum
one hour. Separate UPS systems will be provide for Automation


Building and various control pulpit, TCS rooms, Instrumentation
rooms, PLC rooms depending upon locations The centralized UPS
systems will be distributed as per requirement. PDB will be provided
for distribution of UPS power.
4.8.14 Digital Video Management System (DVMS)
The HSM will be equipped with DVMS system in order to cater to
video surveillance and plant operational requirements. The
system will have its dedicated communication bus enabling
surveillance, alarm and event activated recordings. The video of
both the cause of the event and the results of the event captured
will allow for proper diagnostic & analysis. The control room
operator can not only view & control all the cameras from the
main control rooms from the TV monitors. The plant operators
will monitor and control the process with the aid of live videos.
The Digital Video Recording & Management System will include:
DVM Database & Camera Servers
Network connected cameras (IP based) and/or network
connected camera streamers
Network infrastructure
System software
The CCTV cameras will be located at different strategic locations
from Slab yard to Furnace to Mill to Coil Yard.
4.8.14.1 System Requirement
The camera will be suitable for day and night operations. The
camera will be IP based with digital output signals. Each of the
TV cameras will be hooked up to the network. Remote viewing of
camer5as will be provided. The monitors along with its controls
and its associated equipment will be installed at main control
pulpit. All control functions related to CCTV systems comprising
of Cameras, Monitors, Water cooling jacket, blower unit and wipe
& wash unit of the weather proof housing will be affected from the
control unit to be installed in pulpit & main control room.
The CCTV system will comprise of colour TV cameras with
manual and motorized zoom lenses as required, camera
mounting platforms/ structure as required at site, Water cooling
jackets, complete with wipe & wash units, Remote controlled Pan
& tilt units, Control console with control units for complete control
of cameras and associated devices, colour TV TFT monitors,
Interconnecting video & control cables, UPS system, Video
distribution amplifier/ Video cable equalizers, Camera streamers ,
DVM Database & Camera Servers etc. as per requirements. All other

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auxiliary equipment, connectors, erection accessories etc. will be
provided as required.
4.8.15 Intelligent Automatic Fire Detection System
Intelligent type digitally addressable Fire Alarm System will contain
one or more Intelligent type addressable Fire Alarm panel(s) and
Intelligent type addressable detector and multi criterion devices and
Linear Heat Detection (LHD) cables. All the panel must have in a
strong networking system. There must be a Life Safety Colour Text
and Graphics Annunciation connected in the network. The
description, feature and specification of all the system components
are as described below:
Standard Regulation: Automatic Fire detection & Alarm System will
be designed, manufactured, supplied, erected and tested as per
requirement laid in Fire Protection manual issued by Tariff Advisory
Committee of India and relevant Indian Standard specification /
IPSS. In absence of relevant standards, the system will be designed
in accordance with requirement of National Fire Practice, Fire
officers committee, UK and other International Standards, Codes
and regulations. All imported items will bear under-writers
laboratories (UL), USA/Factory manual (FM), USA/Fire Officers
Committee (FOC), UK approvals and TAC, India Standard approval
certificate for any Indian Supply.
Each Intelligent type addressable smoke detectors sensitivity will be
capable of being programmed individually as most sensitive, more
sensitive, normal less sensitive or lest sensitive. In addition to the
five sensitivity levels the detector will provide a pre-alarm sensitivity
setting, which will be settable in 5% increments of the detectors
alarm sensitivity value.
An alternate alarm sensitivity level will be provided for each detector,
which can be se of any of the five (5) sensitivity settings manually or
automatically using a time of day event. In addition to the five
alternate sensitivity levels the detector will provide an alternate pre-
alarm sensitivity setting, which will be settable in 5% increments of
the detectors alternate alarm sensitivity value.
The detector will be able to differentiate between a long drift above
the pre-alarm threshold and fast rise above the threshold.
The detectors sensing element reference point will automatically
adjust, compensating for background environmental conditions such
as dust, temperature, and pressure. Periodically, the sensing
element real-time analog value will be compared against its
reference value. The detector will provide a maintenance alert signal
that 75% to 99% compensation has been used. The detector will
provide a dirty fault signal that 100% or greater compensation has
been used.


The system will allow for changing of detector types for service
purposes without the need to reprogram the system. The
replacement detector type will automatically continue to operate with
the same programmed sensitivity levels and functions as the
detector it replaced. System will display an off-normal condition until
the proper detector type has been installed or change in the
application program profile has been made.
The areas to be covered under Intelligent Fire Detection & Alarm
system will include the following installation installed new pertaining
to this project:
ECR & Transfer Rooms
Cable Tunnels
Server, TCS & PLC Rooms
UPS Rooms
Control Pulpits
Hydraulic/ lubrication rooms
The system will comprise of main control panel, manual call stations,
repeater panels, response indicators, various type of detectors,
electronics, hooters, power supply units complete with back up
power supply system etc.
4.8.16 Cables & Accessories
All power, control, screened and special cables along with cabling
accessories required for interconnection of all the equipment under
the scope of the work. The following cables will be used for:
Interconnection of I/Os for PLC and TCS systems
Incomers and power distribution for automation system
Cables for panel illumination and lighting
Interconnection between computers and its peripherals,
HMI/ Operators stations, IO systems and other field
sensors/ devices, etc.
FOC and twisted pair cables
Telecommunication cables
Special cables etc.
4.8.17 Telecommunication System
4.8.17.1 Press to talk type loud speaker communication system
Press to talk type Loudspeaker Inter-communication System will be
used to provide quick and reliable communication facility among
various strategic location in the mill.
The system will be flexible as far as expansion and system
configuration is concerned.
Depending upon the requirement, the subscriber stations will be desk
or wall mounting type.

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4.8.17.2 Plant Telephone System
The plant telephone facility will be extended to the new locations to
the mill areas including the above locations where press to talk
system is being envisaged. Suitable telephone sets along with
EPBAX system are being envisaged.
4.8.17.3 Walkie talkie sets
Walkie talkie sets are also being envisaged for efficient and reliable
communication.
4.8.18 Access Control system
Biometric based Access control system is being envisaged for
regulating access/entry to various important rooms like Process
computer room, MES room and control pulpits. The access control
system will include automatic attendance management features. The
system will be installed at different locations to facilitate the
attendance of employees. The system will have a centralized server
to store all the access and attendance records and will also provide
various reports.
4.9 ELECTRICAL SYSTEM AND DRIVE AUTOMATION
4.9.1 Power Requirement
The estimated power requirement for the new 3.0 Mt Hot Strip Mill
(HSM) is as follows:-
Maximum Demand ( 15
minutes)
190 MVA
Average Demand 135 MVA
4.9.2 Present power distribution system
Presently, Rourkela Steel Plant is receiving power from the following
three sources:
Orissa Power Transmission Corporation Limited (OPTCL) is
supplying power from Tarkera Sub-station at 132kV level
NSPCL is supplying power at 132kV level
RSP is generating own power at 33kV level through CPP-1.
At present the average power demand of RSP is around 175MW and
peak demand is around 220MW.
After on-going modernization, average demand of RSP is expected
to increase to 315 MW. Additional Power will be drawn from 220 kV
Tarkera sub-station through 2 nos. 220 kV lines at MSDS-IV
substation.


