Unit Specific Manual on RDCIS & SSO

7/25/2019 Unit Specific Manual on RDCIS & SSO

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UNIT SPECIFIC MANUALOF

R & D CENTRE FOR IRON & STEEL

& SAIL SAFETY ORGANIZATIONFOR

SELECTION OF JUNIOR OFFICERS

Steel Authority of India LimitedRanchi-834002

June 2008


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Unit Specific Manual of

Research and Development Centre for Iron and Steel

and SAIL Safety Organization

For selection of Junior Officers

Contents

Page No

1.0 Overview of RDCIS 4

2.0 Organization Structure, Areas, Divisions, Groups and ISSD 5

3.0 Project Management at RDCIS 6

3.1 Types of R&D Project 6

3.2 Project Planning Procedure 6

3.3 Project Monitoring & Evaluation 9

4.0 Major Research Facilities 13

4.1 State of the art research facilities at RDCIS for scientific work 14

5.0 Research Areas 15

5.1 Basic Research 16

5.2 Major process related achievements 16

5.3 Product Development achievements 19

6.0 Major on going Research Projects 19

6.1 Coal Carbonization 19

6.2 Mineral beneficiation and agglomeration 20

6.3 Iron making 20

6.4 Steel making and casting 20

6.5 Refractory 21

6.6 Rolling Mills 21

6.7 Product development 22

6.8 Energy and Environment 22

6.9 Automation & Engineering 23

6.10 Information Technology 23

7.0 Collaborative Research Work 23

7.1 Research work pursued and completed with foreign institute 23

7.2 Research work carried out with Ministry of Defence 24

7.3 Major on going collaborative research work with foreign and Indianresearch institutes

24


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8.0 Expenditure on R&D Efforts 24

9.0 Impact of R&D Efforts 25

9.1 Paper Publication 25

9.2 Paper Presentation 259.3 Patent 25

9.4 Copyright 26

9.5 Technology Dissemination 26

9.6 Technology marketing 26

9.7 Books Published by RDCIS 26

9.8 Conference organized by RDCIS 27

10.0 SAIL Safety Organization 27

Abbreviation 30

Annexure-1 : Generic Organization Structure 33


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1.0 Overview of RDCIS

The Research & Development Centre for Iron & Steel (RDCIS) is corporate R&D unit of

Steel Authority of India Limited (SAIL). It is Indias premier research organization in the

field of ferrous metallurgy. The main Centre, located at Ranchi, was established in 1972and its modern Laboratory Complex started functioning from 1986.

The main objectives are to pursue basic research programs to innovate new processes

and develop new products. RDCIS also facilitate SAIL plants to improve key

performance indices related to quality, productivity, yield through diagnostic and

research approach.

Equipped with more than 350 advanced diagnostic equipment and 5 pilot facilities under

15 major laboratories, RDCIS undertakes research projects encompassing the entire

spectrum of iron and steel - starting from raw materials to finished products. The Centre

is continuously engaged in improving the process parameters, development of value

added products, energy conservation, improvement in product quality, up-gradation of

existing technologies and introduction of new technologies in the plants and units of

SAIL. The Centre has acquired several patents and copyrights during the last few years.

The technical accomplishments of the Centre are regularly published in prestigious

journals in India and abroad.

While making significant contributions to the overall performance of SAIL, RDCIS has

developed and introduced innovative systems and procedures which have enabledquantification of inputs, outputs and measurement of the performance. Highest priority

and attention is accorded to the customer needs and the Centre delivers the

technological services to the full satisfaction of the customers.

RDCIS enters into collaboration agreements with leading research and academic

institutes, from time to time, both from India and abroad. Some of the leading

collaborating institutes from abroad have been TSNIICHERMET from Russia, National

Science Foundation of USA etc. The Centre collaborates with the IITs, IISc, CSIR

laboratories and other reputed organizations of India.

While catering primarily to the needs of the SAIL plants and units, RDCIS has opened its

doors for other public and private sector organizations in India and abroad. RDCIS can

transfer some of its proven technologies to other organizations, provide technical

consultancy, render specialized testing services, undertake contract research and

conduct training program.


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RDCIS has consistently enhanced its capabilities over the years. This has been possible

due to the highly dedicated team of technical and scientific personnel, possessing high

level of expertise and wealth of experience matching the best available elsewhere.

RDCIS has developed a broad spectrum of expertise which can readily be utilized for

solving complex problems in numerous technological disciplines. Major activities of the

Centre extend from developing new products processes to guiding contract research

program for specific needs of the steel industry. In addition, the Centre also imparts

training on multifaceted technology of iron and steel production.

RDCIS is accredited with ISO 9001 : 2000 Certification which was awarded by M/s.

Lloyds Register of Quality Assurance ( LRQA ), UK. To obtain ISO 9001 certification,

RDCIS had to resolve the innate conflict between standardization and creativity. These

two aspects have been stimulating and reinforcing each other to propel RDCIS to

achieve new peaks of excellence in its performance. RDCIS takes customer as a partnerin its innovations and is prepared to meet the challenges ahead.

2.0 Organization Structure, Areas, Divisions, Groups and ISSD

RDCIS has 3-tier structure consisting of AREAS, DIVISIONS & GROUPS in technical

disciplines. In addition there is Infrastructure & Support Services Department (ISSD) to

support the research activities. The areas are supported by 12 divisions, 6 Plant Centers

and 2 City Offices, one at Kolkata and one at Delhi.

The six technical areas are as given below;

i) Coal

ii) Iron

iii) Steel

iv) Rolling Technology

v) Product

vi) Automation and Engineering.

Total manpower distribution as on 31.05.08 are as follows;

Technical Non Technical

Executive 288 122

Non-Executive 145 154

Total 433 276

Total employee 709

The centre is enriched with 50 Ph.Ds and 84 Post Graduates


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A generic organization structure is given in Annexure-1

3.0 Project Management at RDCIS

3.1 Types of R&D Project

RDCIS pursues mainly following five different types of research programmes: Plant Performance Improvement (PPI);

Product Development (PD);

Scientific Investigation & Development (SID);

Basic Research (BR); and

Technical Services (TS)

3.2 Project Planning Procedure

Project-based technological services to SAIL plants are the main stay of RDCIS, SAIL;

focus lies on the following:

Improvement in Yield, Productivity, Quality and Equipment Performance & Effectiveness Reduction in Material usage and Energy Consumption

Development/ Marketing of Bye Products/ Refractories etc.

