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Growth through Sustainability
QUALITY
01
Vision : 02
Quality Policy : 03
Corporate Social Responsibility Policy : 03
Occupational Health & Safety Policy : 03
Total Quality Management : 04 - 06
Certificates & Licenses : 07
Integrated Steel Plant : 08
DRI Plant - Flow Chart : 09
Electric ARC Furnace - Flow Chart : 10
Rolling Mill - Flow Chart : 11
Manufacturing Process : 12 - 14
Quality Check - Flow Chart : 15
Inspection Process : 16
Guidelines : 17 - 20
Quality Assurance : 21 - 25
Responsibility Matrix : 26
Scope & Responsibility of QMD : 27
Product Realisation : 28
Control of Non-conforming Product : 29
Inspection : 30
Lab and Test Equipments : 31
Testing Codes & Standards : 32
02
Total Quality Management VisionCustomer Satisfaction
=
Organizational Performance
=
Manufacturing Excellence
=
Employee Contentment
=
Social Responsibility
03
Quality PolicyShyam Steel Industries Ltd is committed to:
= Delivering the required products at the right place at the right time at the right cost from our Integrated Steel
Plant(original producer) form the very backbone of our Principles of Manufacturing.
= We view improvement as a continuous process. We are constantly aspiring to achieve betterment
of our core processes, be it manufacturing, quality control, sales or delivery. There is a joint effort
to achieve Manufacturing Excellence.
Corporate Social Responsibility PolicyAs a Corporate Organisation we believe that it is our primary purpose to give back to society. Giving and sharing
what we have received is embedded deeply in us. We have actively pursued to raise the quality of life of the
people around us. We hold hands in our joint effort to create better tomorrows.
Occupational Health & Safety PolicyAt our world class Integrated Steel Plant we treat our worker's well being as a mandate and not as an option.
Ensuring the highest standards of safety is imperative. We follow the occupational health and safety policy certified
under ISO 18001 : 2007.
We aim to:
= Create an environment which is safe and secure for everyone in its vicinity, be it a worker, contactor, visitor
and even the local community. All identifiable OHSAS risks and hazards are treated with the gravest concern.
= To constantly endeavour towards the highest level of health and safety such that injuries, waste and emissions
are reduced to the bare minimum.
= Train all employees to work safely and responsibly thus preventing injury to themselves and others.
= Ensure that optimum conditions exist for the proper execution of all the stipulated health and safety norms.
Following and implementing the OHSAS responsibilities is the prerogative of everyone, at all levels of
management and employees.
S. S. Beriwal
Chairman and Managing Director
04
Total Quality Management
Continual Improvement of
The Quality Management System
Plan : Establish the objectives and processes necessary to deliver
precise results, in accordance with the Customer's
requirements and the organization's policies.
Do : Implement the processes.
Check : Monitor and measure processes and products against policies,
objectives and requirements for the product to ensure strict
adherence to them and detailed reporting of the results.
Act : Take action to continuously improve process performance.
ManagementResponsibility
PLAN
DO ACT
CHECK
ResourceManagement
Measurement Analysisand Improvement
Product Realization
The P-D-C-A Cycle
05
Total Quality ManagementTQM or Total Quality Management is designed to create a
comprehensive and all encompassing module which aides in achieving
Manufacturing Excellence. Every element of this term speaks of an
important aspect.
Total : Made up of the whole
Quality : Degree of excellence of a product or service
Management : The art and science of planning, controlling,
directing
. therefore, TQM is the art & science of managing
the whole to achieve excellence
The TQM System
Continuous Improvement
ProcessImprovement
TotalInvolvement
Customer Focus
Obj
ectiv
e
Prin
cipl
es
Leadership Education and Training Supportive Structure
Communications Reward and Recognition Measurement
Elem
ents
Electric ARC Furnace
06
Total Quality ManagementTQM is an approach to quality assurance that emphasizes a thorough
understanding by all members of a production unit, of the needs and
desires of the ultimate service recipients and a viewpoint of wishing to
provide service to internal, intermediate service recipients in the chain of
service.
