You are on page 1of 127

BO

OKARO
O STEEL
L PLAN
NT
B
BOKARO
O STEE
EL CITY
Y

MO
ODERNIS
SATION OF SMS
S-I
(S
STAGE-1
1)

FEASIBIILITY REPORT
R
T

STEEL AUTHOR
RITY OF INDIA
I
LIM
MITED
CENTRE FOR ENGINEERING
G & TECHNOLOGY
NCHI 8340
002
RAN

DECEMBER 2012
2

C
CET/02/R
N/3498/FR/ST/01/R
R=3

CONTENTS - CHAPTERS
Chapter no.

Description

Page no.

Summary

1.1 1.2

Background

2.1 - 2.11

Selection of Alternatives

3.1 - 3.4

Project Description

4.1 - 4.61

Project Implementation

5.1 - 5.2

Financial Projections

6.1 6.3

Recommendation

7.1

Annexures
Drawings

BSL
Modernisation of SMS-I

CONTENT
PAGE 1 of 3

CET/02/RN/3498/FR/ST/01/R=3

CONTENT - ANNEXURES
Annexure
no.

Description

No. of
Pages

2.1.9-1

Assignment letter from customer (BSL).

2.1.9-2

Minutes of the meeting held at SMS-I, BSL during


September 3-4, 2012.

2.1.9-3

Minutes of the meeting held at SMS-I, BSL on


November 20, 2012.

4.1.6-1

List of proposed equipment & facilities

4.2.2-1

Material Flow Chart (Proposed Case)

5.1-1

Project Implementation Schedule Stage-I: Preordering activities

5.1-2

Project Implementation Schedule Stage-II: Postordering activities

6.1.1-1

Detailed Capital Cost Estimate - Summary

6.4.3-1

Gross Margin Calculation

6.5.1-1

Financial Analysis

BSL
Modernisation of SMS-I

CONTENT
PAGE 2 of 3

CET/01/RN/3498/FR/ST/01/R=3

CONTENTS - DRAWINGS
Sl.
No.

Drawing No.

Description

1.

CET RN 3498 CE0 00 005, R=3

General Layout of SMS-I


Indicating Proposed Facilities

2.

CET RN 3498 ST1 00 002, R=4

Modernisation
of
Technological Layout
CCM Shop

3.

CET RN 3498 ST1 00 003, R=0

Modernisation of SMS-I: Sectional


View of BOF Shop

4.

CET RN 3498 ST1 00 005, R=3

Technological Layout of Slab Caster


Shop

5.

CET RN 3498 ST1 00 006, R=2

Section AA of Slab Caster

6.

CET RN 3498 EE1 00 001, R=1

Single Line Diagram of Power

7.

CET RN 3498 UT0 00 001, R=0

Proposed Cooling Water


Diagram (For CCM & LF)

8.

CET RN 3498 UT0 00 002, R=0

Proposed Cooling Water Flow


Diagram for BOF (Suppressed
Combustion & Lance Cooling)

BSL
Modernisation of SMS-I

CONTENT
PAGE 3 of 3

Area

SMS-I:
of BOF &

Flow

CET/02/RN/3498/FR/ST/01/R=3

SUMMARY

1.1

There are two steel melting shops (SMS) at Bokaro Steel Plant viz. (SMSI) and SMS-II. SMS-I is based on BF BOF Ingot Casting route
producing ingot steels, whereas SMS-II is based on BF BOF
Continuous Casting route producing continuously cast slabs (CC slabs).
The ingots produced at SMS-I are further rolled in Slabbing Mill to produce
slabs. Both rolled slabs and CC slabs are finally sent to Hot Strip Mill
(HSM) to produce hot rolled (HR) coils.

1.2

SMS-I consists of 5 Basic Oxygen Furnaces (BOF) / converters each of


100/130 t capacity out of which 3 converters are in operation. This creates
logistics problems in hot metal charging, scrap charging and other related
operational activities.

1.3

The overall modernisation of SMS-I has been envisaged in two stages:


Stage-1: Phasing out of ingot casting and introduction of 100% continuous
casting.
Stage-2: Expansion of capacity by introduction of endless thin slab casting
with direct rolling facility.
The present FR covers the scope of work envisaged in Stage-1
modernisation only.

1.4

Following major technological facilities have been envisaged in Stage-1


modernisation:
a) Replacement of 1 no. BOF converter (5E) of 130 t heat size along with
its associated facilities including tilting gear, drive system, suppressed
combustion system and gas recovery (gas holder).
b) New slag bay including all associated facilities like EOT cranes, slag
transport system, etc. to handle the slag pots. Existing slag pots will be
used.
c) New double track swivelling roof type Ladle Furnace (LF) of 130 t heat
size (1 no.).
d) New single strand slab caster (1no.) with all associated facilities like
cooling water system, power sub-station, utilities and gas facilities,
EOT cranes and other material handling facilities.
e) Dismantling & re-routing of existing rail tracks, cable tunnel, utility
pipelines etc in the location of proposed Continuous Casting Shop
(CCS).

1.5

The total period of implementation of Stage-1 modernisation of SMS-I has


been estimated to be 30 months.
Existing production of ingot steel will be maintained during construction
stage. Ingot casting may also be required subsequently during stabilisation
period of the slab caster. Two days shutdown of SMS-I for re-routing of
utility pipelines & other related jobs have been considered.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 1.1

1.6

No addition
N
nal manpow
wer is envissaged for the
t propose
ed facilitiess at SMS-I
a
after
mode
ernisation. However
H
necessary training
t
willl be impartted to the
o
operation
& maintenan
nce staff for the new fa
acilities intrroduced.

1.7

The
T Capita
al cost of the
e project M
Modernisatiion of SMS-I, BSL wo
orks out to
be Rs 136
65.71 Crore
es net of CENVAT
C
crredit of Rss 130.27 Crores and
inclusive of
o an IDC of Rs 67
7.84 Crores
s. The capital cost estimates
envisage
e
a foreign excchange com
mponent off Rs. 336.98
8 Crores.

1.8

The benefitts envisage


T
ed after imp
plementatio
on of propo
osed facilitie
es include
s
savings
in cost
c
of prod
duction of slabs
s
throug
gh continuo
ous casting route vis
-vis
ingot route and
d gainful utilisation of BOF gass recovered
d through
s
suppressed
d combustion system in Power Plant as fu
uel in place
e of boiler
c
coal.

1.9

Gross Marrgin after implementa


G
ation of proposed
p
m
measures has
h
been
e
estimated
to
t be Rs. 296.74 Cro
ore. The Financial An
nalysis (sum
mmary) is
f
furnished
b
below:
1

NP
PV (@ 10%
% p.a)

IR
RR (Post Ta
ax)

Rs Crorre

476.96
6
15.90%
%

1.10

The projectt is techniccally feasible, financially viable an


T
nd recomm
mended for
i
implementa
ation.

1.11

As
A mention
ned at para
a 1.3, the S
Stage-2 mod
dernisation for augme
entation of
capacity
c
off SMS-I ma
ay be conssidered in liine with 10
0.75 Mtpa expansion
e
plan of BSL
L. The follo
owing major facilities could
c
be en
nvisaged forr Stage-2:

1.12

2 x 130 t De-S unitts


Modernization of 2 nos. BOF
F converterrs with sup
ppressed co
ombustion
system
2 x 130 t Ladle Furrnaces

1 x 130 t RH degas
ssing unit
Unloading station of
o hot meta
al from Torp
pedo car
1 x 1 strrand endles
ss thin slab
b caster with
h direct rolling

Stage-2 modernisati
m
ion can b
be taken up for im
mplementattion after
stabilisation of prod
duction from Stage-1
1 modernissation and
d after a
easibility sttudy. Howe
ever, enabliing works for
f Stage-2
2 can start
separate fe
earlier. Alo
ong with capacity
c
au
ugmentatio
on, Stage-2
2 modernis
sation will
address th
he issues of
o pre-treatment (desu
ulphurisatio
on) of hot metal
m
and
secondary refining fa
acilities whicch are stan
ndard featu
ures of mod
dern steel
uctivity and good qua
ality of prod
ducts. The indicative
plants for high produ
2 modernisa
ation is estiimated at Rs.
R 5000 Crrore.
block cost for Stage-2

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE1.2

BACKGROUND

2.1

INTRODUCTION

2.1.1

Bokaro Steel Plant (BSL) has two Steel Melting Shops (SMS) viz., SMS-I
and SMS-II. SMS-I produces steel through BOF converter Ingot Casting
route. There are five (5) BOF converters of 100/130 t capacity in SMS-I out
of which three (3) converters are in operation. The nameplate capacity of
SMS-I is 2.25 Mtpa of ingot steel.

2.1.2

The liquid steel produced in the BOF converters of SMS-I is cast into ingot
moulds to produce ingots. The ingots are sent to Slabbing Mill (through
soaking pits) for further rolling into slabs. The slabs produced in Slabbing
Mill are sent to Hot Strip Mill (HSM) for its further processing to produce
hot rolled coils / sheets. There are stripper yard, mould yard and mould
cleaning yards to prepare the moulds for ingot casting.

2.1.3

The SMS-I building consists of four (4) parallel bays i.e., teeming bay (AB
bay), ladle repair bay (BC bay), converter bay (CD bay) and charging bay
(DE bay). Two numbers of scrap yards adjoining the main building exist at
both the ends of the main building of SMS-I. The belt conveying system for
feeding bulk materials (fluxes) into the BOF converter is arranged over the
converter bay. Hot Metal mixers (Mixer Nos. 1 & 2) are situated at one end
of the shop between SMS-I and Blast Furnaces.

2.1.4

The working volume of each converter (after new refractory lining)


considered in the DPR was 90.7 m3 with a nominal capacity of 100 t.
However, presently the converters are being operated with a nominal
capacity of 130 t. With heat weight of 130 t, the specific volume of the
converters has come down to 0.697 m3/t of liquid steel.

2.1.5

Operating the BOF converters with low specific volume brings with it
associated operational problems. The slopping and spitting creates
jamming of the tracks below the converter during transfer of slag & steel
and causes delay in production.

2.1.6

There is one rail track between mixer bay and converter bay to transfer the
Hot Metal (HM) in ladles. The HM is brought from mixers to converter bay
with the help of locomotive. Beyond the converter bay, the track slopes
down from working platform level of converter bay to ground level over a
ramp through which locomotives are sent for re-fuelling/repair. Slag pots
are transferred with the help of railway locomotive from the converter bay
to slag bay which is located at a distance of approximately 500 m from the
shop. It leads to higher cycle time and logistics problem which result in
higher tap to tap time.

2.1.7

The gas cooling and cleaning system of the converters are of open
combustion type, the converter gases being burnt completely in an open
hood, characterised by a large gap between the converter mouth and the
bottom of the hood to allow adequate excess air for ensuring complete
combustion of gases. Waste Heat Boilers (WHBs) have been installed to

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 2.1

rrecover the
e heat ene
ergy of the
e outgoing gas from the converter. After
c
cooling,
the
e gases are
e cleaned by wet wash
hing.
2.1.8
2

Since ince
S
eption, ope
eration & maintenancce of the WHBs ha
ave been
p
problematic
c. Operation of BO
OF converrters with open co
ombustion,
m
maintenanc
ce-prone WHBs
W
and leakages of flue ga
as through corroded
d
ducts
lead to non-com
mpliance off required pollution
p
co
ontrol norm
ms at work
z
zone.
More
eover, for many
m
years now, no he
eat recoverry is being done
d
from
t WHBs and
the
a the ste
eam genera
ated is being
g vented ou
ut.

2.1.9
2

BSL requessted Centre


B
e for Engine
eering and Technology (CET) to prepare a
Feasibility Report for modernisa
ation of SM
MS-I with 1
130/150 t converters
c
w suppre
with
essed comb
bustion, 2 n
nos. of LF and
a 2 nos. o
of casters with
w return
l
ladle
to pro
oduce 2.5 Mt
M of cast steel per annum. A cop
py of BSLss letter no.
D
DGM
(P) I/c
c DB, TIC & IPU / 214
4 dated 10-0
08-2011 in this regard
d is placed
a Annexu
at
ure-2.1.9-1. Subseque
ently, CET submitted in Octobe
er 2011 a
p
pre-feasibil
PFR) and in
n February 2012 a fea
asibility repo
ort (FR) of
ity report (P
a Expansion
n Plan (Pha
ase II) of Bokaro
B
Ste
eel Plant which,
w
inter
10.75 Mtpa
a
alia,
envisa
aged a prod
duction of 3.15
3
Mtpa of
o crude ste
eel from modernized
S
SMS-I.
The
e FR (R=0) for modernisation was
w submittted to BSL in March
2
2012.
Subssequently, observation
o
ns of BSL were
w
received in June 2012 and
t same were
the
w
discusssed betwee
en BSL and
d CET durin
ng June-July 2012 to
f
finalise
the
e scope an
nd battery limits.
l
Acco
ordingly, th
he revised FR (R=1)
w submittted in Julyy 2012. The
was
e scheme for
f dismanttling/re-routting of rail
t
tracks
for ingot moulld trains w
w.r.t. existin
ng and pro
oposed faciilities was
f
finalised
in consulta
ation with BSL in August 2012. Alsso, some
i
improveme
ents in the overall con
ntent, layou
ut and packkaging strattegy were
d
done
base
ed on obse
ervations o
of BSL and
d subseque
ent meeting held at
S
SMS-I,
BSL during September
S
3-4, 2012. Copy off the minuttes of the
m
meeting
(M
M.O.M.) is enclosed
e
a
at Annexurre 2.1.9-2. Accordingly, the FR
(
(R=2)
was prepared and subm
mitted. Subssequently, BSL vide letter no.
G
GM/SMS-I/
/12/2698 da
ated 15.11.2012 sentt their comments on FR
F (R=2).
T
The
comments were discussed and resolv
ved in a me
eeting held
d between
B
BSL
and CET.
C
Copy
y of the M
M.O.M. date
ed 22.11.2
2012 is en
nclosed at
A
Annexure
2.1.9-3. Ac
ccordingly, tthe FR (R=
=3) has been prepared
d.

2.1.10
2

Co-operatio
C
on and asssistance re
eceived from BSL forr preparatio
on of this
report is gra
atefully ack
knowledged
d.

2.2
2

EXISTING FACILITIE
ES

2.2.1
2

In the firstt stage of BSL consstruction, 4 converterrs of 100 t nominal


c
capacity
w
were
erecte
ed to give a producttion of 1.7
7 Mt of ste
eel ingots
a
annually.
A fifth conv
verter was added during the se
econd stag
ge of BSL
c
constructio
n. At any given
g
time, three (3) converters
c
are in operration and
r
remaining
t
two
(2) converters are
e under repa
air / relining
g. The rated
d capacity
o the shop
of
p was evaluated as 2.2
25 Mtpa of ingot
i
steel.
N
Nomenclat
ure of the 5 BOF convverters at SMS-I are given below::

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 2.2

Converter
Converter
Converter
Converter
Converter

D (1)
C (2)
B (3)
A (4)
E (5)

The converter E(5) is located towards the Mixer end of SMS-I and
converter A(4) is located towards the Slabbing Mill end of SMS-I.
2.2.2

The SMS-I building consists of four (4) parallel bays i.e., teeming bay (AB
bay), ladle repair bay (BC bay), converter bay (CD bay) and charging bay
(DE bay). Two numbers of scrap yards adjoining the main building exist at
both the ends of the main building of SMS-I. The belt conveying system for
feeding bulk materials (fluxes) into the converters are arranged over the
converter bay. Hot Metal mixers (Mixer Nos. 1 & 2) are situated at one end
of the shop between SMS-I and Blast Furnaces.

2.2.3

The brief technological features of the SMS-I are given below.


No. of BOF converters
Heat size of BOF converters
Working volume of each converter
Casting of liquid steel
No. of ingot casting platforms
No. of scrap yards
No. of Mould yard
No. Of mould cleaning & cooling bays
No. of stripper yard
No. of Hot metal mixers
Hot metal ladle capacity
Steel teeming ladle capacity
Gas cleaning system

2.2.4

5 (3 operating)
100 / 130 t.
90.7 cum
Ingot casting
4.
2
1
2
1
2 x (1300 t each)
140 t
130 t
Open combustion with waste
heat boiler, wet scrubber, ID
fan, etc.

The working volume of each converter is 90.7 m3 which, at nominal heat


size of 100 t, provided a specific volume of 0.907 m3 per tonne of liquid
steel. After the heat size was raised to 130 t, the specific volume came
down to 0.697 m3 per tonne.
Salient design details of existing BOF converters are given below:
1.
2.
3.
4.
5.
6.
7.

Heat size (max.)


Working volume (m3)
Specific volume (m3/tonne)
Oxygen blowing rate (Nm3/minute)
Blowing time (avg.)- as per DPR
Power of tilting Drive (kW)
Bottom of converter

BSL
Modernisation of SMS-I

130 tonne
90.7
0.697
320
25 minutes
120 x 2
Detachable type
CET/02/RN/3498/FR/ST/01/R=3

PAGE 2.3

2.2.5
2

The heat making cycle


T
e (tap to ta
ap time) in BOF convverter as pe
er DPR is
given below:
Op
peration

Tim
me in minuttes
3
4
25
5
5
5
2
11
60

Scrap cha
arging
Hot metal charging
Oxygen bllowing
Intermedia
ate de-slagg
ging
Sampling & waiting fo
or analysis
Steel tapp
ping
Slag tapping
Un-foreseen delays
Total (T
Tap to Tap ):
2.2.6
2

Each converter is equipped with


E
h an indep
pendent sysstem of gas cooling.
The
T system
m consists of
o a cooling
g hood conssisting of up
ptake and down
d
take
sections
s
co
omprising of main boiler,
b
evap
porator-I & II and ec
conomizer
sections
s
to cool down the exhaust gas and recovery o
of steam. Th
his cooled
gas
g is finallly cleaned in a ventu
uri scrubber before be
eing led to the stack
through
t
the
e ID fan. Th
he waste he
eat boiler & GCP systtem is desig
gned for a
3
maximum blow
b
rate off 320 Nm /m
minute.

2.2.7
2

Mixer bay is
M
i located by
b the side of the exissting SMS-II. There are
e 2 nos of
h metal mixers
hot
m
in this bay. Th
he hot mettal from the
e blast furn
naces are
r
received
in this bay an
nd poured into
i
the mixxer for stora
age. The ho
ot metal is
d
discharged
into the mixer
m
ladle and transfferred with
h the help of railway
l
locomotive
to the convverter bay for
f charging
g into the co
onverter.

2.2.8
2

There is no
T
o facility off pre-treatm
ment of hot metal or ssecondary refining
r
of
s
steel
at SM
MS-I. Afterr tapping from
f
BOF converterss, the liquid
d steel is
t
teemed
into
o moulds to produce ingots of various
v
size
es. For this
s purpose,
s
stripper
ya
ard, mould yard and
d mould cleaning
c
& cooling yards
y
are
p
provided.

2.2.9
2

Slag from the


S
t convertter is dump
ped into sla
ag pot placced on a tra
ansfer car
b
below
the converters.
c
The slag pot
p is transfferred from the converrter bay to
s
slag
yard lo
ocated at a distance of about 500 m from SMS-I buiilding with
t help of railway loccomotive.
the

2.2.10
2

There are 2 nos. of scrap


T
s
yardss which pre
epares the scraps forr charging
i
into
the con
nverters.

2.2.11
2

All the bays are equip


A
pped with required
r
EO
OT cranes of
o various capacities
f material handling & movemen
for
nt.

2.3
2

BRIEF DES
SCRIPTION
N OF OPER
RATION IN
N SMS-I

2.3.1
2

Hot metal from


f
the Mixer departm
ment is bro
ought to the
e charging bay
b in 140
t Hot Metall (HM) ladle
es on Hot m
metal transsfer cars pu
ulled by loc
comotives.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 2.4

Scrap is fed to the converter in scrap boxes of 10 m3. Charging of scrap


and hot metal is done with the help of 180/50 t charging cranes.
2.3.2

After the scrap & HM has been charged, oxygen is blown at a rate of 300320 Nm3/min with the help of oxygen lance. Intermediate de-slagging is
carried out in most of the heats. The converter is blown for about 25
minutes to produce liquid steel of desired composition and temperature.

2.3.3

Corrective measures are taken in the form of re-blow for temperature &
analysis of liquid steel bath after completion of oxygen blowing. After this
the steel is tapped from the converters in 130 t ladles. Ferro-alloy and
deoxidisers are added into the ladle during teeming. Inert gas is purged
through the porous plug fitted at the bottom of the ladle (while the ladle is
placed on the transfer car) to rinse the liquid steel. The ladle with liquid
steel is transported to the teeming bay in steel transfer car. Teeming of the
liquid steel is carried out with the help of 180/50t teeming cranes. The slag
from the BOF converter is tapped into 16 m3 slag pots mounted on transfer
cars. These slag pots are hauled by locomotives to slag yard for dumping.

2.3.4

The ingots produced in SMS-I are sent to soaking pit of Slabbing Mill for
production of slabs, and subsequently slabs are sent to Hot Strip Mill
(HSM) for production of Hot Rolled (HR) coils. .

2.4

GRADES OF STEEL

2.4.1

Following grades of steel are generally produced in SMS-I.


a) Low and Medium carbon steel,
b) Mild steel,
c) Low alloy steel.

2.5

PRODUCTION OF SMS-I
Considering a tap to time of 60 minutes in BOF converter, the nameplate
capacity of the shop was fixed at 2.25 Mtpa of ingot steel. But the shop
has never been able to produce more than 2.0 Mt/year of ingot steel. In
fact, over the years, there has been gradual decline in production as can
be seen from the production figures of the last 4 years tabulated below:
Year
2008-09
2009-10
2010-11
2011-12

Production of
ingot Steel (tonne)
1054690
1021690
911632
798814

The main reason for low productivity of SMS-I is logistical constraints


inherent in a 5 converter BOF shop leading to operation delays and low
BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 2.5

availability
a
of BOF co
onverters. T
The tap to tap time of
o 60 minuttes as per
DPR has now shot up to 105
5 minutes reducing productivity
y of BOF
converters.
c
.
2.6
2

H
HOT
META
AL SCENARIO
As per CPF
A
FR plan pre
epared by MECON fo
or modernizzation and expansion
e
of
o BSL, it was
w envisag
ged to upgrrade 3 nos. of the Blasst Furnaces
s to higher
volume
v
to meet a ho
ot metal prroduction of
o 7.441 Mtpa.
M
The expansion
e
proposal off BSL was approved in Decemb
ber06 and also in July08. The
break-up of
o hot mettal producttion under expansion
n proposal is given
below:BF No.