New value added Product Development and Commercialisation

Plant investigation

Feasibility studies

Environmental Studies

Specialised Testing

Process Investigation

Mathematical Modeling Instrument and Equipment Development

Software Development

Flow sheet Development

New Knowledge Generation

Existing Knowledge Up-gradation

In general, the plant-based projects are selected based on the requirements of

customers, determined through interaction with customers, both formally and informally.

It covers the requirements specified by the customer as well as the requirements

deemed necessary, though not specified by the customer, and the associated statutory

and regulatory requirements. Before committing to plants, requirements and

expectations are identified and documented. If necessary, more relevant data are

collected from plants and other sources (published literature etc.) to assess the technical

requirements for formulation of scope of the project. Then, the initial project proposal,

termed as Project Profile (Preliminary) is prepared. It comprises of the followings:


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Project Title

Category

Background & Justification

Objective

Approach

Resources

Duration ( Date of Start, Date of Completion)

Engineerdays Required (Group-wise, Year-wise)

Capital Cost ( with equipment details), Direct Revenue Cost (Year-wise)

Task-force Members

Benefits (Technological and Monetary)

The project of multi-assignment in nature i.e. when a particular project entails

involvement of more than one technical discipline, is divided into various assignments for

better management of the project. The overall responsibility of the project is assigned toa Co-ordinator. The Co-ordinator manages the interface amongst the concerned groups

judiciously for successful implementation of the project. For a project, other than multi-

assignment project, a Spokesperson takes the lead role.

The Project Profile (Preliminary) prepared by the technological group/ plant centre is

submitted to Project Co-ordination Division. The preliminary list of proposed projects is

compiled in the PC Division, who organizes a preliminary presentation for the proposed

projects. The Chief Executive along with Heads of Areas, Head of Finance, and Head of

Material Management participate in this meeting. The concerned spokesperson of the

project makes a presentation on the details of project. Based on the discussion in the

meeting, the list of projects is finalized. If required, Spokespersons make necessary

changes in the Project Profile (Preliminary). The List of projects along with the Project

Profiles (Preliminary) is sent by Chief Executive, RDCIS to Chief Executives and Heads

of Works of SAIL Plants and Units.

For Laboratory based projects, similar presentation is made by Spokesperson and the

list of laboratory based project is finalized.

After the concurrence is received from SAIL Plants/ Units, the concerned technologygroups are requested to prepare Project Microplan Document, which comprises the

following:

A. PROJECT PROFILE

B. QUALITY PLAN & RESPOBSIBILITY

C. PROJECT OUTLAY


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D. MAJOR RESOURCES AND CONSTRAINTS

E. ESTIMATED ANNUAL BENEFIT

The Project Microplan Document (PMD) is submitted to Project Co-ordination Division,

which initiated the process for approval. The PMDs are put up for discussion in meetings

of Project Approval Committee (PAC). There are seven PAC : PAC(Coal), PAC(Iron),

PAC(Steel), PAC(Rolling Technology), PAC (Product), PAC (Automation and

Engineering), PAC(RDCIS). Plant based projects having capital cost requirement more

than Rs 25 Lakh as well as all laboratory based projects are discussed in the meeting of

PAC(RDCIS). Rest plant based projects of different Areas are discussed in the meetings

of respective PACs. Based on the recommendation of PAC, Chief Executive approves

the project. The approval is obtained on A Project Approval sheet which comprises the

following:

Project Title Category

Project Number

Project Duration

Engineerdays Required ( Group wise Year-wise)

Budget (Year-wise)

Capital

Direct Revenue

Engineerdays Cost

Funding Classification

Once the project is approved, Project Sanction Order is issued for each individual

project. This comprises the following:

Sanction Order Number with date

Project Title

Project Number

Spokesperson, Group

Date of Start

Date of Completion

Engineer-days ( Year-wise) (Group-wise)

Sanctioned Cost

Capital ( Year-wise) (with Foreign Exchange, if any)

Revenue

Engineer-days

Sanctioning Authority

Details of Capital


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Details of Equipment

Details of Revenue

For monitoring the activities of the project, the project activities are broken into numbers

of milestones; every milestone bears a unique Milestone Number in a particular

Financial Year and a Milestone Sheet is prepared for each individual project (for a

financial year only). This comprises the following:

Project Title

Category

Project Number

Participating Groups

Plant/ Unit

Spokesperson

Starting Month Completion Month

Activities

3.3 Project Monitoring & Evaluation

It is universally known that the project monitoring is an essential tool for project

management; starts right after launching a project; helps in systematic analysis of

project performance; and answers: whether on / ahead/ behind schedule; where & how

the delay occurred; and the trend of performance.

So the basic purpose of project monitoring is: regular review of progress & timely

completion; optimum usage of scarce resources by scheduling/ rescheduling; their

utilisation as per the actual progress of the project; feedback to future plans for practical

estimation of activity duration, cost and vendor rating; and finally achieving the project

objectives & benefits.

Project monitoring / control involve:

A regular comparison of performance against targets

A search for the causes of deviation

A commitment to check adverse variances

The monitoring systems and procedures in operation at RDCIS are:

Monthly Monitoring & Review

Review at Plant

Quarterly Review of Performance (QRP) at RDCIS

Monthly Monitoring & Review

The R&D projects are primarily monitored and reviewed regularly with respect to the

Book of Milestones (BOM). Steps are described below:


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HOGs/ HODs report the progress of projects as per Monthly Progress Report (MPR),

format to HOD (PC) by 25th of the month

HoPCs reports the progress of projects whose Spokespersons belong to the Plant

Centre and also report physical progress on all other projects related to the concerned

plant centre to HOD (PC) by 25th of the month

Monthly Progress Reports are checked at PM & U Group against Milestones (as

mentioned in BOM) & adequacy of reporting and discuss with concerned HOG/

Spokespersons, if required, to remove discrepancies and bring clarity

MIS report is prepared stating fulfillment of Milestones (monthly as well as cumulative)

Division wise & Plant/ Unit wise at PM & U Group

Performance is analyzed critically and Performance at a glance is prepared and it is

presented it in ED I/cs monthly review meeting and follow-up of the action points are

also prepared to overcome the constraints by PM & U Group

Monthly Highlights of performance are prepared for Director (Technical), SAIL / SAIL

Board Monthly compliance report is prepared for the Projects included in MOU between SAIL &

MOS

Plantlevel Review by ED (W) / MD

Steps:

The date for review meeting at plants is finalized with Head of Works/ Chief Executive.