TQM, as defined for ISO 8402Management approach of an organization centers on quality, based on
the participation of all its members aiming at long term success through
customer satisfaction and benefits to all members of the organization and
the society. TQM is the mutual co-operation of everyone in an
organization and associated business process to produce products, which
meet the needs and expectations of customers. Total Quality Management
is both a philosophy and a set of guiding principles for managing an
organization efficiently.
Quality ManagementQuality Management has four levels: Inspection, Control, Assurance and
Total Quality Management (TQM). Quality inspection and quality control
rely on supervision to make sure that no mistakes are made. The basic
approach to quality is inspection, detection, and correction of errors. The
next level quality control is to inspect, correct, investigate and find the
causes of problems; and take action to prevent errors from re-occurring.
Both methods rely on supervision and inspection. The third level quality
assurance includes the setting of standards with documentation and also
the documentation of the method of checking against the specified
standards.
Quality inspection, control and quality assurance are aimed at achieving
an agreed consistent level of quality, first by testing and inspection, then
by rigid conformance to standards and procedures; and finally by efforts
to eliminate the causes of error so that the defined accepted level is
achieved.
Total Quality Management is a comprehensive and integrated way
of managing any organization in order to:
a) Meet the needs of the customer requirements.
b) Achieve continuous improvement in every aspect of the
organizational activities
07
Certificates & LicensesCertificates1. ISO 9001 : 2008 Quality Management System
2. ISO 14001 : 2004 Environmental management System
3. OHSAS 18001 : 2007 Occupational Health and Safety Management
System
4. TUV approved Total Management System
BIS Licenses1. IS: 1786/2008 HSD Bar: Grade : Fe - 415, Fe - 415D, Fe - 500,
Fe - 500D, Fe - 550, Fe - 550D, Fe - 600
2. IS: 2062/2006 structural Steel Grade E 250 A
3. IS: 2830/1992 - Carbon Steel Cast Billet for General Engineering
Grades A, B & C
4. IS: 2831/2001 - Carbon Steel Cast Billet for Low Tensile
Structural Steel
Control Room - DRI Plant
Spectrometer
Universal Testing Machine
Universal Testing Machine
08
Production Flow Chart
Integrated Steel Plant
Iron ore Coal Dolomite (Flux)
DRI
Electric Arc Furnace (EAF)
Continuous Casting Unit
Reheating Furnace
Rolling Mill
Thermex Unit (QST)
Cooling bed
Finished Stock Yard for
TMT Bars
Billet
Sponge Iron
Heated Billet
09
DRI Plant
Stock house
I/C (0-8 mm)F/C (4 -18 mm)
Return for crushing Return for screening
Crusher house Transfer house
Ground hopper Iron Ore
(5 to 40mm)+Dolomite
Ground hopper
Coal (0-150mm)
Dol
omite
Ore
Siz
e
(5-1
8mm
)
Kiln (reduction)
Cooler
Product separation bin
Lumps
(5-20 mm)
Sponge Iron(stored with heat
No. marking)
Char(unburned coal)
Sponge IronChar
(unburned coal)
Fines
(0-5 mm)
10
No
Yes
Billet
EAF & Concast Plant
Raw material Yard Sponge Iron
Charging at Electric Arc Furnace
Melting
Chemical Analysis and Mix Finalization
Carbon Charging Refining Oxygen Charging
Chemical Addition as Per Requirement
Bath sample checking for chemical analysis
Conforms?
Deslagging
Hot material transferred from furnace to ladle (Tapping)
Concast plant
Sizing in required length
Cooling bed
Visual Inspection & Testing
Batch number wise stocking at finish stockyard
CRS grade additionof Cu (Copper) and
Cr (Chromium)
11
Rolling Mill
Raw material (Billet) yard
Raw material inspection: visual & chemical
Reheat Furnace
Roughing mill
Intermediate mill
Finishing mill
Thermex Unit (QST)*
Cooling bed
Sizing
Checking of dimension & weight
Physical & Chemical testing
Section & lot wise stacking at despatch yard
* QST - Quenching and Self Tempering
12
Shyam Steel's Durgapur unit is a automated integrated
steel plant comprising of:
= DRI Unit.
= Steel Melting Shop equipped with Electric Arc Furnace.
= Continuous Billet Casting Unit; and
= Rolling Mill with Thermex system.
It has been setup in Collaboration with World-
renowned companies viz; Concast AG-Zurich and HSE
Germany.
