Project Management at Blast Furnace Essar Ltd

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					PROJECT MANAGEMENT AT
BLAST FURNACE ESSAR
PROJECTS (I) LTD.
Rohan Rajesh Chopde DABS - 109038
Essar Group Profile
           Group Mission
    The ESSAR group mission is to create
      enduring values for customers &
  stakeholders in core manufacturing and
   service businesses, through world-class
    operating standards, state-of-the-art
technology and the ¶positive attitude· of our
                   people.
KEY VALUE DRIVERS:
Totally integrated global carbon steel producer
Footprint covering India, Canada, USA and Indonesia
10 MTPA Steel Plant at Hazira - largest in Western India
5.5 MTPA HBI plant ² the world·s largest gas-based sponge iron plant
Nearing 20 MTPA palletisation capacity
2 MTPA cold rolling capacity
1 MTPA galvanizing capacity
0.4 MTPA colour coating facility
A 1.5 MTPA extra wide plate mill
A 0.6 MTPA pipe mill
4 MTPA integrated steel plant at Ontario, Canada
0.4 MTPA cold rolling mill and 0.15 MTPA galvanising line in Indonesia
Essar Steel Minnesota in the US has iron ore
reserves of over 1.4 billion tonnes
Strategic tie-up with Kobe Steel, Japan
Iron Ore Beneficiation Plants
Visakhapatnam Pelletisation Plant
Hazira Steel Complex
Cold Rolling Complex, Hazira
PT Essar Indonesia
Pune Facility
Plate Mill & Pipe Mill
Essar Steel Algoma & Essar Steel Minnesota
The retail thrust
           Oil & Gas (Fuelling the future)
KEY VALUE DRIVERS:
World-class US$ 2.14 billion (Rs 100 billion), 12.5 MTPA
refinery
Ratna and R-series fields, with reserves of 500 million
barrels of oil
Rights in exploration blocks in Gujarat, West Bengal,
and Assam
Rights in oil blocks in Australia, Madagascar, Nigeria and
Indonesia
An all-India retail network
Marketing tie-ups and infrastructure sharing agreements
with public sector oil companies
KEY VALUE DRIVERS:
Set up India·s first independent power plant and first multi-fuel plant, in
Hazira, Gujarat, India
World-class plant design and construction; equipment from General Electric,
Siemens and Honeywell
Highly automated, with India·s lowest manpower to megawatt ratio
One of the few companies to receive the ¶Sword of Honour· from the British
Safety Council
One of India·s best technical teams, capable of setting up varied power
plants in operations and maintenance
Executing projects to enhance our generating capacity to 6,000 MW
KEY VALUE DRIVERS:
Vodafone Essar - one of India·s most valuable telecom
companies
Serving over 85 million satisfied customers
Aegis, an integral part of India·s business process
outsourcing revolution.
Aegis has 38 delivery centres across India, Sri Lanka,
Philippines, USA, UK, Costa Rica, Australia, Kenya and South
Africa.
The Mobile Store - Retail telecom venture for one-stop
mobile solutions
Building telecom tower infrastructure
KEY VALUE DRIVERS:
A leading integrated logistics company
Experts in transportation solutions for the global energy business
Several safety and quality awards
First Indian Shipping Company to be certified at ISO 14001
Bulk and oil terminals
Contract drilling services for the oil industry
KEY VALUE DRIVERS:
A leading EPC contractor with 40 years of experience
Pipeline SBU certified at ISO 9001:2000
Wide range of capabilities including industrial, civil and infrastructure construction
Special skills in marine construction
Strategic links with over 20 companies including large
Multinationals Skilled, experienced team
One of the largest banks of construction equipment
Centralised global sourcing enables timely completion of projects and economies of scale
Forty years of Engineering, Procurement & Construction (EPC) capabilities
Built 300,000 bpd of refining capacity
Developed over 10 million tonnes of steel capacity
Laid more than 3,500 km of pipelines
Developed 1,220 MW of power projects, and is developing another 10,250 MW
Offshore EPCI capabilities; currently executing a USD 220 million project
for ONGC
Owns over 3,000 nos. construction equipment worth over USD 250 million
12,000 TPA (tonnes per annum) of fabrication facility with waterfront load-
out facility
Dedicated Engineering Centre specializing in Engineering and Design for
the Process and Industrial sectors, with over 1,200 engineers
Over USD 3 billion procurement capability. Global procurement support in
Middle East and China
Global workforce of over 5,000
BLAST FURNACE
Blast Furnace is a classic example of ´Adversity converted to
 opportunity ´by ESSAR team at Hazira. When CFMCC, the
Chinese company left the project in Sept09, for VISA problem
  in a critical stage. It was really an acute adverse situation.
But the Team Blast Furnace took the challenge. Majority of the
 remaining job was awarded to EPIL with necessary support
   And close monitoring and within a very short period The
Project area is humming with never before activities with 2600
                 workers working on 24X 7 basis.
 Meanwhile some of the utilities like power and Instrument air
System are commissioned and the team is rushing towards the
           target of Hot Metal tapping on daily basis.
Blast Furnace: Works on counter-current
principle to reduce iron ore to molten iron
Raw materials: Lump ore, coke, sinter,
pellets, limestone, dolomite, quartzite, Mn-
ore
Output: Molten iron, slag, gases, flue dust
                  MAJOR HIGHLIGHTS
BLAST FURNACE PROPER:
†   All Stave coolers (1200 MT) Erection complete
†   All Throat Armor ( 200 MT) Erection complete
†   Gas sampler Erection Complete
†   Tuyer Stock ² 75% complete ² Balance in progress
†   Bustle to Stove Connection complete
†   Bell less Top Erection in Progress
†   Erection of Mud Gun completed
†   Drilling Machine Erection in Progress
†   Erection of Material Bucket and receiving hopper under progress
STOVE:
†   All equipment Erection, Piping and Structural Erection Complete
†   Hydraulic and punch List Job under progress All Refractory job complete
†   Leak test preparation under progress
SLAG GRANULATION PLANT:
†   90% Structure and equipment Erection complete, balance by 31st March
†   Chimney ( 70 meterx2 No·s) Erection started (out of 15 pieces 3 pieces are erected) balance will be complete
    by 10th April
INTERPLANT PIPING:
†   90% Erection Complete (444659 IM out of 504275 IM)
†   6.2 Balance Erection, Supporting, Hook Up will be completed by 20th April
STOCK HOUSE:
†    90 % equipment and Structure Erection complete balance by 15th April.
†    Belt Laying work in BF-OSBL started
†   Electrical Instrumentation in progress
†    Hydraulic work in progress
MAIN PUMP HOUSE:
†   All structures, Pumps, Motors, Equipment·s erected aligned.
†   18 Motors no-load running complete.
†    Final Piping in progress likely to be completed by 31st March.
†   Water Flashing (Cooling water circuit b/w Hot stove to Main pump house)
    completed on 19/3/2010
GAS CLEANING PLANT:
†   7.1 out of 100 Mt, 50 MT Equipment Received from china on
    12/03/2010.
†   7.2 Erection of the same is in progress
GAS HOLDER:
†   286 MT of Ground Level Erection Complete
†   Preparation in progress for Air Jacking
†   Blower and Chinese Expat waited
BLOWER STATION:
†   60% Equipment erection completed
†    Condenser, Turbine and blower lower casing and all filter
    erection completed.
†    Balance Erection will be completed by 20th April
BF general arrangement
   Technical specifications