The date of internal meeting at RDCIS is finalized.

Briefs are prepared taking into consideration the minutes of the previous meeting, forinternal review.

Internal review meeting at RDCIS is conducted with the participation of concernedproject Spokespersons/ HOGs/ HODs/HOPCs/HOAs.

Co-ordination is done along with HoPC for holding the review meeting at plant withparticipation of plant personnel and engineers from RDCIS.

Action Points are prepared and distributed to all concerned

Record Notes/ Minutes of the review meeting are prepared from plant and distributedto all concerned within a weeks time.

Follow up done with the technology groups for accomplishment of the action points.

Quarterly Review of Performance

This review is a unique review for adding quality to the R&D pursuits; performance

assessment of the Centre at the end of every quarter; and effecting communication of

R&D outputs within RDCIS by providing a forum for joint exploration through critical

questions and stimulating Spokespersons/Taskforce to bring forth new ideas /approach


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Review Mechanism

The Reviewees tasks:

Earmarks the stage for review at the beginning of the project or as per need

Provides project details in project assessment sheet

Prepares posters highlighting progress

Answers the questions at poster site

Explores the possible means jointly to improve the quality of project

The Reviewers tasks:

ED I/C/ HOA/ HoPC/ HOD/ HOG depending on the category and cost of the project:

Critical examination of project details provided in the project assessment sheet & thedisplayed poster

Interaction between reviewers & reviewees at poster site

Assessment of projects outcomes against the factors of review sheet &

Handing over the review sheet to the reviewees

Review Result:

Specific observation / explanation / suggestion of reviewers for qualitative improvementsin project content

Necessary modification/ corrective action by HOD in consultation with HOA as persuggestions of the reviewers

Prepare QRP Record Notes enlisting the key observations & the suggested action points

by the reviewers

Project Evaluation

On implementation, an R&D project may produce scientific, technological, social and

monetary benefits. The benefits other than monetary are expressed in terms of

publications, patents and copyrights, however, the latter may be quantified based upon

an improvement in plant operating parameters such as productivity, quality, energy

consumption etc. R&D innovations initiated and subsequently implemented in steel

plants generate monetary benefit, which is quantified and its impact on the overall

economy of the organisation is evaluated.

The basic reasons for the evaluation of R&D projects in terms of monetary benefit are:

It provides the justification for the expenditure incurred on the project;

Based on the feedback, it enables RDCIS to select projects with high returns;

It ensures that RDCIS would follow up the utilisation of the innovations after they are

transferred and implemented;


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It sensitises the plant about the benefit derived from an innovation, and which if

substantial, in turn, can induce the plant to make a continued utilisation of the innovation;

and

It develops a clear insight as to how an innovation impacts on the economics of cost

reduction, quality improvement and the value addition of new products.

Sources of Monetary Benefit

As mentioned above main sources of monetary benefit are:

Improvement in productivity, yield, quality, machine availability, equipment life, etc.

Reduction in rejection, material consumption, energy consumption; and

Value addition through new product development

Quantification of Monetary Benefit:

An improvement made due to the innovation in the plant operating parameters may betransformed into monetary benefit using the following guideline:

Monetary Benefit = Improvement made X Volume of Utilisation

(Rupees) (Rs. per ton) (Tons)

Based upon the above, parameter sensitive standard procedures are designed for each

category of innovation.

In order to assess the impact of the implemented innovations benefit is calculated at the

four stages:

i. Estimated Annual Benefit (EAB) is calculated at the selection stage based on

assumed values of plant operating data (PODs)

ii. Anticipated Annual Benefit (AAB) is calculated at the project completion stage using

demonstrated values of PODs

iii. Certified Annual Benefit (CAB) is calculated based upon actual values of PODs for a

utilization of 12 months just after completion of the project and it is termed as

Incremental CAB (ICAB). At this stage the benefit is certified by a Standing Committee

(SC) headed by ED(W) of Plant

iv. Recurring Benefit(RCAB) : In order to assess the sustenance of the innovation, benefit

is further computed for additional 24 months and it is certified by internal standing

committee headed by ED I/c, RDCIS.

Procedure of Benefit Certification

Incremental Benefit (ICAB) and Recurring Benefit (RCAB) are certified by plant and

RDCIS, respectively, in the following manners:


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Incremental CAB:

Actual PODs are collected and authenticated by shop heads

Benefit is calculated using parameter sensitive standard procedure

Calculated benefit along with shop signed data and a brief technical summary of

project are put up to Plant finance routed through RDCIS Plant Centre I/c and

Chief of R&Q of respective plants

Plant Finance examines the calculations and modifies, if requires

The benefits are discussed in the Standing Committee Meeting and on

finalisation, recommended for approval of ED (W) of plant.

Recurring CAB:

Actual PODs are collected and authenticated by RDCIS Plant Centre In-Charge.

Based upon the PODs and corresponding price/cost figures, benefit is calculated

using the same procedure as recommended by plants Standing Committees

during ICAB certification

Benefits are put up to an internal Standing Committee constituted by ED I/c,RDCIS

Committee examines the calculations and modifies, if requires

The benefits are finalised by the committee and recommended for approval of

ED I/c, RDCIS

4.0 Major Research Facilities

The research facilities comprise of 15 major laboratories encompassing 6 pilot facilities

and 350 equipment and advanced diagnostic facilities. The pilot facilities and major

laboratories are listed below;Pilot Plants & Simulation facilities

Pilot Coke Oven

Pot Sintering

Experimental Hot / Cold Rolling Mill

Combustion Research Unit for design & testing of burners

Thermo-mechanical simulator (Gleeble system)

Hot dip process simulator for coated products

Major Laboratories

Coal Carbonization Laboratory

Mineral Beneficiation

Sintering and Agglomeration

High temperature reduction

Melting and Solidification

PLC and Software development

Physical metallurgy


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Mechanical Testing

Chemical analysis and corrosion engineering

Refractory

Tribology

Environment

Computational laboratory

Computer Centre with state-of-art development tools

4.1 State of the art research facilities at RDCIS for scientific work

The state of the art research facilities available at RDCIS are being used to generate

reliable data as input to the plant based projects and scientific investigation. The

diagnostic capabilities of major laboratories are described as under;

Pilot Coke oven

This is an electrically heated and PLC controlled moving wall pilot coke oven with a

capacity to carbonize about 250 kg of coal and is the only one of its kind in India. It is

capable of operating under wide range of carbonization conditions and can simulate

industrial coke oven conditions. Coke mass temperature, oven wall pressure, vertical

shrinkage etc. can be measured. These are being extensively used for pilot coke oven

carbonization studies for coal preparation, coal selection / evaluation and blend

formulation / optimization.

