1. Introduction

Alloy Steels PlantASP, Durgapur, the only Alloy Steels Plant is SAIL is bestowed with modern technology of EAF. It has an installed capacity of 2.4 Lakh tons per annum of liquid steel & 1.78 lakh tons of salable steel. ASP has emphasized on producing wide range of more than 400 grades of steels round the year. Our products meet stringent demands of customers within India & abroad. Products used in defense , Railways, nuclear power, automobile, aerospace, chemicals, engineering industries are our major gains. These products meet international quality standards such as major grades in major fields mentioned above.ASP has become one of the plants in the country to be certified to all the three International Standards for Quality /(ISO-9001),for Environment Management(ISO-14001) .The certificate covers quality systems of all operational, maintenance, service units besides purchase systems Training & Marketing functions spreading over all stockyards Located all over the country.Alloy Steel products are wide ranging as described in the book in different pages subsequentlyThe profile of the book ASP an Overview is divided broadly into three sections as detailed below Section IThese are major departments like Steel Melting Shop, Continuous Casting Shop, Refractory Engg. Deptt., Forge Shop, Blooming & Billet Mill, Roll Design & Roll Section, Conditioning Shop, Heat Treatment & Finishing Shop, Plate Mill, Research & control Laboratory .Section IIThese is one more broader section covering Utilities & Services. Main among these are Total quality Management, Mechanical Repair Shop, Electrical Repair Shop, Projects, Traffic & ALRS, Electronics &Telecom , C & IT, Power Distribution & General Maintenance. This part functions like blood stream of the plant. Safety Engineering & Environment Management Department, Shipping & PPCD (Plant Production & Control Department).Section IIIThis includes PRO, Personal & Administration, Finance & Accounts, Marketing & Materials Management Department & encompasses major role in maintaining essential services. Administrative control & flow of Information & materials required essentially to the plant.BACKGROUND NOTE ON ALLOY STEELS PLANT2. BackgroundAlloy Steels Plant (ASP), a unit of Steel Authority of India Limited (SAIL) was commissioned in January 1965 at Durgapur in Burdwan district of West Bengal with initial capacity of 100,000 tonnes per annum (TPA) of liquid steel, with major facilities such as Steel Melting Shop (SMS) with Electric Arc Furnaces (EAF), Blooming & Billet Mill, Forge Shop, Conditioning Shop, Bar Mill, Plate & Sheet Mill and Heat Treatment & Finishing Shop. ASP was the first major producer of alloy & special steel in the eastern region. The capacity of the plant was increased to 1,60,000 TPA of liquid steel in 1985 and thereafter, further enhanced to 2,60,000 TPA of liquid steel in 1989. Subsequently, in 2007, facilities at SMS were upgraded with installation of Argon Oxygen Decarburising (AOD) unit along with EAF no. 8 for enhancing stainless steel production. 3 Existing facilities:Alloy Steels Plant has following existing facilities:3.1 Steel Melting Shopa) Electric Arc Furnaces (EAF): 3 nos with a capacity of 50 T each.b) Secondary Steel Refining units : Ladle Furnace : 60 T Vacuum Arc Degassing unit (VAD) : 60 T Vacuum Oxygen Decarburising unit (VOD) : 60 T Argon Oxygen Decarburising unit (AOD) converter : 60 TMills & finishing units:c) Blooming & Billet Mill : Fuel-fired Soaking Pits : 12 nos Blooming (roughing) Mill 2 high : 900 mm Billet Mill 2 high : 700 mm (1 no) Finishing stands 2 high : 650 mm (2 nos) Hot scarfing and shearing facilitiesd) Forge Shop : 2000 T Oil Hydraulic Forging Press : 1 no Pneumatic Hammers : 1x5 T, 1x2 T Charging machines & manipulators Heating &dispositioning Furnacese) Conditioning Shops I & II: Heat treatment Furnaces Surface Grinding and Shot Blasting Machines Straightening and Cutting facilitiesf) Heat Treatment & finishing shop: Annealing Furnaces Heat Treatment Furnaces Cutting & Straightening facilitiesg) Plate Mill Walking beam re-heating furnace 3 High non-reversing Mill Annealing Furnace Shear for sizing & stretcher leveler for straightening 2.0 Product-mixASP has a product portfolio of nearly 400 grades conforming to national/ international standards and meets the varied requirement of Defence, Nuclear Power, Aerospace, Railways & Automobiles etc. The product profile comprises of billets/blooms, concast slabs, forgings & value-added products like rolls, discs, die-blocks etc. Crankshaft-quality steels, ball bearing steels, high-quality stainless steel for kitchenware/process industries and coloured stainless steel gift items in small quantity are also some of ASPs products. ASP is the first plant in India to manufacture creep resistant steels used in boiler manufacturing industries, conventional & nuclear power plants, aerospace etc. ASP also produces Hadfield steel, which is extremely tough and non-magnetic alloy steel used in coal and steel industry. B. Modernisation& Expansion As a capacity enhancement of BBM, number of fuel pits has been increased from 6 to 12 during the period 1998 to 2007 in phases. In 2007, Steel Melting Shop (SMS) was upgraded with commissioning of Argon Oxygen De-carbonization (AOD) unit & new EAF no.8 for augmenting stainless steel production. In 2008, the Hydraulic Press (2000 T) at Forge Shop has been revamped to increase productivity by reducing rejection of finished material and substantial saving in electric energy.