1) DRI Unit: In the Direct Reduced Iron (DRI) plant,production of sponge iron using a solid reductant
involves reducing iron ore (lumps/pellets) with a
carbonaceous material such as coal. The reduction
is carried out in a rotary kiln (which is inclined and
rotates at a pre-determined range of speeds) at a
stipulated temperature (8500C -10,500C). The
inclination and the rotary motion of the kiln ensures
that the raw materials moves from the feed end to
the discharge end of the kiln and during this
movement the actual reduction of iron ore to iron
takes place. The material discharged from the kiln
is taken to a rotary cooler for cooling and the
cooled product is separated from the coal char.
The basic reactions involved are as follows:
3Fe2O3 + CO = 2Fe3O4 + CO2 (1)
Fe3O4 + CO = 3FeO + CO2 (2)
FeO + CO = Fe + CO2 (3)
2) Electric Arc Furnace: Steps involved in an ArcFurnace can be summarized as follows:
a) Charging: The charge is prepared according to
the proposed chemistry for the targeted grade.
Sponge Iron and other ingredients along with
lime in a close requisite ratio is charged in the
Arc Furnace.
b) Melting: Melting is accomplished by injecting
energy to the charge materials in the form of
electrical energy through three graphite
electrodes. Carbon injected inside the furnace
reacts with oxygen producing CO, which
bubbles through the bath creating foamy slag.
The excess CO reacts with oxygen, converting
to CO2 again generating heat. Oxygen will
react with several components present in the
bath including silicon; manganese; phosphorus
and sulphur. The oxides thus formed will end up
in the slag. In arc furnace charged materials gets
melted at about 1800C.
Production Process
DRI Plant EAF
13
Once sufficient charge has been melted and
enough space has been created, second charge
can be taken and the process is repeated. Once
the final charge has been melted and is reached
at melt stage, temperature measurement is taken
and sample is drawn for determining the
amount of oxygen to be blown during refining.
c) Refining: Refining means reduction of
undesirable elements in steel like sulphur,
phosphorous etc and also bringing down the
carbon to required levels.
Phosphorus and sulphur which cannot be
removed in Induction Furnace, can be easily
removed in EAF. Phosphorous is removed in the
early stage of refining. Sulphur is removed as
sulphides in slag and is better achieved during
reducing stage.
Aluminium, silicon and manganese react with
oxygen before carbon to form oxides which
goes into the slag. CO, which is produced due
to the reaction of carbon with oxygen, bubbles
through the bath causing the slag to foam and
has many beneficial effects. The foaming also
helps in bringing down nitrogen and hydrogen
levels in steel. At the end of refining stage
temperature measurement is done and sample
is drawn for analysis.
d) De-slagging: De-slagging is the process by
which the slag layer above the steel is removed
from the furnace. This process is important for
removing impurities from the molten material.
The furnace is tilted towards the slag door for
slag removal. Phosphorus is transferred to the
slag, during the early stage of the heating while
the temperature is relatively low. The first de-
slagging (at the beginning of refining) removes
a substantial portion of the phosphorous as
P2O5, thus preventing phosphorous reversal to
the metal. Typically during the refining stage,
the furnace may be de-slagged several times.
e) Tapping: After reaching the required
temperature and composition, the tap hole is
opened and metal is tapped into the ladle and
sent to continuous casting unit for casting of
billets. During the tapping process bulk alloys
are added based on the bath analysis for the
desired steel grade. De-oxidizers may be added
to the steel to control the oxygen content, prior
to further processing. This is commonly referred
to as killing of steel. This is done by adding
aluminum or silicon in the form of ferrosilicon
or silicon manganese.
A typical construction of Arc Furnace has shown
below:
EAF - Electrodes Concast
14
3) Continuous Billet Casting: Molten steel fromEAF is tapped into a ladle and taken to the
continuous casting machine. Liquid steel flows out
of the ladle into the tundish and then into a water-
cooled mold. Solidification begins in the mold. The
continuous billets coming out from the CCM is
sized according to the length required.