Pilot sintering unit

This unit can simulate the commercial sintering process and has a capacity of 100 kg

per batch. It is used extensively for evaluation of impact of sinter chemistry, bed height,

sinter granulometry etc. on sinter quality such as Tumbler Index (TI), Reducibility Index

(RI) and Reduction Degradation Index (RDI).

Experimental rolling mill

It is a 2 Hi / 4 Hi experimental rolling mill capable to roll in hot and cold rolling condition

and is equipped to measure and record all rolling parameters. It is used for simulation of

rolling condition, product characterization, mathematical modelling, development of

products and cold rolling oils.

Air and vacuum Induction furnaceThis equipment is used for simulation studies for steel making process in the laboratory

condition using 50 to 300 kg furnaces. It is also used for development of special and

alloy steels in air / vacuum environment.


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Thermo mechanical simulator (Gleeble 3500C)

The Gleeble 3500C system is only of its kind available in India. It is capable to simulate

various metallurgical processes namely Continuous casting, Hot rolling and Annealing

etc and also used for material testing. Presently, this is used for development of

optimised hot rolling parameters for a number of special steel products.

Hot dip process simulator (HDPS)

This unique National facility is a vital tool for development of coated products like

galvanised, gavanneal, galvalum, etc. This system is capable of simulating all vital

process parameters (e.g. line speed, bath chemistry, strip entry temperature etc.) to

control the coating thickness. This system is currently being used for developing a

working model for coating mass control.

Electron beam wide area analyser (EBWA)

This is an indispensable research tool for analyzing chemical composition of steelinclusion, second phase particle, precipitates and elemental analysis of segregation.

This is being used extensively for material characterization, failure investigation and

product development.

Optical emission spectrometer (OES)

The OES system is being used for accurate determination of major, minor / trace

constituents in analyte material such as low alloy, high alloy steel etc. It is equipped with

latest software to overcome inter element effect and back ground correction.

Particle Image velocity meter (PIV)This system finds its application in determining flow characteristics including velocity

profile of fluid in a water model system. Presently, this is being used for cold / water

model simulation studies of different metallurgical system namely tundish and mould in

continuous casting.

Image Processing unit for analytical ferrography

This vital equipment is extensively being used for monitoring the health of machineries

working in the shop floor. The principle behind operation of such predictive system lies

with the analysis of oils and lubricants, contaminated with wear debris / particle

generated during the service of equipment. Microscopic analysis of such particles (size,

shape and colour) provides information on health of running equipment.

5.0 Research areas

The basic research activities provide scientific insight into processes and products for

enabling utilization of advancing science and technology for steel plants applications.

The main areas of basic research at RDCIS include the following;


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i) Coal Carbonization

ii) Mineral Processing and agglomeration

iii) Iron making

iv) Steel making

v) Continuous casting

vi) Refractory

vii) Rolling Mills

viii) Tribology

ix) Energy conservation and environment management

5.1 Basic Research

The major basic research activities pursued in the recent times are:

Studies on coke texture to correlate coal blend properties and coke qualities

Mathematical simulation of solidification and fluid flow in continuous casting.

Measurement of heat transfer property for mould powder during continuous casting

Microstructure modeling to enhance the properties of coils and plates

Influence of critical process parameters in hot rolling and annealing for development of

high performance steels namely low carbon Extra Deep Drawing (EDD) steel, line pipe

steel, high strength rail with superior corrosion resistance property, Earth Quake

Resistance Steel (EQR) etc.

5.2 Major process related achievements

A glimpse of major achievements of the centre in different areas is outlined below;

(i) Coal Carbonization

Enhancement of supply base of imported coking coals through formulation of

specifications, evaluation of imported and indigenous coals. Evaluation is done

through laboratory characterization, pilot oven tests and industrial scale trials.

Coke oven performance evaluation and process improvements.

Introduction of in-house developed Integrated coking control system for reduction in

specific heat consumption by 5 % at BSP and DSP.

(ii) Mineral processing and agglomeration

Improvement in productivity, quality and reduction in specific energy consumption in

sinter plants at RSP and BSP.(iii) Iron making

Increase in Blast Furnace productivity (0.80 to 1.30 t/m3/day at RSP, 1.35 to 1. 78

t/m3/day at BSP), through optimization of burden distribution, control of blowing

parameters, etc.

Decrease in BF coke rate(600 to 563 kg/thm in BF#3 at BSL, 633 to 607 kg/thm at

RSP) through improved gas utilization, heat flux control, etc.


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Campaign life of BF enhanced through hearth protection measures in the form of

charging titaniferrous ore and injection of ilmenite. Campaign life in BF 4, DSP was,

increased by 6 months recently.

Stabilization of pulverized coal and tar injection at BSP and BSL.

(iv) Steel making

Enhancement of BOF converter lining life through development of slag splashing

technology and improvement in lining design and brick quality at RSP.

Reduction of Aluminum consumption by approximately 1 kg / ton of liquid steel

through improved deoxidation practice at BSP, RSP and BSL.

Reduced residuals (P & Si) for low carbon extra deep drawing (BSL) and sulphur in

rail (BSP) steel through refining technique.

Optimization of porus plugs location and purging regime in ladle at SMS-II, BSL for

reduction of LF hood jamming and increase in ladle lining life.

(v) Continuous Casting

Casting technology for CRNO grade leading to 100 % continuous casting route at

RSP resulting yield improvement from 48 to 75%.

Introduction of Electro Magnetic Stirring (EMS) at DSP and ASP for quality

improvement, enabling switching over to CC route for difficult to cast grades (crank

shaft quality etc.)

Development and Installation of automatic secondary cooling system in billet caster

at DSP.

Development of a system for aligning tundish and mould in billet caster at DSP.

