Bhilai Steel Plant is a unit of Steel Authority of India Limited (SAIL), which is one of the largest state-owned steel producers in India. The presentation provides an overview of BSP, including its establishment, products, production processes, key departments, and achievements. BSP has an annual production capacity of over 3 million tons and specializes in producing rails, plates, and structural steel. It describes the key production facilities and processes, including the rail and structural mill, plate mill, and steel melting shops. The presentation also outlines some of BSP's certifications and awards it has received for its products, safety, sustainability, and corporate social responsibility efforts.

1. BHILAI STEEL PLANT
TRAINING PRESENTATION
BY
MUKESH KUMAR KASHYAP
ROLL NO-3352808033
SSITM BHILAI (CG)
1

2. CONTENTS
Steel Authority of India Limited (SAIL)
Introduction
Products Profile
Process flow
Rail and Structural Mill
Plate Mill
Steel Melting Shops
Telecommunication Dept
Achievements
2

3. Steel Authority of India Limited (SAIL) is one of the largest state
Owned steel makers in India and one of the top steel makers in
the world, With a turnover of 8681crore (US $10.71billion), the
company is among top five highest profit earning corporate of
the country
Type
State owned enterprise public
Industry
Steel
Founded
1954
Headquarters
New Delhi, India
Products
Steel, flat steel products, long steel
products, Wire Products, plates
Employees
131,910 (2006)
www.sail.co.in
Website
3

4. SAIL integrated Steel Plants
oBhilai Steel Plant (BSP) in Chhattisgarh setup with Soviet Collaboration
oRourkela Steel Plant (RSP) in Orissa setup with German Collaboration
oDurgapur Steel Plant (DSP) in West Bengal setup with British Collaboration
oBokaro Steel Plant (BSL) in Jharkhand setup with Soviet Collaboration
oIISCO Steel Plant (ISP) at Burnpur, West Bengal
Special Steel Plants
oSteel Authority of India Limited (SAIL), Kanpur, Uttar Pradesh
oAlloy Steels Plants (ASP), Durgapur, West Bengal
oSalem Steel Plant (SSP), Tamil Nadu
oVisvesvaraya Iron and Steel Limited (VISL), at Bhadravathi, Karnataka
Ferro Alloy Plant
oChandrapur Ferro Alloy Plant (CFP) in Maharastra
4

5. INTRODUCTION
Bhilai Steel Plant (BSP), a unit of Steel Authority of India Ltd.
Inaugurated at 1959 by the President of India Dr. Rajendra Prasad
with a production capacity of 1.0 million tonne. A-public sector
undertaking was conceived under aegis of Indo-USSR Treaty in the
2nd Five year plan.
The captive mines of the plant located at Dalli-Rajahara supplies
iron ore and lime stone used to be available from Nandini captive
mines. At present lime stone is procured from outside. The other
major raw material, coal is purchased from outside either through
import or from indigenous market.
5

6. Nine times winner of Prime Minister’s Trophy for best
integrated Steel Plant in the Country, Bhilai Steel Plant is
India’s sole producer for the rails and heavy steel plates and
major producer of structural. The Plant is sole suppliers of
the country’s longest rail tracks of 260 meters. With an
annual production capacity of 3.153 MT of saleable
steel, the plant also specializes in other products such as
wire rods and merchant products. Since BSP is accredited
with ISO 9001:2000 Quality Management System
Standards, all saleable steel products of Bhilai Steel Plant
come under The ISO umbrella.
At Bhilai ISO:14001 has been awarded for Environment
Management System in the Plant, Township and DALLI
MINES. It is only Steel plant to get certificates in all these
areas.
6

7. Company Profile
Type
Central Public Sector
Industries
Metallurgical process
Founded
1955
Headquarters
Bhilai, Chhattisgarh, India
Products
Rails, Plates, Structurals
Website
https://www.sail-bhilaisteel.com/
7

8. PRODUCTS PROFILE
Product Type
Product
End use
Production
(Tonnes/an
num)
A. Finished
Product
Rail and
structural mill
Rails in 13m, 26m, 65/78 m
length and welded panels of
130m/260m length Indian
Railways, Export Heavy Structural
Construction Crane Rails Cranes
Crossing sleepers Broad gauge
sleepers
7,50,000
Merchant Mill
Light structural engineering and
construction, medium rounds
(plain & TMT), heavy rounds
(plain)
5,00,000
Wire Rods Mill
Wire rods - plain construction
wire rods - TMT EQ wire rods
electrodes
4,20,000
Plate Mill
(upto3600mm
wide)
Plates boilers, defence, railways,
shipbuilding, LPG cylinders,
export
9,50,000
8

9. Type
B. SEMIS
(Tonnes/an
num)
Billets (from BBM)
Re-rollers
5,33,000
Blooms (from BBM)
Narrow width slabs
CC blooms
Killed slabs
C.
Pig iron
Foundry
D.
By products
Coal chemicals, ammonium
sulphate (fertiliser), tar and tar
products, (pitch, napthalene,
creosote oil,, Anthracene oil,
Dephenolised oil, PCM etc.),
Benzol & its products (NG
Benzene, Toulene,
Xylene,solvent
oilslag,granulated slag from
CHSG plants & SGP for cement
manufacture
9