1
2
3
4
5

Usefful
Volume/W
Working
Volum
me,
m3
2585/ 2250
2
2585/ 2250
2
2000/ 1758
1
2000/ 1758
1
2585/ 2250
2
Shop

HM Production,
tpd

H
HM Produc
ction,
tpa

4900
0
4900
0
3280
0
3280
0
4900
0
21260
0

171500
00
171500
00
114800
00
114800
00
171500
00
744100
00

India witn
nessed the
e effects of globa
al econom
mic slowdo
own from
September
S
r2008 and the deman
nd for steel products sstarted declining with
drastic
d
fall in selling price. Keeping this in
n view, ME
ECON was asked in
April09
A
to study the possible
p
op
ptions / alte
ernatives wh
hich may re
educe the
capital
c
costt of expanssion. The exxpansion of
o BSL was accordinglly decided
to
t be imple
emented in two phasess. The Phasse-I expanssion was ap
pproved in
June09
J
witth one upgraded furna
ace and 4 nos.
n
of exissting furnacces for hot
metal production of 5.775 Mtpa. The brea
ak-up of hott metal pro
oduction is
given
g
below
w:BF No.
1
2
3
4
5

BSL
B
Modernisation
M
n of SMS-I

Useful Vo
olume,
m3
2000
0
2585
5
2000
0
2000
0
2000
0
Shop

HM
M Production,
tpd
3000
4500
3000
3000
3000
16500

HM Production,
tpa
1050000
1575000
1050000
1050000
1050000
5775000

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 2.6

The above target of 5.775 Mtpa was envisaged subject to fulfilment of the
following:

Installation of 4th series conveyor for BF highline charging


Upgradation of SP-1
Installation of a new sinter plant SP-2
Upgradation of SMS-I for crude steel production of 3.1 Mtpa from
SMS-1
At 5.775 Mtpa stage, the possible off-take of hot metal by SMS was
envisaged as 5.4 Mtpa. The balance hot metal was envisaged to be
poured at PCMs. However, for emergency pouring of hot metal in
PCM, the existing PCMs at Bokaro are old & inadequate and needs
revamping to meet the requirements of hot metal pouring. An
approach note for revamping of the existing PCMs was submitted by
CET to BSL in this regard in April 2011 covering revamping of 2
PCMs. BSL is presently carrying out revamping of one of the PCMs
separately. Further action on the approach note is pending.

Since, the above facilities have not been incorporated under Phase-I
expansion, BSL has re-worked the hot metal production capacity to 4.8
Mtpa. It can be seen from the table given below, that a hot metal
production of 4.7 Mtpa was achieved in the year 2005-06, hence the
projected hot metal production capacity of 4.8 Mtpa was thought to be
possible to achieve with the existing facilities available in BF complex.
Hot Metal production data at BSL during 2004-05 to 2011-12 are given in
the table below:
Year
2004-05
2005-06
2006-07
2007-08
2008-09
2009-10
2010-11
2011-12

HM Production (Tonne)
4131792
4706517
4588222
4657959
4020992
4065568
4107760
4012263

M/s MECON was asked to prepare a roadmap for Phase-II expansion of


BSL in February2010. However, subsequently CET/SAIL was entrusted
with this job and a Feasibility Report was submitted to BSL for 10.75 Mtpa
expansion plan (Phase II) in the month of February 2012. The report
considered hot metal production capacity at BSL to be enhanced from a
base HM production level of 5.775 Mtpa to a level of 11.375 Mtpa during
the Phase-II expansion by installation of 2 more Blast Furnaces of 4060
cum useful volume each. The details are given below:BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 2.7

BF No.
1
2
3
4
5
6
7

Useful Volume,
V
m3
200
00
258
85
200
00
200
00
200
00
406
60
406
60
Shop

H
HM Produc
ction,
tpd
3000
4500
3000
3000
3000
8000
8000
32500
0

H
HM Produc
ction,
tpa
105000
00
157500
00
105000
00
105000
00
105000
00
280000
00
280000
00
11375000

The ultima
T
ate hot me
etal producction capac
city of BSL
L is presen
ntly being
projected as
a 17.57 Mtpa
M
by addition of 2 more Blasst Furnacess of 4500
cum
c
usefull volume ea
ach. This iss as per the report SA
AIL Growth
h Strategy
2012
2
prep
pared by CET and submitted to SAIL Corp
porate Offic
ce in May
2012.
2
The details
d
are given below
w:BF No.
1
2
3
4
5
6
7
8
9

2.7
2

Useful Volume,
V
m3
20
000
25
585
20
000
20
000
20
000
40
060
40
060
45
500
45
500
Shop

HM Produ
uction,
tpd
3000
0
4500
0
3000
0
3000
0
3000
0
8000
0
8000
0
8857
7
8857
7
50214

HM Production,
tpa
105000
00
157500
00
105000
00
105000
00
105000
00
280000
00
280000
00
310000
00
310000
00
175750
000

N
NEED
OF MODERNIS
M
SATION
As indicate
ed at para 2.5, there
e has been
n gradual decline
d
in production
p
from SMS--I over the years.
y
Thiss steady de
ecline in pro
oductivity off the shop
is attributa
able to vario
ous reason
ns such ass obsolesce
ence of tec
chnologies
and ageing
g of plant & equipment. The ma
ajor issues contributin
ng to poor
productivity
y at SMS-I are enume
erated below
w:

2.7.1
2

Poor logis
stics of 5 Converter
C
S
Shop
The BOF shop
s
at SMS-I is havin
ng 5 converrters each o
of 130 t hea
at size. To
meet the current
c
prod
duction req
quirement of
o about 1.2
2 Mtpa ingo
ot steel, 3
out of 5 co
onverters are in opera
ation. This creates
c
log
gistic proble
ems in hot
metal charging, scra
ap charging, slag po
ot handling
g and othe
er related

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 2.8

operations. Modern converter shops are mostly designed with not more
than 3 converters out of which 2 or 3 are in operation at any given time.
2.7.2

Low specific volume of BOF converters


The specific volume of converters is about 0.70 m3 per tonne of liquid
steel. With an operating silicon range of 0.6-1.0 % in hot metal, the slag
volume during the blow is high and making it difficult to blow straight
heats. With poor blow and temperature condition in the BOF, the loss of
metal in slopping and spitting is as high as 2-4% of the metallic charge.
Apart from reducing the yield of the final product, slopping and spitting
also impair the life of the converter lining, especially of the throat, so that
the vessel has to be stopped for repairs at shorter intervals leading to
decreased productivity.

2.7.3

Problems with Waste Heat Boilers


Gas cooling and cleaning system of the converters are of open
combustion type. Dedicated waste heat boiler has been installed over
each converter to recover the heat energy of the outgoing gases. After
cooling, the gases are cleaned by wet washing. These boilers are over 30
years old and are prone to breakdowns of tubes and drums. There are
frequent breakdowns due to slag-metal jamming in boiler tubes leading to
tube leakages and production delays. Generation of steam is cyclic as the
gas evolution is cyclic, depending on blowing period of converter.
Moreover, following an accident in the year 1996, the steam pipelines
have been isolated from the plant grid and the steam generated during
blowing is discharged to atmosphere using silencers. This is not only
wasteful as the sensible heat of BOF gas is not gainfully utilised but also
leads to corrosion of building roof sheeting. Operation of BOF converters
with open combustion, maintenance-prone WHBs and leakages of flue gas
through corroded ducts lead to non-compliance of required pollution
control norms at work zone.

2.7.4

Constraints in Slag Disposal from BOF Converters


One of the reasons of low productivity in SMS-I is operational delays due
to non-availability of slag pots. The existing slag handling system causes
delay and imposes hindrances for smooth operation of the shop. At
present the slag pots are handled by loco, which brings in and takes away
the slag pots from BOF converters. In modern BOF shops, slag pot
placement/removal below the converter is generally done by self propelled
slag pot transfer car. This reduces faster turnaround time of empty slag
pots and eliminates waiting times/delays due to non-availability of slag
pots.
Dependence on loco should be avoided by providing self propelled slag
pot transfer cars for each converter and a slag pot handling bay to transfer
these pots to self dumping cars for further movement to the slag yard by

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 2.9

lloco. This will improve shop lo


ogistics an
nd will perm
mit more intensified
i
o
operation.
2.7.5
2

Obsolete Ingot
I
Casting Techno
ology
SMS-I follo
ows ingot casting tech
hnology for production of crude steel (ingot
steel) from the liquid steel
s
produced at BOF
F converterrs. Ingot cas
sting is an
hnology suffering from
m several drawbacks
d
obsolete and uneconomical tech
ow yield, high
h
energyy consumption, inferio
or quality of
o finished
including lo
steel and offering hardly any possib
bility of p
process au
utomation.
Accordingly
y, steel ma
akers all ovver the worlld have bee
en phasing
g out ingot
casting and
d changing over to con
ntinuous ca
asting.
Introduction of continu
uous castin
ng technolo
ogy in SMS
S-I will give a number
ude:
of benefits which inclu
a Improvement in yield,
a)
b Improvement in qu
b)
uality of the
e finished stteel,
c Reducttion in enerrgy consum
c)
mption.
d Phasing out of mo
d)
ould & stripp
per yard, so
oaking pits
e Reducttion in man
e)
n power req
quirement as
a a resultt of phasing
g out of a
number of operatting units (e.g., Mould
d Yard, Strripper Yard
d, Soaking
ntroduction of process automation
n.
Pits, Slabbing Mill etc) and in
Apart from the issuess of techno
A
ological obsolescence
e, poor logistics and
e
, there is th
he issue off capacity utilisation of
o existing
ageing of equipment,
hot strip mill
m (HSM). The existin
ng HSM is rated to p
produce 4.5
5 Mtpa for
which inpu
ut slab requ
uirement is 4.655 Mtpa
a. Out of th
his, 3.35 Mtpa of CC
slabs will be
b fed from
m SMS-II. Th
he remainin
ng 1.305 M
Mtpa of CC slabs can
be met fro
om SMS-I. This can b
be done gainfully and
d economiccally after
phasing ou
ut of ingot casting
c
and introduction of continu
uous castin
ng.

2.8
2

From the above


a
discu
ussions it a
appears tha
at SMS-I iss the weake
est link at
BSL from technologic
t
cal and tech
hno-econom
mic conside
eration. Witth this end
in view, th
he 10.75 Mtpa
M
expan
nsion plan of BSL, fo
or which a FR was
submitted by CET in February 2012,
2
cons
sidered mod
dernisation of SMS-I
p
imporrtance.
as one of prime

2.9
2

The presen
T
nt FR for modernisatio
m
on of SMS--I has been
n prepared broadly in
a
accordance
e with the philosophyy followed in the said
d FR of 10
0.75 Mtpa
E
Expansion
wever, the overall mo
odernisation
n plan of SMS-I
S
has
Plan. How
b
been
envisaged in two
o stages, na
amely stage-1 and sta
age-2.
The presen
T
nt FR has been prepa
ared for Stage-1 mod
dernisation of SMS-I,
B
BSL.

2.10
2

The main objectives of Stag


ge-1 mode
ernisation of SMS-I may be
summarise
ed as below
w:
i)

To ph
hase out obsolete
o
in
ngot castin
ng route a
and introdu
uce 100%
contin
nuous casting of steel to achieve yield & qua
ality improvvements.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 2.10

ii)

iii)
iv)
v)

To provide suppressed combustion system and BOF gas recovery in


place of non functional WHBs and modernization of BOF gas
cleaning & handling system;
To gainfully utilize most of the existing assets of SMS-I.
To achieve above objectives without any disruption in present
production;
To produce adequate quantity of CC slabs to supplement slabs
produced at SMS-II for full capacity utilization of existing HSM.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 2.11

SELECTION OF ALTERNATIVE
In the FR for 10.75 Mtpa expansion of BSL submitted by CET in February
2012, one of the main schemes is modernisation of SMS-I. The overall
modernisation plan of SMS-I has now been conceived in two stages:
Stage-1: Phasing out of ingot casting and introduction of 100% continuous
casting.
Stage-2: Expansion of capacity by introduction of endless thin slab casting
with direct rolling facility.
Implementing both the stages of modernisation together would require
much longer period and huge capital investment. Accordingly,
implementation of only Stage-1 modernisation has been considered now
and he present FR has been prepared for Stage-1 modernisation of SMSI, BSL.
Various alternatives considered for Stage-1 modernisation of SMS-I are
deliberated in the following paragraphs.

3.1

Alternatives of Technologies

3.1.1

Primary Steelmaking

3.1.1.1

Blast Furnace - BOF converter route of steel making is a proven


technology for primary steel making in an integrated steel plant. Existing
SMS-I at BSL has been in operation for steel making as a link in the chain
of production units with the upstream units of Blast Furnace iron making
and downstream units of flat rolling and finishing. Hence, continuation with
BOF converter technology with modern features has been considered for
steel making in the modernisation of SMS-I. In upgrading the converters,
attention has been given to the following factors:

Heat size.
No. of operating converters.
Vessel design.
Converter specific volume.

3.1.1.1.1 To gainfully utilise most of the infrastructures of existing SMS-I such as


building, working platforms, EOT cranes, material handling systems, hot
metal ladles etc, the maximum heat size possible to be accommodated
works out to 130 t. Accordingly, the heat size of BOF converters has been
selected as 130 t.
3.1.1.1.2 There are 5 converters out of which, at any given time, 3 are in operation.
Managing 5 converters creates logistical problem and consequent delays
in hot metal charging, scrap charging and other related activities. Modern
BOF shops are mostly designed with not more than 3 converters out of
which 2 or 3 are in operation at any given time. Accordingly, replacement
of 3 new BOF converters is envisaged in SMS-I after its modernisation,
BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 3.1

out of whicch only one converte


er is envisa
aged at Sta
age-1 mode
ernisation.
The remain
ning two are
e envisaged at Stage--2 modernissation.
3.1.1.1.3 The
T
vessell design ad
dopted is very
v
vital fo
or good con
nverter perfformance.
The
T
design
n has to ta
ake into acccount many conflictiing factors including
profile of th
he vessel and its suspension system. For a reconstruc
ction job to
be done in an existing
g operating
g plant, the options available are limited. A
taller
t
conve
erter results
s in lesser spill over during blow
wing due to
o slopping
and
a spitting
g. From this point of view,
v
a tall converter w
with a large
er volume
will
w be prefferable. However, a ta
aller BOF converter
c
w
would necesssitate the
building height to be raised.
r
Thuss for SMS-II, BSL situa
ation where
e a smaller
volume
v
con
nverter is to
o be replacced by a co
onverter witth a larger volume in
an
a existing building, itt would be advisable to keep the
e height un
nchanged.
n specific vo
olume of co
onverter wo
ould then be
e obtained mainly by
Increase in
increasing the vessel diameter and then wo
orking with a shallowerr bath.
Since the existing ga
as cooling & cleaning system off converters
s are also
being repllaced with suppresse
ed gas co
ombustion system, an integral
bottom is envisaged
e
w top relining facilitty. Modern trend is to
with
o carry out
converter relining fro
om top witth fixed bo
ottom. Thiss provides improved
relining fea
atures of th
he convertter. A top relining
r
tow
wer with fa
acilities for
transport of
o the lining materials sshall be add
ditionally re
equired.
3.1.1.1.4 Specific vo
olume of BO
OF convertter is generrally undersstood as th
he working
volume ins
side the fresshly relined
d converter per tonne o
of liquid ste
eel. Higher
specific vo
olume of converter
c
d
decreases the possibility of sllopping &
spitting and
d vice versa
a.
The
T
speciffic slag gen
neration off 190-220 kg/t
k
of liquid steel at SMS-I is
quite
q
high in the abse
ence of anyy hot metal pre-treatm
ment facilityy. Low hot
metal temp
perature, po
oor lime quality and sllag carry-ovver further increases
the
t slag vo
olume inside
e the conve
erter and aggravates tthe operatin
ng regime
in a converrter vessel with
w low specific volum
me.
Design con
nsiderationss and dime
ensions for the bigger converter shell
s
have
to
t be deterrmined on the
t necessity of its insstallation within
w
the diimensions
of
o existing shop
s
building.
A higher specific volu
ume can b
be adopted for increassed rates of
o oxygen
3
blow. The present ratte of Oxyge
en blowing
g is of 300--325 Nm /m
min. Since
the
t present system off waste hea
at boilers and
a G.C.P are not dessigned for
higher rate
es of blow, it is not po
ossible to adopt
a
the h
higher blow
wing rates
with
w the exxisting syste
em. Howevver, since new gas han
ndling syste
em based
on
o suppresssed comb
bustion is b
being considered as part of thiss FR, the
Oxygen
O
blo
owing rates can be inte
ensified witth a change
e in lance design and
blow characteristics.
In order to ensure sta
able operattion and to contain slo
opping due
e to higher
rates of Oxxygen blowiing with hig
gh Silicon content
c
in hot
h metal, itt would be
desirable
d
to
o design th
he specificc volume in
n the highe
er side of the
t
range,
3
say,
s
aboutt 0.9 to 1.0 m /t of liquid ste
eel. Higher volume will
w permit
BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 3.2

maximum oxygen blow rates, greatly reduce slopping and allow flexibility
of operation.
3.1.2

Secondary Refining
Ladle furnaces are nowadays integral parts of any SMS with continuous
casting to aid temperature/composition homogeneity and to facilitate
sequence casting. In view of the above, 1 no. of LF unit have been
envisaged in SMS-I.

3.1.3

Casting
Presently the casting of liquid steel is done in the form of ingot steel. The
ingots are sent to Slabbing Mill through soaking pits for production of
slabs.
Continuous casting (CC) technology has been universally adopted for
casting of almost all types of steel grades due to beneficial impact on
yield, product quality, energy saving and reduced operating cost.
Therefore, to maintain competitive edge of BSL, introduction of continuous
casting of liquid steel at SMS-I is considered for implementation.

3.1.3.1

BSL has been earmarked to produce flat products since its inception. The
downstream facilities at BSL are all designed for flat products.
For a flat products based plant like BSL with product mix consisting of
HR/CR coils and sheets, options available for continuous casting are:
- Conventional slab casters
- Thin slab casters
- Endless Thin Slab Caster with Direct Rolling

3.1.3.2

The existing HSM, after upgradation, is rated to produce 4.5 Mtpa of HR


coils. For production of 4.5 Mtpa of HR coils, total requirement of CC slabs
work out to 4.655 Mtpa. Out of this quantity, SMS-II will provide 3.35 Mtpa
of CC slabs. The balance quantity of CC slabs i.e., 1.305 Mtpa are
necessarily to be supplied from SMS-I.

3.1.3.3

The requirement of 1.305 Mtpa CC slabs may be met by providing one


single strand conventional slab caster.

3.2

Selection of Converter for Replacement

3.2.1

As only one BOF converter is considered for replacement in Stage-1 with


all associated facilities, selection of the converter needs to be done
judiciously considering the following:
i)
ii)

Operational consideration
Long term perspective

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 3.3

3.2.2

The opera
ational conssiderations include bo
oth ease off movemen
nt of steel
ladles from
m BOF shop to propossed CCS and
a possibility of any hindrance
to ingot teeming in Teeming
T
Platform Noss. 2, 3 & 4 during co
onstruction
period.

3.2.3

erm perspe
ective involvves conside
eration of tthe ultimate
e layout of
The long te
modernised SMS-I, when
w
endlesss casting with direct rolling facility will be
T location
n of the pro
oposed end
dless casting facilities
installed att Stage-2. The
would be beside the existing B
BOF shop towards
t
the slabbing mill. The
aster would require the
e BOF convverters to be located as
a close to
endless ca
the caster as possible. Also, att Stage-2, 2 nos of HM
H Desulp
phurisation
b installed.
units are planned to be
ational con
nsiderationss, BOF con
nverter no. 5 (E) appe
ears to be
From opera
most suita
able. Howe
ever, from a long term perspecctive of SM
MS-I, BOF
converter no.
n 2 (C) ap
ppears to be most suittable
The
T
related all issue
es were discussed with
w
BSL and
a
consid
dering the
al convenience it wass decided to
t replace BOF Convverter no.
operationa
5(E) in Stage-1.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 3.4

PROJECT DESCRIPTION

4.1

GENERAL

4.1.1

The Steel Melting Shop-I will be modernised with latest facilities. Ingot
casting practice will be phased out and 100% continuous casting of liquid
steel will be introduced in the shop. The tap-to-tap time will be reduced to
provide high productivity to BOF converters.

4.1.2

Measures will be taken during project implementation so that production of


SMS-I (ingot casting) shall not be affected during construction period of
CC shop. For this purpose, some of the existing rail tracks shall be rerouted to facilitate the construction of the CC shop.

4.1.3

The following underlying


preparation of this report:

4.1.4

assumptions

have

been

considered

in

Existing 2 nos. of mixers will continue after modernisation of SMS-I.


Present production of about 1 Mtpa of ingot steel will continue.
Movement of moulds through rail tracks will continue between stripper
yard and mould yard during construction period.
Rail tracks passing through the proposed site of new CCS will be
dismantled and re-routed/diverted.
Rail track No. 300 passing by the side of SMS-I will be retained during
construction period.
Teeming Platform No. 1 and Mould Cooling & Hydro Cleaning Plant
Nos 1 and. 2 will be dismantled. A new Mould Cooling Station (instead
of existing Mould Cooling Plant # 2) will be provided for operation till
phasing out of ingot casting practice.