4.9.3 Power Distribution network of the proposed Mill
4.9.3.1 As the existing 220 kV transmission line from OPTCL to RSP is not able
to take additional load of the proposed Hot Strip Mill (HSM). The
following are proposed:
Construction of 2 nos. 220 kV bays at Tarkera grid sub-
station, extension of the control room, boundary wall and
associated jobs
It is proposed to tap the bulk power at 220 kV level through
transmission lines/ cables (part) from Tarkera grid substation
for catering to power demand of the proposed HSM and its
associated auxiliaries.
4.9.3.2 Addition of 2 nos. 220 kV bays at NSPCL new unit S/s. Connectivity
with the proposed 250 MW NSPCL power plant with new MSDS-VII
through transmission lines.
4.9.3.3 All transmission lines have been considered with optical ground wire
(OPGW).
A new Main Step Down substation, i.e. MSDS-VII is planned to be set
up in the vicinity of HSM site at a strategic location and will broadly
consist of the following:

220 kV double circuit power from Tarkera through overhead
transmission lines/ cables (part) will be brought to MSDS-VII
220 kV indoor Gas Insulated Substation (GIS)
Three nos. 160/ 140 MVA, 220/ 33 kV ONAF/ ONAN outdoor
power transformers
33 kV indoor GIS for feeding mill drives and power supply to
for 33/ 6.6 kV substations
4.9.3.2 The power supply at 220 kV from Tarkera OPTCL substation will be
brought through transmission lines. A route survey is to be conducted to
establish the route of transmission line. Cable routing in short span,
wherever necessary depending upon route survey will be considered.
4.9.3.3 Two nos. 33kV/6.6 kV HT substations 1 & 2 are also envisaged to be
set up at strategic load centres. 33 kV incoming power supply to these
HT substations will be fed from 33 kV GIS to be installed at MSDS VII.
4.9.4 Necessary approval and sanction for additional power requirement from
OPTCL is to be taken up by RSP separately.
4.9.5 Total power requirement of new HSM is proposed to be met from the
following two substations:

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a. Main Step Down Substation (MSDS-VII) to be located near HSM
for the following purpose:
To receive power at 220 kV level from Tarkera substation
and in future also from new NSPCL/ MSDS-IV
To step down from 220 kV to 33 kV level for catering to major
mill loads. Roughing Stand motors and to Finishing Stand
motors shall be fed through Converter transformers 33kV/6.6
kV HT substation no. 1: To step down from 33 kV to 6.6 kV level for
catering to mill and auxiliary loads.
c. 33 kV/ 6.6 kV HT Substation no. 2 for RH Furnace and auxiliaries
is proposed to be located near Re-Heating Furnaces for catering to
Re-Heating Furnace loads
4.9.6 Emergency power:
Critical loads (Category I) including for illumination has been considered
as 1 MVA. This will be met from CPP-I through new plate mill 6.6 kV HT
Board. One 6.6 kV emergency HT board has been considered in Re-
Heating furnace switchgear room. This 6.6 kV HT Board will be fed by
two nos. 6.6 kV incomers, one from new MSDS VII and another from
existing CPP-I through new plate mill substation. Auto changeover
facility has been considered. Existing 6.6 kV HT Board in new Plate mill
will be extended by one panel for the purpose of tapping power for 6.6
kV emergency HT Board. Cable route of 1 kM distance has been
considered from new Plate mill to the proposed 6.6 kV emergency HT
Board for new HSM. All category I loads, mainly pump motors for Re-
heating furnaces and complete illumination, will be fed directly from this
emergency 6.6 kV HT Board. Same make of 6.6 kV HT breaker as
considered for new plate mill 6.6 kV HT Board will be preferred.
4.9.7 MSDS-VII will consist of the following:
a. Indoor type double bus configuration 220 kV Gas Insulated
Substation (GIS)
b. Three nos. of outdoor 160 MVA/ 140 MVA, 220 kV/ 33 kV each
ONAF/ ONAN transformers
c. Switchyard to 220 kV GIS and from GIS to transformer connection
will be through SF6 bus-duct
d. Indoor type double bus configuration 33 kV GIS HT Board for catering
to major mill loads, HT substation no. 1 & 2 for mill auxiliaries and Re-
heating furnaces, respectively and also for start up of Coal
gasification plant


e. Substation automation system. SAS will be integrated with the
existing SCADA at MSDS-IV. Necesssary hardware and software
have been considered. Necessary number of OPC gateways will be
provided in the SAS for down loading required data to process
automation.
f. Nitrogen injection based fire protection system for above mentioned
transformers
g. On line condition monitoring for above mentioned transformers
h. Hydrant system for outdoor switchgear equipment protection
i. All protection relays will be numerical type and communicable on IEC
61850 protocol
4.9.8 33 kV/6.6 kV HT Substation No.1
The above substation is proposed to be installed close to the Finishing Mill
zone and will be catering power supply to Finishing mill equipment, coilers,
transfer bed and auxiliaries. The substation will broadly consist of the
following:
a. 2x31.5 MVA, 33 kV/ 6.6 kV HT substation to be fed from 33 kV HT
Board in MSDS-VII through cables for Mill equipment.
b. Substation automation system
c. Nitrogen injection based fire protection system for above mentioned
transformers
d. On line condition monitoring for above mentioned transformers.
e. All oil filled transformer will be kept in a separate room with
independent inlet & outlet ventilation for each transformer room
f. Static VAR compensator with detuned filter at 6.6 kV level
4.9.9 33 kV/6.6 kV HT Substation No.2
The above substation is proposed to be installed close to the Reheating
furnace and will be catering power supply to Reheating furnace. The
substation will broadly consist of the following:
a. 2x31.5 MVA, 33 kV/ 6.6 kV HT substation to be fed from 33 kV HT
Board in MSDS-VII through cables for RH Furnace
b. Nitrogen injection based fire protection system for above mentioned
transformers

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c. On line condition monitoring for above mentioned transformers
d. Hydrant system for outdoor switchgear equipment protection
e. 33 kV feeders for start-up of Coal gasification plant.
f. All oil filled transformer will be kept in a separate room with
independent inlet & outlet ventilation for each transformer room.
4.9.10 Brief description of the power distribution scheme is indicated in the
enclosed Single Line Diagram, drg. No. CET RN 3379 EE1 00 001,
R=0. The SLD is indicative. Smaller 6.6 kV substations for sub-plant
units like Furnace, Coiler, Pump House, Dividing line, etc. to be located
nearer to the load will be considered during TS finalisation.
4.9.11 Around 1000 m3/h of make up water will be required for the proposed
HSM. The same will be taken from the existing Lagoon outside the plant
boundary. Tentative power requirement for necessary treatment facilities
is around 1000 kW at 415 V. Power at 6.6 kV level for the purpose will
be tapped from the existing spare 2 nos. feeders of 6.6 kV board of new
substation at Tarkera pump house.
4.9.12 Design considerations
The power distribution network has been designed as a simple radial
system, with two alternative supply feeders to each load centre. The
design of power distribution system and selection of equipment will
be based on the main consideration of simplicity, safety, reliability
and ease of operation & maintenance as well as convenience of
future expansion.
The equipment will conform to relevant IS/IEC specifications and
code of practice to meet the operational requirements and to ensure
reliable and trouble free service in the plant.
4.9.12.1 Basic Design Criteria
The electrical system is proposed to be designed to suit the following
power system parameters:
Sl.No. Description Technical parameters
1. HT Power
supply
220 kV( +/-)10%, 50 Hz( +/- 5%), 15000
MVA,
Solidly grounded system
2. HT Power
supply
33kV( +/-)10%, 50 Hz( +/- 5%), 1800
MVA


Solidly grounded system
3. HT Power
supply
6.6kV( +/-)10%, 50 Hz( +/- 5%), 450 MVA
Resistance grounded system

4.9.12.2 Power supply to various HT & LT Loads / load centres
1. All the stand motors
including of Roughing
Train, Vertical Edgers,
Finishing stand motors &
all other motors above
2000 KW
33kV, 3 ph, 50Hz as primary
source to the different
converter transformers (i.e.
through unit transformer).
2. Motors rated above 200kW
and up to 2000kW
6.6 kV, 3 ph, 50 Hz
3. Motor rated above 90kW
and up to 200kW Fed from
direct Power Control
Centres (PCCs)
415V, 3 ph, 50 Hz
4. Motor rated up to 90 kW
feed from MCCs
415V, 3 ph, 50 Hz
5. Illumination and small
power
240 V, 1 ph. 50 Hz
6. Control power supply AC
for LT switchgear, MCC,
etc.
240 V, 1 ph, 50 Hz through
control transformers
7. Control power supply DC
for HT switchgear
220V DC through Battery
bank