   PARTICULARS                          UNIT
   Effective volume     2200m3

     Production         4400t/d

      coke rate         380kg/thm

 Coal dust injection    150kg/thm

      Slag rate         380kg/thm

Hot blast temperature   1150°C

   Blast humidity       60g/Nm3

Oxygen enrichment       3%

    Top pressure        0.176 to 0.196 MPa
Hot Blast stoves
                       HBS
 Purpose: To preheat blast before introducing it in
 blast furnace.
 KSS ² Top combustion type,Works on regenerative
 principle
Stages of operation:
 On blast
 On gas
 Isolation
 Black draught
Inter plant piping
Stock house
Main pump house
Gas cleaning plant
Gas holder
Blower station
Cast house chimney
Boiler house
OSBL
De - dusting
Water purifier
         Blast furnace Reports
    Blast Furnace Structural Manpower Report (Skilled or
                          Unskilled)
Blast Furnace Piping Manpower Report (Skilled or Unskilled)
   Blast Furnace Daily Progress Report Structural Erection
    Blast Furnace Daily Progress Report Piping Erection &
                         Fabrication
   Blast Furnace Daily Progress Report Equipment Erection
    Blast Furnace Daily Progress Report Sheeting Erection
  Blast Furnace GAS HOLDER structural, Piping, Equipment,
                      Sheeting Erection
                    Crane Status Reports
  Reach my office where all the contractors will give me
                  manpower reports .
  These came by three medium i.e. by paper, on phone
                      and emails.



                                   Now my job was to edit
         9.00 a.m.                  them and forward it to
I was to visit all the sites &    concerned. (Bibekananda
verify with the supervisors       Mishra Vice president EP(I
      about the DMR.                  )L , Rajendra mehra.



Around 10.00 a.m. reach back
my office with DPR·s given by
                                        Reports to be send by
 site supervisors . Edit them &
                                        evening & then attend
 send them to concerned. No
                                          6.30 p.m. meeting
  cross-verifications of DPR·s
            needed.
         Formula on MY
        Equations(essaeinf
        o.com/90:announ
               ce)
           For a particular area in blast furnace e.g. Stock house
             : enter the scope of work like 50, now these values
scope                             could be in
                     MT ² Structural & Equipment Erection
                 INM or IND ² Piping Erection & Fabrication
                           SQM ² Sheeting erection
                         With diagram no. WJ-1567




                   Get the time line to complete the work in
                   the respected areas with the contractors
                  (along with their ratings) and then fill up a
                   GS-13 form for any amendment in work
            Actual learning
What is the importance of handling manpower,
reporting the progress of work & to complete the
project in given time line(i.e. commissioning).
Importance of working in team, time management.
The importance of HSE policy in these types of
projects.
How to arrange resources at cheapest and fastest
Etc«
              CONCLUSION
My training at essar was a continuous learning
experience from F knot to Fushun carrier, things I
learned and responsibilities designed for me were
great. I am thankful to my project guide Mr.
BIBEKANANDA MISHRA Vice ² President, Essar
Projects (I) Ltd for his selfless support and
Encouragement during my entire training program. My
sincere thanks to Dr. Sudhir S. Fulzele (Director- Dr.
Ambedkar Business School, Nagpur) for giving me the
privilege to be associated with such an esteemed
organization and carry the institute name forward.
              THANK YOU




Questions, suggestions and comments are
                         always welcome

				
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posted:4/1/2011
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