Quality improvement of cast slabs e.g. reduction of centre cracks from 7.2 to 1.6 %

at BSL and reduced steel defects in high strength grade by 4% at BSP.

Development of 880 MPA grades rails through BOF-CC route, which improved the

yield of rails from 77 to 88 %.

(vi) Refractory

Development of wide varieties of castables for application in steel ladles, caster

tundish and mill reheating furnaces. Know how transferred to several suppliers; 5

patent sealed.

Development of MgO-C bricks and in-house manufacturing for converters and steelladles at RSP, BSP and BSL.

Improvement of steel ladle life in SAIL plants (RSP: 49 to 80 heats, BSP: 38 to 62

heats and ASP: 30-150 heats).

Introduction of low thermal mass (Ceramic fiber lining) in heat treatment and

reheating furnaces for energy saving at BSP, RSP, ASP and DSP


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(vii) Rolling Mills

Flat rolling

Productivity improved by 10% at Hot Strip Mill of RSP by introduction of longer slabs

(7.7 m to 8.6 m). Yield improved from 96.2% to 97%

Modification of process parameters of CRNO coils at Silicon Mill, RSP, improved millproductivity from 5400 to 7000 tons per month.

Next generation cold rolling oils developed for tandem mills of BSL and RSP

facilitated in rate by 10 % and surface reflectance to 85 % .

Accelerated cooling of plates at BSP eliminated normalizing treatment of plates of

thickness 14-28 mm for all grades of steel.

Shape rolling

Development of Micro alloyed (Nb/V) rails to withstand higher axle load.

Development of corrosion resistant rail for coastal area.

Improvement in production of loco wheel at DSP (from 43000 to 65000 nos per year) Introduction of hot charging and round ingot technology to increase yield of superior

quality wheels.

(viii) Tribology

Condition Based Monitoring System (CBMS) introduced in all plants helped in

preventing major break down of critical equipments.

Developed plasma spray coating technology for reclamation of PBCC rolls at BSP.

Superior wear resistance plates for sinter plants exhauster housing of BSL increased

working life to 4 years.

(ix) Energy Conservation and Environment Management

Introduction of high capacity BF gas burner in Boiler 6, BSP to eliminate use of

pulverized coal (saving of Rs. 11 crore per annum).

Dual fuel burner for rotary kiln of BSP for replacing Pitch Creosote Mixture (PCM) by

coke oven gas.

Gaseous fuel burner for reheating furnaces of BSP and DSP for reduction in heat

consumption by 5-10 %.

Introduction of multislit burner for sintering at BSL, BSP and RSP.

Regular monitoring of Polycyclic Aromatic Hydrocarbon (PAH) in Coke Oven

emissions in all SAIL plants as a statutory requirement.

Simulation study and process optimization of biological treatment plant at BSP.


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(x) Automation and Engineering

Automation of Looper and Entry guide control systems introduced in hot strip Mill,

RSP, resulted in finishing mill yield improvement by reducing number of cobbles from

42 to 10 per annum.

New loop sensor for wire rod mill, BSP, reduced rejection by 15%. Integrated monitoring and display system for fault indication and centralized electrical

fault indication reduced mill delays.

Level-II automation in reheat furnaces of Rolling mills at BSP, RSP and DSP

Computerized Human Resource Information System (BSP, DSP and RDCIS)

Computerized Refractory Management System (BSL, BSP)

On line Financial Accounting System at BSP & RDCIS

Air humidification and steam injection system for sinter plants

On line argon purging system at steel ladles at RSP

Oil water emulsion system for coal charged at DSP, BSP and BSL

5.3 Product Development achievements

Product development is one of the core activities, which entail development of market

oriented value added products and their commercialization. The major contributions

made are:

Introduction of micro alloying concept for development of high tensile long and flat

products, marketed as SAILMA variety steels.

Adaptation of thermo mechanical controlled processing for production of high

performance steels with respect to combination of high strength and toughness

properties.

Evolution of optimized chemistry and process parameters for contemporary / new

special quality steels, processed through continuous casting route.

Commercialized more than 20 special grades during last four years and marketed

around 6 lakhs ones.

Introduced Early Vendor Involvement concept (EVI) / Application engineering for

promotion of new products in the market place through continuous collaboration with

major customers (Maruti, Tata motors vendors) i.e. Original Equipment

Manufacturers (OEM).

Different products developed for Defence, Automotive, Construction, Earth moving

equipment, Electrical steels, Power and Oil & Gas sectors.

6.0 Major on going Research projects

6.1 Coal Carbonization

Rationalization of coal preparation scheme to improve coke quality

Improvement in coke quality w r t moisture and M40


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Study on the effect of chemical/ mechanical treatment on tar quality

Improvement in the performance of Ammonia stripping unit

Coking process management and control system in COB #4

6.2 Mineral beneficiation and agglomeration

Upgradation of slime beneficiation system to decrease silica content in iron ore fines atDalli Mines

Stabilisation of productivity of Sinter Plants

Utilisation of lime fines in sinter mix for improving productivity of sinter plant at BSL.

Automatic control of dampers of exhausters in Sinter PlantII for lowering energyconsumption at DSP.

Development of system for air humidification on sinter bed for improvement inproductivity and quality in Sinter Plant

Incorporation of Burn Rise Point (BRP) and heat pattern control systems at SP-II, RSP.

Incorporation of design modification to improve crushing index and to decrease fines in

crushed coke at RMHP

6.3 Iron making

Laboratory simulation of reduction behavior and microstructure analysis of ferrousburden material under simulated BF condition

Improvement in performance of BF #3 & 4, ISP

Status monitoring of charging conveyer of BF, BSL

Stabilisation of coal dust injection in BF # 1, BSP

Improvement in quality of hot metal and reduction in coke rate in BF shop at RSP

Reduction in undersize fraction of skip sinter of BF of BSL

6.4 Steel making and casting

Increase in BOF lining life at DSP, Durgapur

Improvement in steel making practices to achieve lower rejection level at HSM, ISP,Burnpur

Optimization of hot metal desulphurization parameters for achieving low sulphur at BSP,Bhilai

Stabilisation of steelmaking process parameters for commercial production of API X-60and production of extra low carbon CRNO steel

Indigenous development of BOF process automation system at RSP Rourkela (SDFfunded project)

Production of low sulphur (< 0.010% S) Al-killed steel like CRNO, API, EDD grades byusing fluxes like lime, calcined bauxite and synthetic flux.