4.9.13 LT Sub-Station
4.9.13.1 Transformers
LT substations complete with double ended 1600 / 2000 kVA, 6.6 kv/
433 V power distribution transformers, power control centers (PCCs)
have been envisaged for meeting the power requirements of furnace
drives, mill auxiliaries, cooling system, air compressors, EOT cranes,
ACVS equipment, illumination and welding network workshop

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facilities, water facilities, etc. the proposed power transformers will be
dry type (AN), winding insulation classF and will conform to IS-
11171.
It is also envisaged that no transformers will be placed in the shop
floor. All transformers will be placed in rooms with approach road
suitable for movement of vehicle for transportation of transformers.
4.9.13.2 6.6 kV HT Isolators
6.6 kv, 630A load break type HT isolators at the primary side of
power transformers are considered. Further HT stop push buttons
will also be provided in each transformer room for tripping the
breakers
4.9.13.3 LT Bus duct
Secondary side of transformers will be connected to the incomers of
the proposed Power Control Centres (PCCs) by non phase
segregated LT aluminum bus ducts of adequate rating.
4.9.13.4 Power control Centres (PCCs)
The 415 v switchboards will comprise of air circuit breakers, in draw
out design and multi tier formation. The switchboard will have two
incomers and one bus coupler breaker with provision for auto
changeover in the event of loss of power on any one bus section.
The circuit breakers will be electrically operated and equipped with
microprocessor / static type direct acting releases for over load and
short circuit as well as earth fault protection, indicating lamps and
meters. All motor control centers (MCCs), large drives starter panel
(above 90Kw and up to 200 Kw) and power distribution boards
(PDBs) will be supplied power from the 415v switchboard. The 415v
switchgear will confirm to IS-8623 and IS 13947.
4.9.14 Power Distribution Board (PDB)
4.9.14.1 LT PDBs are proposed to be set up for feeding power supply to various
auxiliaries like EOT cranes, hoists, exhaust fans, welding network,
machine shop, mechanical and electrical workshops, illumination
system, ACVS system, etc.
4.9.14.2 Roller table distribution boards are also considered for roller table
motors for different zones.
4.9.15 Converter Transformers
4.9.15.1 The following type of converter transformers have been considered:
a. 33Kv / 3.6 kV converter transformers are considered to feed large
rating stand motors through medium voltage VFD controller.


33 kV grade converter duty transformers for main mill motors will
preferably be imported from reputed OEM & will be conform to IEC-
61378.
b. 6.6Kv / 690V Converter transformers are considered to feed
motors of 690V through VFD controllers.
c. More over the ratings of converter transformers (of same voltage
ratio) will be of identical kVA rating to extent possible.

4.9.15.2 Main Features:
a. Two winding / 3 winding
b. Isolation from power supply network.
c. Capable of handling RMS load current drawn by the motor
d. Class H Insulation
e. OCTC and voltage variation +/- 7.5 % in steps of 2.5%
f. Dry type up to 2000 KVA and ONAN cooled for more than 2000
kVA.
g. Conforms to IEEE 444, 1973 and IS; 2026,1977
4.9.16 Shop Electrics and Automation
The electrical drives, controls and automation equipment, envisaged
for smooth and efficient operation of new units will be of modern
design and with latest technology. The following major equipment
has been envisaged:
4.9.17 AC Motors for Mill Stand Application
The large rating AC motors employed for stand application. These
motors are considered as Inverter duty AC motors. These motors are
considered to be fed from Converter Transformers (33kV / 3.6kV)
and MV VFD drives. VFD motors will be fitted with accessories such
as base plate, pulse encoder, RTDs, space heater etc. These motors
are to be provided with proper Air to water heat exchangers will be
provided water cooling system.
4.9.18 MILL Auxiliaries & Utilities

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4.9.18.1 The Squirrel cage induction motors above 200kW & up to 2000 kW for
auxiliaries system of fixed speed are considered to be fed directly from
6.6kV level.
Fixed speed motors above 200 kW, will be started & controlled by
symmetrically operated thyristor based electronic soft starter.
However, in case of motors above 200kW like CA fan, ID fan, vertical
edger, etc which may need speed variation are proposed to be fed
through converter transformers (6.6kV / 690V) and 690V LV VFD drives.
VFD motors will be fitted with accessories such as base plate, pulse
encoders, RTDs, space heater, etc. These motors are to be provided
with proper Air or water cooling system.
4.9.18.2 The squirrel cage induction motors equal or below 200kW is considered
on 415V. All the motors equal and above 110kW and up to 200kW are
considered with 415V Variable Frequency Drives (VFDs).
4.9.18.3 The squirrel cage induction motors below 110kW is considered with
Direct on line. However, the mechanism needing speed regulation like
roller table motors, pinch rolls and also other auxiliaries are considered
with VFD. Motors having VFD controller will be inverter grade.
4.9.18.4 VFD motors will be fitted with accessories such as base plate, pulse
tacho, PTCs etc. Space heater for motors above 75 KW will be
provided.
4.9.18.5 Intermittent duty, reversible, heavy duty squirrel cage Induction motors
for crane duty application are proposed to be installed in all the drives of
the EOT cranes & transfer car. These motors will be provided with
thermistors & will have min. 150 starts per hours. All motors of EOT
cranes are considered to be controlled by VFD and will be inverter
grade.
4.9.19 AC Drives
4.9.19.1 For Larger rating drives
Main AC drives will be IGBT/ IGCT based depending upon the rating
of the drive. These main AC drives will be digital drives with active
front end. These high efficiency drives with DC link, will result in
approx unity PF. These drives will have following features:
Fully regenerative topology for bi-directional power flow.
High output frequency, which may result in smaller motors.
Minimum torque ripple
Synchronous & induction motor drive capability


Low harmonics
Close to unity power factor
High efficiency
Speed precision
Soft water cooled heat exchangers
4.9.19.2 AC Drives for Mill auxiliaries
IGBT based VVVF drives with sine coded PWM & vector control are
envisaged. These drives will be with:
High response & control precision
Adaptable to actual supply frequency
Quick Fault localization
4.9.20 Intelligent Motor Control Centers (MCCs)
The intelligent MCCs are considered for feeding power supply for
controlling the auxiliary drives of fixed-speed mechanisms, drives of
utilities & services equipment. Each MCC will have one single
incomer with requisite no. of out-going feeders. MCCBs, power
contactors, thermal overload relays, auxiliary relays, meters,
indicating lamps are considered to be provided in MCC Electronic
Motor protection relay will be considered for motor ratings greater
than equal to 55KW. The MCC will be equipped with Signal modules,
Microcontrollers and profibus interface cards.
4.9.21 Electrics of Miscellaneous items
It is proposed that Hydraulic power packs, lubrication system, pumps
for emulsion, compressors, air conditioning & ventilation system,
equipment for mechanical & electrical workshop, water facilities
system will be supplied complete with soft starters, Vacuum
contactors etc.
4.9.22 Sensors/ Field Devices and measuring devices
Field devices and sensors like pulse encoders, proximity switches,
HMDs, limit switches, level switches, load cells, etc. as required for
feedback, inter-locking and sequencing have been considered.
4.9.23 Control Desk / Local control stations (LCS)