Following major facilities have been envisaged in Stage-1 modernisation


of SMS-I:
a) Replacement of 1 out of 5 nos. of existing BOF converters (BOF
converter No. 5E) with a new BOF converter of 130 t (max.) heat size
and higher specific volume. For this purpose, the shell of the
converters along with its tilting gear & drive system will be replaced.
b) Suppressed combustion system in the new BOF converter replacing
waste heat boilers. Gas recovery system with gas holder (1 no.).
c) Secondary emission control system in the new BOF converter.
d) Oxygen blowing lance system with handling & maintenance system.
e) Combined blowing facilities including valve stand, piping etc in new
BOF converter.
f)

Existing slag splashing facilities in BOF converters shall be retained.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.1

g New se
g)
elf propelled
d steel transfer cars (2
2 nos.) for BOF
B
converters
h New se
h)
elf propelle
ed steel tra
ansfer car (1 no.) fo
or handling of return
heats frrom CCS to
o BOF convverters
i
i)

Modific
cation of existing self propelled
p
stteel transfer cars (2 no
os.)

j
j)

New steel ladles (10


( nos.) wiith slide gatte system.

k Ladle Tilter
k)
T
(1 no.)
l
l)

Replaccement of Ladle Pre-he


eaters (2 no
os.) to suit the new ste
eel ladles.

m Self pro
m)
opelled slag
g pot transffer cars (2 nos.).
n
n One ne
n)
ew slag bay including
g all associated facilitiies like EO
OT cranes,
slag tra
ansport sys
stem, etc. to
t handle the
t
slag po
ot. Existing slag pots
will be utilised.
o Lime / flux additiion system
o)
m from both
h sides of the BOF converter.
c
ntly there are
a facilitiess for flux addition fro
om one side of the
Presen
convertter.
p Replaccement of 2 nos magne
p)
et cranes in
n Scrap Yard No. 1
q Modific
q)
cation of existing teeming crane
es (2 nos..) and HM charging
crane (1
( no.) for lifting of the new steel ladles.
l
r
r)

Control room for


f
BOF
mentation sy
ystem.
instrum

converter

with

ne
ew

contro
ol

desks,

s New La
s)
adle Furnac
ce of double
e track swiv
velling roof type (1 no..).
t
t)

New single strand


d conventio
onal slab ca
aster (1 no.) with all associated
a
wer sub-stattion, utilities and gas
facilities like cooling water syystem, pow
her materia
al handling ffacilities.
facilities, EOT cranes and oth

u Processs control system


u)
s
for BOF conv
verters, lad
dle furnace and slab
caster.
v New sllab caster shop build
v)
ding to accommodate the LF, sllab caster
and asssociated facilities inclu
uding slab despatch
d
fa
acilities;
w Cooling
w)
g water sysstem for the
e existing SMS-I
S
will b
be augmentted to suit
the new
w requireme
ent of the sshop.
x Refracttories for BOF convverter, stee
x)
el ladles, tundishes etc. with
relining
g & mainten
nance facilitties.
y Diversion of existing rail trackks to create
y)
e space for the new sh
hops.
z)
z New ra
ail tracks ins
side CCS fo
or slab transfer to HSM
M.
aa)
a Laying of rail track
ks at Scrap Yard No.1 for revival of rail linka
age.
bb) Goods cum Passe
enger Eleva
ator at BOF
F Shop.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.2

4.1.5

Following existing facilities of the shop will be retained / utilized.


a) Shop building of SMS-I, cranes, slag pots, etc. However, existing
building structures may be checked for any deformation/corrosion by
BSL through in-house or through external agency before installation of
new facilities.
b) Flux and Fe-alloy addition facilities including belt conveyers.
c) Cooling water system for SMS-I (This will be augmented to suit the
new requirement).
d) Power supply system for SMS-I
e) Oxygen, Argon, Nitrogen, CO gas, compressed air system for SMS-I
(This will be augmented to suit the new requirement).
f)

Civil foundations for shop buildings.

g) Hot metal mixers and HM transfer ladles.


h) Workshop facilities (existing) for SMS-I.
i)

Handling & storage facilities for CC slabs at HSM.

4.1.6

The list of proposed equipment & facilities envisaged for the project is
given at Annexure-4.1.6-1.

4.1.7

Drawings
i) General layout of SMS-I indicating proposed facilities is shown at Drg. No.
CET RN 3498 CE0 00 005 (R=3).
ii) Technological layout of BOF & CCM Shop is shown at Drg. No. CET RN 3498
ST1 00 002 (R=4)
iii) Sectional view of BOF Shop is shown in Drg. No. CET RN 3498 ST1 00 003
(R=0)
iv) Technological layout of Slab Caster Shop is shown in Drg. No. CET RN 3498
ST1 00 005 (R=3)
v) Sectional View of Slab Caster is shown in Drg. No. CET RN 3498 ST1 00 006
(R=2)

4.2

TECHNOLOGICAL FEATURES
PRODUCTION PLAN

4.2.1

Technological Features:

OF

MAIN

FACILITIES

AND

BOF Converters :
No. of BOF converters

: 1 nos.

Heat size

: 130 t (max.); 125 t (avg.)

Oxygen blowing rate

: 36,000 Nm3/h (max), at 10-12 kg/cm2.

Tap to tap time


Gas collection system

: 50 minutes.
: Suppressed combustion system.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.3

S
Slag
dispossal

Secondary Refining Unit:


S
U
L
Ladle
Furna
ace
T
Type
T
Transforme
er rating
Heating ratte
A
Alloy
addition system

: Self p
propelled trransfer car.

A
Automation
n

: 1 x 130 t; Doublle track swivelling rooff type.


: AC, 3-electrode
es,
: 3 ph
hase, 50 Hzz, 33 kV and
d 24 MVA
: 3o C - 5 o C perr minute
: Ferrro alloy and
a
flux fe
eeding arra
angement
(FAFA
A) and wire feeding de
evice
: Gas collecting through la
adle hood, duct & ID
fan a
and cleanin
ng through b
bag filters.
: Level-2

Continuouss Caster:
C
C
Convention
nal Slab casster
S
Slab
thickness
S
Slab
width
L
Length
of slab
s
C
Casting
tim
me

: 1 x 1 strand.
: 200 - 250 mm
: 950 1650 mm.
: 7500
0 10500 mm.
m
: 40 - 5
50 minutes (Dependin
ng on steel grade)
g

G cleanin
Gas
ng system

4.2.2
4

P
PRODUCT
TION PLAN
NNING

4.2.2.1
4

P
Production
of liquid ste
eel has bee
en calculate
ed as given
n below:
Tap to tap time
T
t
N of heatts/day
No.
Heat weigh
ht (liquid ste
eel)
N of workking days available
No.
capability of
P
Production
o BOF sho
op

: 50 minutes
: 34
: 125 t (avg.); 130
0 t (max.).
: 320 days/year
d
p
per converte
er
: 1.36 Mtpa of liqu
uid steel

Out of 34 heats
O
h
per day
d required
d to achievve target an
nnual produ
uction, the
m
modernised
d BOF convverter will p
produce ab
bout 28 hea
ats. For production of
b
balance
he
eats, one off the existin
ng converte
ers will be used. The proposed
s
slab
caste
er will rece
eive liquid steel from
m any of the opera
ating BOF
c
converters
after secondary refining. Ingot casting
c
willl be phased out and
uced. Howe
ever, ingot
100% continuous casting of liquid steel willl be introdu
c
casting
route will be re
etained durring stabilisa
ation period
d of the casster.
4.2.2.2
4

Material Fllow Chart


The propos
T
sed materia
al flow cha
art of BSL after Stage
e-1 modern
nization is
s
shown
at Annexure-4
A
4.2.2-1.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.4

4.2.2.3

Grades of Steel
After Stage-1 modernisation of SMS-I, the process route for finishing of
steel will be BOF - Slab Caster Hot Strip Mill.
The grades of steel which are envisaged to be produced through this
process route are given below:
a)
b)
c)
d)
e)
f)
g)
h)

4.3

Mild steel
Low carbon steel
Medium carbon steel
Deep drawing quality steel
Carbon construction steel,
Boiler quality steel,
Galvanized quality steel,
Tin-plate quality steel.

MECHANICAL
Mechanical work envisages provision of the following:
[A]

BOF converter

i)

Replacement of BOF Converter shell / vessel with trunion ring,


bearing, supporting arrangement between shell and trunnion ring, &
pedestal assembly complete with fasteners, base frames for
pedestals etc. with Tilting Drive, Oxygen Lance System (600
Nm3/min) & Bottom Inert gas blowing system - 1 Set

ii)

Relining car facility above BOF - 1 No.

iii)

Slag arrestor system (dart type)- 1 Set

iv)

Tap hole maintenance facility / De-bricking machine- 1 Set

v)

Self propelled steel ladle transfer car for heat weight 130 t - 2 Nos.

vi)

Modification of existing self propelled steel ladle transfer car for


transfer of steel ladle from converter bay to teeming bay (AB bay)
for existing BOF converters & new steel ladles- 2 Nos

vii)

New Steel Ladle transfer car for return ladle from BC bay to DE bay
with associated facilities - 1 No.

viii)

Steel Ladles (130 t heat weight) with 600 mm freeboard & slide gate
system - 10 Nos.

ix)

Modification of flux charging facilities

x)

Ladle Tilter (Hydraulic type) - 1 No.

xi)

Ladle Stand- 4 Nos.

xii)

Augmentation of Ferro-alloy charging system including bins & telfers

xiii)

Dismantling of existing equipment/facilities

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.5

[B]

New Slag
S
Yard

i)

Self propelled slag


s
pot tra
ansfer car with
w provisiion of placiing 1 slag
3
n each car and new tra
ack- 2 Nos
pots of 16 m on

ii)

Slag Pot Standss - 10 Nos.

iii)

e coating un
nit- 1 No.
Lime

iv)

Doze
er- 1 No.

v)

Pay Loader (1 m)
m - 1 No.

[C]

Ladle
e Furnace
1 No.

[D]

Continuous Cas
sting Mach
hine (CCM)) - 1 No.

[E]

Handling Equipments (Cra


anes, Hois
sts etc.)

[F]

ssenger Elevator in BOF


B
Shop
Goods cum Pas

4.3.1
4

Equipment
E
t Descriptio
on

4.3.1.1
4

BOF
B
Conve
erter
Converter
C
Shell
S
The
T Converrter shell will
w comprise
e of a cast mouth welded to a conical
c
top
section,
s
a cylindrical
c
centre secction and spherical
s
bo
ottom weld
ded to the
bottom
b
edge of the cy
ylindrical shell. The tap
p-hole sockket will be welded
w
on
the conical top section
n. Brick reta
aining ringss will be pro
ovided on convenient
c
ocations to facilitate co
onverter relining.
lo
A part of th
he platform in front of the converrter will be made deta
achable to
have
h
approa
ach for cha
anging of the vessel.
The
T
Conve
erter shell and trunn
nion ring shall
s
be de
esigned ke
eeping all
provisions
p
r
required
forr the combin
ned blowing
g (Bottom b
blowing) syystem.
Design
D
of Converter
C
sh
hall have suitable clea
arance betw
ween Converter shell
and
a trunnion ring for ad
dequate cirrculation of air and hen
nce cooling
g of shell.
Itt is propossed to incrrease the specific vo
olume of th
he Convertter to the
maximum
m
extent
e
possiible.
Trunnion
T
Riing
The
T
trunnio
on ring will be of box section de
esign of we
elded low-a
alloy steel
plate
p
construction. Th
he forged ttrunnion will be securrely welded
d into the
trunnion ring. Design of
o converte
er will proviide a larger clearance
e between
Converter
C
s
shell
and tru
unnion ring
g for adequate circulattion of air and
a hence
cooling
c
of shell.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.6

Converter suspension
The converter will be fixed in the trunnion ring by means of a suitable
support system.
Trunnion Bearing and pedestals
i) The trunnion shaft will be supported by bearing assemblies. The
bearing will be double-row spherical type. The bearing will be designed
to take all static and dynamic loads during converter operation.
ii) The bearing assembly located at the drive end of the converter will be
fixed bearing support while the non-drive end will be sliding bearing
support. The sliding support will allow thermal expansion of the trunnion
ring that may occur during operation of converter.
iii) The bearings will be provided with oil lubrication system.
iv) The drive side bearing will be split type.
v) The bearings will be mounted on supporting pedestals of welded steel
plate construction which will be anchored on concrete foundation.
vi) The pedestals will be supplied with a set of regulating shims to be
placed on shop foundations with the aim to regulate, if necessary,
supporting bearing assemblies.
vii) On-line condition monitoring system for Converter trunnion shaft
bearings shall be provided.
Slag Shields
i) The upper part of the trunnion ring and vessel fixing parts in the
trunnion ring will be protected from splashing and spitting of molten
steel and slag by protective shields.
ii) Protective elements will be fabricated from rolled steel in the form of
cone shells and will be welded to supporting brackets. The pedestals
from the converter side will be protected with refractory material.
iii) Stationary slag shields will be also provided below the converter for
deflecting sloppy slag to the slag pot during blowing.
Tilt Drive
i) The converter will be tilted with the help of electro mechanical drive.
Brake with emergency release mechanism will be provided. The drive
system will incorporate pneumatic motor which will be used for
emergency tilting back of converter to vertical, in case of power failure.
Drive system shall have suitable access for maintenance purposes.
ii) The drive will be designed taking into account all the dynamic loads
arising in the course of starting and braking, converter loading, skull
removal and converter relining.
iii) New oil lubrication system for bearings of output shaft of tilting drive
gear boxes and bull gears proper will be provided. There will be one
BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.7

system for trunnion shaft bea


aring and one
o
system
m for outpu
ut shaft of
tilting drive gear bo
oxes and bu
ull gears.
Oxygen
O
Lan
nce System
m
i)) Converte
er will be equipped
e
w an oxyg
with
gen lance system
s
con
nsisting of
two oxyg
gen lancess (one workking and on
ne standbyy). The lanc
ce system
will have
e the following features:

Exchange of the opera


ating lance
e with the stand-by lance, if
uired.
requ

Insta
allation / dismantling
d
g of oxyge
en lance in
nto/ from the lance
carrriage.

Use
e of the blowing la
ance for preheating
p
the newlly relined
convverters.

Oxyygen supplyy to the con


nverters will be through
h two identiical watercoolled oxygen
n lances. One
O
of the lances will be in the
e blowing
posiition and the other will be in the standby
s
possition.

Con
nverter will be provide
ed with fou
ur lances one opera
ating, one
stan
nd-by and 2 Nos. as sspares. The
e tube for ssupply of oxxygen will
be made
m
of sta
ainless stee
el. Other tubes will be of carbon steel. The
lancce casing will
w be fabricated from seamless pipes and will be of
straight cylindrrical design.

Lance tip will be


b fabricated from malleable, high
h conductivvity copper
hout any oxygen
o
con
ntent. The constructio
on of the lance as
with
asse
embled witth hose and
d suspending brackett will be su
uch that it
will provide saffety of operration and ensure
e
verttical alignm
ment along
he converte
er.
centtre line of th

Carriage
C
with Guide
i))

One movable
m
lan
nce carriage will be provided.
p
Th
he guide frrames will
be mo
ounted on the
t
platform
m, one for working
w
lan
nce and se
econd one
for the standby. The
T carriage
e will be ins
stalled on ra
ail tracks.

iii)

The rig
gid lance guides
g
will consist of two guide rails interc
connected
with each other by welded
d structure and will se
erve for gu
uiding the
g rollers an
nd the guid
de rollers fo
or the lance
e carrier. Top
T
of the
running
guide will
w be equiipped with 2 limit switc
ches interaccting with carriages.
c

Lance
L
Carriier
i))

Two la
ance carrierrs will be prrovided for converter. The
T lance carrier
c
will
be equ
uipped with 4 pairs of mutually pe
erpendicula
ar rollers, ro
olling over
the guide ensurin
ng that the lances will be alwayss in the cen
ntre-line of
he carrier w
will be manu
ufactured frrom steel plates
p
and
the converter. Th
ot upper cantilever fea
aturing vertiical slot forr lance trunnions and
has go
a bottom cantile
ever featuring screw type lock. The carrie
er will be

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.8

equipped with special device providing its fall within the guides in
case of wire rope breakage.
ii)

Rigid guides consist of 2 shafts guiding rollers of the lance carriage.


Top of the guide will be equipped with 4 limit switches interacting with
carriers. Suitable interlocks will also be provided.

Lance hoist mechanism

4.3.1.2

i)

Two identical lance hoists, one for each lance, will be provided for the
vertical movement of the lance within the lance guide frame.

ii)

The lance hoist mechanism will be complete with drive motor, flexible
couplings to electro-magnetic brakes, a gear reducer, coupling,
bearing, rope drum, rope and kinematic block. In addition to the main
motor one auxiliary motor will be provided for emergency lifting of the
lance from converter. The pneumatic drive consists of cylindrical
reducing gear with pneumatic drive and pneumatic motors.

iii)

The mechanisms for lifting and lowering lances consist of a differential


reducing gear & provided with wheels.

iv)

Wire ropes will be fixed to the suspension of the carriage with pulleys
and will be wound on the drum. Additional safety ropes will be
provided to the carriage body. The drum installation will be equipped
with devices for tripping the drive in case of wire rope breaker or
slackening.

Relining car facility


Relining car facility above BOF will be provided. Same track will be utilised
for Relining car as well as BOF hood positioning car.

4.3.1.3

Slag arrestor system


Slag arresting darts are used in the converter as a means to cut off the
slag from entering into the ladle during taping of steel. Dart type slag
arrestor system will be provided to prevent slag from entering into the ladle
during taping of steel.

4.3.1.4

Tap hole maintenance facility / De-bricking machine


This will be used for converter de-bricking, mouth cleaning, removal of
mouth jam and other tap hole maintenance job of the converter.

4.3.1.5

Self propelled steel ladle transfer cars


2 (Two) Nos. new self propelled steel transfer cars will be provided for
transferring steel ladles from Converter bay (CD bay) to Teeming bay(AB
bay) in the existing BOF shop. The cars will have facility for on-line argon
purging.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.9

Brief descrription of Stteel Transfe


er car is as below:Pa
arameters

Brie
ef descripttion

1.

Qu
uantity (Nos.)

2.

Ca
apacity(t) - Heat Weight

130

3.

Sp
peed
ap
pprox

4.

Drrive

Elec
ctro-mechanical

5.

Trravel length
h (m) approx

80

6.

Le
evel (m)

0.0
0

7.

Po
ower supply
y

Thro
ough cable reeling dru
um

8.

Co
ontrol

From
m control post(
p
2nos)) at 0.00
leve
el

Sl
No.

4.3.1.6
4

of

Car

(m//min) 30

Modificatio
M
on of existiing self pro
opelled ste
eel ladle tra
ansfer car - 2 Nos
Existing
E
self propelled
d steel ladlle transfer cars for tra
ansfer of steel
s
ladle
from
f
Conve
erter bay (C
CD bay) to Teeming bay
b (AB bayy) will be modified,
m
if
required,
r
to
o suit existing ladles a
as well as new steel ladles with
h 600 mm
free
f
board,

4.3.1.7
4

New
N
Steel Ladle trans
sfer car for return lad
dle from BC
B bay to DE
D bay:Brief descrription of Stteel Transfe
er car is as below:Sl No.

Paramete
ers

B
Brief
descrription

1.

Quantity (Nos.)
(

2.

Capacity((t) - Heat Weight


W

1
130

3.

Speed
approx

4.

Drive

E
Electro-mec
chanical

5.

Travel len
ngth (m) ap
pprox

6
60

6.

Level (m)

0.0

7.

Power supply

T
Through
ca
able reeling drum

8.

Control

From contrrol post (2


F
2 nos) at 0.00
level

BSL
B
Modernisation
M
n of SMS-I

of

Car

(m/min) 30
3

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.10

4.3.1.8

Steel Ladles
Brief description of Steel ladles is as below:Sl No.
1

4.3.1.9

Parameters
Ladle capacity in t of liquid Steel

Brief Description
130

Quantity (nos)

10

Freeboard (mm)

600

Discharge

Through slide gate system &


Porous Plug arrangement

Modification of Flux Charging Facilities


Existing flux charging facilities shall be modified. Feeding direction of one
of the existing two nos. vibro-feeders below existing bunkers will be
reversed for feeding of flux from other side of convertor for uniform feeding
of flux to the convertor.

4.3.1.10 Ladle Tilter


1 (One) No. new ladle tilter will be provided for tilting of ladles and will be
located at suitable location in ladle preparation bay of existing SMS-I
shop.
Brief description of ladle tilter is as below:Sl.
No.

Parameters

Brief Description

1.

Quantity(Nos)

01 (one)

2.

Location

Ladle preparation Bay of existing


SMS-I shop

3.

Weight
of
refractory

4.

Angle of Tilting

5.

Time of Tilting the Ladle 60 sec.


through 900

6.

Tilting of Ladle

By means of hydraulic cylinders


actuated by the Hydraulic Power
Pack arrangement

7.

Gripping of Ladle

By means of hydraulic jammers


actuated by the Hydraulic Power
Pack arrangement

BSL
Modernisation of SMS-I

Ladle

with 60t approx.


900

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.11

Sl.
No.

Pa
arameters

Brrief Descrip
ption

8.

No
o. of Hydraulic Power Pack

On
ne (01)

9.

Mo
ovable Plattform

Mo
otorised typ
pe

10.

Mo
ovable
sh
hield

11.

Ma
aximum
hy
ydraulic
cyylinders

tro
olley

with

heat Mo
ovable tro
olley along
g with hea
at
sh
hield shall be
b designe
ed in such a
wa
ay that it should not havve
ten
ndency to
o overturn. It should
alw
ways be in stable cond
dition.

temp.
a
around 30
00 oC
jammers
and

4.3.1.11
4
La
adle Stand
4 nos of new Ladle Sttands will b
be provided
d. It will be
e made of structural
d at suitable
e location in ladle prep
paration Ba
ay.
stteel and willl be located
4.3.1.12
4
Augmentat
A
tion of Ferro-alloy ch
harging sys
stem
Two
T
nos ne
ew bunkers of 3 m ca
apacity each
h for Ferro--manganesse & Ferro
Silicon
S
shall be provided at suitable location
n along with
h vibro feed
ders, load
cells
c
and necessary
n
a
nt for feed
ding of Ferro alloys
feeding arrangemen
directly
d
to th
he steel lad
dle on transfer car.
One
O no. 3 t electric ho
oist shall be
e provided above the bunkers fo
or lifting of
ferro
f
alloys from + 8.1 m level and
d filling it in
nto the bunkkers.
4.3.1.13
4

D
Dismantling
g of existing
g equipmen
nt /facilities
i. Dismanttling of the
e Converterr shell, trun
nnion ring, pedestal assembly,
a
bearings
s, complete
e oil lubriccation systtem and itts electricss, support
arrangem
ment, comp
plete drive system, all utilities & services, piping
p
and
fittings, laying and
d routing of cables etc., as req
quired, for combined
s
blowing system- 1 set
and its handling system - 1 set
ii. Dismanttling of Oxyygen lance a
iii. Dismanttling of Selff propelled steel ladle transfer ca
ar (heat weiight 130 t)
- 2 Nos.
iv. Any othe
er equipme
ent /facilitiess as require
ed.