Production of low sulphur (< 0.025% S) Si-killed steel like rails and wheels using limeand synthetic slag.

Production of low nitrogen (


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External earnings through consultancy assignments for different refractorymanufacturers.

Development and application of CFD model for decision of tundish furnitures e.g. turbostopper and other flow control devices.

Improvement in ladle lining life at SMS-II, BSL through optimization of LF operating

parameter Improvement in tundish flow in six strand billet caster of DSP, Durgapur

Development of heat transfer and fluid flow model for determination of melting time ofdifferent ferro-alloys in ladle

6.5 Refractory

Development and application of spinel castable.

Development and application of purer grade mag-carbon brick for better performance.

Development of basic castables.

Introduction of improved lining practice with better quality bricks for hot metal and steelladles for better performance.

Development of better design for sinter hood for introduction of curtain flame ignition

system.

Improvement in the lining life of BOF to 10,000 heats and above for better BOFavailability.

6.6 Rolling Mills

Microstructure modeling of hot rolled strips at BSL

Development of models of plate rolling for closer gauge control at BSP

Introduction and stabilization of roll bite lubrication in hot strip mill of BSL

Model based control of hot strip rolling at RSP

Improvement in Quality of Cold rolled coils at RSP Control of bare spot and zinc peel-off defects in galvanized strips at BSL

Improvement in quality of plate at RSP

Advancement in emulsion application system at TCM1, BSL

Improvement in surface cleanliness of CR products at TCM2, BSL

Measurement of residual stress of Rails

Microstructure modeling of bars

Development of simulated models of Locomotive wheel processing

Wear characteristics of different grades of rails

Increase in mill utilization of Light Structural Mill, ISP

Improvement in productivity of Section Mill, DSP Improvement in hot saw life of Rail & Structural Mill, BSP

Qualifying criteria tests of Rails

Improvement in productivity of 16mm TMT in Merchant Mill, ISP

Application of Portable UST & ECT systems for inspection of Hot Strip Mill Rolls

Improvement in roll performance of CRM & SSM mills with NDT assisted roll grinding


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Improvement in equipment availability and enhancement of lubricant life through oilcondition monitoring techniques

Optimization of back up babbit bush bearing performance to reduce failures in TCM#2

Development of system for monitoring of slow speed running equipment

6.7 Product development

Development of micro alloyed high strength cost effective steels using nitrogen enrichedvanadium

Development of SUP 9 grade billets for leaf spring

Commercialization and market promotion of earth quake resistance TMT rebars.

Development and commercialization of identified special steel products

Development of low carbon formable and cold reducible HR / CR grades

Characterisation of corrosion behavior of low nickel austenitic stainless steels.

6.8 Energy and Environment

Curtain Slit burners for sinter ignition hoods: at all Sinter machines of BSL, RSP, BSP

(Sp-II two Machines) Variable flame length dual fuel burners were introduced in the Rotary Kilns of the

Refractory material plant at BSP and BSL

Dual fuel burners have been introduced in new boiler house at ASP. Burners using BF

gas and oil have been developed for the heat treatment furnaces and have been

introduced in the heat treatment furnaces of VISL

Tube-in-Tube type burner for ladle heating: This design of burner is being used in all the

ladle repair and heating stations in SAIL plants.

High Capacity BF gas burner: Introduced in boiler house no-6 in Power & Blowing

Station at BSP

Retrofitting/Revamping of Reheating Furnaces at almost all SAIL plants through

investigation, up-gradation of combustion and flue system, insulation and through

improved operating practices

Energy Audit: It is being carried out in different shops of plants to identify energy

conservation projects to reduce specific energy consumption. Monitoring of energy

performance indices at intra plant level is also being done.

Development of Integrated process for treatment of coke oven effluent

Statutory Monitoring of PAH in coke oven of steel plants (BSP, RSP, DSP, BSL and ISP)

Investigations into non-invasive techniques for water pollution control

Development of integrated enrichment process for re-cycling of mill sludges Improvement in quality of water in BOF

Development of fine particulate monitoring system for BOF gas pipe lines

Development of analytical methods for determination of trace elements such as Hg, As,

Sb etc in ores, metals, wear debris and process based waste material through ICP

technique


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6.9 Automation & Engineering

Development of on-line Surface Inspection for hot rolled flat products.

Development of improved lance control system at SMS#1, BSL.

Improved speed control system at Skelp Mill, DSP.

Automation of BF charging conveyors at BSL. Measurement system for Mould Width control at Concast, BSL.

Tail end cutting system at Hot Strip Mill, RSP

Modification of hydraulic circuit for edge guide system at DCR mill, BSL

Introduction of edge guide system at PL#2, BSL

Improvement of productivity of SP#1, RSP by suction improvement

Cooling of turret ladle weighing system

Improved monitoring system for machine cooling water circuit at CCM#2, RSP.

6.10 Information Technology

On-line storage, update and retrieval system for employee base data at IISCO SteelPlant, Burnpur

Integrated refractory information system at Rourkela Steel Plant, Rourkela

Integrated on-line information system for blast furnace operation at Bhilai Steel Plant,Bhilai

Enhancement of office automation facilities

Modeling and control of microstructure and mechanical properties during Hot StripRolling at HSM, BSL (SDF)

Indigenous development of BOF process automation system at RSP

Improvement in the performance of sinter machines at BSL by optimizing sinter mix

permeability in three sinter machines Installation of permeability measurement system in both sinter machines of SP-I, RSP

7.0 Collaborative research work

7.1 Research work pursued and completed with foreign institute

Indo-USSR program: Two types of collaborative programs ware pursued by RDCIS; (i)

Bhilai Modernization Program and (ii) Specific research project activities. A few bilateral

symposiums were also organized.

Indo-US NSF program: To improve upon the expertise of the R&D engineer and

exposed them to the latest Research and Development trend, a major program was

initiated with National Science Foundation, USA. Six products development activities

were pursued.

NKK, Japan: Agreement was made for know how transfer in the area of Computerized

combustion control system for coke ovens and Blast furnace revamping.