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A number of desks, LCB and pulpits are envisaged for control of
lines/ mills and utilities. Pulpit will be structural, aesthetically
designed with false ceiling, false floors, decorative lighting and will
have toughened glass front. All the pulpits will be air-conditioned.
Desks will be floor mounted and will house HMI PCs in additions to
other controlling devices. LCSs will be wall-mounted type and will be
used for local control of different mechanisms, pumps, fans, etc.
4.9.24 Uninterrupted power supply (UPS)
Uninterrupted power supply (UPS) of required rating will be provided
in different unit for supplying power to automation system (CPU),
controllers and in some cases important instrumentation. UPS will be
of digital type with PWM technology based in IGBT. This will be hot
redundant type with a provision to power change over through a
static switch. The batteries will be of Ni-Cd type along with battery
charger. Distribution board for distributing uninterrupted power
supply is also considered.
4.9.25 Automation System
Two levels of automation are envisaged. Basic automation (Level-1)
and Process automation (Level-2).
4.9.25.1 Basic automation
The basic automation ie level -1 comprises of Technological control
system (TCS), PLC & drive system HMI stations & measuring
instruments suitably integrated on high performance local area
network, which controls the actuating system and ensures fast
dynamic performance. This level will consist of all closed loop & open
loop controls, regulatory controls, logic & sequential controls,
dialogue & display for operators, process interface, alarm & extent
registration etc.
4.9.25.2 Technological Control system (TCS)
Complete technological functions of the mill like Mill stand motors,
screw down motors, mechanical equipment & instruments of HAGC
system are proposed to be controlled and monitored by dedicated
multitasking process controllers. These controllers will also cater the
following functions:
Reference generation, Sequencing & interlocking
Interfacing with control console & drives
Fault annunciation
Real time calculations


4.9.25.3 Programmable Logic Controllers (PLC)
Apart from TCS, Programmable logic controllers (PLCs) are also
envisaged for the functional control of various auxiliaries like
Reheating furnace , water management, air compressors, oil
lubrication, roller tables etc. Wherever necessary remote I/Os are
envisaged to provided.
4.9.25.4 Human Machine Interface (HMI)
Visualization system will be through PC based HMI terminals. These
have been envisaged for control & operation of plant. Different
screens will be provided in these PC terminals showing different
sections of the plant and their status graphically. The graphic display
will be interactive type. These screens will be programmable through
engineering stations. The HMIs will have process diagnostic system
to provide status & fault signals of the process along with process
error display.
4.9.26 Cables
4.9.26.1 HT Power Cables
220 kV single core XLPE insulated welded corrugated
aluminium-alloy sheathed with copper conductor conforming
to IEC 68040 cables from switchyard to 220 kV GIS, from GIS
to 160 MVA, 220 kV/ 33 kV transformers.
220 kV earthed grade, XLPE insulated armoured aluminium
conductor cables from switchyard to the primary of 33kV/ 3.6
kV Converter Transformers.
33kV earthed grade, XLPE insulated armoured aluminium
conductor cables from 33 kV GIS to 30 MVA, 33 kV/ 6.6 kV
transformers.
33kV earthed grade, XLPE insulated armoured aluminium
conductor cables from switchyard to the primary of 33kV/ 3.6
kV Converter Transformers.
6.6 kV unearthed grade, XLPE insulated armoured aluminium
conductor cables are considered for supplying power to the
primary of 6.6kV / 433V transformers at different LT Sub-
stations, to converter transformers (6.6kV /690V) and also to
6.6kV HT motors.
3.3kV grade unearthed grade, XLPE insulated armoured
copper conductor cable from medium voltage (MV) VFD
controller to the large rating stand motors.

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HT power cables will conform to IS: 7098.
Minimum size for 6.6 kV will be 185 sq.mm. Short circuit
duration of 0.25 S will be considered for cable sizing
4.9.26.2 LT Power Cables & Control Cables
LT power cables for 415 V system will be heavy duty, 1.1 kV grade,
XLPE insulated PVC sheathed aluminum conductor, armoured. The
control cables will be multi strand copper conductor, XLPE insulated
and PVC sheathed with minimum cross section of 2.5 sq. mm for
control voltage circuit and 4.0 sq. mm for power circuit. The LT
power and control cable will confirm to IS-1554-1988.
4.9.26.3 Special cables
Screened cables, signal cables, coaxial cables, etc are also
considered for the project.
4.9.26.4 Cabling
Power inside the plant will be distributed through cables to various
premises through RCC cable tunnels (of size 2.5mx 2.5m with 600
mm cable tray on both sides of tunnel) and through RCC cable
trenches. GI pipes/ hume pipes will be used at road/ rail crossings.
Inside the substations and covered premises, the cables will be laid
in basement or in concrete trenches (over cable supporting
structures/ cable trays) or on columns and other structures. Power
cables will be laid on ladder type trays, whereas control cable will be
laid on perforated cable trays.
4.9.27 Illumination
4.9.27.1 For supply of various illumination loads in the sub-station building,
provision of Main lighting distribution boards (MLDBs) has been
considered. These MLDBs will be installed in HT / LT substation room
and will be fed from the 415 V switchboard. MLDBs will supply power to
the various Lighting Distribution Boards (LDBs) installed in various
buildings. Further the LDBs is considered to supply different Sub-lighting
Distribution Boards (SLDBs). Lighting fixtures is considered to be fed
from SLDBs.
4.9.27.2 The internal illumination of low roof buildings will be with fluorescent
tube light fittings whereas for shops as well as high roof building will be
illuminated with HPSV lamp fittings. Wherever high colour rendering is
required (low colour distortion) metal halide lamp fittings will be used.
For mill bay illumination High bay/ medium bay lighting fixtures are
considered. Average illumination inside the shop building will be 100-
150 lux, however the illumination level in control rooms will be 300 lux.


Illumination in open yard and area illumination will be provided with
HPSV flood light fittings. The average illumination level will be 15 to 30
lux for outdoor illumination. The use of energy saving, high power factor
lamp fittings will be preferred. The code of practice for illumination
system is considered as per IS: 3646.
4.9.28 Welding System
For ease of maintenance 3 ph welding sockets suitably located along
length of the bay and near other premises are envisaged. Welding
distribution boards (WDB) are considered for feeding the welding
receptacles.
4.9.29 Harmonic filtering system
In the proposed plant harmonic filtering system is also considered for
suppressing of harmonics.
4.9.30 Air conditioning & ventilation system (ACVS)
4.9.30.1 Air conditioning system for GIS, 6.6 kV switchgear rooms including
cable vaults suitable for upto 38
0
C has been considered.
4.9.30.2 Ventilation of MCC rooms, basement floors, LT switch gear rooms are
envisaged. Areas of ECR housing electronics/ automation equipment,
UPS, telephone exchanges, weighing panels and all pulpits will be air-
conditioned. Complete electrics of ACVS has been considered.
4.9.31 Earthing
4.9.31.1 An outdoor protective earthing network made of number of electrode
stations interconnected by means of GI strip earth continuity conductor
are envisaged to be provided around the main shops and auxiliary
buildings. A low earth resistance is envisaged to be obtained by using
sufficient number of earth electrode. Main earth rings effectively bonded
to the outer ring will be provided inside the electrical control and building
structures. Parts of electrical equipment and machinery, not intended to
be alive, are envisaged to be connected to the main earth rings by two
separate and distinct earth connections in accordance with Indian
Electricity rules and as per IS-3043.
4.9.31.2 A separate electronic earthing system will be provided for the earthing
of electronic equipment such as PLCs & drives. Special earthing,
Foundation earthing if any, will be as per suppliers practice /
recommendation

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4.9.32 Lightning Protection system
Lightning Protection system will be provided for protection of plant
and equipment against lightning. The design of this system will be as
per IS: 2309-1969. The lightning masts / rings / down leads will be
connected to earthing pits specifically provided for lightning
protection.
4.9.33 Crane and Crane trolley lines/ electric hoists
4.9.33.1 Electrics of all EOT Cranes and electric hoists are considered. All the
motors of the EOT cranes is considered with VFD controllers and radio
remote controls. Electric hoists are considered with all electrics including
festoon cable arrangement.
4.9.33.2 Power to the electrical overhead travelling (EOT) cranes are envisaged
to be fed through the crane trolley line system. The crane trolley lines
are envisaged to run longitudinally along crane girder, suitably
supported on intermediate and sectionalizing brackets and are
envisaged to be fed from nearby power distribution boards.
4.10 CIVIL WORKS
4.10.1 The following are the major civil engineering jobs envisaged for the
project
a. Construction of RCC/Pile foundations and all civil works for all
machine / equipment, reheating furnace, chimney, mill
equipments and its drive, transfer car track if any, auxiliaries and
other technological structures to be installed in the proposed Hot
Strip Mill.
b. Construction of RCC/Pile foundations for all steel structural shed
like slab yard bay, furnace charging bay, furnace bay, mill bay,
motor bays, coil storage and dispatch bay , roll shop, shearing
line and dispatch bay etc. for the proposed Hot Strip Mill
c. Construction of RCC framed with brick cladding HT/LT
Substation, PCC Room, MCC rooms Transformer Room, ECR
buildings, Compressor buildings, PLC and Control rooms etc.
d. Construction of RCC foundation of switch yard structures
including RCC cable trenches with RCC Pre-Cast cover
slabs/chequered plates as per requirement
e. Civil works for soft water plant, chilled water plants etc.
f. RCC framed and RCC walled underground cellars along with
RCC foundations for various equipment etc.