4) Rolling Mill with Thermex Technology: Thebillets manufactured are re-heated at a temp. of
1200C in the re-heating furnace and are rolled
into specific sections of finished material in the
Rolling Mill Unit. In the case of manufacturing TMT
Re-bars, from the finishing stand of the rolling Mill,
the Re-Bars are guided through a specially designed
proprietary Thermex pipes to obtain special
property 'Thermex Process' as explained below:
Quenching: The hot rolled bar from the finished
mill stand enters into the 'Thermex System' and is
rapidly quenched by a special water spray system.
This rapid quenching hardens the surface of the
TMT Re-bars to a depth optimized for each section,
forming a Martensitic rim while the core remains
hot & Austenitic.
Self Tempering: After Re-bars leave the quenching
box, the core remains hot compared to the surface
allowing heat to flow from the core to the surface
causing Tempering of the outer Martensite layer thus
forming a structure called 'Tempered Martensite'.
Atmospheric Cooling: This takes place on the
cooling bed, where the Austenitic core is
transformed into ductile Ferrite-Perlite structure.
Thus the final structure consists of stronger outer
layer (Tempered Martensite) with ductile core
(Ferrite-Pearlite). This process increases the tensile
strength of the material while keeping high ductility
and weldability. This whole process is a patented
technology from HSE, Germany under the brand
name of 'Thermex'.
Production Process
Rolling Mill
Thermex Plant
15
Schematic Diagram of QC
Quality Check flow chart
Hold Point Activity
1. Chemical analysis of iron ore,
coal, dolomite
2. Final chemical analysis of
sponge iron
3. Chemical analysis of sponge iron,
ferro alloys & other elements
4. Refining and deslagging
5. Chemical analysis and visual
inspection of billets
6. Final chemical analysis of billets
7. Re-heating furnace temperature
check
8. Splitting tendency check
9a. Incoming material temperature
check
9b. Water temperature and pressure
check
9c. Outgoing material temperature
check
9d. Equalising temperature check
10. Final physical and chemical
analysis of finished product
Sponge Iron
FerroAlloys Sponge
& Other IronElements
HOLD PT(2)
HOLD PT(3)
HOLD PT(4)
HOLD PT(5)
HOLD PT(6)
HOLD PT(7)
HOLD PT(8)
HOLD PT(9A)
HOLD PT(9B)
HOLD PT(9C)
HOLD PT(9D)
HOLD PT(10)
Irone Ore Coal Dolomite
HOLD PT (1)
EAF
BILLET CASTER
COOLING BED
BILLET YARD
REHEATING FURNACE
Roughing Mill
Intermediate Mill
Finishing Mill
THERMEX PLANT
COOLING BED
FINAL PRODUCT
LAB
LADLE
16
Inspection ProcessPurpose: To conduct inspection, testing, identificationand traceability of materials and products in various
stages of production in accordance with the applicable
IS specifications and customer requirements.
Scope: The process covers inspection, testing,
identification and traceability of the product from
receipt stage, in process inspection and final inspection
till desptach.
ProcedureDirect Reduced Iron Unit (D.R.I.): The sized iron-ore
is tested for its Fe content and coal for its ash content
and is then charged to D.R.I plant. The finished product
of DRI plant i.e. sponge iron is then tested for its Fe
content and chemical composition and is identified by
day wise production.
The conforming material is taken to SMS plant for
charging and in case of non-conformation, material is
sent to rejection yard.
Steel Melting Shop (SMS): In the SMS plant the material
is melted at about 18,000C in an Electric Arc Furnace.The slag is removed automatically in the Arc furnace
to achieve precision control of chemistry of
the molten metal. The hot molten metal is checked for
its chemical composition. Depending upon the
composition required, various ferro alloys are added to
it. Then the molten steel with requisite chemical
composition from Electric Arc Furnace is sent to the
continuous casting unit for casting billet.
Continuous Casting Machine (CCM): The billets thus
produced are first visually inspected for the surface
condition and then tested for its chemical composition.
If any surface discontinuity is observed in the material
it is then sent to SMS unit for recycling. The tested billet
is then sent to the Rolling Mill raw material yard with
a proper batch number.
Rolling Mill: The billets are then taken for production
in the Rolling Mill. During the production process,
inspection is done at various stages. The non-
conforming products are identified and segregated
properly for recycling. The finished product is then
subjected to final inspection (visual inspection &
physical property) and a Lot Number is allotted to it
before being stored in the finished product yard.