International Flame Research Foundation, Netherlands:


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7.2 Research work carried out with Ministry of Defence

RDCIS in association with various defence agencies like CQA (Met), Ichhapur, DMRL,

Hyderabad, CVRDE, Avadi, DQA (Amm), Ordinance factory, Ambajhari, developed a

range of special steel products namely ME 10 grade (for manufacture of ammunition),

SAIL Kavach (for production of bullet safety jacket and personal carrier vehicles), HSLA

80 and DMR 249 Grade A&B (for manufacture of warship and submarine). RDCIS also

developed process technology for production of thicker spade quality plates (up to 85

mm) through concast route, resulted in yield 38 to 67%. This product is found suitable for

Arjun MBT.

7.3 Major on going collaborative research work with foreign and Indian researchinstitutes.

CBMM, Brazil

RDCIS is having collaborative work on development high strength HT 750 and API X 70

grades Plates & HR coils at BSP and BSL.

IITs and IISc

Collaborative work in connection with different projects; (i) Model development for plate

rolling with IIT, Chennai, (ii) Model development for BOF process at RSP, (iii) Waste

utilization process with IIT, Mumbai.

8.0 Expenditure on R&D efforts

Expenditure (Capital and Revenue) on R&D efforts incurred by RDCIS in the last seven

years is given below;

The above expenditure does not include the cost incurred for carrying out plant trials

including cost of raw material & consumables, cost of testing at plants Research &Control Laboratories (RCL).

Year Expenditure, Rs Crore

2001-02 47.86

2002-03 52.22

2003-04 51.79

2004-05 58.39

2005-06 58.22

2006-07 71.51


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9.0 Impact of R&D efforts

9.1 Paper Publication

Average publication per year of RDCIS is 55. RDCIS had published around 360 original

papers in International journals since inception. Most of the papers have been published

in the following journals;

Metallurgical Transaction-USA,

Acta Metallurgica-USA,

Scripta Metallurgica-USA,

Solid State Ionics-UK,

Ironmaking and Steelmaking UK,

Transaction of Iron and Steel Institute of Japan,

ISIJ International-Japan,

IEEE Transaction on Magnetics-USA,

Journal of Material Science and Engineering-USA, Scndanavian Journal of Metallurgy-Sweden,

Transaction of British Ceramic Society-UK,

Ceramic International-Italy,

American Ceramic Society Bulletin-USA,

Coke Making International,

Journal of Material Science and Performance-USA,

Metallurgical Plant and Technology-Germany,

South East Asia Iron and Steel Institute,

International Journal of Mineral Processing-USA. Steel Times International-UK

RDCIS publishes Steel India journal, which is a biannual technical journal for the Iron

and Steel Industries. Its prime objective is to provide a technical forum for operating

personnel, engineers, managers, scientists and academicians to exchange ideas and

information that may eventually lead to technological breakthroughs and innovations.

9.2 Paper presentation

In last two years RDCIS has presented 228 papers in both National and Internationalconferences. On an average RDCIS presents 120 papers in conferences.

9.3 Patent

With over increasing competition in the global market, the importance of obtaining

Intellectual Property Rights for the innovations made by the company employees has

become increasingly more important from the point of view of building monopolies.


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Further in order to remain globally competitive it has become necessary for SAIL to align

business strategy with the prevailing IPR laws.

RDCIS has filed 473 patents out of which 240 have been sealed.

9.4 CopyrightRDCIS has filed 309 copyright since inception out of which 261 has been granted.

9.5 Technology Dissemination

In order to update the knowledge of SAIL executives with the latest development in Iron

and steel, making technology, RDCIS conducts several technological awareness

program in RDCIS Ranchi and plant. Such programs helped SAIL executives in

functioning in their respective filed more efficiently. RDCIS has conducted 197 such

programs

9.6 Technology marketing

RDCIS has a dedicated group for Technology marketing to interact with the customers

outside SAIL and facilitate the marketing of technological services. RDCIS offers

technological services to various organizations in the form of;

(i) Know-how transfer of technologies developed by RDCIS

(ii) Consultancy services

(iii) Specialized testing services

(iv) Contract Research

(v) Training

9.7 Books Published by RDCIS

The following are the list of books published by RDCIS

Sl.No

Title of the book Authors / Editors Year ofPublication

1. Trends in beneficiation andagglomeration of Iron ore

RDCIS 2001

2. Sponge Iron Making in RotaryKiln

Krishna Kant Prasad & Asim KumarRay

2002

3. Steel Plant Technologies (Acompilation of Techno trends)

G I S Chauhan, K K Prasad, R KVijayavergia, B B Agarwal & NeetaChakravarty.

2004

4. The metallurgy of Work Rolls forHot and Cold Strip Mills

Amitav Ray & Sudhakar Jha 2004

5. Blast Furnace Design,Operation, Maintenance andPerformance in FerrousMetallurgy (in Hindi)

Vijay Krishna Jha 2004


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6. Thermo Mechanical Simulationand Processing of Steels

Sudhakar Jha, A K Dasgupta, SChakraborty, S K Chowdhury, R KVijayavergia & Ramen Datta.

2004

7. Surface Quality of steel products Dr Santanu Kumar Ray 2005

8. Coking Coal and Coke making:

Challenges and opportunities

G I S Chauhan & R K Vijayavergia 2005

9. Measurement and Control in HotRolling of Steel

Asoke K Paul and N Neogi 2006

10. Sponge Iron An Introduction M P Srivastava 2007

11. Flat Rolling Lubrication P Pathak and S Jha 2008

12. Steel Plant Technologies Anoverview

RDCIS 2008

9.8 Conference organized by RDCIS

In view of rich experience gained over last three decades in different disciplines of Iron

and Steel technology, RDCIS has organized around 38 National and International

conferences / seminars since inception.

10.0 SAIL Safety Organization

Iron and Steel production being a complex activity, Steel Authority of India Limited

(SAIL) gives adequate emphasis on safety & occupational health of human resources.

SAIL Safety Organization (SSO) formed in 1988 at Ranchi to co-ordinate, monitor,

promote and enhance the safety & fire services activities of plants / units of the company

at corporate level. SSO formulates & prepares appropriate Safety Policies, procedures,

systems, action plans, guidelines etc. and provides technical guidance, advice &direction to the plants/units for enhancement of safety standards.

Periodic meetings are conducted with Heads of Safety, Fire Services and Project &

Construction departments where review of the status of the performances of all

plants/units are made and strategic action plans are developed for bringing in definite

improvement on identified issues which are closely followed up for timely

implementation.