g. Construction of RCC framed with brick cladding hydraulic rooms,
heat exchanger rooms, filter house, rooms for AHU, ventilation
rooms, booster house, blower house, different rooms for
instrumentation and automation etc.
h. Construction of RCC framed with brick cladding roll shop,
mechanical and electrical shops, Product Testing Laboratory,
Pump House, DG room, stores, security posts, watch towers,
Administrative Building, Shift room, rest room, utility rooms &
canteen building with toilet and drinking water facilities, buildings
for Oil & lubrication systems, air condition and ventilation system
etc.
i. Construction of RCC foundation for Compressor, booster,
blowers, pumps, A/c and ventilation equipment, electrical
equipments, equipments for fire fighting and water circulating
system etc.
j. RCC overhead soft and make up water tanks
k. RCC cooling towers
l. Construction of trestle foundations for different pipe lines,
foundations for vehicle parking shed etc.
m. Construction of RCC floor in new shed and hard stand as per
requirement
n. Construction of flue duct/tunnels as per requirement. RCC
Sumps, Settling tanks, channels, scale bins and pits, etc
o. Construction of RCC foundation for furnace oil day tank.
p. Construction of RCC framed with brick cladding pump house at
old HSM.
q. Construction of RCC foundations for furnace oil pipe line supports
from old HSM to new HSM.
r. Construction of new railway track and connection with existing
network.
s. Construction of approach roads to all new units for operation and
maintenance purposes and connection to plant main road.
t. Suitable Surface drainage around the new buildings / facilities
and the entire area and connection of the same to the existing
storm water drainage system. Plant drainage system including
culverts is also considered

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u. Area survey and soil investigation has been envisaged and it will
be carried out in separate package.
v. Bush and jungle clearance, site leveling, land and area
development for the areas where the new units are to be
installed.
w. Dismantling of existing RCC, PCC, Brickwork, railway lines etc.
as per site requirement.
x. Existing over head/ under ground communication lines are
envisaged to be suitably protected/diverted
y. Dismantling of existing boundary wall and diversion of connecting
road between Plant and NH
z. New RCC framed boundary walls with masonry cladding and
barbed wire anti climbing arrangement with necessary entry and
exit gates.
aa. Water harvesting and green area as per requirement
The sizes, finishes, doors, windows, rolling shutters, floors, ceilings
etc of the buildings/rooms will be as per technological and process
requirements
4.10.2 Land & site development
The proposed HSM is planned on east side of the present BF Slag
Granulation Plant in the slag dump area partly and by the side of
National highway. The proposed plant area is surrounded on north
side by existing MSDS 2, east side by existing boundary wall of
plant, south side by hillocks and west by National Highway. The part
of new mill is planned over the existing BF/SMS slag dump. The slag
dump is still operated by Rourkela Steel for dumping BF slag and
rubbish materials etc. The area for the proposed plant is undulated
and having the slope towards both north and south side.
The proposed site has huge slag heap and there are low lying areas
also. The facilities envisaged in this report pertain only to the units
inside the boundary of the hot strip mill.
The water treatment plant has been envisaged to installed on the
space available in between the Lagoon and National Highway. Area
requirement will be to the tune of 100mx200m, which will be
developed accordingly.
Other infrastructures like external linkage railway lines, etc
need to be studied by specialized agencies. External railway
connection is to be taken up with railway authority. However,


cost towards these has been assumed considering certain rail
length.
Topographical survey of the land, soil investigation, boundary wall,
entry gates, drainage of the land, etc are all included. Leveling &
terracing of the plant area will be done taking care of the needs of
the different units, drainage requirement, natural drainage system,
etc. The leveling will be done in such a way that cutting & filling will
be optimized.
The present finished ground level of Plate mill has been kept as
+214.6 m AMSL. It is considered that the same FGL will be kept for
new HSM
As per eye estimation, it is estimated that about 2.0 million cu.m of
Slag for site-filling will be required for the project. Further, the project
also will involve removal and disposal of 2.1 million cu.m of BF slag
out of total 4.1 million cu.m of Slag. Since this is a massive volume,
advance action will have to be taken for undertaking the site filing /
grading work and other development work.
4.10.3 General Layout
The layout of the new HSM will be such that the movement of raw
materials, semi finished goods, and finished goods will follow a
logical sequence. The incoming raw materials will be received from
the nearest road/rail head and will be dispatched through rail/road
network. There will be provision for incoming railway rakes, truck
parking space, weigh bridges, etc. to cater to the needs of the logical
movements.
The layout indicated in drawing no. CET RN 3379 CE0 00 001 R=0
and enclosed in this FR is preliminary and will be finalized during DE
stage considering technological requirement, survey drawing and
reports by specialized agencies for external/internal railway
connection.
4.10.4 Rail and Road network
Movements of incoming raw materials etc and dispatch of finished
goods, etc will all be done by railway/road system. Movement of semi
finished goods; inter plant transfers, and disposal of waste materials
like scrap, scales etc. will be done by roadway/ railway system as per
system requirement.
In laying the tracks, norms of Indian Railways, as formulated by
RDSO, with regard to radius of curve, sizes of switches, distance
between tracks, gradients, clearances on the sides and above, etc.
will be followed. Signaling and communication facilities with

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interlocking arrangement will be provided. Over head electric traction
will be provided to enable Indian Railways electric locos coming
inside the plant and will be limited to the yard area only. Proper
drainage system will be provided along the tracks and yards. Level
crossings with drop gate arrangement will be provided at rail-road
crossings
Generally the roads will be 5 m/7 m wide. Berm of proper width will
be provided for all roads. Road drainage, arboriculture etc will be
duly taken care of. Road and rail crossings will be protected for
safety of men, road vehicles and rail traffic with proper signaling,
gates, visual and sound alarms. Wherever heavy movement of rail
traffic is envisaged, road and rail gate separators will be provided.
Proper road approaches to all units will be provided. In addition
peripheral road along the inside of the boundary wall be provided for
patrolling by security personnel. Necessary service corridor on either
side of main roads will be earmarked for laying of underground
facilities like cable tunnel, drains, water pipe lines, gas lines, power &
communication cables, etc
Logistic for Rail Transportation
The finished products i.e. sheets and coils from new HSM will be
dispatched to two destinations
a. Internal destination i.e. to Cold Rolling Mill, Pipe Plant Silicon
Steel Mill and dividing Line of RSP.
It is envisaged that about 1550 t of HR coils will be dispatched
per day from new HSM to different internal destinations
mentioned above. The mode of transportation will be through
internal railway wagons.
b. External destination i.e. outside RSP through railway
exchange yard.
It is envisaged that about 6700 t of finished product will be
dispatched per day from new HSM to railway exchange yard for
different external destinations. The mode of transportation will be
through Indian railway wagons.
It is envisaged that there will be three bays in which finished products
will be loaded to railway wagons for different destinations as stated
above from new HSM. The loading bays are:
Coil Yard -1,
Coil Yard -2 and
Sheet Shearing Line.