ASP Technology - State of Art

SECTION-I

3.2 Continuous Casting Shop

3.3 FORGE SHOPForge Shop is one of the shaping unit of Alloy Steels Plant where ingots and blooms are converted to finished forged product through the press and hammer operation. Ingots are received from Steel Melting Shop and blooms are received from various shops as per production requirement. Ingots and Blooms are heated in reheating furnaces. Sometimes smaller size ingots are cogged in 5T hammer.In Forge Shop, there are six reheating furnaces in the Press bay and two reheating furnaces in the hammer bay. There are three dispositioning furnaces for isothermal annealing for normalizing of critical grades. Some reheating furnaces are dual fired using both coke oven gas and furnace oil while other reheating furnaces can run with coke oven gas only. Out of the three dispositioning furnaces two are operated with gas while one can be operated electrically.All finished forged materials are inspected in forge shop. Dimension checking, surface defect and internal defect checking is done in forge shop by inspection wing of R & C Lab. After inspection, only confirming materials are dispatched to Heat Treatment Shop for further heat treatment and finishing. Product mix of Forge Shop2000 T Press----270 mm to 770 mm.Press products are rounds, V die rounds, squares, flats, step forging, disc and ring.5T hammer----100 mm to 270mm.Hammer products are rounds, squares and flats.There is a 2T hammer for forging of test samples for different products.

3.4 BLOOMING & BILLET MILLBlooming & Billet Mill is the major rolling mill in Alloy Steels Plant for hot rolling of various alloy steels incorporating strict dimensional control . The various inputs are ingots, continuous cast blooms and slabs and double conversion blooms received from Steel Melting Shop, DSP and other sources. The major facilities are twelve numbers fuel fired soaking pits run either by coke oven gas or oil , roughing and finishing stands 900 Mill , 700 Mill , 650 Mill , hot scarfing machine , hot shears like 1200 T bloom shear and 500 T billet shear , hot saws and cooling bed.Metals are heated to rolling temperature as per the heating standard and then cogged to intermediate stage or finished to blooms, billets or slabs as per production requirements. After rolling the finished materials are dispatched to Conditioning Department for further processing and the revert scrap which is collected separately according to their scrap class is sent to Steel Melting Shop.Product mix of Blooming & Billet Mill Major Products: RCS Blooms from 160 mm2 to 340 mm2 RCS Billets from 90 mm2 to 150mm2 Rounds from 80 dia to 205 dia Flats & Slabs as per mill capability

3.5 CONDITIONING DEPARTMENTConditioning Department is the nerve centre of Alloy Steels Plant. Whatever material is being produced in the plant are passed through this department except some forgings which do not require any conditioning. Conditioning is a process by which materials are made suitable for further rolling or forging to finished goods. The following are the processes carried out in the department :1. Disposition of the hot rolled blooms/billets/rounds/flats eg., air cooling, slowcooling in boxes covered with refractory linning, furnace cooling etc.2. Swing grinding : grinding by swing frame grinding machine in a zigzag or 100% grinding.3. Slab grinding : grinding of slabs, flats, blooms by zigzag/sopt/100% gringing.4. New auto billet grinding : 100% grinding of billets and blooms.5. Auto slab-cum bloom grinding : for grinding of concast slabs and blooms.6. Heat treatment : only annealing and dispositioning treatment is given in two twin hearth furnaces.7. Straightening : for billets and rounds.8. Saw cutting and Gas cutting.9. Inspection and Testing including ultrasonic testing.10. Painting and colour-coding.11. Packing /Bundling.12. Stacking.The various equipments used in the department are as follows:1. 12 nos. of small & 10 nos. of big cooling boxes for slow cooling.2. 2 nos. of Boigie Hearth Furnaces of 35 t capacity.3. 12 nos. swing frame grinders.4. 3 nos. slab grinding machines.5. 2 nos. new auto billet grinding mahines.6. 2 nos. auto-cum-bloom grinding machines.7. 2 nos. straightening machines.8. 4 nos. of saw cutting, 2 sets of oxycutting and 3 sets of hand torch cutting machines to take care of entire cutting load.Types of materials processed are mainly alloy steels eg. Carbon constructional, alloy constructional, tool steel, ball bearing steel, stainless steels, creep resistant steels, spring steels, the sizes are ranging from 80 mm round to 200 mm round and 100 mm RCS to 340 mm RCS. Almost 80% of materials are shipeed to external customers and balance to other departments for further processing.