4.3.2
4

Ne
ew Slag Ba
ay

4.3.2.1
4
Se
elf propelled
d slag pot trransfer car

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.12

2 (Two) Nos. new Self propelled slag pot transfer car with provision of
placing 1 slag pots of 16 m3 on each car along with new track will be
provided for transferring Slag Pots from Convertor bay to New Slag Yard.
Brief description of Steel Transfer car is as below:Sl No.

4.3.2.2

Parameters

Brief description

1.

Quantity(Nos)

2.

Capacity(t)

100

3.

Speed
approx

4.

Drive

Electro-mechanical

5.

Travel length(m) approx

100

6.

Level(m)

0.0

7.

Power supply

Through cable reeling drum

8.

Control

From Control post (2 nos) at 0.00


level

of

Car

(m/min) 30

Slag Pot Stand


10 nos of new Slag Pot Stands will be provided. It will be made of structural
steel and will be located at suitable location in New Slag Bay.

4.3.2.3

Lime coating unit


1 no. new lime coating unit will be provided for coating of lime inside slag
pots inside new slag yard.

4.3.2.4

Dozer
1 no. Dozer will be provided for dozing of slag inside new slag yard.

4.3.2.5

Pay Loader
1 no. Pay loader of 1 m bucket capacity will be provided for loading of slag
into dumper at new slag yard. It shall be heavy duty and tyre mounted. The
pay loader shall be complete in all respect with diesel engine, transmission
system, drive system, hydraulic brake etc. All operations of the bucket shall
be done hydraulically.

4.3.3

Ladle Furnace
1 no. new double track swinging roof type Ladle Furnace will be installed in
the PQ bay of new CCM shop for secondary refining of liquid steel.
i) Ladle Furnace shall broadly consist of following equipment / system:

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.13

Water Cooled Lad


dle Roof Co
omplete witth Supporting System
Roof Lifting
L
Arran
ngement
Electro
ode Nippling and Stora
age Stand / Station:
Ferro Alloy
A
Feeding Arrange
ement (FAF
FA)
Ladle Transfer
T
Ca
ars (2 nos)). Transfer car
c track w
will be exten
nded up to
AB bayy of existing
g SMS-I shop.
Arc Heating
H
Syystem con
nsisting Ele
ectrode Masts
M
and Arms &
Electro
ode Holder and Clamp
p System
Hydrau
ulic System
m
Centra
alized Lubrication Systtem
Wire fe
eeding systtem
Tempe
erature mea
asurement and sampliing Lance
Inert Gas
G Stirring System
4.3.4
4

Co
ontinuous Casting Machine (CC
CM)

4.3.4.1
4
It is proposed
d to install a Continuous Casting Shop in SMS-1. The
e shop will
e equipped with state--of-the art, high produ
uctivity con
ntinuous sla
ab casting
be
ma
achine and auxiliary fa
acilities for production
p
of crude ste
eel.
4.3.4.2
4
The
e salient de
esign feature
es of the prroposed CC
CM are as b
below:
S
Sl.

Descrription

D
Design feature

Ladle Turret

L
Ladle Turre
et with lifting / lowering, rotating and

N
No.
1.

w
weighing fa
acility, equ
uipped witth ladle co
over
m
manipulatorr.
2.

Ladle stream protection

C
Ceramic shroud

3.

Tundissh

R
Refractory lined,
l
suitab
ble for hot lining

4.

Tundissh

stream T
Through submerged entry nozzle
e

protec
ction
5.

Tundissh transfer car

2 nos. overrhead cantilever desig


gn with lifting /
lo
owering an
nd weighing
g facility

6.

Type of
o mould

P
Plate mould, straight, multi tap
per / parab
bolic
d
design

7.

Mould lubrication

BSL
B
Modernisation
M
n of SMS-I

C
Casting pow
wder for clo
osed casting
g
CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.14

Sl.

Description

Design feature

8.

Mould level control

Eddy current type

9.

Mould

No.

10.

oscillating Hydraulic design, adjustable stroke, oscillation

mechanism

frequency linked to casting speed

Secondary cooling

Multi

zones,

controlled

high-pressure

spray/air

mist

automatically

cooling

system,

dynamic control of cooling water flow w.r.t.


casting speed
11.

4.3.4.3

Withdrawal

and Multi point straightening, hydraulic pinching,

straightening unit

modular design

12.

Dummy bar

Chain link type bottom fed

13.

Strand cutting device

Oxy-propane torch cutting machine

14.

Marking unit

Automatic Slab marking machines

15.

Slab discharge

By EOT crane

Proposed CCM will broadly consist of following equipment / system:


i) Ladle Turret
The steel ladle from the BOF is placed on the ladle turret by means of a
crane and positioned above the tundish. Ladle Turret will consist of
following equipments:
Ladle cover lifting device
Ladle slide gate connecting platform
Ladle slide gate mechanism
Emergency launder for ladle
ii) Ladle slide gate lance
In the event that liquid steel does not flow after opening of the slide
gate, the Ladle slide gate oxygen lance is utilized to burn open the ladle
nozzle. The lance is also used for cleaning of the ladle shroud between
ladle exchanges.
iii) Shroud manipulator
Mechanized Ladle Shroud Manipulator will be provided for quick & easy
positioning and connection of the shroud to the ladle. The shroud
manipulator applies an upward force sealing the ladle shroud to the

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.15

ladle noz
zzle during the pouring process. With the sh
hroud manipulator all
necessa
ary moveme
ents of the shroud
s
can
n be perform
med.
ivv) Tundish
h
The tund
dish receiv
ves the liqu
uid steel an
nd distributes the stee
el through
one tund
dish bottom
m opening to
o the mould
d.
There shall be pro
ovision for h
hot tundish
h with dual heating syystem with
CO gas as well as Propane.
Slide ga
ate system
m along witth system for emerge
ency closin
ng will be
provided
d for controlling the flow of liquid metal from tundish to mould.
The sub
bmerged en
ntry nozzle quick chan
nge mechan
nism will be
e provided
under th
he tundish outlets so that prehe
eated subm
merged entrry nozzles
can be quickly
q
cha
anged durin
ng casting without inte
erruption or
o delay in
the proccess.
The tund
dish will be
e made of w
welded stee
el plates of heavy secttion. Each
tundish will be su
upplied witth refractory lined m
metal covers having
suitable openings.
It shall also
a
be prov
vided with w
weighing facility.
v)
v

Tund
dish Car
Tundish car picks up the tund
dish in heating positio
on and transport it to
ove the mo
ould. In combination
the castting position and posiitions it abo
with a second tu
undish carr, tundish change iis possible
e without
interruptting the cassting processs.
The tundish cars will
w be ope
erating on the casting
g platform. It will be
d with elecctro mecha
anical drive
es for trave
elling and hydraulic
provided
system for
f lifting an
nd lowering
g. It will also
o be provided with hyd
draulically
operated
d centering
g mechanism to faccilitate centtering of SEN
S
with
respect to mould.
It will have both normal
n
and
d creep sp
peed for proper posittioning of
m
Therre will be a cable trolley mechanism with
tundish over the mould.
ain arrange
ement for ssupplying power
p
to th
he drive mo
otors and
drag cha
controls. Local con
ntrol deskss with nece
essary controls, indication and
ation will be
b provided. Arrangem
ment for tun
ndish weigh
hing (load
annuncia
cell bassed) will als
so be provvided in th
he car, and
d display of
o tundish
weight will
w be indica
ated on con
ntrol desk and
a casting platform.

vi)
v

Moulld & Mould assembly


Mould assembly is located below tundish
h on the on the oscillatting table.
des initial solidificatio
on to form
ms slab sh
hell in the adjusted
It provid
thicknes
ss an width..
Straight type mould
d shall be provided.
p
M
Mould
assembly along
g with foot
w be quick
k change ca
artridge type
e. The mou
uld will be lo
ocated on
rollers will

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.16

the oscillating tables at the start of the casting machine. The mould
assembly will be having water cooling arrangement for the copper
plates and complete with necessary fittings for cooling water
arrangement for fixing on to the mould oscillation table and protection
cover to avoid damage due to metal splash and metal overflow.
The machine will have automatic gravity type feeder system for adding
flux (casting powder) in the moulds during casting.
vii)

Automatic Mould Level Control (AMLC)


An Automatic Mould Level Control (AMLC) system will be provided.
AMLC will be mounted directly above the mould. AMLC will be used to
maintain the level in the mould constant during casting.

viii)

Mould Oscillation System


Hydraulic type mould oscillation system will be provided. Oscillation
frame will be water cooled. Frequency of oscillation will change
automatically with change in casting speed. Quick release coupling will
be provided for water hose connection / disconnection.
Necessary grease lubrication system will be provided. All necessary
access and maintenance platform will be provided.

ix)

Strand Guide System

Sets of rollers and their supports, strand guides and segments along
with all accessories will be provided.
x)
Withdrawal & Straightener Unit
Withdrawal & straightener units with direct drive will be provided. The
withdrawal & straightener units will have reversible drives with infinitely
variable speed and will be complete with motors, gear boxes, brakes
etc. Withdrawal speed will be synchronized with the frequency of mould
oscillation. Top rolls will be provided with hydraulic cylinders. The
design of frame and housing will be such that roll changing can be
carried out with minimum dis-assembly within minimum time. The
housing frame, rolls and bearing housings will be water cooled.
An electric hoist of suitable capacity shall be provided for maintenance
of Withdrawal & straightener units.
xi)

Dummy Bar System


Dummy Bar System consisting of Dummy bar, Dummy bar body,
Dummy bar heads, Dummy bar disconnecting device, Dummy bar
receiver with platform, Storage stand and transport device for dummy
bar heads, Roll gap checker (dummy bar head type) etc. will be
provided.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.17

xii)
x

Torch
h Cutting Machine
M
(TC
CM)
The casst strands will
w be delivvered from the last se
egment of the
t strand
guide to
o the approach rolle
er table off torch cutting mach
hine. The
products
s will be cut with the h
help of oxy--propane flame. A cuttting torch
for the strand
s
of CC
CM will be provided for
f cutting the productts and the
operatio
on of the un
nit will be fu
ully automa
atic. The un
nit will comprise of a
machine
e frame, oxxy- propane
e torches with
w pre-hea
ating burne
ers, a gas
distribution system
m including
g necessa
ary hoses, connecto
ors, hose
t
and pneumatic clamping mechanism
m
for the torch cutting
guides, travel
machine
e and the re
elated conttrol and ele
ectrical equipment. The unit will
be suita
able for cuttting the ma
aximum siz
ze of produ
ucts envisag
ged to be
cast in the
t
CCM. Facilities
F
fo
or sludge granulation and dispos
sal will be
provided
d. The carrriage and th
he holding arms will be
b soft watter cooled
and pro
ovided with necessaryy heat shie
elds. Emerrgency torcch cutting
facility will
w be provvided by the side of the
t
machine to cut prroducts in
case of failure of the GCM torches. De-burring facilities
f
willl also be
d.
provided
The rolle
er tables supporting
s
tthe produc
cts during ccutting operation will
be of shifting type / tilting type
e to protectt the rolls frrom the flam
me of gas
cutting torches. Each roller wiill be individ
dually drive
en and wate
er-cooled.
o strand movement
m
will be sy
ynchronized
d with the speed of
Speed of
casting.

xiii)
x

Run out equipm


ment
Run out equipmentt will consisst of the following:

xiv)
x

In
ntermediate
e Roller Tab
bles
De-burrer
D
Weighing
W
Ro
oller Table
Marking
M
macchine
Automatic
A
Le
ength Meassuring Systtems
Disappearin
D
g Stopperss
Pusher
P
and Piler
Roller
R
Table
es inside Pu
usher and Piler
P
Fixed End Stops
S
Discharge
D
Roller
R
Table
e

Tund
dish maintenance facilities
Tundish
T
tiltin
ng stand
It will be prrovided to support th
he tundishe
es and rottate them
g.
hydraulicallyy for skull and refractory dumping
Tundish
T
coo
oling device
e

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.18

Tundish relining stand


Tundish drying station
Tundish support stand
Stopper rod stand
Tundish nozzle aligning, gunning & drying equipment
xv)

Mould maintenance facilities


Following facilities will be provided in the mould maintenance area.
Mould assembly storage stand
It will be provided to support the moulds for storage. The stand
will be made of welded steel sections complete with centering
pins for moulds and lifting trunnions.
Mould tilting stand
It will be provided to support the moulds during maintenance,
operation and allow the pressurized testing of moulds. The stand
will be made of a frame for mould support with tilting facility. The
tilting will be provided with motorized system. A pressurised
circuit will be supplied to allow pressure test of the mould.
Mould alignment stand
It will be provided to hold the mould in the correct position to
allow their alignment prior to the casting. The stand will be
designed to hold the mould for each casting section.
Mould measuring instruments
These will be provided to measure the mould internal
dimensions for all sections.

xvi)

Segment maintenance facilities


Following facilities will be provided in the Segment maintenance
area.
Segment storage stand
Segment tilting stand
Segment Loose side frame alignment stand
Segment Fixed side frame alignment stand

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.19

xvii)
x

Auxilliary mainte
enance equ
uipment
Follo
owing facilitties will be
e provided in the Segment maintenance
area.
Mould
M
and segment
s
cle
eaning and water test stand area
Hydraulic
H
co
ompact unitt for mould and segme
ent maintenance
Pump
P
station for mould
d and segm
ment testing stands
Movable
M
gre
ease pump unit
Cranes
C
and hoists
Movable
M
pla
atform
Tundish
T
tran
nsfer car

led) from AB
xviii)
x
Steel ladle & slag pot transfer car (self-propel
(
A bay of
SMS
S-I to PQ ba
ay of CCS
Brieff description
n of Steel T
Transfer carr is as below
w:Sl No.

Paramete
ers

B
Brief
descrription

1.

Quantity (Nos.)
(

2.

Capacity((t) - Heat Weight


W

1
130

3.

Speed
approx

4.

Drive

E
Electro-mec
chanical

5.

Travel len
ngth (m) ap
pprox

5
50

6.

Level (m)

0.0

7.

Power supply

T
Through
ca
able reeling drum

8.

Control

From conttrol post( 2nos) att


F

0.00
level

of

Car

(m/min) 30
3

It sha
all be desig
gned to tra
ansfer slag pots from AB bay off SMS-I to
PQ bay
b of CCS also.
xix)
x

Tund
dish transfe
er car (selff-propelled) AB bay off SMS-I to PQ
P bay of
CCS
A Tundish transfer car sha
all be provided to transfer tundish
h from AB
bay of
o SMS-I to
o PQ bay(Tu
undish prep
paration bay) of CCS.
Brieff description
n of Steel T
Transfer carr is as below
w:Sl No.
1.

BSL
B
Modernisation
M
n of SMS-I

Paramete
ers

B
Brief
descrription

Quantity (Nos.)
(

1
CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.20

xx)

2.

Capacity(t)

3.

Speed
approx

4.

Drive

Electro-mechanical

5.

Travel length (m) approx

40

6.

Level (m)

0.0

7.

Power supply

Through cable reeling drum

8.

Control

From control post( 2nos) at


0.00 level

of

50
Car

(m/min) 30

Segment transfer car (self-propelled) PQ bay to RS bay of CCS


1 no. Segment transfer car shall be provided to transfer segments
from PQ bay to RS bay of CCS.
It will also be used for transferring slabs from RQ bay to RS bay in
case of emergencies. Slabs will be lifted from the strands in case of
emergencies and placed on the transfer car by means of a suitable
tong type attachment attached with the EOT crane. Design
parameters of the existing SMS-II slab transfer car shall be
maintained to the extent possible for interchangeability purpose.
Brief description of Steel Transfer car is as below:Sl No.

Parameters

Brief description

9.

Quantity (Nos.)

10.

Capacity(t)

100

11.

Speed
approx

12.

Drive

Electro-mechanical

13.

Travel length (m) approx

60

14.

Level (m)

0.0

15.

Power supply

Through cable reeling drum

16.

Control

From control post( 2nos) at


0.00 level

BSL
Modernisation of SMS-I

of

Car

(m/min) 30

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.21

xxi)
x

Slab transport buggies


b
for dispatch off CC slab to
o HSM
18 no
os buggies
s of 100 t capacityy each will
w be pro
ovided for
transp
portation off continuou
us cast sla
abs from dispatch
d
ba
ay of new
CCM Shop to Ho
ot Strip Mill (HSM).

xxii)
x

Moulld & Segme


ent Repair sshop
Moulld & Segme
ent Repair shop will broadly conssist of lathe
es, drilling
mach
hine, milling
g machine, grinder etcc for repair of Mould & Segment
along
g with mate
erial handlin
ng equipme
ents.

4.3.5
4

Handling Equ
uipments

4.3.5.1
4
BO
OF Shop:Brief
B
descrip
ption of EO
OT cranes iss as below:Sl.
No.
1
2
3

Qty (N
Nos)

De
escription

Re
eplacementt of 30 t magnet cran
nes 2
at Scrap yard
d No. 1
Mo
odification of
o Teeming crane
2
Mo
odification of
o Hot Meta
al Crane
1

Capa
acity(t)
30
180 + 50/10
180 + 50/10

Necessary
N
modification will be ca
arried out in
n teeming ccranes (2 No
os) & Hot
Metal
M
Crane
e(1 No.) wiith respect to spreade
er beam to suit new stteel ladles
with
w free bo
oard of 600 mm.
4.3.5.2
4

New
N
Slag Bay:B
Brief
B
descrip
ption of EO
OT cranes iss as below:Sl.
No.
1.

Qtyy(Nos)

escription
De

Ne
ew Slag handling crane 1
(10
00/20 t) with
w
traverse and
gra
ab incl. ma
aintenance hoist
Ne
ew Slag handling crane 1
(10
00/20 t) with
w
traverse and
ba
alling incl. maintenance
ho
oist

C
Capacity(t)

Span(m)

100 + 20

27

100 + 20

27

4.3.5.3
4
CCM Shop:Brief
B
descrip
ption of EO
OT cranes iss as below:-

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.22

Sl.
No.
i.
ii.
iii.
iv.
v.
vi.
vii.

Description

Qty (Nos)

Capacity (t)

EOT crane for steel ladle handling


in Turret bay
EOT crane in CC machine bay
EOT crane in Despatch bay for
slab handling
Pump houses, compressor rooms,
scale pits, etc
Mould / segment repair shop
Mould / segment repair shop
10 t EOT crane with grab for scale
pit

200+50/20

Span
(m)
27

2
2

100+20
100

27
27

10

20

2
2
1

40+10
20+5
10

22
22
12

4.3.5.4 Electric Hoists :Electric Hoists will be provided at suitable locations for maintenance of
EOT cranes.
Broad details of the electric hoists shall be as follows:Sl. No.

Nomenclature

Description

Location

At suitable locations

Purpose

Maintenance of Cranes

Quantity

10

Type

Motorised, trolley suspended, pendant


operated electric hoist

Capacity (t)

Lift (m)

As per Requirement

Hoisting
(m/min)

Travel speed (m/min)

As per Requirement

Hoisting and travel

All motorised

10

Duty class

II as per IS 3938:1983

11

Monorail for hoist

Suitable for electric hoist along with


festoon cable arrangement, pendant
push button station etc.

12

General

The
design
and
constructional
requirements of major components like
load chain, hook, gear, trolley wheel, all
structural components, lubrication and
bearings, load brakes, safety devices
and clearances etc. shall be as per the

BSL
Modernisation of SMS-I

speed As per Requirement

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.23

Sl. No.

N
Nomenclatu
ure

Descripttion
relevant standards.
s
The lift and
a
travel length of the hoists
shall be suitable for handling equipmentt
from the floor level.

i)

The
e hoists sha
all have dc electro-ma
agnetic brakkes

ii)

The
e control pa
anel and brrake panel of
o the hoistts shall be separately
s
mo
ounted on sttructures and shall not be mounted on the hoist
h
The
e hoist shalll have trailing cable arrangemen
nt for powerr supply.
The
e hoist shalll have provvision of ma
aintenance platforms.
The
e motors offfered for ho
oist shall be
e standard frame moto
ors only.

iii)
iv)
v)

4.3.5.5
4
Ba
ackhoe load
der:1 no. heavy duty Backh
hoe loader of 1 m loa
ader buckett capacity and
a 0.3 m
ucket capacity will be
e provided for
f cleaning
g and loading of deexxcavator bu
brricking debris, slag dump etc. on the pit side
e of Converrter shop.
4.3.5.6
4
Bo
obcat:1n
no. Bobcat of 1 m bucket capaccity will be provided
p
forr cleaning purpose.
p
It
sh
hall be hea
avy duty and tyre mounted. The pay
p loader shall be co
omplete in
alll respect with
w diesel engine,
e
tran
nsmission system,
s
drive system, hydraulic
brrake etc. Alll operations of the buccket shall be
b done hyd
draulically.
4.3.5.7
4

G
Goods
cum Passenger Elevator
Existing 5 t Goods
G
cum
m passenge
er Elevator will be replaced by ne
ew Goods
um Passenger Elevato
or of similarr capacity & size at the
e existing lo
ocation.
cu
Brief techniccal parametter of the G
Goods cum
m Passenge
er Elevator will be as
elow:
be
i))
iii)
iiii)

Capa
acity- 5 t
Total lift - 42.5 m
No. of
o Stoppage
es / landing
gs - 7

4.3.5.8
4
50
0 t Tractor-ttrailer
O
One
no. Trractor-traile
er shall be provided fo
or transporttation of re
eplaceable
e
equipments
s from Replaceable Eq
quipments Repair Sho
op (RERS) to shop.
ler shall co
T
Tractor-trai
onsist of a standard
s
tra
actor capab
ble of haulin
ng a trailer
w payloa
with
ad capacity of 50t.
B
Brief
techniical parame
eter of the T
Tractor-trailler will be a
as below:

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.24

Sl.no.

Description

Specification

Quantity (set)

One

Type

Tractor with low deck full trailer

Prime mover

Tractor capable of hauling trailer of


50t payload capacity

Capacity of
(payload) kg

Bed area of trailer

As per requirement

Max. Speed(kmph)

50

Frame

All steel

Brake

Internal expanding shoe type service


brakes, automatic emergency brake,
hand wheel operated parking brake

9
10

Handling material
Loading arrangement

Moulds of slab caster


Overhead crane

trailer 50,000

Trailer shall be of welded steel structure platform mounted on tyre mounted


wheels. The platform of trailer shall have a flat top surface to accommodate
moulds of slab caster. The platform shall be adequately stiffened along the
entire length and corners. The trailer shall be equipped with suitable
arrangement at one end for manual coupling with the tractor.