It is proposed to accommodate half rake of railway wagons in each
loading bay of new HSM.
4.10.5 Buildings
Main administration building, other departmental offices, spot/shop
laboratory, computer building, Security building etc, canteen
buildings, etc will be provided as per requirement. Each office
building will be provided with adequate parking facilities and required
amenities.
4.10.6 Statutory Requirement
A separate Report will be prepared by specialized agencies for
Indian railways approval for the new railway system for HSM and its
connectivity from Indian railways. Further, Rail Traffic clearance
(RTC) also will be obtained from railways for the proposed traffic
Provision for green belt and rainwater harvesting will be kept in
layout.
4.10.7 Civil Works
4.10.7.1 General
The civil works will comprise land development, site preparation&
leveling, design and construction of building structures, shed
structures, underground structures, foundations for equipments, its
auxiliaries, foundation/civil works for all technological units, electrical
and power distribution system, utility and services facilities,
ventilation and de-dusting system, instrument and control system,
water supply facilities, fire fighting and detection system, floors,
surface channels, tunnels, drainage and sewerage network, cellar
structures, roads, railways, hard stand, modification of boundary
walls and new boundary walls etc. and all other infrastructural
facilities for HSM.
Dismantling of existing civil buildings and all other civil foundation
has also been considered
Dismantling of existing plant boundary has been considered.
Diversion of connecting road between NH and plant has also been
considered
Soil characteristics and site data
The site is filled up with heterogeneous slag fill of 1m to 13 m depth
whose N values are not representative of the consistency of
material. In absence of soil report and the nature and magnitude of
proposed construction, bored cast in situ RCC piles has been
considered. The bottom of pile will be embedded in weathered rock

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and it is assumed that the same will be available at 8-10 m depth
below virgin soil.
Further, the allowable bearing capacity of soil is assumed to be 10
ton/sq. meter at a depth of 3m from virgin soil. Moreover, ground
improvement by removing slag and fill up with granular material has
been considered.
Water Table has been considered to be at 1 meter below the finished
terrace level
Soil characteristics will be known after the soil investigation is
got done in the proposed area for HSM. This is required prior to
detail engineering. Type of foundations to be adopted for each
equipment/building/structure will be decided based on the soil
characteristics at that particular location. Independent foundations,
combined footings, raft foundations or piling will be adopted to suit
the quantum of load and the Safe Bearing Capacity of soil. For piling,
mostly bored cast in situ piles will be used.
4.10.7.2 Site surveying and leveling
Contour survey of the site needs to be carried out first. This is
required prior to finalization of detail engineering. The extent of
site leveling will be decided based on the level difference between
the highest and lowest places and also keeping in view the
connection to the nearest railway network. Terracing will be done in
such a way that cutting and filling will be optimum. Drainage of the
plant area will also be suitably planned.
4.10.7.3 Advance Action
Soil investigation and survey
Bush and shrub clearance, site preparation, site leveling and
land development work
4.10.8 Design Philosophy & Guideline
i) Foundations
In general pile foundations have been envisaged based on the soil
report of nearby plate mill. However, on the basis of actual report of
soil investigation for HSM, which is proposed to be carried out
separately before detail engineering, the final selection of type of
foundation will be made.
ii) Plain Cement Concrete & Reinforced Cement Concrete


All RCC structures will be designed as per IS: 456-2000.In general,
cast-in-situ concrete will be used for all RCC works and the minimum
grade of concrete will be M-25C. Jigs, fixtures will be used to fix all
anchor bolts, inserts etc., wherever required. Grade of concrete for
mud mat has been envisaged as M-10B.
iii) Building Materials
Cement
Ordinary Portland cement conforming to IS 12269-1987 [53 grade
cement], IS:8112-1989 [43 grade cement] and Portland slag cement
conforming to IS:455-1989 will be used in all constructions. Special
types of cements will be used wherever required for specific
applications.
Reinforcing steel
Reinforcing steel conforming IS: 1786-2008 with minimum yield
strength of 500 N/mm
2
will be used and as far as possible will be
from SAIL.
Aggregates
Locally available best quality Coarse and fine aggregates will
conform to IS:383-1970 and
Bricks
Building bricks to be used in the works will be common building burnt
clay bricks/ Fly ash bricks & locally available best quality conforming
to the requirements of IS:1077-1992 [burnt clay bricks] or IS:13757-
1993 [Fly ash bricks] depending on the availability locally.
iv) Doors and Windows
Steel/Aluminum doors, window and ventilators with glass panes will
be as per IS: 1038: 1983/ INDAL specifications.
v) Road
Flexible pavement/ road have been envisaged. Thickness of different
layer of road/ pavement will be adequate for traffic intensity and
imposed loading.

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vi) Railway Track
Railway track materials and construction will be as per specification
of Indian Railway Standard (IRS). The rail for the railway track will be
of section weighing 60-kg/ m length and conforming to IRS T-18. The
sleeper density will generally be M+7 where m is the length of rail (13
meters). In general pre-stressed concrete sleepers/Steel sleeper will
be laid over crushed stone ballast.
Abstract of specifications of major civil work has been assumed as
follow:

R.C.C :M20C or M-25C or M-30C as per
requirement
P.C.C :M-10B/M10C
Anchor pocket grouting :M-30D with anti-shrinkage
compound/epoxy
Flooring :RCC/PCC (as per design)
Floor finish :Ironite topping or IPS as per requirement
Brick masonry work in C.M :1:6
Cement plaster for walls/ceiling
/drain :1:6/1:4/
Inside finish for buildings : White washing/ Distemper
Outer finishing for buildings : Cement paint
Plinth protection :PCC 100mm thick over brick on flat
around the buildings.(1m wide).
Drainage :Proper drainage will be provided
around the work area.(Peripheral drain
will be provided around buildings).

Sewer/faecal sewer line : To be laid as per requirement & to be
connected septic tank and soak pit.
Drinking water line : To be laid as per requirement & to be
connected with the existing system.
Roads : Flexible/Rigid pavement with shoulder on either side as per
drawings and IRC/MORTH specification.


It will be connected to existing road
network with proper logistic.
Railway Track Will be as per IRS specification. It will be connected to
existing rail network with proper logistic.
4.11 STRUCTURAL WORK
4.11.1 The scope of structural steelwork for Installation of Hot Strip Mill at
Rourkela Steel Plant is as below:-
Fabrication, erection, painting, testing and commissioning of all structural
steelwork required.
The structural steelworks envisaged broadly includes:
i. Multibay Structural Building for;
Sl.no. Description
Approx. Dimension
1 Slab Yard(2 Bays)
220*30 m

2 Furnace Charging 110*36 m
3 Furnace
110*30 m

4 Mill
660*30 m
5 Roll shop
336*36 m
6 Motor Bay-1
24*24 m
7 Motor Bay-2
24*24 m
8 Motor Bay-3
70*24 m
9 Coil Storage & Dispatch
bay(2-Bays)
400*36 m
10 Shearing Line &
Dispatch
400*36 m

ii. Control-Room & Control-Pulpits as required.
iii. Platforms, Staircases & Handrails as required.

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iv. Supporting structures for pipe lines for furnace oil, compressed air,
and water.
v. Shed for Compressed air station 15X12m.
4.11.2 Steel structural work will include columns, column bracings, beams, stairs,
platforms, ladders, handrails, walkways, claddings, supports for piping &
working platforms, storage water tanks and chimneys.
4.11.3 Design Consideration
4.11.3.1 All steel structures will be designed to meet the technological requirement
with due consideration to the existing plant and facilities apart from
technological loads indicated by the equipment manufacturer /supplier to be
supported on steel structures.
4.11.3.2. Design of steel structures will be as per IS 800:1984.
4.11.3.3 Self weight and superimposed loads for the design will be according to IS
875:1987(relevent parts).
4.11.3.4 Structures will be designed for wind or seismic forces as applicable. Seismic
loads will be taken from IS 1893:2002.
4.11.3.5 Material for structural steel will be as per IS 2062:2006 (Grade-A & B) as
applicable. Chequered plate will conform to IS 3502:1994. Steel tubes for
handrail will conform to IS 1161:1998. High strength micro alloyed steel
SAIL-MA: 300/350/410/450 where the numbers indicate the yield strength
in MPa will be used as per technological requirement.
4.11.3.6 In general, steel structures will be of welded construction. The welding
procedure will conform to IS 816:1969 and IS 9595:1996. Covered
electrodes will conform to IS 814:2004.
4.11.3.7 Fabrication and erection of steel structures will conform to IS 800:1984 and
tolerances of fabrication will be as per IS 7215:1974.Tolerances for erection
will be as per IS 12843:1989.
4.11.3.8 All the structures will be duly inspected and made defect free.
4.11.3.9 All structures will receive two coats of zinc phosphate in phenolic alkyd
medium primer (DFT/coat 35 micron) of approved make and finishing paint
on erected structures will be two coats of synthetic enamel paint(DFT/coat
30 micron) conforming to IS 2932:2003.
4.11.3.10 Galvanized corrugated sheets will be as per IS 277:2003.
4.11.3.11 Plastic translucent sheets made from thermo-setting polyester resin (glass
fibre reinforced) will be as per IS 12866:1989.


