REPORT

Bhilai Steel Plant

Introduction to Bhilai Steel Plant:

The Bhilai Steel Plant, which is located in Bhilai, Chhatisgarh, is Indias largest steel plant and it
is the prime producer of steel rails. It was constructed in 1955 with the help USSR with an initial
capacity of one million tons of steel ingot. Bhilai Steel Plant (BSP), has been India's sole
producer of rails and heavy steel plates and major producer of structural steel. The plant is the
sole supplier of the country's longest rail tracks, which measure 260 meters (850 ft). The plant
also produces products such as wire rods and merchant products.
The main consideration for choosing Bhilai was the availability of iron ore at Dalli Rajhara,
about 100 km from the site; limestone from Nandini, about 25 km from the plant, and dolomite
at Hirri, about 140 km away. The plant was commissioned on 4 February 1959. It was inaugrated

by then president of India Dr. Rajendra Prasad. It has gone through a number of expansion
programs since then. The plant was expanded to 2.5 million tons in September 1967 and a further
expansion to 4 MT was completed in 1988. The main focus in the 4 MT stage was the continuous
casting unit and the plate mill, a new technology in steel casting and shaping in India
Vision:
The SAIL Vision reads as follows:To be a respected world class corporation and the leader in Indian business in quality,
productivity, profitability and customer satisfaction.
The guiding principle CREDO on which the vision statement is based are :- We build lasting relationships with customers based on trust and mutual benefit.
- We uphold highest ethical standards in conduct of our business.
- We create and nurture a culture that supports flexibility, learning and is proactive to change.
- We chart a challenging career for employees with opportunities for advancement and rewards.
- We value the opportunity and responsibility to make a meaningful difference in peoples life.
BSPs organizational objectives are based on the vision and credo & reflect the organizational
intents in its journey towards excellence. The objectives are : To enhance customer satisfaction through:
1. Improvement in productivity and product quality.
2. Skill enhancement of our people.
3. Reviewing market trends.

Achievements:

BSP is the most profitable unit of SAIL. It has also won the Prime Minister's Trophy for best
integrated steel plant eleven times (highest number of times by any steel plant). BSP has
received Integrated Management System (IMS) Certificate by a single certifying agency (M/s
DNV), integrating QMS, EMS, OHSAS & SAMS - becoming the first SAIL unit and among few
corporate houses in India to achieve this unique distinction. Among the long list of national
awards it has won, Bhilai has bagged the CII-ITC Sustainability award for three consecutive
years. BSP won 1st prize in National Energy Conservation Award2013 in Integrated Steel
Sector in recognition of major energy saving initiatives in 2011-12 and '12-13. The Plant again
won this award for Year 2014 for achieving a 5% saving in thermal energy consumption and
savings of 2% in electrical energy consumption over the previous year
Special Programs:
The Bhilai steel plant has developed steel for one of the Railways' most challenging projects,
construction of the 345 km (214 mi) railway line between Jammu and Baramulla at an
investment of 19000 crore (US$2.8 billion). BSP has also developed a special grade of TMT
rebars for use in the high altitude tunnel inside the Banihal Pass. BSP had also developed the
special soft iron magnetic plates for the prestigious India-based Neutrino Observatory (INO)
project of the Bhabha Atomic Research Centre (BARC). It has also developed special grade
high-tensile (DMR249A) steel for building India's first indigenously built anti-submarine
warfare corvette, INS Kamorta.
Eco-Friendly Initiatives:
BSP has taken measures in the areas of waste management, resource utilisation and pollution
control and has initiated several waste reduction programmes. Besides reducing greenhouse gas

output, BSP is replacing the ozone-depleting CTC, aided by UNDP. BSP has earned Voluntary
Emission Reduction (VER), (a sort of carbon credit) for two of its projects. Abiding by
Corporate Responsibility for Environment Protection (CREP) guidelines and monitoring, it has
taken steps to "check fugitive emissions from Coke Ovens and has installed Air cooled self
sealing doors resulting in significant reduction in door emissions"[citation needed] The plant has
introduced a de-dusting system, electrostatic precipitators and a coal dust injection system in the
blast furnaces and in other units. Bhilai Steel Plant manages Bhilai Nagar township which has 13
sectors.