3.6 HEAT TREATMENT AND FINISHING DEPARTMENTAfter the steels materials are rolled or forged, a sizeable amount is subjected to different types of heat treatment for achieving required mechanical and physical properties. Following types of heat treatment are carried out in the department :1. Annealing : sub-critical annealing, iso-annealing, spheroidising annealing, N2 annealing are done depending upon customers requirement.2. Normalizing : to achieve homogenized structure.3. Hardening.4. Tempring.Equipments used to carry out heat treatment are as follows :1. 5 nos. of twin hearth bogie hearth furnaces of 35 T capacity for doing annealing and normalizing treatment.2. 7 nos. of single hearth bogie hearth furnaces of 10 T capacity for doing annealing/normalizing/hardening/tempering treatment. 3. 2 nos. of semigantry crane of 10 T capacity used to load/unload small capacity furnaces as well as quenching.4. 2 nos. water quenching tank and 1 no. Oil quenching tank of 70,000 liter capacity. Other than heat treatment, following processes are also carried out in the department:1. Straightening: 2 nos. rotary straightener and 1 no. Bumper straightener is there, to take care of the total straightening load.2. 4 nos. of band saw cutting machine.3. Inspection and testing including ultrasonic testing machine.4. Hardness testing machine.5. Painting/colour coding.6. Packing/bundling.7. StackingTypes of material heat treated are mainly creep-resistant grades, alloy constructional grades, tool steels etc.

3.7 PLATE MILLThe existing PLATE MILL complex of Alloy steels Plant, Durgapur,is designed to produce hot rolled stainless and non stainless plates. The reheating facility in Plate Mill consists of 2 nos. of Walking beam furnaces heated gas/oil.The only rolling stand is a 3 hi- 800/640/800 mm size with 2000 mm barrel length which is followed by a hot-roller-leveller and cross cut shear for shearing upto 12 mm thick plates.

1 no. Of of Roller hearth Annealing Furnace with arrangements for simple air cooling ,air blast quenching and water quenching facilities are available.After annealing of the plates are stretcher levelled in a 300/800 T Stretcher leveller,then they are resquared in a guillotine shear for packing after carrying out in line inspection for each and every plates on both surfaces .

3.8 MRS DEPARTMENTMechanical Repair Shop caters to the need of different production shops & service departments by manufacturing & fabricating different type of spares as per requirement in MRS there are mainly three sections1) Machine Shop 2) Fabrication unit 3) Fitting unitMachine ShopIn machine shop there are variety of machine tools viz.Heavy duty lathesMax length of workpieceMax wt carrying capacity

LC-125 LATHE A020515

RUSSIAN LATHE A030505

HHD LATHE A151010

POREBA LATHE A160510

Beside this machine shop has Vertical Turret lathe, H / Boring, Precision lathes, Milling m/c Shapes, Drill machines , Copy Planning machine, Planning machine & Band Saws. Heavy duty lathes are mostly involved in machining of CRM Roll, Tandem Roll, Reversing Roll, Silicon Rolls as per requirement of marketing department. Rest machines are utilized for manufacturing spares as per requirement of different departments.

Fabrication UnitIn fabrication unit mainly are welding, gas cutting is done for fabrication spares as per requirement . Besides these plasma cutting is also done for cutting stainless steel plates of thickness up to 32 mm.Bending machines are also used for fabrication ducts of various sizes as per requirement. Major fabricated items are H/ Hood, Tundish cover, Cooling gland, Brick retainer plate Ducts etc.

Fitting unitThis unit is involved in overhauling, different assemblies &sub assemblies of different equipments of Plant. In this section two Hydraulic presses are installed to ease the manual labour.Two EOT cranes having capacity 15 & 10 tons operated by remote control in two bays for loading & unloading of jobs.