The finished product is properly tagged which carries
the following information:
I. Name of the Company II. Lot No.
III. Size of the product IV. Grade
Control Panel - Universal Testing Machine Control Panel - Electric ARC Furnace
17
MISCELLANEOUS TERMS:
Steel Melting Scrap: Steel waste/scrap not usable as such in its existing form which are further re-meltedto produce liquid steel to produce various products. Depending on their form/type, they are classified asHeavy Melting Scrap, Light Melting Scrap, Turnings/borings etc.
Re-rollable Scrap: Seconds & defective products, cuttings/end cuttings, used steel products like used railsetc which could be directly used for re-rolling (without resorting to re-melting) into finished products forspecified applications. These are substitutes of steel billets /pencil ingots. Ship breaking generates substantialquantity of re-rollable steel scrap.
Integrated Steel Plants: Steel plants using iron ore as the basic raw material for production of crude steelwhich is further rolled into finished shapes in-house. Conventionally, these plants have captive coke ovensalso and the sensible heat of the outgoing gases from iron/coke making are utilised as fuel for variousapplications. It therefore, includes units with in-house coke making (optional), iron making followed byproduction of liquid steel & crude steel and finished steel. So all ISPs adopting BF- BOF route and Majorproducers adopting Corex-BOF or DRI-EAFor MBF-EOF technology would technically, fall under thiscategory.
Mini Steel Plants: Conventionally, EAF/IF based steel plants with/ without captive rolling mills were coveredunder this category. However, now all steel plants (based on any technology) of capacity upto 5 lakh tpaare covered under this category.
Primary Steel Producers: Steel (crude and/or finished steel) producers using iron ore as the basic rawmaterial/input. It therefore, includes in-house iron making followed by production of liquid steel & crudesteel with/without in-house rolling. So, all ISPs adopting BF- BOF route and Major producers adoptingCorex - BOF or DRI-EAF or MBF-EOF technology would fall under this category.
Hot Rolling: Rolling of steel at above the recrystallisation temperature of steel (normally above 1000 C) toproduce Hot Rolled Long products/Flat Products from semis. Ingots are also hot rolled to get semis. Attimes blloms are also hot rolled to produce billets. Rolling Mills used for hot rolling are known as HotRolling Mills.
Cold Rolling: Rolling of steel (normally flat products) below the recrystallisation temperature of steel(normally at room temperature) to produce cold rolled sheets /strips /coils. Mills used for the purpose arecalled Cold Rolling Mills.
2Hi/4 Hi/6 Hi/20 Hi Mills: Rolling Mills are classified as 2-High / 2 Hi, 4 Hi and so on depending onNumber of Rolls used in the arrangement/configuration of rolls in single stand. For example, a 2 Hi millconsist of 2 rolls one above the other known as upper roll and the lower roll. In a 4 Hi mill, there are 4rolls in a stand2 upper rolls one above the other and 2 lower rolls one above the other.
Glossary of Terms/ Definitions Commonly used in Iron & Steel Industry
18
Integrated Steel Plant Vs Ordinary Re Roller
Integrated Steel Plant Ordinary Re-Rolle
Manufacturing flow chart process: Iron Ore Manufacturing flow chart process: Ingot RM DRI SMS CCM (Billet Plant) RM TMT TMT Route TMT Re-bar Ingot produces from Route TMT Re-bar different type of steel scrap SMS Ingot
Integrated Steel Plant conforms the consistency Ordinary Re-Roller cannot conform the in quality product consistency in quality product
Chemical properties of billet top, middle & bottom Chemical properties of ingot top, middle & portion all are same. Shape of billet is square bottom portion are different types. Shape of
ingot is taper.
Continuous casting billet is a very minor casting Ingot is another harmful defect such as centerdefect in respect of ingot piping, blow hole, cracks & inclusions etc.
This has a very bad effect in rolling product
Achievement of proper levels of sulphur & Major Re-rollers/Ingot producers are unable to phosphorus is a process of capability inherent meet even these relaxed standard consistently to the iron ore based integrated steel making route. As per Indian Standard (IS 1786) calls for sulphur & phosphorus content of 0.060% max. each for the Fe 415 grade with further provision that S&P added together would not exceed 0.110%.