4.3.5.9

35 t Dumper
One no. Dumper of 35t capacity shall be provided for disposal of skull and
muck to Scrap & Salvaging Department (SSD).

4.3.6

Scheme for Rail Movement of Ingot Moulds between Mould Yard and
Stripper Yard during construction period

4.3.6.1

Proposed rail tracks for movement of ingot moulds between Mould yard and
Stripper yard during construction period of Slab Caster shop is shown in
enclosed drawing no. CET RN 3498 CE0 00 005 R=1.

4.3.6.2

Following assumptions have been considered for transportation / handling


of ingot moulds:

Teeming of ingots will be done at teeming platform #2, #3 & #4.


Teeming platform # 1 will be closed.
After the required cooling, the ingot mould will be placed in stripper yard
# 1 for stripping.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.25

4.3.6.3
4

The stripped ingots will be sentt to Slabbin


ng Mill as pe
er existing practice.
The stripped mouldss will be se
ent to the re
elocated mo
ould cooling
g yard # 2
oling.
for its coo
Each bog
ggy will ha
ave maximu
um three numbers
n
of moulds fo
or teeming
purpose.
Capacity of each boggy will be apprroximately 100t ingott carrying
capacity.
For one heat
h
teemin
ng (125t), tw
wo numberss of buggie
es are required.
Each rakke of bogie
es for teem
ming mould will be ha
aving mould
ds for two
heats.
Details of movements
s of ingot m
moulds for different te
eeming plattforms will
w:
be as below

i)

Teeming Platform # 2 & 3:


Empty
E
mould rake wiill be place
ed from in
ngot mould
d yard by
pushing from
m Blast Furnace side.
New
N
rail tracck # 301A will
w be laid down as sshown in the drawing
prior to dism
mantling of ttrack # 300
Rail
R track # 300 will be
e dismantled for consttruction of foundation
f
off proposed caster sho
op.
During
D
this period,
p
movvement of moulds
m
willl be through new rail
trrack # 301A
A.
After
A
comple
etion of foundation, ne
ew track # 3
300A will be laid at a
different loc
cation towards existing
g converto
or shop as shown in
th
he drawing..
Movement
M
of
o moulds will
w be through new raill track # 300A.
Rail
R track # 301A will b
be dismantle
ed for erecttion of equipments of
proposed ca
aster shop.
After
A
Teemin
ng, the rake
e with ingott will be pullled / evacu
uated from
Rolling
R
Mill side
s
as per existing practices.
Empty
E
moulld will be re
eturned to ingot moulld yard from
m stripper
ya
ard #1 thro
ough reloca
ated mould cooling ya
ard at trackk # 334 &
th
hrough new
w rail trackk # 334A, #333A,
#
#33
32A, #332B
B, #317B,
#317C and other
o
trackss as shown in the draw
wing.

ii)

g Platform # 4:
Teeming
Mould
M
rake will
w be placced from ing
got mould yyard by pus
shing from
Blast
B
Furnac
ce side as per
p existing
g practices.
After
A
Teemin
ng, the rake
e with ingott will be pullled / evacu
uated from
Blast
B
Furnac
ce side as per
p existing
g practices.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.26

Rake with ingot will be pulled / evacuated through track #310,


new track #310A, & # 301A during shut down of track #300.
After laying of new track #300A, movement of rakes will be
through track #300A.
Empty mould will be returned to ingot mould yard from stripper
yard #1 through relocated mould cooling yard at track # 334
through new rail track # 334A, #333A& 332A and other tracks as
shown in the drawing.
4.3.6.4

Details of movements of concast slabs from proposed caster shop will be


as below:

Concast slabs will be dispatched from dispatch bay of proposed


caster shop through new rail tracks# 326A, #332A, 333A, #317A
and existing tracks #317, #331, #332, #333, #323 etc.

4.3.6.5

All rail tracks in the area of proposed caster shop will be dismantled /
modified / relocated as per requirement as shown in the enclosed
drawing.

4.3.6.6

New rail tracks will be laid as shown in the enclosed drawing (NO. CET
RN 3498 CE0 00 005, R=3). All new rail tracks will be 60 kg/m along with
steel sleepers, necessary fixtures, ballast etc.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.27

4.4
4

ELECTRIC
E
CAL SYSTE
EM AND DR
RIVE AUTO
OMATION F
FOR
M
MODERNIS
SATION OF SMS-1 (S
STAGE-1)

4.4.1
4

P
Power
Req
quirement
The estima
T
ated powerr requireme
ent for Sta
age-1 mode
ernization of SMS-I,
B is as fo
BSL
ollows:
Stage-1 (fo
S
or new facilities like L
Ladle Furna
ace- 1 no.,, Single Strand Slab
C
Caster
1 no. and 1 no. BOF
F Converter with suppressed co
ombustion
s
system):

4.4.2
4

Peak
k Demand

51 MVA
M

Averrage Deman
nd

28 MVA
M

P
Present
po
ower distribution sys
stem
The presen
T
nt power demand
d
of Bokaro Ste
eel Plant (BSL)
(
is arround 350
M
MW.
It catters its pow
wer require
ement of 350 MW pa
artly through in-plant
c
captive
gen
neration (2x
x55MW + 1x12MW) frrom TPP, partly (3x60MW) from
B
BOKARO
P
POWER
SU
UPPLY CO LTD (BPSCL), a jointt venture co
ompany of
D
DVC
and SAIL
S
and re
est by impo
orting powe
er from DVC
C Chandrap
pura Grid.
P
Power
to ex
xisting SMS
S-I is being fed through 6RP subsstation.

4.4.3
4

P
Power
Distribution network
n
of the propos
sed moderrnization of
o SMS-I

4.4.3.1
4

S
Stage-I:
a
a)

Power supply to
o new Slab caster, BO
OF converte
er and its auxiliaries,
a
s
d combustiion system
m is propossed to be
Ladle furnace, suppressed
V from bay nos. 9 & 10
0 from MSD
DS-I.
tapped at 132 kV

b
b)

A new
w 132 kV GIS & 33
3 kV conv
ventional ssubstations with two
transfformers 50// 63 MVA, 132/ 33 kV
V, ONAN has been co
onsidered.
Ladle furnace tra
ansformer load
l
will be
e fed from tthis 33 kV HT
H Board.
er 33 kV po
ower throug
gh cables shall
s
be bro
ought near proposed
Furthe
BOF suppressed
d combustiion system. A new su
ubstation comprising
c
V transform
mer, bus ducts & HT
T board is
of 20 MVA 33 kV/ 6.6 kV
osed for catering 6.6 kV
V loads and
d LT substa
ations.
propo

c
c)

Doublle ended LT
L substatio
ons each with
w 2 MVA
A 6.6 / 0.41
15 kV dry
types of transfo
ormers and
d LT boards have b
been consiidered for
ent of Ladle
e Furnace and Slab Caster
C
and
catering LT loads requireme
aries.
auxilia

4.4.3.2
4

automation
S
Substation
n system ha
as been considered.

4.4.4
4

P
Power
facto
or compenssation has b
been considered.

4.4.5
4

Power disttribution sccheme envisaged at 132 kV, 33


P
3 kV and 6.6 kV is
i
indicated
in
n the enclossed Single Line Diagra
am, drg. no
o: CET RN 3498 EE1
0 001, R=
00
=1

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.28

4.4.6

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 shall be
based on the main consideration of simplicity, safety, reliability and ease of
operation & maintenance as well as convenience of future expansion.
The equipment shall 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.

4.4.7

Basic Design Criteria

4.4.7.1

The electrical system is proposed to be designed to suit the following


power system parameters:
Sl.No. Description
1.

HT
supply

Technical parameters

Power 132 kV(+/-)10%, 50 Hz(+/- 5%), 10000


MVA,
Solidly grounded system

2.

3.

4.

5.

HT
supply

Power 33kV(+/-)10%, 50 Hz(+/- 5%), 1800 MVA

HT
supply

Power 11kV(+/-)10%, 50 Hz(+/- 5%), 500 MVA

HT
supply

Power 6.6kV(+/-)10%, 50 Hz(+/- 5%), 450 MVA

LT
supply

Power 0.415kV(+/-)10%, 50 Hz(+/- 5%), 50 kA for


1 Sec

Solidly grounded system

Unearthed system

Unearthed system

Solidly earthed system

4.4.7.2

Power supply to various HT & LT Loads / load centres


1.

Motors rated above 200kW 6.6 kV, 3 ph, 50 Hz


and up to 4000kW

2.

Motor rated above 90kW 415V, 3 ph, 50 Hz


and up to 200kW Fed from
direct
Power
Control
Centres (PCCs)

3.

Motor rated up to 90 kW 415V, 3 ph, 50 Hz

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.29

feed from MCCs


4.

Illumination
power

5.

Control po
ower supp
ply AC 24
40 V, 1 ph, 50 Hz th
hrough
for LT sw
witchgear, MCC, co
ontrol transfformers
etc.

6.

Control po
ower supp
ply DC 22
20V DC through Battery
B
for HT switchgear
ba
ank

4.4.8
4

L Sub-Sta
LT
ation

4.4.8.1
4

T
Transform
mers

and

small 24
40 V, 1 ph. 50 Hz

LT substations comple
L
ete with double ended
d 2000kVA (max), 6.6 kV/ 433 V
p
power
distrribution tran
nsformers, power con
ntrol centress (PCCs) have
h
been
e
envisaged
for meetin
ng the pow
wer require
ements of Ladle furnace, Slab
C
Caster,
au
uxiliaries, EOT
E
crane
es, ACVS equipmen
nt, illumina
ation and
w
welding
ne
etwork worrkshop faciilities, wate
er facilities, etc. the proposed
p
power
transsformers sh
hall be dry type (AN), winding inssulation cla
assF and
s
shall
conform to IS: 20
026-2006.
4.4.8.2
4

6
6.6kV
HT Is
solators
6.6 kV, 630A load brreak type H
6
HT isolators
s at the prrimary side of power
t
transforme
rs are con
nsidered. F
Further, sto
op push bu
uttons shalll also be
p
provided
in each transsformer roo
om for tripping the brea
akers

4.4.8.3
4

L Bus duct
LT
Secondary side of transformers shall be co
S
onnected to
o the incom
mers of the
p
proposed
P
Power
Con
ntrol Centre
es (PCCs) by non ph
hase segre
egated LT
A
Aluminium
bus ducts of
o adequate
e rating.

4.4.8.4
4

P
Power
con
ntrol Centre
es (PCCs)
The 415 V switchboarrds shall co
T
omprise of air circuit b
breakers, in
n draw out
d
design
and
d multi tier formation.
f
hboard shalll have two incomers
The switch
a
and
one bus couplerr breaker w
with provisio
on for auto
o changeovver in the
e
event
of los
ss of powe
er on any o
one bus secction. The circuit
c
brea
akers shall
b electrica
be
ally operated and eq
quipped witth micropro
ocessor / static
s
type
d
direct
acting releases for over lo
oad and short circuit as
a well as earth
e
fault
p
protection,
l
and meters. Alll motor con
ntrol centress (MCCs),
indicating lamps
l
large
drives starter panel
p
(abovve 90Kw and up to 2
200 KW) and
a
power
d
distribution
boards (PDBs)
(
shall be sup
pplied pow
wer from the
t
415V
s
switchboard
d. The 415
5V switchge
ear shall confirm to IS
S-8623-200
08 and IS
13947-2004
4.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.30

4.4.9

Power Distribution Board (PDB)

4.4.9.1

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.

4.4.9.2

Roller table distribution boards are also considered for roller table motors
for different zones.

4.4.10

Shop Electrics and Automation


The electrical drives, controls and automation equipment, envisaged for
smooth and efficient operation of new units shall be of modern design and
with latest technology. The following major equipment has been
envisaged.

4.4.11

Auxiliaries & Utilities

4.4.11.1

The Squirrel cage induction motors above 200kW for auxiliaries system of
fixed speed are considered to be fed directly from 6.6kV level. 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 shall
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.

4.4.11.2

The squirrel cage induction motors equal or below 200kW is considered on


415V.

4.4.11.3

The squirrel cage induction motors below 110kW is considered with Direct
on line. Motors having VFD controller shall be inverter grade.

4.4.11.4

VFD motors shall be fitted with accessories such as base plate, pulse
tacho, PTCs etc. Space heater for motors above 75 KW shall be provided.

4.4.11.5

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 shall be provided with
thermistors & shall have min. 150 starts per hours. All motors of EOT
cranes are considered to be controlled by VFD and shall be inverter grade.

4.4.12

AC Drives for auxiliaries


IGBT based VVVF drives with sine coded PWM & vector control are
envisaged. These drives shall be with:

High response & control precision

Adaptable to actual supply frequency

Quick Fault localization

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.31

4.4.13
4

L
Ladle
Furn
nace

4.4.13.1
4

Power at 132
P
1
kV for the ladle ffurnace willl be tapped
d from the proposed
G
GIS.

4.4.13.2
4

ID fans mo
otors will be fed from 6.6 kV fee
eders. These motors will be of
DOL start type.
D

4.4.13.3
4

415V powe
4
er Supply: 6.6kV/ 433
3V transforrmer substa
ations one for Ladle
f
furnace
will be set up for the requ
uirement off 415V LT p
power supp
ply.

4.4.13.4
4

An indoor type powe


A
er factor (P
PF) compe
ensation eq
quipment to
o improve
p
power
facto
or to 0.9 is considered
d at 33kV voltage
v
levvel. The pow
wer factor
e
equipment
g of capacitor bank, airr cored seriies reactorss, isolator,
comprising
s
surge
arres
stors, disch
harge PT, bus bar syystem, neuttral CTs etc., will be
l
located
in the power fa
actor comp
pensator roo
om provided for the pu
urpose.

4.4.14
4

I
Intelligent
Motor Con
ntrol Centrres (MCCs))
The intellig
T
gent MCC
Cs are con
nsidered for
f
feeding
g power supply
s
for
c
controlling
the auxiliary drives of fixed-s
speed mecchanisms, drives of
u
utilities
& services
s
eq
quipment. E
Each MCC shall have
e one single
e incomer
w requisite no. of out-going feeders. MCC
with
CBs, power contactors, thermal
o
overload
re
elays, auxiliary relays,, meters, in
ndicating la
amps are considered
c
t be pro
to
ovided in MCC Elecctronic Motor protecttion relay shall be
c
considered
eater than equal
e
to 55
5KW. The MCC
M
shall
for motor ratings gre
b equippe
be
ed with Signal module
es, Microco
ontrollers an
nd profibuss interface
c
cards.

4.4.15
4

E
Emergency
y Power
Emergencyy power sha
E
all be tappe
ed from nea
arby TPP source at 6.6 kV level
a shall be fed as thiird section of the proposed 6.6 kV
and
V HT Board
d.

4.4.16
4

E
Electrics
of
o Miscellaneous item
ms
It is propos
sed that Hyydraulic power packs,, lubrication
n system, pumps
p
for
e
emulsion,
compresso
c
ditioning & ventilation
n system, equipment
e
rs, air cond
f mechan
for
nical & ele
ectrical wo
orkshop, wa
ater facilities system shall be
s
supplied
co
omplete with soft starte
ers, Vacuum
m contactors etc.

4.4.17
4

S
Sensors/
F
Field
Devic
ces and me
easuring devices
Field devices and sen
nsors like pulse encod
ders, proxim
mity switche
es, HMDs,
l
limit
switch
hes, level switches,
s
lo
oad cells, etc. as req
quired for feedback,
i
inter-lockin
g and sequ
uencing havve been con
nsidered.

4.4.18
4

C
Control
De
esk / Local control sttations (LC
CS)
A number of
o desks, LCB and pulpits are en
nvisaged for control off lines and
u
utilities.
Pulpit shall be
e structurall, aesthetically designed with fals
se ceiling,
f
false
floorss, decorativ
ve lighting a
and shall have
h
toughened glasss front. All
t pulpits shall be airr-conditione
the
ed. Desks shall
s
be floo
or mounted
d and shall
h
house
HMII PCs in additions to other conttrolling devvices. LCSss shall be

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.32

wall-mounted type and shall be used for local control of different


mechanisms, pumps, fans, etc.
4.4.19

Uninterrupted power supply (UPS)


Uninterrupted power supply (UPS) of required rating shall be provided in
different unit for supplying power to automation system (CPU), controllers
and in some cases important instrumentation. UPS shall be of digital type
with PWM technology based in IGBT. This shall be redundant type with a
provision to power change over through a static switch. The batteries
shall be of Lead acid type sealed maintenance free type along with battery
charger. Distribution board for distributing uninterrupted power supply is
also considered.

4.4.20

Basic automation
The basic automation i.e. 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
shall consist of all closed loop & open loop controls, regulatory controls,
logic & sequential controls, dialogue & display for operators, process
interface, alarm & extent registration etc.

4.4.21

Programmable Logic Controllers (PLC)


Programmable logic controllers (PLCs) are also envisaged for the
functional control of various auxiliaries like, water management, air
compressors, oil lubrication, roller tables etc. Wherever necessary remote
I/Os are envisaged to provided.

4.4.22

Human Machine Interface (HMI)


Visualization system shall be through PC based HMI terminals. These
have been envisaged for control & operation of plant. Different screens
shall be provided in these PC terminals showing different sections of the
plant and their status graphically. The graphic display shall be interactive
type. These screens shall be programmable through engineering stations.
The HMIs shall have process diagnostic system to provide status & fault
signals of the process along with process error display.

4.4.23

Cables

4.4.23.1

HT Power Cables

132 kV earthed grade, XLPE insulated armoured aluminium


conductor cables.

33 kV earthed grade, XLPE insulated armoured aluminium


conductor cables.

11/ 6.6 kV unearthed grade, XLPE insulated armoured


aluminium conductor cables.

HT power cables shall conform to IS: 7098.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.33

4.4.23.2
4

L Power Cables
LT
C
& Control Cablles
LT power cables for 415 V sysstem shall be heavy duty, 1.1 kV
L
k grade,
X
XLPE
insu
ulated PVC
C sheathed
d Aluminiu
um conducctor, armou
ured. The
c
control
cab
bles shall be
e multi stra
and copper conductor, XLPE insu
ulated and
P
PVC
sheatthed with minimum ccross sectiion of 2.5 sq. mm fo
or control
v
voltage
circcuit and 4.0
0 sq. mm fo
or power cirrcuit. The L
LT power and control
c
cable
shall confirm to IS-1554-19
988.

4.4.23.3
4

S
Special
cab
bles
Screened cables,
S
c
signal cables,, coaxial ca
ables, etc. are also considered
c
f the proje
for
ect.

4.4.23.4
4

C
Cabling
Power insiide the pla
P
ant shall b
be distributted through
h cables to
t various
p
premises
th
hrough RCC
C cable tun
nnels and th
hrough RCC cable tre
enches. GI
p
pipes/
hum
me pipes shall
s
be used
u
at ro
oad/ rail crrossings. Inside the
s
substations
s and coverred premise
es, the cables shall be
e laid in bassement or
i concrete
in
e trenches (over cable
e supporting
g structures/ cable tra
ays) or on
c
columns
an
nd other sttructures. P
Power cable
es shall be
e laid on la
adder type
t
trays,
wherreas control cable shall be laid on
n perforated
d cable trayys.

4.4.24
4

I
Illuminatio
on

4.4.24.1
4

For supply
y of variou
us illumina
ation loads
s in the ssub-station building,
p
provision
of Main lighting distribution boards (M
MLDBs) has
h
been
c
considered
ed in HT / LT substa
ation room
. These MLDBs shall be installe
a shall be fed from the 415 V switchboard
and
s
d. MLDBs shall
s
supplyy power to
t
the
various Lighting Distributio
on Boardss (LDBs) installed in
n various
b
buildings.
Further
F
the LDBs is considered
c
d
Su
ub-lighting
to supply different
D
Distribution
n Boards (S
SLDBs). Lig
ghting fixturres is considered to be
e fed from
S
SLDBs.
Illu
umination of
o all HT & L
LT substatiion building
gs cable ga
allery, new
r
room/
build
dings, casting bay, La
adle furnace
e area, bassements, if any have
b
been
considered.

4.4.24.2
4

The interna
T
al illuminatio
on of low ro
oof building
gs shall be with
w fluoresscent tube
l
light
fittings
s whereas for shopss as well as
a high ro
oof building
g shall be
i
illuminated
erever high colour ren
ndering is
with HPSV lamp fitttings. Whe
r
required
(lo
ow colour distortion) m
metal halide lamp fitting
gs shall be used. For
b
bay
illumin
nation High bay/ medium bay lig
ghting fixtu
ures are co
onsidered.
A
Average
illumination inside the
e shop bu
uilding sha
all be 100
0-150 lux,
h
however
the illumination level in contrrol rooms shall be 300 lux.
n in open yard and area illumination sha
all be provvided with
Illumination
HPSV flood
d light fittin
ngs. The avverage illum
mination levvel shall be
e 15 to 30
l for outd
lux
door illumin
nation. The
e use of en
nergy saving, high pow
wer factor
l
lamp
fitting
gs shall be
e preferred
d. The cod
de of pracctice for illlumination
s
system
is considered
c
as per IS: 3646.
3

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.34

4.4.25

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.

4.4.26

Air conditioning & ventilation system (ACVS)


Air conditioning and ventilation system for various electrical buildings and
control rooms have been considered.

4.4.27

Earthing

4.4.27.1

An outdoor protective earthing network for sub stations 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 shall 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.

4.4.27.2

A separate electronic earthing system shall be provided for the earthing of


electronic equipment such as PLCs & drives. Special earthing, Foundation
earthing if any, shall be as per suppliers practice / recommendation

4.4.28

Lightning Protection system


Lightning Protection system shall be provided for protection of plant and
equipment against lightning. The design of this system shall be as per IS:
2309-1969. The lightning masts / rings / down leads shall be connected to
earthing pits specifically provided for lightning protection.

4.4.29

Crane and Crane trolley lines/ electric hoists

4.4.29.1

Electrics of all EOT Cranes and electric hoists are considered. Electric
hoists are considered with all electrics including festoon cable
arrangement.