4.11.3.12 Pre-painted galvanised steel sheet/Polyester-coated galvanised steel sheet
will be of IS 14246:1995 made from cold rolled steel conforming to IS
513:2008, zinc galvanised (hot dipped) as per IS 277:2003.
4.11.3.13 The steel chimney will be designed as per the provisions of IS 6533:1989.
4.11.3.14 Structural steelworks, if any, to be dismantled/strengthened, are to be
properly identified. Adequate protection is to be taken during
dismantling/strengthening in order to ensure safety/stability of the adjoining
existing structures.
4.12 MAN POWER & TRAINING
A total of around 690 manpower including 90 executives and 600
non executives will be required for operation & maintenance of the
proposed Hot Strip Mill along with associated facilities. Training to
the man power will be provided by the Suppliers in the area of
operations, maintenance, automation, process simulations,
hardwares, softwares, etc. 180 man weeks of training at suppliers
premises and similar Hot Strip Mills has been considered besides
training at RSPs site.


5 PROJECT IMPLEMENTATION
5.1 COMPLETION SCHEDULE
It is estimated that the project will be completed in 42 months from
the date of sanction and 36 months from the date of stage-II
approval. The activity-wise implementation schedule is enclosed at
Annexure-5.1-1 and 5.1-2.
5.2 IMPLEMENTATION STRATEGY
5.2.1 The complete project is proposed to be implemented under following
packages :
Pkg-1 : Soil Investigation & Survey
This package will be executed in advance.
Pkg-2 : Site development
Pkg-3 : Rail network
This is to be done under a specialized agency
Pkg-4: HOT Strip Mill
This package will include all the equipment including
auxiliaries, electrics, utilities, material handling, etc.
Civil foundation of all equipment and other associated
civil work will be under this package. Construction of
bays, rooms, buildings, etc. will also be under this
package. Major scope under this package is indicated
below :

Reheating Furnaces with auxiliaries
Mill proper with auxiliaries
Sheet Shearing Line
Roll Shop
Water supply & Utilities
Automation system
Power Supply Facilities & Electrics
Eqpt. Foundation & other civil work
Cranes & material handling
Construction of bays, rooms, buildings, etc.


6.0 FINANCIAL ANALYSIS
6.1 Capital Cost Estimates:
6.1.1 The capital cost estimate for the project Installation of a Hot Strip
Mill, RSP has been estimated to be Rs. 3879.42 crore, net of cenvat
credit of Rs. 356.03 crore and inclusive of IDC component of Rs
192.06 crore. The capital cost estimate envisages expenditure in
foreign currency to the tune of
Rs. 1231.37 crore. The capital cost estimate (summary) is appended
at Annexure-6.1.1-1 and the Capital cost estimate at Annexure-
6.1.1-2. Basis of estimate and volume of work is appended at
Annexure 6.1.1-3 and 6.1.14 respectively.
6.1.2 The cost estimates are based on available in-house information,
budgetary quotations and costs extracted from similar projects being
executed in SAIL plants, suitably adjusted to reflect current prices.
The base date for the estimate is 1st Quarter of 2012. FE parity has
been taken as 1Euro = Rs 65.82. The estimates do not include any
provision for future escalation or foreign exchange fluctuations.
6.1.3 Necessary provisions have been made in the estimates as per the
details given below:
i) Taxes and duties:
1. Excise duty @ 12.36% on basic cost of indigenous
equipment and structures.
2. Customs duty @ 5% on CIF cost of imported equipment
and landing charges, CVD @ 12.36% on CIF & landing
cost of imported equipment and CD and ADC @ 4% on
CIF cost of imported equipment & landing charge , CD,
CVD and educational cess on CD & CVD.
3. CST @ 2% on basic cost of indigenous equipment and
structures and excise duty amount on the same.
4. WCT/VAT@ 13.5% on 67% of civil work & 30% of erection
work.
5. IT (grossed-up) @ 11.80% on foreign services.
6. Service tax @ 12.36% on erection, 33% of civil work,
foreign /indigenous design engineering and services, IT and
freight & insurance.
7. Educational cess @3% on Customs duty, Counter veiling
duty and Additional Duty on Customs.
8. Entry tax @ 2% on supplies
ii) Ocean Freight & Insurance Charges:
@ 7% on FOB price of imported equipment.
iii) Freight & Insurance charges:

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@ 2% of basic cost of indigenous equipment and @9% of the
basic cost of indigenous structures & refractory
@ 3% of CIF cost of imported equipment towards port
handling, customs & port clearance as well as inland
transport to site.
iv) Erection & commissioning charges:
@ 6% for imported equipment, @ 12% for indigenous
equipment and @20% of basic cost of structures.
v) Engineering & construction and foreign supervision:
@ 12% of basic cost of both imported & indigenous
equipment, Structures, Refractories, Civil works and erection
and commissioning charges. Besides, suitable provision on
perdiem basis has been kept towards foreign supervision
during erection & commissioning.
vi) Contingencies: @ 5% on overall basis.
6.2 Mode of Financing:
6.2.1 The total capital requirement of the project is proposed to be
provided from debt equity ratio of 1:1. An interest rate @ 10% per
annum is considered on commercial loan borrowings.
6.3 Phasing of Capital Expenditure:
6.3.1 With the project duration of 36 months from Final /Stage-II approval,
the phasing of capital expenditure is proposed as indicated below:
(Rs. Crore)
Year Plant
Cost
Equity Market
Loan
IDC Total
1
st
Year 202.17 101.08 101.08 5.05 207.22
2
nd
Year 1617.36 808.68 808.68 50.54 1667.90
3
rd
Year 1819.53 909.76 909.76 136.46 1955.99
Post Comm. 404.34 202.17 202.17 404.34
Total 4043.39 2021.69 2021.69 192.06 4235.45
Cenvat Credit 356.03

Total
Investment
net of Cenvat
3879.42

6.4 Interest During Construction (IDC)
6.4.1 Based on the mode of financing and phasing of capital expenditures
indicated above, the total IDC has been calculated to be Rs. 192.06


crore.
6.5 Techno-Economics:
6.5.1 It has been envisaged that the proposed Hot Strip Mill will produce
2,940,000 HR coils out of which 720,000 tpa would be processed in
the Sheet shearing line to produce 705,600 tpa of saleable HR
Sheets & Plates.
6.5.2 Annual Manufacturing Expenses:
6.5.2.1 Raw Materials & Consumables:
The cost raw materials (CC slabs) has been estimated based on
specific consumption (for the slabs to be sourced from within RSP
based on Std cost 2011-12)/ Market price (for slabs to be sourced from
the market)
6.5.1.2 Salary & Wages:
Manpower cost of existing HSM as per Standard cost 2011-12 has
been considered. For the operation & maintenance of new shearing
line, manpower cost corresponding to 10 executives & 60 non
executives has been considered, based on prevailing pay scales in
SAIL.
6.5.1.3 Operating Consumables & Utilities:
The costs of various Operating Consumables has been estimated
based on sp.cost per ton of HR coil and that of utilities & services such
as power, water, & oxygen etc. has been considered based on specific
consumption and unit costs as per Standard Cost 2011-12 of RSP.
6.5.1.4 Repair & Maintenance:
Provision for repair & maintenance of plant & machinery, building/
structures, and civil engineering works etc. has been considered
while computing the total manufacturing expenses @ 2.5% of capital
cost net of cenvat.
6.5.1.5 Overheads
Provision towards works overhead has been kept @ 2% of the total
operating cost.
6.5.1.6 Based on the above, the manufacturing expenses for production