To provide an accident free work environment, spot study of fatal accidents & serious

incidents occurred at plants/units are conducted and report prepared with

recommendations are disseminated amongst all plants & units for arresting recurrence.

Recommendations of expert committees constituted are followed up for implementation.

Investigation of accident cases / fire incidences as & when occurred at RDCIS complex

or MTI are being made and remedial measures are suggested for preventing recurrence.


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Safety Management systems like Risk Control Grading System introduced through

National Safety Council Australia at three major departments of BSL was subsequently

spread in other departments of BSL and in major departments BSP, DSP & RSP.

Emphasis is also being laid upon introduction of OHSAS-18001 in the plants/ units

where the system is yet to be implemented.

To assess the prevailing Occupational Safety & Health (OS & H) system, compliance to

regulatory requirements etc. and identify areas for improvement Safety audits are

conducted as per IS 14489:1998 at various departments of all plants/ units including

Mines and Ware Houses. Emphasis is laid to cover all the Major Accident Hazard units

of the plants.

To bring in continuous improvement in Safety performance, SSO organises area specific

workshops and disseminate recommendations for implementation of relevant learning as

an effective tool of loss control at respective work areas of the plants/units. Efforts are onfor adopting proactive measures coupled with laying more emphasis on behavior

aspects and attitude of employees at all levels to bring in cultural change at

organizational level.

Consistent efforts are made for competence building in the area of safety management

through HRD intervention. Training modules prepared & published for identified thrust

areas for imparting modular training. Safety Training programmes are organized at plant

premises or centrally at MTI/TDC for Heads of shops / Sr. Managers, Line Managers,

Safety Officers, Safety & Workmen Inspectors. Faculty support is rendered for Safety

sessions in various programmes held at MTI & different plants/ units. Safety trainingprogram is also conducted by SSO at MTI for the executives of RDCIS, CET and MTI.

Due emphasis is being laid upon the safety aspects of project & construction sites in

view of deployment of large number of contractor workers during large scale

modernization & capacity expansion. Review meetings are conducted with HoDs / In-

Charges of Project & Construction departments of all plants/units periodically for

ensuring the safety standard.

Standards Committee on Personnel Safety Appliances and Procedures, IPSS 1:11

under the guidance of ED (Safety), SAIL formulates a documented solution to a

recurring problem by pulling knowledge and experience of concerned personnel

connected with that problem. Standards thus formulated through committee method is

printed and distributed by IPSS secretariat to all users for implementation.

The secretariat of Joint Committee on Safety, Health & Environment in the Steel Industry

(JCSSI) which addresses the problems related to these three crucial areas through an


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unique bi-partite forum at National level is continuing with SSO, Ranchi. Winning

member plants for achieving No Fatal Accident and individual winners of various Safety

competitions are awarded during the annual award function organized by SSO.

Safety awareness generation drives are undertaken for SAIL collectives at Ranchi.

National Safety Day is celebrated for all SAIL units at Ranchi. The winners of various

competitions organized by SSO are awarded in the National Safety Day function held at

RDCIS auditorium. Various competitions like Safety Essay & Extempore talk-for

employees, Sit & Draw- for children, Quiz -for housewives & lady employees, Extempore

talk- for students of various institutions are being organized. Programme on Home

Safety is also conducted for the Ladies of Shyamali & Satellite Township.

Various publications regularly made by SSO Ranchi are the Annual Performance Plan

on Safety & Fire Services, Monthly reports & Annual reports on Safety & Fire Services

activities undertaken by various plants/ units & SSO, Annual report of JCSSI, Quarterlyin-house magazine SCAN on Safety, Health & Environment, Annual publication on

Learning from fatal accidents etc.

X


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Abbreviations

Abbreviation Description

5 M Men, Material, Machine, Money and Minute

AAB Anticipated Annual BenefitAPP Annual Performance Plan

ATM Annual Technical Meeting

BR Basic Research

BTSO Branch Transport & Shipping Office

CE Chief Executive

C&IT Computer & Information Technology

CAB Certified Annual Benefit

CFD Computational Fluid DynamicsCMO Central Marketing Organisation

CSI Customer Satisfaction Index

DD Design & Development

DE Designated Executive

DP Designated Person

E.D. Engineer-Day

EAB Estimated Annual Benefit

ED Executive DirectorED(W) Executive Director (Works)

F&A Finance & Accounts

FE Foreign Exchange

GM General Manager

HOA Head of Area

HOD Head of Division

HOF Head of Function

HOG Head of GroupHOPC Head of Plant Centre

HRD Human Resource Development

ICAB Incremental Certified Annual Benefit

IDC Information & Documentation Centre

IPR Intellectual Property Rights


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IPSS Inter Plant Standardization for Steel Industry

IS Indian Standards

ISSD Infrastructure & Support Services Department

Lab. Laboratory

LF Ladle furnace

LS Laboratory Service

MAP Multi Assignment project

MIS Management Information System

MM Materials Management

MOS Ministry of Steel

MOU Memorandum of Understanding

MR Management Representative

MRC Management Review Committee

NCR Noncompliance Report

NMD National Metallurgists Day

NSC National Safety Council

PA Patent Attorney

P&A Personnel and Administration

PAC Project Approval Committee

PAT Preliminary Acceptance Test

PBG Product Business Group

PC Project Co-ordination

PCC Plant Centre Co-ordinator

PD Product Development

PM&U Project Monitoring & Utilisation

PMD Project Microplan Document

PO Purchase Order

POD Plant Operating Data

PP Project Planning

PPI Plant Performance Improvement

QMS Quality Management System

QRP Quarterly Review of Performance

Qtr Quarter


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RCAB Recurring Certified Annual Benefit

RDCIS Research & Development Centre for Iron & Steel

SAIL Steel Authority of India Limited

SCQD Standing Committee on Quality Document

SOP Standing Operating Practices

SID Scientific Investigation & Development

SP Steel Products

SRD Software Requirement Document

SSO SAIL Safety Organization

STA Short Term Assignment

TA Traveling Allowance

TAP Technology Awareness Programme

TDC Technology Dissemination Centre

TM Technology Marketing

TMT Thermo Mechanical Treatment

TQP Total Quality Process

TS Technical Specifications


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Unit Specific Manual on RDCIS & SSO

Documents

Transcript of Unit Specific Manual on RDCIS & SSO