Complete automation TMT route can produce Re-roller neither maintains adequate TMT route the desired yield strength with steel of relatively and chemical composition of material nor lower carbon equivalent by adjusting the on line maintains a specific range since they are using Q& T parameters. IS :1786 limits the carbon an Ingot. content to 0.25% max. & CE to 0.42% max. forguaranteed weldability. The average carbon content maintained by Shyam Steel Industries Limited is 0.19% with a standard deviation of 0.03% across all sections.
Good Thermex TMT Re-bars ensure the Re-bars Major Re-rollers producing TMT Re-bars do not with a uniform and concentric hardened tempered ensure that the Re-bars have a uniform and hard Martensite periphery and the softer Ferrite - periphery signifying the quenching has not taken Pearlite core. place all round the periphery. Rolling mill production
system is either manual or semi automatic & millpersonnel are not fully trained in quenching &tempering technology.
19
Induction Furnace VS Electric Arc Furnace
Sl No. Characteristic Arc Furnace Induction Furnace
1 Operating Principle
The arc forms between the charged Induction Furnace heating is material and the electrode by short- accomplished through induction i.e.circuit between the electrodes and heating an electrically conducting raw materials which causes high- object (usually a metal) by Electrotemperature electric arc to melt raw magnetic Induction where eddy materials current is generated within the
metal and resistance leads to JouleHeating of the metal. An InductionFurnace uses induction to heatmetal to its melting point.
Slag is removed automatically Slag is removed manually
Precision control of chemistry of Control of chemistry of the molten 2 Refining Capability the molten metal metal is not good i.e. lack of
refining capacity
S & P removal capacity is very good Removal of S & P is limited
3 Operating High operating temperature Operating temperature is lowerTemperature than Arc Furnace
4 Dissolved Gas Low content of dissolved gases in Content of dissolved gas in molten molten metal. metal is more than Arc Furnace
5 Reduction in Large reduction in specific energy Large reduction in specific energy Specific Energy (energy per unit weight) required to (energy per unit weight) to produce
produce the steel the steel is not possible in InductionFurnace
6 Starting or stopping Arc Furnace can rapidly start and stop, Induction Furnace cannot startthe Furnace allowing the steel mill to vary or stop rapidly
production according to demand
7 Life of Refractory Life of Refractory lining is more Life of Refractory lining is comparativelylining than Induction Furnace lower than Arc Furnace
8 Variety of Steels Possibility of producing variety Variety of steels cannot beof steels produced
Power Cables Electrodes
Copper induction coils
Refractory material
Molten metal(arrows indicatemixing action)
Cover
Oxygen inlet
Tapping spoutfor molten iron
Iron ore
Door forremoving slag
Hatch for iron ore,lime and other material
20
M.S. Billet vs M.S. Ingot
Ingot Billet
In Ingot casting, the liquid steel flows through a In continuous casting technology liquid steel refractory channel & fills up cast iron mould under flows from furnace to caster through a copper static condition from one side. This process has mould. The water in the mould gets cooled and certain deficiencies. Like:- Refractory particles oscillates at a predetermined rate. The oscillation,chip-off from the channel and get mixed with cooling and pausing is done in such a controlled liquid steel thereby causing undesirable inclusions condition that the liquid steel solidifiesin Ingot leading to rolling defect into equiaxed crystals
The liquid steel during the solidification process The gas in liquid steel escapes during solidificationreleases gas which gets entrapped in the steel and owing to continuous casting technology form blowholes and cavities in Ingot
Owing to the process of solidification segregation In billet owing to continuous casting of chemical alloys takes place. The chemical chemical alloys are uniformly spread properties vary at different portions of Ingot
In Ingot very harmful defects such as center piping, In continuous casting, no centre piping blow hole, cracks & inclusions etc. are found blow hole, crack or inclusion is formed
The surface of Ingot develop scabs and laps due to The surface of billet is clear with no scabs and pouring defects on account of bad mould surface laps due to smooth copper mould surface
TMT Re-bars rolling from Ingots suffer from TMT Re-bars produced from continuous casting deficiency in tensile properties and there is billets show high tensile strength and elongation inconsistency in tensile strength and elongation and there is remarkable consistency of properties
Ingots Billets
21
Qua
lity
Ass
uran
cePl
an fo
r Sp
onge
Iron
Sl.