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of HR coil/ HR sheets and plates have been worked out to be Rs.
26289/t. and Rs. 26806/t. respectively, as per details given at
Annexure -6.5.1.6-1.
6.5.2 Income
6.5.2.1 The total saleable HR coils which will be produced in the new Hot Strip Mill is
estimated to be 2,220,000 tpa whereas the saleable HR plates &
sheets from the new Sheet Shearing Line is estimated to be 705,600
tpa. Considering avg. NSR of Rs 33500/t for HR coil (commercial
grade), Rs 36133/t for special grades of HR coils (API, Boiler, LPG,
Automotive etc) and Rs 39000/t for HR Sheets/Plates, the annual
income works out to be Rs. 10683.53 crore. The total works cost for
HR Coil & Plates/sheets works out to be Rs. 7727.51 crore. Loss of
contribution from the slab sourced from RSP works out to be Rs.
2024.84 crore.
6.5.2.2 Based on the above, the gross margin works out to be Rs.931.18
crore. The details are given at Annexure 6.5.2.2-1.
6.6 FINANCIAL ANALYSIS:
6.6.1 Financial analysis has been carried out on the basis of cash flow
during 23 years. Life of the project is considered 20 years after
commissioning. The detailed profit loss statement, cash-flow
statement, NPV and IRR calculations are appended at Annexure
6.6.1-1.
6.6.2 The financial indices have been worked out and given at Annexure-
6.6.2-1. Some of the important parameters are indicated below:
S. No. Description Value
1 IRR Pre Tax
IRR- Post Tax
21.36%
18.08%
2 NPV Pre Tax @ 10% discount
NPV-Post Tax @ 10% discount
Rs. 2875.83 crore
Rs. 1782.92 crore

6.6.3 Sensitivity Analysis
Sensitivity analysis has been worked out to assess the impact of
variations in capital cost & gross margin on the financial indices of


the project and the results are presented below:

IRR
Sl.No Variance Pre Tax Post Tax
1 Base Case
21.36% 18.08%
2 Capital cost up by 10%
19.34% 16.12%
3 Gross margin less by 10%
19.30% 16.38%
4
Combined effect of above two
factors
17.41% 14.53%
5
Production with own slab (2.67
Mtpa) only
19.34% 16.41%


7 RECOMMENDATION
7.1 A new Hot Strip Mill with modern features is required to roll the
required volume of slabs available after the ongoing modernisation of
RSP and to avoid sales of semis as slabs. Market requirements of
higher coil weight, wider strip, higher strength grades, excellent
product qualities, etc. will be met through the new Hot Strip mill.
7.2 The project is technically feasible and technoeconomically viable and
hence recommended for implementation

RSP Annexure-2.6.2-1 CET/05/RN/3379/FR/RF/01/R-0
NEW HOT STRIP MILL (Page 1 of 1)

Annexure-2.6.2-1
Copy of letter for assignment from RSP
To
GM & I/C, CET,
Rourkela Sub center
CET building, Rourkela
Ref. No.: AMR-M&SC/Consultancy/15/433-37 Date: 17.03.2011
Respected Sir,
Sub: Assignment of consultancy services to M/S CET for Installation of
a New HOT STRIP MILL in Rourkrla Steel Plant
Please find enclosed herewith the copy of approved note sheet (approved by
ED(W) & concurred by Finance ) for working out a comprehensive scheme for
Installation of New HOT STRIP MILL in Rourkela Steel Plant.
We are pleased to appoint M/S CET as the consultant for the study for
Installation of New HOT STRIP MILL with the following scope of services :
1. To study and finalise the location
2. To prepare Feasibility report & TS
3. Budget cost estimation & Financial analysis
4. Preparation of Board Note for sanction & approval
5. Project finalization and monitoring
With regards,
Sd/-
(D R Biswas)
DGM (AMR-M&SC
Copy:
1. GM I/C (Services)
2. GM (HSM)
3. DGM (Finance) Project
4. AGM (Tech) to ED (Works)

RSP Annexure-4.2-1 CET/05/RN/3379/FR/RF/01/R-0
NEW HOT STRIP MILL (Page 1 of 1)

Annexure-4.2-1
Tentative Product Mix
(,000 tpa)
Thickness (mm)
Width (mm) 1.2-1.8 1.9-2.5 2.6-3.5 3.6-6.5 6.6-11.0 11.1-25 Total %
725-1000 15 30 30 15 15 15 120 4.00%
1001-1500 255 420 515 515 150 190 2045 68.17%
1501-1880 30 30 180 165 90 160 655 21.83%
1881-2100 0 15 15 15 120 15 180 6.00%
Total 300 495 740 710 375 380 3000
10.00% 16.50% 24.67% 23.67% 12.50% 12.67% 100.00% 100.00%

RSP Annexure 5.1-1 CET/05/RN/3379/FR/RF/01/R-0

ANNEXURE-5.1-1
PROJECT IMPLEMENTATION SCHEDULE
(Pre-ordering Activities (Stage-I))

Activities 0 1 2 3 4 5 6
Stage-I approval of Project *

Issue of tender & receipt of offers

Scrutiny of offers, TD, tender finalisation

Scrutiny by Corporate Office, reply to queries and stage-II
approval

RSP Annexure 5.1-2 CET/05/RN/3379/FR/RF/01/R-0

ANNEXURE-5.1-2
PROJECT IMPLEMENTATION SCHEDULE
(After Stage-II Approval)

Sl.
Month
Activity
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
Stage II approval Zero date

1 Placement of Order and Contract signing
(effective date of Contract)

2 Submission & approval of
drawings/documents.

3 Civil work

5 Supply of eqpt.

6 Erection

7 Testing & trial run

8 Commissioning

56840
13770 4000
4
0
0
0
350 220 3500 1910 3480 3080 6130 4000 3000 5400 8000
735
700
2000
4000
2
1
3
13
11
10 9 8
7
6
5
4
1. UNCOILER & DUTBOARO BEARING
2. ANTI COIL-BREAK ROLL(OPTION)
3. CENTERING DEVICE
4. PEELER TABLE, PINCH ROLLS AND STRAIGHTENER
5. CROP SHEAR & BLANK REMOVER
6. VERTICAL GUIDES & PINCH ROLLS
7. SCRAP GUIDING SYTEM & SCRAP CHOPPER
8. .LEVELLER-1
10. FEEDING ROLLS & FHYING SHEAR
11. CONVEYOR
12. MARKING MACHINE
13. PILER
9. LEVELLER-2
STEEL AUTHORITY OF INDIA LTD.
CENTRE FOR ENGINEERING & TECHNOLOGY, RANCHI
PLANT ( ) :
DRG. NO.
UNIT( ):
REV
NO. DATE REMARKS BY APPD. DRG. NO. DETAILS
REF. DRAWINGS REVISIONS
C L E A R A N C E
SECTION BY DATE
A
D
B
4
,
D R G . N O .
SIZE : A3 01 01
CET RN 3379 RF1 00 004 SCALE
G KUMAR DRAWN
DESIGNED
CHECKED
APPROVED
ROURKELA STEEL PLANT
DATE:
SHEET OF
File Name: 3379RF004FR.Dwg
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NEW HOT STRIP MILL
LAYOUT OF SHEET SHEARING LINE
G KUMAR
NTS R=0
FOR FR PURPOSE ONLY
S P RAI
S P RAI
08.08.2011
(SCHEMATIC)
12

FR (R 0) 3379 For HSM RSP

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ROURKELA STEEL PLANT

INSTALLATION OF HOT STRIP MILL

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