Safety At Bhilai Steel Plant

In India steel is a deregulated sector with a large number of steel plants in private and public
sector. Steel industry is a very hazardous industry and it is almost impossible not to have a single
accident on plant no matter how much safety measures you take. So, it is the responsibility of the
steel company to ensure safety and security of the steel plant. Bhilai steel plant has taken many
steps to make sure that everybody on plant is safe. The safety function of Bhilai Steel Plant is
based on its policy of commitment to ensure the safety of its employees and the people
associated with it including those living in the neighbourhood of the Plant and pursue the safety
efforts in sustained and consistent way by establishing safety goals, safety accountability and
providing resources to make the safety programmes work. Based on this policy, the Safety
Engineering Department formulates safety measures for BSP, advices to concerned departments
of BSP on how best these measures can be implemented, audits the implementation and results

achieved and advices the Management on improvement measures.

Safety Norms:
To prevent incident of exposure to gas, online Carbon monoxide (CO) monitors with audio
visual alarm system have been provided in all gas prone areas of the plant. Portable CO monitors
have also been provided to workmen involved in prone areas.
Contractual workforce is imparted compulsory induction training before issue of gate pass and
on the job training pertaining to respective area of working.
To prevent accidents due to falling from height, SAIL plants have started making use of rigs for
testing competence of Contractor workers.
Standard Operating & Maintenance Procedures, Safe Commissioning procedure etc. have been
developed which are strictly adhered to.
Penal action is taken on contractors for non-compliance to safety norms
Periodic safety campaigns and drives are undertaken.
Use of Job specific personal protective equipments is enforced.
Permit to work System, Shut down Procedures are strictly followed to implement safety while
carrying out hazardous jobs for regular & contract workers.
Behavior based safety was introduced in order to bring total safety cultural transformation in
the organization.
Third party risk assessment is conducted by an external agency before commissioning of new
units.
Reviewed Hazard Identification and Risk Assessment and Determining Control to mitigate the
risk.

 Spreading Safety awareness through training programs and workshops for employees and
contract workers.
Pre commissioning safety audits are conducted for all the new commission units.
The 5S
Bhilai steel plant have adopted the 5S technique to ensure high productivity and safety. There are
five 5S phases: They can be translated from the Japanese as "sort", "set in order", "shine",
"standardize", and "sustain". Other translations are possible.
Sort: Remove unnecessary items and dispose of them properly. Make work easier by eliminating
obstacles. Reduce chances of being disturbed with unnecessary items. Prevent accumulation of
unnecessary items. Evaluate necessary items with regard to cost or other factors. Remove all
parts or tools that are not in use. Segregate unwanted material from the workplace. Need fully
skilled supervisor for checking on regular basis. Don't put unnecessary items at the workplace &
define a red-tagged area to keep those unnecessary items. Waste removal.
Straighten: Arrange all necessary items so that they can be easily selected for use Prevent loss
and waste of time by arranging work station in such a way that all tooling / equipment is in close
proximity Make it easy to find and pick up necessary items Ensure first-come-first-served basis
Make workflow smooth and easy All of the above work should be done on regular basis
Shine: Clean your workplace completely Use cleaning as inspection Prevent machinery and
equipment deterioration Keep workplace safe and easy to work Keep workplace clean and
pleasing to work in When in place, anyone not familiar to the environment must be able to detect
any problems within 50 feet in 5 seconds.

Standardize: Standardize the best practices in the work area. Maintain high standards and
workplace organization at all times. Maintain orderliness. Maintain everything in order and
according to its standard. Everything in its right place. Every process has a standard.
Sustain: To keep in proper working order Also translates as "do without being told" Perform
regular audits Training and Discipline Training is goal oriented process. Its resulting feedback is
necessary monthly
After Bhilai Gas leak 2014
On June 12, 2014, a gas leak in Bhilai Steel Plant killed six people, including two senior
officials. Over 50 people were affected by the accident. A breakdown in a water pump house
caused a leak of the poisonous gas carbon monoxide, which infiltrated the premises due to
pressure differences along the purification chamber lines. Among the dead were two deputy
general managers, while the injured included Central Industrial Security Force personnel as well
as workers and officials of the public-sector plant. The leak started at around 6:10 pm IST. After
this industry plant authorities gave orders to conduct HAZOP (Hazard Objectification In Process
Industries) studies. Bhilai Steel Plant has also implemented IPSF color scheme on pipelines e.g.
grey color for convertor gas and yellow color for blast furnace gas.