4. ACTIVITIES OF SAFETY ENGINEERING DEPARTMENT1. Reporting & recording of IOW case in relevant forum Organising& coordinating Housekeeping inspection in operation, services & office building through inspection Committee.2. Generating safety awareness among the workmen ( both Contractors and Regular) & executives through Safety Training & Interaction.3. Inspection & reporting the unsafe conditions & act inside the plant daily basis.Plant beautification &dejungling of plant surrounding as well as peripherywall area for plant security.4. Investigation, recording and reporting of fire incident, accident, near miss cases & serious incident inside the plant to ASP Management & Corporate office, SSO.5. Interaction & meeting with legal body and statutory authority.6. Coordination with CISF / Fire wing of ASP for fire safety throughout the plant

5. PRODUCTION PLANNING & CONTROL DEPARTMENT(PPCD)

Introduction :PPCD is working as the nodal agency in the plant for executing orders received from various customers and coordinate between various agencies for smooth operation of the organization as per desired level and dispatch of correct materials to valuable customers..,Background :Since inception of ASP, PPCD is functioning to plan the production of various units. Function of PPCD : The main function of Production Planning and Control Department is to execute customers orders in terms of quantity , quality and delivery schedule received from Marketing as per monthly dispatch plan worked-out after discussion with DGM(MKT-SRM/AS) The planning function starts with making of the Annual Performance Plan in compliance with Corporate Plan which lay down in clear terms at the beginning of the year, the yearly and monthly targets of production and service units. Detail Dispatch Plan is made on monthly basis in consultation with DGM(Mkt-SRM/AS) based on available orders and on that basis monthly Production Plans of various shops are made.The monthly targets are then broken into weekly and daily schedules and day to day monitoring is done to check any deviation. PPCD is in constant touch with Marketing and all operational units to monitor the orders received from Marketing are executed by planning and scheduling production. In case of urgency of any order, necessary change in the monthly plan is done in consultation with Marketing and Operation units.. The Department brings out various manuals and reports , as a part of Management Information Systems. The Annual performance plan and Annual operational statistics is also made and distributed by PPCD.

PPCD is engaged in developing Special Products maintaining close liaison with Marketing, RCL, FAD & Operation Departments Through Contract review.

Monitoring of semi finished and finished inventory and application to various orders is also done by PPCD

6. POWER DISTRIBUTIONAlloy Steel Plant, Durgapur has a power distribution that efficiently handles all the power needs required by various mills and shops. It receives power at the Main Receiving Substation (MRS) from the Durgapur Steel Plant which manages power requirements from NSPCL and DVC. The ASP main receiving substation is well equipped with insulators, Oil Circuit Breakers, Gas Circuit Breakers, transformers etc. The major recipient of power from the ASP Main Receiving Substation is the Electric Arc Furnace in the Steel Melting Shop (SMS) where one can have a look at the Vacuum Circuit Breakers, ABB and MBB. The mills area requires a lower voltage of 6.6 kV and thus a step down transformer of 33kV/6.6kV is used to meet these requirements. The BBM, HTF, Plate Mill and the Forge Shop receive power at this reduced voltage of 6.6kV from this substation. Capacitor banks are installed to improve power factor of the power. Transmission is carried out through underground cables unlike overhead transmission line. Various transmission line components like Connectors, Cables, Switchesetc can be viewed at the store of BBM and SMS.7. TRAFFIC & AUTO LOCO REPAIR SHOP Traffic & ALRS are maintaining different type of equipments which are used for different purpose Providing all types of transport service as per plant requirement. Receiving incoming material through Rail and dispatching the material through Rail. Maintenance of the rail tracks & rolling stocks includes regular servicing,shut-down & breakdown jobs Maintenance of the above equipments includes regular servicing,shut-down & b/d jobs. The jobs generally performed are Changing of engine,gearbox,leaf spring assly,traction motor & generator(for loco),brake parts,propeller shaft,wheel hub etc. Rectification of of hydraulic circuit ( lifting ,tilting& steering cylinders, hydraulic pump,hydraulic motor,hoses etc). Rectification of electrical circuit( horn,battery,starter motor,alternator etc)CONCLUSIONThis training has proved to be beneficial to us since we had a first time exposure of so many field visits watching theoretical concepts applied to real life situation. A systematic procedure of conversion of the input into a desired output is achieved through a series of ordered processes. It was a delight to observe the heavy machines working with accuracy and precision, how various processes hydraulic, pneumatic, and automation working to together to accomplish a common objective. Each operation is handled with high accuracy and precision. It was good to see how safety was given the first priority. It was a nice experience to see the healthy relations of the employees, workers, engineers and the managers. The fifteen days have enlightened us to a great extent and clear our incertitude. Overall, the vocational training was a success and helped us to move forward with full of ambition.

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Product Size Range of ASPRolled Round Cornered Square (RCS) Billets: 75 - 152Rolled Round Cornered Square (RCS) Blooms: 160 - 340 Rolled Rounds: 75 - 205Forged Squares: 100 - 550Forged Rounds: 100 - 625Plates (Non-Stainless Steel): 5 40 thickConcast (CC) Slabs (Stainless / Non-Stn Steel): 170-250 thick x 900-1300 wide

ASPUnit : MM