10. PROCESS FLOW at BSP
10

11. DEPARTMENTS WE VISITED..
oRail and Structural Mill
oPlate Mill
oSteel Melting Shop(SMS)
oTelecommunication Dept.
11

12. RAIL AND STRUCTURAL MILL
Capacity - 7,50,000 T
Products
•Rails - R52 Kg/m & R60 Kg/m ; UTS 880 N/mm2 rails as
per IRST-12/96 specifications , Euronorms and international
standards.
•Thick web asymmetric rail Zu 1-60
•Beams - 600,500,450,400,350,300 & 250.
•Channels - 400,300 & 250.
•Angles - 200 & 150.
•Crossing Sleeper.
•Crane Rails - KP80, 100,120 & 140.
•Bhilai is the sole supplier of the country's longest rail tracks
of 260 metres.
12

13. Bhilai Rails
Largest producer and leading rail maker of the world.
Four and a half decades of experience in rail making.
Produced over 15 million tonnes of rails; 2.7 lakh km in
length.
Indian Railways- World’s second largest rail company
moves exclusively on Bhilai rails.
Bhilai rails are subjected to world’s highest traffic density
and axle loads.
Rails exported to 10 countries with exports to South Korea,
New Zealand, Argentina, Turkey, Iran, Egypt, Ghana,
Bangladesh and Malaysia.
13

14. Technological Superiority
Steel from LD Convertor – Ladle furnace - RH Degasser –
Concast route; achieving world best level of degassing/
refining to less than 1.5 ppm of hydrogen in liquid steel in
100% of heats.
Capability to produce as rolled lengths of 80 meter and
welded panels upto 260 meters.
High degree of Straightness due to world’s most advanced
and Laser straightness measurement based end straightening
machine.
World class tested rails passing through state of art online
NDT equipment; Laser straightness measurement, Ultrasonic
and eddy current testing machines
Computer controlled automatic rail handling system and
automatic yard mapping for rail storage.
Computerised Rail Tracking system for collection and
storage of all process and testing related data of each rail.
14

15. 15

16. 16

17. Bhilai Rails- Universally Certified
RDSO, Indian Railways
RITES Ltd
ISO-9001-2000 certified by LRQA (Lloyds Register
Quality Assurance)
ISO 14000 certified by BIS
Crown Agents, London
General Superintendence Company, Geneva
Lloyds Register Of Shipping
Robert W Hunt & Company
Overseas Merchandise Inspection Company, Tokyo
Egyptian Railways Inspection Team
Tuboscope Vetco Gmbh, Deutcheland
Bhilai’s Special Purpose Rails
Copper Molybdenum Corrosion resistant rails
High yield strength/ UTS vanadium micro-alloyed rails
High conductivity metro rails
Copper-Chromium alloyed High strength Rails
17

18. PLATE MILL
Capacity
Plates thickness
Width
Length
-
9,50,000 T
8-120 mm
1500-3270 mm
5-12.5 M
The modern Plate Mill rolls out heavy and medium plates, as well as
those for pipe manufacturers. Plates of wide variety, in any required size,
and strength, chemical and physical properties, can be produced here.
It has capacity to produce high pressure, boiler quality and high tensile
steels.
Shipbuilding plates, conforming to Lloyds specifications, and pressure
vessel boiler plates, conforming to various ASTM, ASME standards, have
withstood the challenges of nature and time. Some of the unique features
of the mill are on-line finishing facilities and off-line normalising
facilities.
18

19. 19

20. 20

21. 21

22. Bhilai has the widest plate mill in the country, and it uses
continuously cast slabs as input. Liquid steel produced under
controlled conditions in the LD Converters is rinsed with argon
gas to homogenise the composition as well as to remove nonmetallic inclusions before continuous casting so as to ensure the
production of high quality feedstock for the Plate Mill. As per
customers' requirement or specifications, plates are normalised in
a roller hearth normalising furnace.
22

23. STEEL MELTING SHOP (SMS)
A. Steel-making through BOF, VAD/Ladle Furnace/RHDegasser and Continuous casting route
3 converters of 110/130 T
VAD unit, 2 RH degasser,2 Ladle furnace
4 Slab Casters, 1 bloom caster, 1 Combi caster
Annual Capacity: 1.425 MT Cast steel
Converter Shop :
3 BOF 110/130 T Convertors
Secondary Refining facilities : 1 VAD unit, 2 RH degassers,
2 Ladle furnaces, 1 Desulphurisation Unit
Continuous Casting Shop: 4 Slab Casters, 1bloom caster,
1Combi caster
B. Steel-making through Twin Hearth Furnace (THF) route :
4 THFs of 250 T capacity each
Annual capacity 2.5 MT ingot steel
23