4.4.29.2

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.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.35

4.5
4

I
INSTRUME
ENTATION & AUTOM
MATION EQ
QUIPMENT
T & SYSTEM
M

4.5.1
4

BOF CONV
VERTER

4.5
5.1.1

Automation
n & Compu
uterization o
of BOF ste
eel making process will
w depend
mainly on execution of processs model so
oftware. Th
hese mode
els will be
f
a pro
ocess comp
puter, whicch will rece
eive on-line
e process
executed from
data from Basic Auto
omation (Le
evel-I) Syste
em. The Le
evel-I syste
em will get
ata from com
mputer com
mpatible ins
struments.
the field da

4.5
5.1.2

The proposed Computer System


m will be connected
c
with the Continuous
C
S
(CCS
S) Compute
er System
m and Prod
duction Planning &
Casting Shop
Control (PPC) Comp
puter Syste
em for closse coordina
ation betwe
een SMS,
PC. The Syystem will be working
g as a functional linkk between
CCS & PP
these depa
artments. The
T application softwa
are of variou
us models related to
BOF proc
cess will be
b running
g on the system in online real time
environment. All the Manageme
M
ent Informattion System
m (MIS) fun
nctions will
one from this
t
compu
uter system
m including
g printing of
o various
also be do
preformatte
ed reports.

4.5
5.1.3

To ensure maximum flexibility, reliability & availabilitty of the automation


a the tas
sks will be
e divided on hierarrchical bassis. Each
system, all
hierarchica
al level wiill be grou
uped in such a wa
ay that ind
dependent
operation of
o each sub system w
will be pos
ssible as we
ell as they will have
linkages in
n the form of data bu
us connections. The h
hierarchy consists
c
of
following le
evels:
System (B
Level - 1 : Basic Automation
A
BAS)) conssists of BA
AS, serial
interfaces, digital controlled drives, computter compatiible field instruments
f data acq
quisition, m
monitoring and
a control of the proce
ess.
& devices for
Level - 2 : Process Automation System consists o
of process computer
ainly for run
nning the p
process control mode
el software in on-line
system ma
mode. Levvel-2 compu
uter system
m will be su
uitably conn
nected with
h the shop
supervisoryy system and ERP sysstem for ovverall integration.

4.5
5.1.4

MODES OF OPERAT
TION
The autom
mation syste
em will have
e following mode of op
peration:
i) Comp
puter Autom
matic Mode
ii) Semi Automatic Mode
iii) Manua
al Mode
iv) Local Mode

4.5
5.1.4.1

Automatic
C
Computer
c Mode
In this mod
de of opera
ation, the ccomputer, BAS
B
and m
microprocesssor based
instrumentation syste
em are fullyy functional and data link
l
betwee
en them is
he set poin
nts of loop parameters
s as requirred for eac
ch blowing
healthy. Th
programme
e of the converter willl be sent to
o the BAS bus via the
e interface

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.36

link from process computer system. The HMI will display pages at the
process computer level for the parameters under the computer mode. The
other operation of automatic control and data acquisition will be
independently carried out by the instrumentation system and all the data
in the bus (BAS) will be transmitted to the process computer as per predecided protocol.
4.5.1.4.2

Semi Automatic Mode


This mode of operation will be resorted to, in case of failure of link
between the process computer system and the BAS. However, during the
mode both the process computer & the BAS will be fully operational. The
predicted set points of each parameter for the blowing programme will be
displayed on the HMI of the process computer put up on the blower desk
and the required status & the value of the parameters will be transmitted
to the computer using the key board of the CRT. Other operations will be
identical to those indicated under computer auto mode. OFF LINE
computer models will be working in advisory mode.

4.5.1.4.3

Manual Mode
This mode of operation will be employed in case of failure of the BAS or
communication system bus. It will be effective when a particular or a
group of drives/loops cannot be controlled in the semiautomatic mode.
The operation will be carried out from operator desk and the relevant data
will be keyed & single loop controllers will be used for controlling the
process.

4.5.1.4.4

Local Mode
It is used mainly for the maintenance purpose. Local stations will be
provided at field i.e. near the equipment for testing of individual equipment
without interlock.

4.5.1.5

Proposed system

4.5.1.5.1

Control & Instrumentation System


The proposed control & instrumentation system will be based on
hierarchical distributed control philosophy. It will be designed based on
open architecture configuration for effective control and monitoring of the
plant process. The system will be integrated with various sub-systems and
high level process control computer. The control functions will be carried
out through single loop stand-alone controllers. The critical process
parameters will also be displayed on back up instrument panel beside the
display on CRT screen.

4.5.1.5.1.1

The proposed instrumentation system shall tentatively comprise of the


measurements/control of following process parameters :
A. Common Measurement
i)

CO gas flow & pressure at header

ii)

Combustion air flow and pressure in header

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.37

iii)

Main
M
line Oxxygen presssure measu
urement

iv)

Lance coolin
ng & stackk cooling pu
ump house
e: Suction & delivery
elivery flow & temperatture
pressure, de

v)

nstrumentattion & contrrol system for


f all the H
Heating sysstems
In

B. Conve
erter
i)

Oxygen
O
line
e pressure & flow measuremen
nt to both lances of
each converrter

ii)

nlet oxygen flow contro


ol
In

iii)

Drain
D
water pressure and tempera
ature measurement for GCP.

iv)

Cooling
C
water flow, pre
essure & te
emperature
e measurem
ment (both
in
nlet & outlett of lance co
ooling syste
em) / Stackk cooling syystem

v)

Liquid steel temperaturre measurement

vi)

Converter
C
po
osition

vii)

Lance position

viii)

Level of Inte
ermediate b
bunker

ix)

Charging
C
system interlo
ocks

x)

In
ndication to
o be duplica
ated on blo
ower desk for
f H2, O2, CO, CO2,
% & N2 presssure

xi)

Total
T
oxygen
n flow

xii)

Blow
B
time

xiii)

N2
N flow mete
er for purging & slag splashing
s

xiv)

nt of stack temperaturre
Measureme
M

xv)

Differential
D
water
w
flow m
measureme
ent of lance
e inlet & ou
utlet water
co
ooling syste
em

xvi)

Crane
C
weigh
hing system
m for hot me
etal chargin
ng cranes

C.GCP
i)

Stack
S
tempe
erature mea
asurement

ii)

Gas
G
analyze
er system for the analysis of O
O2, CO & N2 in the
co
onverter ga
as output affter the stacck of a convverter

iii)

Suction
S
conttrol before IID fan

iv)

Cooling
C
wate
er level in sstack seal

v)

Water
W
level for
f both cha
ambers

vi)

Waste
W
gas flow measurement

vii)

ID
D fan bypas
ss flow conttrol

viii)

Gas
G analysiss after ID fa
an

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.38

ix)

Water level in change over valve bottom

x)

Nitrogen pressure (alarm) to flare stack

xi)

Soft water tank level measurement & control with alarm in


emergency tank & pump house sump

xii)

Stack cooling system comprising of stack water flow, skirt water


flow, main water flow & Tubular water flow

xiii)

Skirt pressure control

D.BOF Gas Holder


i)

BOF gas analysis

ii)

Booster fan suction & discharge pressure control

iii)

The measurement of gas holder pressure, level and export gas


flow & pressure and U-seal level interlocking

iv)

BF gas network pressure at the point of mixing

v)

Instrumentation & control for Electro Static Precipitator

E. Following facilities will also be provided in the BAS:

4.5.1.6

Digital lance height measurement and recording

Recording of charges into the converter heat-wise and daywise Bulk materials & Ferro alloy addition

Logging/Interfacing of hot metal weighing & scrap weighing

Logging of hot metal temperature

Logging of molten metal temperature

Process Computer System


The Process Computer System will be used for executing process
control model software in real time environment. The system will also
be used for on-line MIS functions, i.e. screen displays, report
generation, colour graphic displays etc. The Computer system will be
connected with Basic Automation System (BAS) for receiving field data
and downloading the set points in on-line mode..
The proposed computer system will be connected with various
terminals/PCs and printers placed at different units of SMS operation.
The terminals/PCs will be used for data entry and on-line status
displays. The printers will be used for report printing in both local and
global mode. The data-base of whole SMS will be maintained centrally
on the computer. The laboratory information will be made available to
the computer system by establishing direct communication or by
entering data through a terminal.
Provision will be kept for connecting the proposed computer system
with the continuous casting shop computer and PPC Computer.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.39

4.5.1.7
4

PC base
ed Termina
als

4.5.1.8
4

4.5.1.9
4

De
esktop PC based term
minals will be
b used at various loc
cations for
on
n line data entry
e
and display of prrocess para
ameters.

Periphe
erals

Do
ot matrix prrinters

Co
olour Inkjet printer

La
aserJet prin
nter

Processs Control Mo
odels
The stan
nd alone co
ombined blo
owing syste
em has alre
eady been envisaged
e
for imple
emented in
n both the cconverters. The propo
osed process control
models will be havving provissions to wo
ork in eithe
er mode, i.e. with or
c
b
blowing
sysstem in operation.
without combined
The main aim of prrocess conttrol models are :
(I)

To
T attain the steel ttemperature
e at the time of ta
apping as
accurately as
a possible.

(ii)

To
T achieve
e the metallurgical composition of the steel as
accurately as
a possible.

(iii)

To
T optimize
e the cost o
of input feed
d stock.

Followin
ng BOF con
ntrol modelss are envisa
aged:
4.5.1.9.1
4

Static model for cha


arge calculation
The model computes the am
mounts of hot
h metal, scrap, flux additions
gen to be re
equired for a heat.
and oxyg
The inputs require
ed for charrge calcula
ation are as follows:
- compo
osition and temperature of hot metal
- requirred weight of
o different kind of scra
ap
-

ta
arget tempe
erature and
d carbon content at end
d point

- targett heat weigh


ht
Outputs
s of this mo
odel are:
- weight of scrap to be charge
ed
- weight of hot metal to be ch
harged
- weight of flux and
d additives
- Fe-allo
oy addition
4.5.1.9.2
4

Blowing pattern mo
odel
Once th
he charging
g of scrap and hot metal
m
is co
ompleted and
a
exact
details of
o the charrge are avvailable, the
e amounts of coolantts, fluxes,
oxygen and
a blowing
g period ca
an be prediccted more a
accurately.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.40

The input of this model are:


- Actual weight, composition and temperature of hot metal
- Target temperature and carbon content at end point
- Oxygen flow rate
- Target heat weight
Outputs of this model will be :
- Amount of oxygen
- Weight of fluxes
- Heat weight at end point
- Manganese content of the steel and iron content of slag at end point
- Prediction for intermediate stop in terms of M3 of oxygen blown from
start of blowing
- Oxygen lance height
4.5.1.9.3

Dynamic process control model


The dynamic process control model improves the hitting rate for carbon
and temperature of oxygen steel making process. The model uses the
intermediate stop measurement values (bath temperature and carbon
content)or waste gas analysis data ( % CO, % CO2, % H2, %O2 ) at
exhaust gas rate as additional input data and controls the steel making
operation to reach the target values of carbon content and steel
temperature at the end of blowing cycle. The dynamic model uses
following control strategy:
Blowing is interrupted in the final stage of the process and the converter
is tilted, after which the steel composition and temperature are
measured. The established carbon content and temperature are input
data for the second blow calculation of the process model, and the
outcome of this calculation is used to carry out the second blow. This is
known as intermediate stop practice.

4.5.1.9.4

Alloy addition model


The model determines the optimum alloy mix to be added to the steel
ladle during tapping. For this purpose, it matches the final steel analysis
with the target figures and consider all combinations of alloying
materials available in the melt shop for achieving the target. The main
element of the alloying material is used for this calculation and total deoxidation during tapping is assumed. A simple algorithm is used to
determine the optimum flux.
The model additionally computes the temperature loss due to alloying
materials.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.41

4.5.1.9.5
4

Model fo
or carbon te
emperature
e curve
The inpu
uts of the model
m
are:
- Actual values / additives
- Actual values / oxygen
m
analyssis
- Hot metal
- Hot metal
m
temperature
- Opera
ating instrucction
- Hot metal
m
weightt
- Steel temperaturre (intermed
diate stop)
- Steel carbon (intermediate sstop)
del are:
Outputs of this mod
- Steel carbon
- Steel temperaturre

4.5.1.9.6
4

Model fo
or extrapola
ation of the tapping analysis calcu
ulation
This calculation ca
an be perfo
ormed in eitther quick ttap mode ( using an
nt measurement ) or in
n a Direct ta
ap mode ( w
without app
plication of
end poin
an end point
p
measu
urement )
Inputs off this mode
el are:
- Analyyzed compo
osition of the intermediate stop sa
ample
- Actual weight of converter additions
a
- Actual amount off oxygen blown
- Measured temperature and carbon content
c
( in
n case of quick tap
e)
mode
Outputs of this mod
del are:
- Estima
ated bath composition
c
n
- Estima
ated tempe
erature

4.5.1.9.7
4

Model fo
or Steel Batth level calcculation
Conside
ering the hot
h
metal and scrap
p weight a
and the liffe of the
converte
er, the steel bath levell is calculatted for each
h heat by th
his model.
Lance height
h
should be ad
djusted eve
ery shift based on bath
b
level
measure
ement afterr charging o
of a known quantity of hot metal.

4.5.1.9.8
4

Model to
o take care of emergen
ncy situatio
on during blowing operration

4.5.1.9.9
4

Model on
n tracking of
o ladles:
The pro
ocess comp
puter syste
em will recceive the messages of actual
status of
o ladle trreated in the variou
us facilitiess through computer

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.42

terminals located in those locations of ladle tracking area. The locations


include:
i)

Ladle treated in maintenance area

ii) Ladles handled by cranes/cars


iii) Evaluation of ladle turn around
iv) Evaluation of ladle age
The status of the ladles in the maintenance area as well as in the
production cycle will be displayed to the BOF ladle dispatcher. The BOF
ladle dispatcher will coordinate the handling of the ladles by cranes &
cars and will assign ladles for a certain heat using the information for
heat & ladle tracking.
4.5.2

SLAB CASTER

4.5.2.1

The following Levels shall form the hierarchical control system of Slab
caster:
Level-0: Instrumentation system consisting of primary sensing elements,
transmitters, converters, gauges, panel instruments, final control elements
etc.
Level-1: Basic Automation System consisting of Programmable logic
controllers (PLCs) complete with operator consoles, engineering stations /
programming terminals, printers etc. The tasks to be carried out by Level-1
system shall be as follows:

Sequence and Logic control of drives,

Feed back and feed forward control of process parameters,

Loop optimization and set point control,

Data acquisition,

Report generation and event logging,

On-line graphical display,

The combination of "Level-0" & "Level-1" equipment shall be capable of


operating, controlling and monitoring the complete process of slab caster.
The set points of various process parameters shall be provided by the
operator or from Level-2 system.
Level-2: The associated software with appropriate hardware like Process
control computer, peripherals, printers shall be associated as part of Level2 Automation with the proposed schemes. Further, the proposed
automation shall be hooked up with the BOF Network through network
switch, patch panel etc.
The tasks to be carried out by Level-2 system shall be as follows:
BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.43

4.5.2.2
4

Execution of Process model software

Data re
eceipt/transsmit from/to Level-1 syystem

Data lo
ogging

Genera
ation of MIS
S Reports a
and Graphiccs

C
Control
& Measurem
ment

4.5.2.2.1
4
The basic functions of Controll & Instrum
T
mentation system shall be as
f
follows:

Monitoring and control


c
of p
process pa
arameters a
as per tech
hnological
ement.
require

Events & Report generation.


g

4.5.2.2.2
4
The
T Controll & measure
ement shalll be provide
ed for the fo
ollowing:

Break Out
O Predicttion System
m (BOPS). :
It is prroposed to run the BO
OPS Mode
el at Level--II Compute
er System
with th
he advice/su
uggestions to be adop
pted by the
e operator. In case of
predicttion of posssible breakkout, and with
w the advvice of BOP
PS Model,
operattor would either advise
e to stop th
he casting or
o reduce th
he casting
speed.

Automa
atic Mould Level
L
Contrrol (AMLC) system

Mould Cooling
C
System

Machin
ne Cooling / Roll Cooling System :

Second
dary Cooling System
Secondary Cooling System
m shall be based on Model which would
of air / misst after taking into acccount the
predictt the flow and ratio o
target Casting Sp
peed etc.

Continu
uous tempe
erature mea
asurement in Tundish

Temperature mea
asurement in Tundish with
w dispossable tips

Torch Cutting
C
macchine
All the necessary instrumentss shall be provided.
p

4.5.2.2.3
4
List of mea
L
asurementt:
T
Though,
me
easuremen
nt for the prrocess para
ameters havve been listted below,
t
these
are in
ndicative
1) Mould:

Flo
ow measurrement and
d control for
f
mould cooling water
w
(soft
water)

Inle
et and outle
et temperatture measurement for mould coo
oling water
(so
oft water)

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.44

Pressure measurement of mould cooling water (soft water) with


low pressure alarm

Break Out Prediction System

2) Secondary cooling circuit:

Flow measurement & control of secondary cooling water


(Industrial water) in branch line.

Pressure measurement of secondary cooling water (Industrial


water) in main line.

Temperature measurement of secondary cooling water (Industrial


water) in main line.

Mist air pressure control.

Mist air flow control.

Differential pressure measurement across Heat exchanger

3) Closed circuit machine cooling:

Flow measurement of machine cooling water (soft water) in main


supply header.

Local pressure and temperature gauges on up-stream and


downstream of pumps (except drain pit pump), heat exchangers

Differential pressure measurement across Heat exchanger

4) Torch cutting station:

Pressure measurement and control of Propane.

Flow measurement of Propane.

Pressure measurement and control of Oxygen.

Flow measurement of Oxygen.

Suitable slab length measurement system

4.5.2.2.4 Level-2 Automation System


Following Process Models shall be implemented on Level-2 Process
Computer System:
4.5.2.2.4.1

Secondary Cooling Model

Air Mist cooling system is proposed in the secondary cooling zone. This
will be controlled by a cooling control model. The purpose is to maintain
the strand surface temperature at predefined levels during the casting
process. The temperature is controlled by adjusting the water flow through
the tuyer and the compressed air. The set point of air/mist control system
shall depend on the casting speed and section size of the slab. This will
BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.45

ffacilitate th
he caster to
o produce the
t
improved surface quality of the slabs
u
under
flexib
ble casting conditions..
4.5.2.2.4.2
4

Breakkout Predicttion System


m
A Break out
o prediction system
m shall be
e provided to predictt possible
breakout co
onditions in
n the mould. It shall co
onsist of the
ermocouple
es inserted
around
a
the mould surffaces for m
measuremen
nt of the tem
mperature gradients.
on in temperature pro
ofile, the m
model will predict
p
the
Based on the variatio
abnormal
a
conditions
c
ould during
g casting. Suitable alarm
a
and
in the mo
annunciatio
a
on shall be provided. Based on the prediction of brea
ak out, the
corrective
c
action
a
shall be taken b
by the opera
ator.

4.5.2.2.4.3
4

Cut le
ength optimisation mod
del

4.5.2.2.4.4
4

Qualitty assurancce model

4.5.2.2.4.4
4

Simula
ation mode
el

4.5.3
4

L
LADLE
FURNACE

4.5.3.1
4

The
T
propossed Instrumentation & Control system shall be based
b
on
hierarchical
h
hilosophy with
w
direct process control func
ctions and
control ph
process
p
su
upervision distributed at differe
ent level as
a per the
e process
requiremen
r
t.
The
T subsys
stems in ea
ach hierarch
hical level shall
s
be gro
ouped in su
uch a way
that indepe
endent ope
eration of each sub system is possible. The sub
systems
s
sha
all be connected throu
ugh high-sp
peed data communicat
c
tions bus.
The
T
instrum
mentation system sh
hall be co
omplete witth field instruments
consisting
c
ance temp
perature sensors, pressure trransmitter,
of resista
pressure/flo
p
ow switche
es, level transmitters/switches,, electronic hopper
weighing
w
syystem, PH measurement etc and
d microproccessor base
ed molten
steel
s
tempe
erature mea
asurement system. A common P
PLC shall be
e used for
handling
h
the
e inputs/outtputs of botth electricall and instrumentation systems.
s
Itt is envisag
ged to provvide follow
wing measurement and
d control fo
or smooth
functioning
f
of Ladle he
eating furna
ace:

4.5.3.1.1
4
action Syste
em
Fume Extra
-

Temperrature indica
ation and ccontrol by re
egulating diilution air da
amper.
Temperrature measurement w
with high alarm
a
at th
he inlet of Bag filter.
The tem
mperature signal sha
all be use
ed for ope
eration of safety air
damperr.
Differen
ntial pressure measure
ement with alarm across bag filter.
Suction measurem
ment and co
ontrol throug
gh fan air damper.
d

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.46

ID fan bearing and winding temperature measurement.


Vibration monitoring

4.5.3.1.2 Inert gas (Nitrogen / Argon) Stirring System


-

Pressure measurement (local indication) with low pressure alarm both


at Nitrogen inlet and delivery points.
Nitrogen pressure control through self actuated type control valve.
Flow measurement and control with totaliser.

4.5.3.1.3 Cooling Water System (both for industrial and soft water plant)
-

Pressure measurement (local) at delivery of all pumps


High and low level alarm at emergency overhead water tank
Level switches for all sumps.
Temperature measurement (local) at the common water header
Pressure measurement with low alarm at the common water header
Temperature measurement with high alarm at the outlet of each branch
line.
Flow switch with low alarm at the outlet of each branch line.
Differential pressure switches across strainers/filters/Heat exchangers.
Flow measurement as per requirement.
PH measurement at the outlet of soft water plant.

4.5.3.1.4 Temperature Measurement and Sampling System


The system shall be used for sampling and measurement of temperature
of the molten metal. The measuring lance shall be suitable for two-in-one
type disposable tip for temperature measurement and sampling in single
stroke. The system shall be complete with immersion lance, measuring
cable, traffic light, large display, horn and related electronics.
4.5.3.1.5 Hopper Weighing System
Load cell based hopper weighing system shall be provided with indication
in the control room
4.5.3.2

Level-2 Automation System


It is proposed to provide Level-2 Automation System for computerized
process control, generation of set points, process tracking, generation of
MIS reports etc.
The system shall be provided with a Computer Server, which shall be
used for receipt of process data from the Level-I system, running of

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.47

process co
p
ontrol mode
el software, provision of
o operator interface in
n the form
o on-line graphical
of
g
dissplays, report generattion etc.
Following process
p
mo
odels shall b
be provided
d:
-

Alloying
g model
Therma
al model
Dynamic model
Deoxida
ation model
Desulph
hurisation model
m
Adaptattion model

The propossed Level-2


T
2 computerr system sh
hall be connected with
h operator
i
interface
sy
ystem (PC), developm
mental system (PC), Level-1 sy
ystem and
BOF comp
puter system
m through a local are
ea network using UTP
P or Fibre
o
optic
cable as per the requiremen
nt.
4.5.3.3
4

Modes of Operation
O
Depending on the availability
a
er system and healtthiness of
of compute
communica
c
ation links, the Ladle ffurnace sha
all be opera
ated in follo
owing two
modes:

Computer mode
e
In th
his mode off operation, all the sett points sha
all be gene
erated and
dow
wnloaded by Level-2 computer system
s
and accordingly, other
actio
ons shall be
e taken up by Level-1 system.