Type
s of
Pro
duct
Cha
ract
eris
tics
Type
s of
Insp
ectio
nFr
eque
ncy
ofA
ccep
tanc
eFo
rmat
of
No.
Ope
ratio
nsch
ecke
dTe
stin
gch
ecki
ngno
rms
Rec
ord
1.Ir
on O
re
Fe c
onte
nt &
Rev
iew
of T
est
As
per
IS
: 584
2 R
aw m
ater
ial r
ecei
ving
size
of I
ron
Ore
Cer
tific
ate,
Siz
eac
cept
ance
IS: 5
843
insp
ectio
n R
epor
tM
easu
rem
ent &
norm
s(D
OC
. No.
QS/
OA
/S1/
00)
Che
mic
al a
naly
sis
2.N
on-c
okin
g C
oal
Ash
con
tent
R
evie
w o
f Tes
t A
s pe
rIS
: 13
50
Raw
mat
eria
l rec
eivi
ng&
siz
e of
coa
lC
ertif
icat
e, S
ize
acce
ptan
cein
spec
tion
Rep
ort
Mea
sure
men
t &.
norm
s(D
OC
. No.
QS/
QA
/SC
/00)
Che
mic
al a
naly
sis
3.D
olom
iteC
hem
ical
R
evie
w o
f Tes
t A
s pe
rIS
: 176
0R
aw m
ater
ial r
ecei
ving
com
posi
tion
&C
ertif
icat
e, S
ize
acce
ptan
cein
spec
tion
Rep
ort
size
of d
olom
iteM
easu
rem
ent &
norm
s(D
OC
. No.
QS/
QA
/SD
/00)
Che
mic
al a
naly
sis
4.Sp
onge
Iron
Che
mic
al
Che
mic
al A
naly
sts
As
per
IS: 1
0812
final
Insp
ectio
n R
epor
tco
mpo
sitio
nac
cept
ance
(Doc
. No.
QS/
QA
/S1/
00)
norm
s
Prep
ared
by
Issu
ed b
yA
ppro
ved
by
GM
- Q
.A.
Man
agin
g D
irec
tor
Prof
esso
r
S. D
asgu
pta
P. B
eriw
ala
Dr.
T.K
. Pal
SSIL
SSIL
JU, K
olka
ta
22
Qua
lity
Ass
uran
ce P
lan
for
M.S
/ C
RS
/ Spe
cial
Gra
de B
illet
Sl.
Type
of P
rodu
cts
Cha
ract
eris
tics
Type
of I
nspe
ctio
nFr
eque
ncy
ofA
ccep
tanc
eFo
rmat
of
No.
Ope
ratio
nch
ecke
dTe
stin
gch
ecki
ngno
rms
Rec
ord
1.Sp
onge
Iron
, CPC
/M
ater
ial
Rev
iew
of T
est
As
per
IS :
1383
9R
aw m
ater
ial r
ecei
ving
Si
lico
Man
gane
se/
Com
posi
tion
Cer
tific
ate
acce
ptan
ce
IS :
1081
2in
spec
tion
Rep
ort (
DO
C.
Ferr
o M
anga
nese
norm
sIS
: 13
502
No.
QS/
QA
/S1/
00 o
rIS
: 11
71Q
S/Q
A/P
1/00
or
IS :
1470
QS/
QA
/M1/
00)
2A.
Elec
tric
Arc
Fur
nace
Che
mic
al
Che
mic
alA
s pe
r IS
: 28
30/2
831
(DO
C N
o.(M
eltin
g / b
ath
com
posi
tion
Ana
lysi
sac
cept
ance
QS/
QA
/B2/
00)
sam
ple
norm
s
2B.
Che
mic
al A
dditi
onC
hem
ical
C
hem
ical
As
per
IS
: 28
30/2
831
(DO
C N
o.co
mpo
sitio
nA
naly
sis
acce
ptan
ceQ
S/Q
A/B
2/00
)no
rms
2C.
Fina
l sam
ple
Che
mic
al
Che
mic
alA
s pe
r IS
: 28
30/2
831
(DO
C N
o.(A
fter
addi
ng)
com
posi
tion
Ana
lysi
sac
cept
ance
QS/
QA
/B2/
00)
norm
s
3A.