24. TELECOMMUNICATION DEPARTMENT
Telecommunication dept. provides the employee a strong,
reliable and state-of-the-art technology for Telephone
Communication.
The responsibility of these different Communication
Equipments is entrusted by Telecomm. Dept.
The different sections of this department take care of
regular maintenance and upkeep of these equipments.
Enlisted below are the various typed of communication
equipments presently installed and used in Bhilai Steel Plant
TELEPHONE EXCHANGE
SHOP FLOOR TELECOM EQUIPMENTS
CABLE LINE NETWORK
24

25. A.TELEPHONE EXCHANGE
BSP is having three exchanges which altogether have an
installed capacity of 7200 landline phones.
Plant exchange is located at Telephone house nearby spat
Bhavan. This is having a 3000 line exchange of Ericsson make
and a 1200 line of Tata make units, serving the Plant area
exclusively.
An ITI make exchange is installed at Sector-5 and having
2000 subscribers capacity and caters to location from Sector1 to Sector-10,Nehru Nagar, Maitri Nagar etc.
25

26. The third exchange is installed at Main Hospital.Tata Telecomm
supplied this 1000 line exchange. It serves Sector-8,9,HS and
Hudco.
26

27. Inter connectivity diagram of Various Exchanges under BSP
27

28. Inter connectivity diagram of Various Exchanges under BSP
28

29. EXCHANGE LAYOUT
Typical exchange consist of:
oSwitch Room
oOperation and Maintenance (OMC) Room
oInput Output Processor (IOP) Room
oPower Plat Room
oBattery Room
oMain Distribution Frame (MDF) Room
The various Sections Under Telephone Exchanges are:
A. Telephone Repair Shop
B. Planning, Stores And Workshop
C. Clock Station
D. Mobile Phones
29

30. B.SHOP FLOOR TELECOMM EQUIPMENT
Despatcher Communication System
It is a hotline communication system between a central
control room and a field locations.
28 such despatcher sets workig in different shops catering to
about 1300 subscribers.
EX-Communication System
This system helps the Executive Director(ED) to hold the
conference with all HOD’s everyday morning directly from his
residence and at afternoon from his office.
100 line Ex-com system is installed in Plant Control.
30

31. Wireless Communication
The shop personnel use walkie-talkies and baseunin for
communication during movement.
969 sets in 30 spots frequencies are being used at various
Departments.
Wireless in Local Loop (WLL)
700 WLL are used in various Departments all over the Plant.
These sets are supplied by BSNL on monthly rental basis.
Communication is established by thedialing four digit code of the
respective user. Eg.-(285-XXXX)
HotLine
This system is used in strategic points for instant communication
between two pre-assigned location.
154 subscribers are given this facility all over the Plant.
31

32. Shop Announcement System
These are used for important announcement in the shop
floor and propagations of safety slogans, etc.
7 Such Systems are installed.
Conference System
The system is being used at the Conference hall of the
senior executives to discuss matter round the table including
presentations.
8 Such Systems are installed in the conference hall of
MD,ED(W),ED(Projects)
Ispat Bhavan Conference hall, GMI/c(M&U),GM(E),GM(P,E&En)
and GM(RSM).
32

33. C. CABLE LINE NETWORK
Cables & Line section refers to the field cable network of Exchanges.
The cables are laid from exchange MDF to DPs in each area.
In Plant area 30 cabinets and more than 1000 distribution points(DPs)
are installed.
The Cable network also provides 100-lease line link for Computer
network of INCOS,C&IT,CMMS and MMIS and maintain it.
The said computer network link is provided only to those areas where
Fiber connectivity is not possible.
In Sector-5 Exchange area there are 12 cabinets and associated DPs.
In Hospital Exchange area there are 7 cabinets and associated DPs.
The township cable network is dedicated to auto telephone even
though there are few other circuits working for the data
communication.
33

34. D.CUSTOMER CARE SERVICES
This is round the clock telephone enquiry services. Dialing “00”
one can access the enquiry services and dialing 2244 we can access
compliant services.
This section maintains a computerized telephone directory for
providing the above services.
34

35. Achievements
SAIL was featured in the 2008 list of Forbes Global 2000 companies
at position 647.
SAIL was adjudged best PSU and conferred with Business and
Economy Leadership and Excellence Awards 2008 by Planman Media.
BSP won CII Sustainability Award – 2008 in independent unit category.
Greentech Safety Gold Award by Greentech Foundation for
outstanding achievement in Safety Management to Bhilai Steel Plant.
Golden Peacock Award for Combating Climate Change – 2008 for BSP.
National Safety Award to Bhilai Steel Plant announced by the Ministry
of Labour & Employment, Government of India – 2008.
Ispat Bhasha Bharati. the Rajbhasha Journal of SAIL has been awarded
with the first prize under the All India House Journal Award Scheme 2008-09.
Golden Peacock Award for Corporate Social Responsibility won by
Bhilai Steel Plant (BSP) for the third year in a row - 2009
35

36. 36