Auto
omatic mod
de
This
s mode of operation shall be ussed when the compu
uter is not
avaiilable or the operator has not se
elected the
e computer mode. In
this mode of operation,
o
t
the
Ladle furnace
f
shall be operated and
m Level-1 syystem.
conttrolled from

4.5.3.4
4

Fire Detection & Alarrm System


m
Microproce
M
essor based
d Fire Detection and Alarm
A
Syste
em shall be
e provided
i control room,
in
r
electrrical roomss and hydra
aulic room. The main fire alarm
p
panel
shalll be installe
ed at location, which is normallyy manned round the
c
clock.

4.5.3.5
4

T
Telecomm
unication System

4.5.3.5.1
4
P
Press
to tallk system
A press to talk based
d loud spe
eaker comm
munication system off requisite
points
p
shall be provide
ed in propossed LF area
a.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.48

4.5.3.5.2 Plant Telephone System


Requisite nos. of plant telephone connection including telephone sets shall
be provided in proposed LF area. Required cabling from nearest DP box of
plant telephone network shall also be included.
4.5.3.6

Propane Supply
i)

Inlet & outlet flow & pressure to Pump

ii)

Outlet pressure & flow from vaporisers

4.6

UTLITIES & SERVICES

4.6.1

Gas Cleaning & Recovery System


The production of steel in the BOF converter releases fumes rich in
Carbon monoxide laden with a significant amount of dust with high
temperature. In order to utilize the calorific value of the gas and to
suppress air pollution, each converter is to be fitted with a Gas Cleaning
Plant which will collect and treat the released fumes called BOF gas, for
further utilisation in the steel plant. In the Gas Cleaning Plant (GCP), hot
gases will be collected above the converter mouth using suppressed
combustion system, cooled through a hood and cleaned at a scrubbing
installation and either recovered in a gas holder or let out to the
atmosphere after combustion in a flare stack. The Gas Cleaning Plant will
achieve the collection of gas without complete combustion by means of
automatic adjustment of the suction rate to the flow rate of gas produced
by blowing, periodically throughout the entire sequence of operation. The
BOF gas is generated during blowing period only.

4.6.1.1

BOF Gas Cleaning Plant


The hot and dust laden gases leaving the BOF converters (called BOF
gas) are collected largely un-burnt with the help of an adjustable (raising &
lowering) skirt ring arranged between the cooling stack & converter mouth.
Skirt and cooling stack will be cooled by soft water to bring down the
temperature of the gases to about 1000oC. Then these gases are cooled
further and at the same time, cleaned by a two stage venturi scrubbers.
The non-combustion control of the system is achieved by controlling the
gas pressure in the hood by means of throat dampers in the secondary
venturi of the two stage scrubbers. Dust content in the gases will be
reduced to less than 100 mg/Nm3.

4.6.1.2

The cleaned BOF gases shall be exported to a gas holder (50,000 m3


volume) or flared through a flare stack by means of a three way valve.
Flaring / export of gas will be carried out depending upon the operational
regime of the plant. The gas recovered in to the holder will be further

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.49

3
ccleaned (from 100 mg/Nm
m
to
o less than 5 mg/Nm3) in Ele
ectrostatic
P
Precipitator
rs (ESP). The final cleaned gases will be boosted
d by gas
b
boosters
be
efore conne
ecting to exxisting BF gas
g mains.

4.6.1.3
4

Indirect Ga
as Cooling System
S
Indirect coo
oling of the
e converterr gas will be
b achieved
d by passin
ng the hot
g
gas
throug
gh a close
ed loop hiigh pressu
ure Soft w
water based
d ducting
c
consisting
of
o skirt, hoo
od & stack.
In the proposed indirect coolin
ng system, heat remo
oval is ach
hieved by
m
means
of concurrent
c
circulation of pressurrized waterr in the tub
bes of the
w
water
coole
ed mainten
nance skirtt, hood & stack.
s
There will be 3 nos. of
c
circulation
water
w
pump
ps (2 working + one sttandby) to provide circculation of
c
cooling
watter in the cllosed loop. The circula
ating waterr will be disttributed to
t
the
skirt, hood & sttack throug
gh variouss branch liines from the main
h
headers.
Hot
H water from various cooling zones will be collected in a
c
common
re
eturn water header. Frrom this he
eader, hot w
water will be
e taken to
a set of fivve fan air cooler
c
consisting of 4 identical ce
ells. Norma
ally all the
f
five
cells will
w be in op
peration and
d, if require
ed, one celll can be is
solated for
m
maintenanc
ce purpose
e. The cellss in operatio
on will be a
automatically started
a the beginning of oxxygen blow
at
wing and sto
opped whe
en the air cooler inlet
w
water
temp
perature is below a fixed set poin
nt. The cooling water from
f
each
c will be
cell
e collected in a heade
er, which will
w be connected to the pump
f
function.
Th
he cooling water will be pumped
d for furthe
er recirculattion in the
c
closed
loop
p.

4.6.1.4
4

An expanssion vessell will be in


A
nstalled on the coolin
ng water return
r
line
d
downstream
m the air cooler
c
and pressurise
ed with nitrogen. The
e nitrogen
p
pressurisat
tion ensurin
ng the allow
wable pres
ssure fluctu
uation of clo
osed loop
d
deciding
the heating and
a cooling cycle.

4.6.1.5
4

A make up water stora


age tank off adequate capacity w
will be provid
ded in the
s
system.
Th
he makeup
p water hig
gh pressurre pumps ( 1 workin
ng + one
s
standby)
w be installed for inje
will
ection of So
oft water in
n the closed loop for
i
initial
filling
g or for compensatin
ng the lossses. Make
e up supply will be
a
automatica
ally carried out throug
gh good in
ndication and control from the
tank. Similarly, filling of makeup water sto
e
expansion
orage tank with Soft
lly carried
w
water
tappe
ed from the
e existing headers
h
wiill also be automatica
a
o the mak
out
keup waterr tank level.

4.6.1.6
4

D
Direct
gas Cooling
C
& Cleaning
C
Syystem
After indirect cooling of
A
o the converter gas to
o a tempera
ature of abo
out 900 to
o
1000 C at the stack exit, the ho
ot gas will be further cooled dow
wn to 607 oC in gass cooling & cleaning syystem. Thiss cooling is achieved by
70
b a direct
c
contact
gass cooling system.
s
The
e contamin
nated gas w
will be clea
aned by a
w type cle
wet
eaning systtem consistting of two stage ventu
uri scrubbers.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.50

The hot gas stream leaving the water cooled membrane and stack will be
firstly quenched and saturated by injection of industrial quality of water at a
flow rate in the range of 350-400 m3/h water injection will be carried out by
a number of spray nozzles, equally distributed in the gas stream. The gas
is cooled to approximately 70 oC in the primary scrubber.
The cooled and partially cleaned gas will enter secondary scrubber at high
speed through adjustable throat of the venturi. On encountering the water,
the gas forms a mist of very fine droplets which capture dust particles The
water required in the scrubber is about 400 m3/h. at 2 kg/cm2 near the
throat partition. The outlet of secondary venturi will be re-circulated to
primary venturi, by means of pumps, with secondary venturi getting the
direct supply from the pump house.
The cleaned gases are discharged by an ID fan through a 3-way valve
either to flare stack or to gas holder for recovery. The ID fan will be
provided with fluid coupling to take care of fluctuating loads.
4.6.1.7

Gas Recovery
After the 3-way valve, in the gas holder direction, gas goes through a
safety hydraulic non return valve. A common collector carries the gas in to
the gas holder of 50,000 m3 capacity. The gas from the holder will be
cleaned in ESPs. Finally gas is exported to main fuel network by means of
gas booster. The gas holder will be of dry fabric seal type.
The ESPs (1 working and 1 standby) will be of wet, tubular type. Capacity
of each will be 40,000 m3/h. Two boosters (1 working + 1 standby) each of
capacity 40,000 m3/h will be installed.

4.6.1.8

Slurry Treatment Facilities

4.6.1.8.1 Contaminated water from gas cleaning plant will be received in the existing
slurry launder and transported to Sludge Pond compartment near BOO
oxygen Plant and then it will go to Cooling Pond-1 under gravity through
existing route. The existing launders will be able to handle the slurry
generated from New BOF.
4.6.2

Water System
The water system envisaged for SMS-1 modernization will be re-circulating
type for Lance cooling, Hood cooling, machine cooling and spray cooling..
All major units will have their own water circulation system. Only make-up
water will be supplied to these units from the proposed make up water
system. The shops circulating water system will be designed for
minimum/zero water discharge. Recirculation system for new units shall
consist of pumps, filters, heat exchangers, chemical dozing, cooling tower,
pipes, valves, fittings etc. Existing system for recirculation of slurry water
system from GCP shall be utilized for modernized plant also as increase in
slurry water is not envisaged technologically. High pressure water for GCP

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.51

will
w be tapp
ped from exxisting header near SMS-1.
S
One
e new line of DN300
shall
s
be provided
p
f
from
Pump
p house No.4 to S
SMS-1 to facilitate
replacemen
r
nt of existing
g GCP water lines in future.
f
4.6.2.1
4

Source
S
of Make-up
M
Wa
ater
Make
M
up water
w
for ex
xpansion plant shall be
b drawn from
f
existin
ng cooling
water
w
syste
em of SMS
S-1. The present con
nsumption o
of SMS-1 is around
4500
4
m3/h. The make
eup water ffor modern
nized SMS--1 complex
x including
3
new
n
caster,, ESP and Rolling Milll will be arround 1100
0 m exclud
ding water
for
f
GCP. Recirculatio
R
on water for
f
new GCP
G
and make up water for
modernized
m
d SMS-1 shall be tap
pped from existing ccooling watter supply
system
s
of SMS-1.
S
Ma
ake up watter will be tapped from
m ND400 water
w
line
near
n
SMS-1
1.

4.6.2.2
4

Measuring
M
facilities
f
will be provid
ded at each
h taping points to mon
nitor water
consumptio
c
on of respecctive shops.

4.6.2.3
4

The
T
water system
s
sha
all be fully automatic with PLC. However, facility for
lo
ocal start/stop shall also be provvided for ea
ach individu
ual drive. The control
scheme
s
sha
all be such that human interventiion will be limited to filling up of
chemicals;
c
l
lubricants
a attendin
and
ng to sched
duled/ break down ma
aintenance
work.
w
Under normal op
peration all water syste
em equipment shall work
w
based
on
o process feed backss received ffrom field in
nstruments.
All
A pumps and pipe lines will be provid
ded with corrosion protection
coatings,
c
wh
herever req
quired.
Extension
E
of
o AB bay of
o SMS-I to match with
h the new la
ayout of con
nventional
caster
c
is envisaged. Rerouting of industria
al and process waterr line has
been
b
envisa
aged accord
dingly.

4.6.2.4
4

Proposed
P
Cooling
C
water Flow Dia
agram for CCM
C
& Lad
dle Furnace
e and BOF
(Suppresse
ed combusttion & Lancce cooling)) are shown
n in Drgs Nos.
N
CET
RN
R 3498 UT0 00 001,
0
R=0 and
a
CET RN 3498 UT0 00 002,
0
R=0
respectively
r
y.

4.6.3
4

Oxygen,
O
Niitrogen / Argon
A
Facillities
Since
S
the production of
o liquid steel will rema
ain same Oxygen,
O
Nitrrogen and
Argon
A
requiirement to be
b used in SMS-1 for various
v
me
etallurgical processes
p
will
w not cha
ange. How
wever there
e may be some cha
anges in flow rates.
Approximat
A
e requirement in gene
eral is given
n below:
Sl No Utilities

Quantity ( Nm3/hr)

Purity %

1.

Oxygen

14000

>99.5

2.

Nitrogen

10000

99.9998
8

3.

Argon

200

99.9995
5

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.52

To meet above requirement following facilities are envisaged:


4.6.3.1

Oxygen, Nitrogen and Argon Supply System


The present Oxygen, Nitrogen & Argon supply system will continue to
supply gases to the shop. New pipeline shall be provided within the
shop and rerouted/modified suitably during modernisation. New
pipelines will be laid first and interconnection will be done during two
days shutdown of SMS-I.

4.6.4

BOF gas Generation & Supply

4.6.4.1

Upgraded SMS-I will generate around 32,227 Nm3/h of BOF gas. This
gas will be cleaned in GCP and will be received in a BOF gas holder of
50,000 m3 capacity. From gas holder this gas will be further boosted to
distribution network pressure and mixed to BF gas network at suitable
location: Boosters of 40,000 Nm3/h (1W+1S) with delivery pressure of
1200 mmWC shall be provided for this purpose.
1 no. Flare stack will be provided with auto ignition and flaring facility as
a safety requirement.

4.6.4.2

Design Aspect of Gas network


Safety aspect will be the first consideration while designing the gas
network and gas facilities. Isolation facilities for 100% isolation such as
water seal, blank flange and isolation valve shall be provided for each
consumer. Drain pots, nitrogen/steam purging system, vents etc shall
be provided at suitable locations with access platform and sampling
points. Compensators/U bends shall be provided as per requirement
based on flexibility analysis.

4.6.5

Fuel Facilities

4.6.5.1

CO gas will be required for mixer heating, ladle pre-heating and


miscellaneous heating requirements. The CO gas requirement will be
around 8000 Nm3/h. Existing CO gas facility will be used for this
purpose, however all the pipelines & valves will be replaced.
Re-routing of CO gas pipeline has been envisaged as per requirement.
New pipelines will be laid first and interconnection will be done during
shutdown of SMS-I.

4.6.5.2

Propane For Gas Cutting


Propane Gas for cutting purposes will be provided. This purchased fuel
requirement will be around 100 Nm3/h. Existing propane storage
facilities will be used for the purpose. One new pump with two new
vaporisers have been considered for this purpose.
Propane gas will be used for slab cutting operations in Continuous
Casting Shop and other cutting requirements. Propane is low cost,
pollution free fuel, which is readily available in bulk supplies.
Advantages claimed for propane/CBM are smooth cut edge, less slag

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.53

adhesion and lowe


er plate edg
ge hardening because
e of the low
wer flame
tempera
ature.
4.6.6
4

Compre
essed Air Facilities
F
Dedicate
ed compresssors & dryyers for ha
ave been envisaged. Dedicated
D
facilities shall be included in the ma
ain techno
ology packkage. The
ssed air sta
ation shall b
be designed for a disccharge pres
ssure of 8
compres
bar(a).

4.6.7
4

NG & VENT
TILATION SYSTEM
S
(A
ACVS)
AIR CONDITIONIN
ed air conditioning & vventilation system
s
sha
all be provid
ded based
Dedicate
on their technologic
cal requirem
ment. Dedic
cated facilitties shall be
e included
in the main technological packkage.

4.6.8
4

GHTING SY
YSTEM
FIRE FIG

4.6.8.1
4

In generral existing fire fighting


g facilities available
a
in
n the SMS--I area will
be used. However it will be augmented as per requ
uirement to
o meet the
g requireme
ent:
following
i)

Portable
P
Fire
e Extinguishers as firsst aid fire fig
ghting syste
em

ii)

Water
W
based
d fire fightin
ng system

iii)

Automatic
A
W
Water
Sprayy System

iv)

Automatic
A
Foam Injectiion System

v)

Automatic
A
ga
as flooding system

vi)

Passive
P
fire protection

Dedicate
ed facilities shall be included in th
he main tecchnological package.
4.6.9
4

POLLUT
TION CONT
TROL
Pollution
n Control asspect will be
b taken intto account w
while formu
ulating the
technica
al specificattion as per CPCB norrm and all tthe facilities
s required
for the purpose
p
off meeting the current and likely Statutory Norms as
well ass fulfilling the Corp
porate Ressponsibility for Environmental
Protectio
on (CREP)) shall be provided. Also,
A
specialist agenccy will be
engaged
d to conduct Environm
mental Imp
pact Assesssment (EIA
A) studies
and prep
pare Enviro
onmental M
Managemen
nt Plan (EM
MP). This EIA & EMP
report will
w addresss all the ele
ements pro
oposed und
der latest guidelines.
g
Based on
o this, required clearrances from
m State and
d Central Regulatory
R
Authoritiies will be obtained.
o
Broadly,, the pollutio
on control measures
m
are
a in the fo
ollowing are
eas:
-

Air
A Pollution Control

Water
W
Polluttion Control designed for Zero Discharge

Noise
N
Pollution Controll

Solid
S
Waste Management

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.54

To provide facilities for Environmental and pollution control aspect as


per statutory requirement will be the responsibility of main technology
supplier.
4.7

REFRACTORIES
For the installation of proposed facilities, the shop-wise equipments/items
to be covered under refractory work are given below:
S. No.
1.

2.

3.

4.7.1

Description
BOF Converter Shop
-Converter
-Steel Ladles
Continuous Casting Shop
-Tundish
-Casting Refractories
Secondary Refining Units
-Ladle Furnace

BOF Converter Shop


Converter:
130T converter shell will be lined with Dense Magnesia-Carbon bricks and
backup lining will be of Magnesite/ Chrome Mag material. The gunning will
be resorted during campaign life of the converter.
Steel Ladles:
Steel ladle design shall be suitable for secondary refining in ladle furnace.
The composite lining will be used for hot face. The Mag-Carbon/ Alumina
Mag-Carbon bricks will be used. Permanent lining will be with high alumina
castable and bricks. Ladle will have provision of attaching slide gate
system at the bottom.

4.7.2

Continuous Casting Shop


Tundish:
Hot tundish practice will be followed for operation. The tundish will be lined
with composite layers of castables. Working layer will be thick gunnitted
magnesia based refractory material. Tundish will have slide gate
mechanism for casting of steel.

4.7.3

Misc. Casting Refractories:


The casting refractory items like Slide gate plates for Steel Ladles &
Tundishes, Well block, Nozzles, Ladle Shroud, Sub-merged entry nozzles

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.55

etc. shall be used, commen


e
nsurate with design and tech
hnological
specified fo
p
parameter
or casting m
machine
.
4.7.4
4

S
Secondary
y Refining Unit
L
Ladle
Furna
ace:
For raising the temperature of stteel and composition a
F
adjustment, the ladle
f
furnace
witth water coo
oled tube h
hood is envisaged. The
e water coo
oled tubes
w be protected with
will
h suitable rrefractory castable
c
fro
om radiation / arcing
h
heat

4.8
4

C
CIVIL
WOR
RK

4.8.1
4

This part of
o the Feasibility Reporrt deals with
h the broad
d scope of civil
c works
envisaged for design philosophyy, construction materia
als and othe
er aspects
1 Modernisa
ation of SM
MS-I at BSL.
for the job of Stage-1
C works sshall be as under:
The broad scope of Civil

caster she
Civil works for continuous
c
ed, equipme
ent foundations &
floorring

Civil works for ladle


l
furnacce

Mod
dification of foundation for one converter

RCC
C framed bu
uilding for Pump
P
Housse for Suppressed Com
mbustion

RCC
C framed bu
uilding for Control
C
Roo
om, MCC an
nd ACVS

RCC
C casting platform with
h steel fram
ming

RCC
C framed bu
uilding for Control
C
Roo
om for GCM
M

RCC
C framed bu
uilding for Control
C
Roo
om for Run out

RCC
C framed bu
uilding for Hydraulic
H
ro
oom

Foun
ndation for Equipmentt Storage area

Foun
ndation for Gas Holde
er and Pipe trestles

RCC
C framed bu
uilding RCC
C Pump House for Sla
ab caster

emission fo
Civil works for Secondary
S
or SMS inccluding RCC
C chimney

RCC
C Water Tanks includin
ng staging & foundatio
ons

RCC
C framed CCS office b
building cum
m stores and toilet

RCC
C framed Co
ompressed
d air building
g

Civil works for Scale


S
Pit & Scale Tunnel

RCC
C foundation for Slag B
Bay

RCC
C foundation for Mould
d & Segmen
nt Repair Shop

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.56

Faecal water pump House

Rerouting of Gas pipeline trestle foundations.

Rerouting of faecal water pipelines, fire & drinking water pipelines


and storm water pipelines

RCC cable trench

RCC Cable tunnel

Civil works for Outdoor switch yard.

RCC framed HT Switch gear room.

RCC foundations for supporting overhead Cable Gallery

RCC framed buildings for GIS Substation, control room and related
Civil works.

RCC framed building for Substation (BOF)

RCC framed building for Substation (CCM & LF)

RCC foundations for transformers along with oil pits

New drainage system

Foundation for Fin Fan Cooler

Foundation for Transfer Car track for slag & molten steel ladle.

RCC framed building (stores cum operator building) for relocated


operators & locker rooms at first floor and spares and equipment
storage at ground floor.

3 nos. of structural sheds with brick cladding walls for housing the
relocated Mechanical maintenance stores, SRU stores and
preventive maintenance room.

Dismantling of toilet block and Ambulance Post and providing the


same at a suitable location.

Dismantling of existing Rly tracks and laying of new tracks.


(Dismantling of 6 Km and laying of 6km of new tracks have been
considered between Mould Yard and Stripper Yard as per
requirement.)

Dismantling of the existing road in the portion of new CCS shop and
Laying of new roads and approach roads to new facilities.

Dismantling of existing Heavy maintenance shed, Electrical repair


room and Crane maintenance shed.

Protection scheme of for new foundations near running tracks.

Dismantling of Offices and Toilet block along the existing road.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.57

Dism
mantling of Ingot mould
d cooling Plants
P
(2 No
os) & provis
sion of
one Ingot Mould Cooling S
Station.

Dism
mantling of Pump Accu
umulator Sttation (2 No
os)

Dism
mantling of cable Tunn
nel

Geo
otechnical investiga
ation and Geodetic
c surveying work
inclu
uding tran
nsferring & fixing of
o referen
nce lines & bench
marrks, through a separa
ate packag
ge

4.8.2
4

Desig
gn Conside
eration

Ope
en foundations has b
been envissaged for the proposed units
assu
uming bearring capaccity of 20 ton/Sqm a
at 3 m dep
pth below
existting ground
d level.

All RCC
R
structtures shall be design
ned as per IS: 456-20
000. Jigs,
fixtures will be used to fiix all ancho
or bolts, in
nserts etc., wherever
uired.
requ

Sinc
ce the exec
cution of the proposed
d project will
w take pla
ace in and
arou
und the running plant, all possible
e care shall be taken to ensure
no disruption
d
of the produ
uction. The movement of men and material
for Civil
C Works will be coordinated to ensure thiss objective..

Majo
or activities
s relating to civil works
w
are earthwork, plain &
reinfforced concrete workk, flooring, plastering
g and finishing, etc.
Follo
owing criterria will be a
adopted in the design
n of civil en
ngineering
work
ks:
R.C
C.C

M--25C for strructural con


ncrete

P.C
C.C

M--10B
forr
mud-m
mat,
Ap
pron/encasing

M-15C

Anchor
p
pocket
nt
M--30 D orr non-shrink cemen
outing/groutting
gro
outing compound / epo
oxy
gro
und
der base plate

for
based

Reinforcing ba
ars

TM
MT bars Fe 500 as perr IS: 1786-2
2008

Flo
oor finish

Ass per techno


ological req
quirement

Ceiling

Ass per techno


ological req
quirement

Cement morrtar in 1:6


6
Brick work
Brickwork:

5D
Designation
n bricks

Cement plastter for 1:6


6
walls
Cement plastter for 1:4
4
ceiling
BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.58

Doors & windows

Steel / Aluminium, glazed doors & windows /


rolling shutters, as per requirement

Building material

Locally available material and conform to


specification of IS

Outside finish for Weather coat


buildings
Inside finish
buildings

4.9
4.9.1

for As per technological requirement

Roof Treatment

Atactic Polypropylene modified plastomeric


bitumen based membrane.

Drainage

Proper drainage as per requirement

STRUCTURAL STEEL WORKS


Structural steel works for building & equipment supporting structures
including painting within the battery limits of proposed modernisation of
SMS -1, BSL as per technological requirements.
Major structural steel works envisaged for this job are as follows:
A.) Dismantling of existing structures:
a) Dismantling of existing 1 no ingot mould coating yard. The major
structures to be dismantled are columns, roof legs, crane girders,
auxiliary girder, roof girder, roof trusses, purlins, runners & CGS
roof, side & gable end sheeting.
b) Dismantling of existing mould cooling & hydro-cleaning plant nos
1 & 2. The major structures to be dismantled are columns, roof
legs, crane girders, auxiliary girder, roof girder, roof trusses,
purlins, runners & galvanized colour coated roof, side & gable
end sheeting.
c) Dismantling of the entire temporary shed with structural roof truss
& CGS roof sheeting between existing electrical substation
building & toilet block in front of the road located near existing
SMS-1 shop.
B.) New structural steel work:
a) Structures for new CCS shop of approx. size of 180m x 85m x 29
m (Crain rail height). The major structures are columns, roof legs,
crane girders, auxiliary girder, roof girder, roof trusses, purlins,

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.59

a)

b)

c)
d)

e)
f)

g)
h)
i)

j)

4.9.2
4

ru
unners & galvanized
g
colour co
oated roof, side & gable
g
end
sh
heeting etc.
Sttructures fo
or new slag
g bay of ap
pprox. size of 102m x 30m x 15
m (Crain rail height). Th
he major strructures are
e columns, roof legs,
crrane girderrs, auxiliaryy girder, roof girder, rroof trusses
s, purlins,
colour co
ru
unners & galvanized
g
oated roof, side & gable
g
end
sh
heeting etc.
Sttructures fo
or new mou
uld & segm
ment repair shop of ap
pprox. size
off 120 m x 30
3 m x 15 m (Crain ra
ail height). The
T major structures
arre columns, roof legs, crane girders, auxiliary girder, ro
oof girder,
ro
oof trusses, purlins, rrunners & galvanized
g
colour coated roof,
side & gable end sheeting etc.
Sttructures fo
or new open gantry for scale pit of approx. size of 26
m x 12 m x 8 m (Crain rail
r height).
Sttructures fo
or electrica
al cable brridge, Cable Bridge supporting
s
tre
estles, pipe
e trestles, pipe
p
bridgess, including
g access sta
air, ladder
& handrail ettc as per te
echnologica
al requireme
ent.
or 1 no new
w 132 KV ou
utdoor switcch yards.
Sttructures fo
Cross over walkway
w
brridge from new
n
CCS o
office building to new
CCS shop of
o size 120
0 m x 2 m x 8 m he
eight with galvanized
g
co
olour coate
ed roof she
eeting alon
ng with acccess stair, ladder &
ha
andrail etc.
3 no of main
ntenance sh
hed/ store shed
s
of size 30 m x 10m x 5 m
htt. with CGS
S roof sheetting & brickk cladding o
on side & ga
able end.
Access staiir, ladder, handrail & handlin
ng facilities
s as per
te
echnologica
al requireme
ent.
A the build
All
dings shall be
b covered
d with Galva
anized colo
our coated
sh
heets on ro
oof, sides & gable en
nd. Glazing / Transluccent sheet
sh
hall be pro
ovided at regular in
ntervals forr natural lighting in
bu
uilding.
Dismantling// Modificatio
on/ strength
hening of steel structu
ures in the
arrea of interrconnection
n of new facilities with existing fa
acilities as
pe
er technological requirrements.

Design Co
onsideratio
ons
All steel structures will be designed to meett the tech
hnological
requiremen
nts with due
e considera
ation to the existing pla
ant and facilities.
Design of steel
s
structu
ures will be
e as per IS 800:
8
1984.
Apart from
m technolog
gical loads to be supp
ported on ssteel structtures, self
w
weight
and superimpo
osed loads for the des
sign will be according to IS 875:
1
1987.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 4.60

Structures will be analysed either for wind or seismic as applicable. Due


allowances for impact vibration and temperature loads to be kept.
4.9.3

Technical Specifications
Material for structural steel will be as per IS 2062: 2006. Chequered plates will
be as per IS 3502 :1994. All bolts and nuts shall conform to IS 1363: 2002 and
IS 1364: 2002 as applicable. All HSFG bolts shall conform to IS 3757: 1985.
Assembly of joints using HSFG bolts shall conform to IS 4000: 1992. Nuts and
washers for HSFG bolts shall be as per IS 6623: 2004 & IS 6649: 1985
respectively. For Switchyard structures IS 4759:1996 shall be used
All steel structures will be welded construction. The welding procedure will
conform to IS 816: 1969 and IS 9595: 1996. Electrodes for welding shall
conform to IS 814: 2004. Use of welding in bridges and structures subjected to
dynamic loading shall be as per IS 1024:1999.Inspection of welds shall be as
per IS 822: 1970. Steel tubes wherever used shall be as per provisions of IS
806: 1968.
Fabrication and erection of steel structures will conform to IS 800: 1984 and
tolerances of fabrication will be as per IS 7215: 1974. Tolerance of erection of
steel structures will be as per IS 12843: 1989.
All the structures shall be duly inspected and made defect free before erection.
Unless specified otherwise, a minimum of two primer coats and two finish
coats of paint shall be applied, each primer coat having a dry film thickness of
about 35 microns and each finish coat of about 30 microns. The total dry film
thickness shall not be lower than 130 microns.
For outdoor structures one intermediate coat of synthetic micaceous iron oxide
paint shall be applied over primer coats before application of finish paint. The
dry film thickness of the coat shall not be less than 75 microns.
Translucent sheet of thickness 1.10 mm shall be provided after every seventh
sheet on the side walls as per IS 12866: 1989. Rough cut wired glass glazing
shall be as per IS: 3548: 1988.
Pre-painted galvanised steel sheet/Polyester-coated galvanised steel sheet
will be of IS: 14246-1995 made from cold rolled steel conforming to IS: 5132008, zinc galvanised (hot dipped) as per IS: 277-2003.
Structures steel works, 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

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 4.61

PROJECT IMPLEMENTATION

5.1

The estimated time schedule for the implementation of the project is


shown in the form of a bar chart. The pre-ordering activities are shown at
Annexure 5.1-1 and the post-ordering activities after final approval are
shown at Annexure 5.1-2.

5.2

It has been assumed that the complete project shall be executed on


limited turnkey basis, i.e., the project shall be divided into different
packages and work order for each package shall be placed on turn-key
basis. Tentatively, the following main packages have been envisaged:
i)

Soil Investigation & Survey

ii)

Enabling works (including dismantling/ re-routing/ laying of rail tracks,


diversion of underground facilities including cable tunnel/ trenches,
diversion of utility pipelines, sewerage lines, storm water lines,
drainage and provision of one new ingot mould cooling Station,
relocation of existing rooms/offices/stores/toilet block etc from the
proposed locations of new facilities.).

iii) Slab Caster and Ladle Furnace with associated facilities.


iv) Suppressed combustion system along with BOF gas recovery facility
(BOF Gas Holder), replacement of BOF converter (1 no.) and
provision of new Slag Bay.
v)

Augmentation of 132 kV power supply system

Civil & structural works are considered in the respective packages on


turnkey basis. Actual packaging will be decided later at the time of
preparation of Tender Specifications.
5.3

Attempts will be made to procure maximum equipment and facilities


indigenously.

5.4

Existing facilities shall be used to maximum possible extent.

5.5

The complete project of modernisation of SMS-I has been envisaged to be


implemented in two stages viz. Stage-1 and Stage-2 as described earlier
at Para 2.9. The present FR covers only Stage-1 modernisation. The
Stage-1 of modernisation of SMS-I shall be completed in 30 months after
final approval.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 5.1

5.6

P
PRODUCT
TION SHUT
TDOWN
Existing prroduction frrom SMS-I will contin
nue. However, shutdo
own for 2
days
d
have been estim
mated for in
nter-connec
ction of re-ro
outed Oxyg
gen, Coke
Oven
O
gas, Nitrogen and
a
Argon pipelines and
a
re-routting of rail tracks for
mould train
n, slag pot car,
c steel tra
ansfer car.

5.7

MANPOWE
M
ER
has been envisaged
N additional recruittment of manpower
No
m
d for this
p
project.
The
e existing manpower
m
o SMS-I shall be re-d
of
deployed an
nd utilized
f the prop
for
posed proje
ect. Proper training sha
all be imparted to the personnel
f efficientt operation of new equ
for
uipment and
d facilities.

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 5.2

FINANCIAL PROJECTIONS

6.1

CAPITAL COST

6.1.1

The Capital cost of the project Modernisation of SMS-I, BSL works out to be
Rs 1365.71 Crore, net of CENVAT credit of Rs 130.27 Crore and inclusive of
an IDC of Rs 67.84 Crore. The capital cost estimates envisage a foreign
exchange component of Rs. 336.98 Crore. The Summary Capital Cost
Estimate is appended at Annexure 6.1.1-1.

6.1.2

The cost estimates are generally based on 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 4th
Quarter, 2012. FE parity has been taken as 1 EURO =Rs 68.14.

6.1.3

Necessary provisions have been made in the estimates as per the details
given below:
For indigenous items
i. Excise duty @12.36 % on basic cost of equipment, refractory and
structure;
ii. CST @2% on basic cost of equipment, refractory, structure and on excise
duty;
iii. VAT @12.5% on 67% of Civil works and 30% of erection;
iv. Service Tax @12.36% on Engg. & construction (C), Erection &
commissioning, freight & insurance and 33% of Civil works;
For imported components
i. Ocean freight & insurance: @7% of FOB cost;
ii. Custom Duty @7.5% on (FOB price+ Ocean freight &Insurance+ landing
charges). Landing charges has been taken @1% of (FOB price + Ocean
freight &Insurance);
iii. CVD incl. Edu. cess @ 12 % on (Assessable value +CD);
iv. Edu. cess @3% on (CD+CVD)
v. ADC @4% (Assessable value +CD+CVD+Edu. Cess);
vi. Income Tax @ 11.80% (Grossed up) on foreign design & engineering and
services.
vii. Service Tax @12.36% on foreign design & engineering and services

6.1.4

Freight & Insurance charges: @2% of basic cost of indigenous equipment and
@9% of basic cost of refractory and indigenous structure. Inland Freight &
Insurance charges for imported equipment have been taken @3%.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 6.1

6.1.5
5

Erecction & com


mmissioning
g charges: @ 6% of ba
asic cost off imported equipment
e
and @ 12% of
o basic cost of indige
enous equipment, @ 10% of in
ndigenous
actories and
d @20% off basic cost of structure
es.
refra

6.1.6
6

Engineering & constructio


on is proviided @ 7.5
5%of basicc cost of equipment,
actory, stru
uctures, civil, erectio
on & commissioning charges. Besides,
refra
provvision for foreign
f
sup
pervision h
has been kept on per
p
diem basis
b
and
estim
mated man-days requ
uired for deputation of foreign exp
perts during
g erection
& co
ommissionin
ng.

6.1.7
7

Contingencies: @ 10 % on overall ba
asis.

6.2

MOD
DE OF FINA
ANCING:
The total capital requirem
ment of the
e project is proposed to be provvided from
A interest rate @ 10%
% per annu
um is conssidered for
debtt equity ratio of 1:1. An
com
mmercial borrowing.

6.3

PHA
ASING OF CAPITAL
C
EXPENDIT
E
URE & IDC
C:

6.3.1
1

With
h the project duration
n of 30 mo
onths from the date o
of stage 2 approval,
phas
sing of capital expenditure and ID
DC is propo
osed as indicated belo
ow:
Rs. in Crore
e)
(R
ars
Yea

Internall
Resource
es

n
Loan

IDC

Tota
al

1st

142.8
81

142.81

7..14

292
2.77

2nd

357.0
04

357.04

32..13

746
6.21

3rd (6 month
hs)

142.8
81

142.81

28..56

314
4.19

Post
P
Comm
m.

71.4
41

71.41

714.0
07

714.07

CAPITAL
L COST
CENVAT CREDIT
C

142
2.81
67..84

1495
5.99
130
0.27

CAPITAL
C
COST
C
NET
N
OF CE
ENVAT

1365.71

6.3
3.2

Base
ed on the mode
m
of financing and
d phasing of
o capital exxpendituress indicated
abov
ve, the tota
al IDC workss out to be Rs. 67.84 Crore.
C

6.4
4

TEC
CHNO-ECO
ONOMICS

6.4
4.1

The benefits en
nvisaged affter implem
mentation off proposed facilities are in terms
avings in cost
c
of prod
duction of slabs
s
throu
ugh Caster route vis-
-vis Ingot
of sa
route
e. Based on Standard
d Cost shee
et of BSL fo
or the prese
ent financial year, the

BSL
B
Modernisation
M
n of SMS-I

CET/02/RN
N/3498/FR/ST//01/R=3
PA
AGE 6.2

savings in unit cost of production of slabs thru caster route Vs Ingot route
comes to Rs 2220/t. Thus the annual savings in proposed case for the
envisaged production of 1.3 Mtpa of cast slabs works out to Rs 288.60 cr.
6.4.2

Presently, BOF gas generated from SMS-1 is being utilised in waste heat
boilers to generate steam which is then vented to the atmosphere. After
installation of BOF gas holder proposed under the present scheme, the gas
can be gainfully utilised in Power Plant as fuel in place of boiler coal.
Considering an avg. gas generation of 80nm3/t of crude steel and CV of 1800
Kcal/nm3, the total energy available from BOF gas is estimated to be 93600
Gcal/annum. Assuming CV of Boiler coal as 3000 Kcal/kg, the BOF gas
generated can replace nearly 31200 t of boiler coal per annum. Considering
boiler coal cost of Rs 2609/t, the annual savings in monetary terms comes to
Rs 8.14 cr.

6.4.3

Based on the above, the total Gross Margin after implementation of proposed
measures has been estimated to be Rs. 296.74 crore. The details are
presented at Annexure 6.4.3-1.

6.5

FINANCIAL ANALYSIS

6.5.1

Financial analysis has been carried out on overall basis considering


discounted cash flow over a period of 23 years. Life of the project is
considered 20 years after commissioning. The shop will have to be taken
under shutdown for a period of 2 days in order carry out some of the activities
envisaged in the project. Hence, for the purpose of techno-economic
evaluation, differential production loss in terms of HR coil over pig iron
corresponding to the loss of ingot steel production over a period of two days,
amounting to Rs 1.60 cr. has been considered in the cash flow. The Financial
Analysis (summary) is furnished below details of which is attached at
Annexure 6.5.1-1:
1 NPV (@ 10% p.a)

Rs. Crore

2 IRR (Post Tax)

BSL
Modernisation of SMS-I

476.96
15.90%

CET/02/RN/3498/FR/ST/01/R=3
PAGE 6.3

7.

RECOMMENDATION

7.1

Modernisation of SMS-I (Stage-1) is technically feasible. It is necessary


primarily to phase out obsolete ingot casting route, introduce 100%
continuous casting and to enable full capacity utilisation of existing HSM.
The project is financially viable. Therefore, it is recommended for
implementation.

BSL
Modernisation of SMS-I

CET/02/RN/3498/FR/ST/01/R=3
PAGE 7.1

ANNEXURE 2.1.9-1

BSL
Modernisation of SMS-I

ANNEXURE 2.1.9-1
PAGE 1 of 3

CET/02/RN/3498/FR/ST/01/R=3

ANNEXUR
RE 2.1.9-1

BSL
B
Modernisation
M
n of SMS-I

ANNEX
XURE 2.1.9-1
PAG
GE 2 of 3

CET/01/R
RN/1741/FR/T//01/R=3

ANNEXURE 2.1.9-1

BSL
Modernisation of SMS-I

ANNEXURE 2.1.9-1
PAGE 3 of 3

CET/02/RN/3498/FR/ST/01/R=3

ANNEXURE-2.1.9-2

BSL
Modernisation of SMS-I

ANNEXURE 2.1.9-2
PAGE 1 of 2

CET/02/RN/3498/FR/ST/01/R=3

ANNEXUR
RE-2.1.9-2

BSL
B
Modernisation
M
n of SMS-I

ANNEX
XURE 2.1.9-2
PAG
GE 2 of 2

CET/01/R
RN/1741/FR/T//01/R=3

ANNEXURE-2.1.9-3

BSL
Modernisation of SMS-I

ANNEXURE 2.1.9-3
PAGE 1 of 2

CET/02/RN/3498/FR/ST/01/R=3

ANNEXUR
RE-2.1.9-3

BSL
B
Modernisation
M
n of SMS-I

ANNEX
XURE 2.1.9-3
PAG
GE 2 of 2

CET/01/R
RN/1741/FR/T//01/R=3

ANNEXURE 4.2
2.2-1
MATER
RIAL FLOW
W CHART (Proposed Case)
Stage-1
1 Modernis
sation

BSL
Modern
nisation of SMS-I

A
ANNEXURE 4.2.2-1
4
PAGE 1 off 1

CET/02/RN/3498/FR/ST/01/R=3

ANNEXURE 4.1.6-1
LIST OF PROPOSED EQUIPMENT & FACILITIES

BSL
Modernisation of SMS-I

ANNEXURE 4.1.6-1
PAGE 1 of 4

CET/02/RN/3498/FR/ST/01/R=3

ANNEXUR
RE 4.1.6-1
LIST
T OF PROP
POSED EQUIPMENT & FACILITIES

BSL
B
Modernisation
M
n of SMS-I

ANNEX
XURE 4.1.6-1
PAG
GE 2 of 4

CET/01/RN
N/3498/FR/ST//01/R=3

ANNEXURE 4.1.6-1
LIST OF PROPOSED EQUIPMENT & FACILITIES

BSL
Modernisation of SMS-I

ANNEXURE 4.1.6-1
PAGE 3 of 4

CET/02/RN/3498/FR/ST/01/R=3

ANNEXUR
RE 4.1.6-1
LIST
T OF PROP
POSED EQUIPMENT & FACILITIES

BSL
B
Modernisation
M
n of SMS-I

ANNEX
XURE 4.1.6-1
PAG
GE 4 of 4

CET/01/RN
N/3498/FR/ST//01/R=3

ANNEXURE 5.1-1

PROJECT IMPLEMENTATION SCHEDULE


Stage - I : Pre-ordering Activities
Modernisation of SMS-I, BSL
(Duration in months)

Sl.
No.

Activities

In principal approval for tendering (Stage-I approval )

Tendering & receipt of offers

Scrutiny of offers, Tender evaluation & issue of


report(TER)

Opening of price bid & finalisation of of L1 offer

Stage-II approval

BSL
Modernisation of SMS-I

Tender evaluation

ANNEXURE-5.1-1
PAGE 1 of 1

CET/02/RN/3498/FR/ST/01/R=3

PROJECT IMPLEMENTATION SCHEDULE

ANNEXURE 5.1-2

After Stage-II approval (Post-ordering Activities)

Sl
No
.
1.
2.

Activities

Modernisation of SMS-I, BSL


(Duration in months)
10 11 12 13 14 15 16 17 18 19

20

21

22

23

24

25

26

27

28

29

30

Stage II approval
Placement of Order

3.

Design &
engineering and
drawing approval

Enabling Works

5.

Dismantling & Civil


Work

6.

Manufacture &
Supply of Equipment
& Structure

7.

Erection of
Structures

8.

Erection of
Equipment

9.

Testing &
Commissioning

BSL
Modernisation of SMS-I

ANNEXURE-5.1-2
PAGE 1 of 1

CET/02/RN/3498/FR/ST/01/R=3

ANNEXURE 6.1.1-1
DETAILED CAPITAL COST ESTIMATE - SUMMARY

BSL
Modernisation of SMS-I

ANNEXURE 6.1.1-1
PAGE 1 of 1

CET/02/RN/3498/FR/ST/01/R=3

ANNEXURE 6.4
4.3-1
GROSS
G
MA
ARGIN CALCULATIO
ON

BSL
L
Moddernisation of SMS-I

ANNEXURE
E 6.4.3-1
PAGE 1 of 1

CET/02/RN/33498/FR/ST/01/R=3

ANNEXURE 6.5.1-1
FINANCIAL ANALYSIS

BSL
Modernisation of SMS-I

ANNEXURE 6.5.1-1
PAGE 1 of 1

CET/02/RN/3498/FR/ST/01/R=3

You might also like