Con
cast
bill
etSu
rfac
e fin
ish
&V
isua
l ins
pect
ion
&
As
per
IS :
2830
/283
1Fi
nal I
nspe
ctio
n R
epor
tdi
men
sion
of
mea
sure
men
t of
acce
ptan
ce(D
oc. N
o. Q
S/Q
A/B
3/00
)fin
ish
Prod
uct
finis
h Pr
oduc
tno
rms
3B.
Con
cast
bill
etC
hem
ical
Che
mic
al A
naly
sis
As
per
IS :
2830
/283
1Fi
nal I
nspe
ctio
n R
epor
tco
mpo
sitio
nac
cept
ance
(Doc
. No.
QS/
QA
/B3/
00)
norm
s
Prep
ared
by
Issu
ed b
yA
ppro
ved
by
GM
- Q
.A.
Man
agin
g D
irec
tor
Prof
esso
r
S. D
asgu
pta
P. B
eriw
ala
Dr.
T.K
. Pal
SSIL
SSIL
JU, K
olka
ta
23
Qua
lity
Ass
uran
ce P
lan
for
Ther
mo
Mec
hani
cally
Tre
ated
(TM
T) R
ebar
s
Sl.
Type
of P
rodu
cts
Cha
ract
eris
tics
Type
of I
nspe
ctio
nA
ccep
tanc
eFo
rmat
of
No.
Ope
ratio
nch
ecke
dTe
stin
gno
rms
Rec
ord
1.R
aw m
ater
ial-
Surf
ace
finis
h /
Vis
ual /
Rev
iew
IS
: 28
30D
oc. N
o. Q
S/Q
A/B
3/00
bille
tC
hem
ical
com
posi
tion
of B
illet
Cer
tific
ate
IS :
1786
2A.
TMT
Reb
arSu
rfac
eV
isua
l /
IS :
1786
Fi
nish
/Sur
face
Mea
sure
men
tD
oc. N
o.Q
S/Q
A/T
3/00
Cha
ract
eris
tics
&
2B.
Do
Stan
dard
Wei
ght p
er m
eter
leng
th b
yIS
: 17
86
Doc
. No
: QS/
QA
/T4/
00w
eigh
tel
ectr
onic
bal
ance
2C.
Do
Mat
eria
l C
hem
ical
Ana
lyst
s IS
: 17
86D
oc. N
o : Q
S/Q
A/T
3/00
com
posi
tion
%C
, %S
& %
P an
d ot
her
for
low
allo
y st
eel (
CR
E)
2DD
oM
echa
nica
l pro
perti
esTe
nsile
test
ing
0.2%
P.S
. / Y
.S,
IS :
1786
Doc
. No
: QS/
QA
/T3/
00(N
orm
al &
. D g
arde
UTS
, % E
long
and
% T
otal
TM
T R
ebar
)El
onga
tion
at M
axim
um fo
rce
2ED
oB
enda
bilit
y &
B
end
test
& R
eben
d te
stIS
: 17
86D
oc. N
o : Q
S/Q
A/T
3/00
Reb
enda
bilit
y
2FD
oId
entif
icat
ion
&V
isua
lEa
ch b
undl
e of
bar
mus
tD
oc. N
o : Q
S/Q
A/T
3/00
Mar
king
have
met
al ta
g in
dica
ting
Lot n
o, g
rade
r, si
ze,
spec
ifica
tion
No.
, Tr
ade
mar
k.
Prep
ared
by
Issu
ed b
yA
ppro
ved
by
GM
- Q
.A.
Man
agin
g D
irec
tor
Prof
esso
r
S. D
asgu
pta
P. B
eriw
ala
Dr.
T.K
. Pal
SSIL
SSIL
JU, K
olka
ta
24
Qua
lity
Ass
uran
ce P
lan
for
Stru
ctur
al S
ectio
n (A
ngle
, Che
nnel
& Jo
ist)
Sl.
Type
of P
rodu
cts
Cha
ract
eris
tics
Type
of I
nspe
ctio
nA
ccep
tanc
eFo
rmat
of
No.
Ope
ratio
nch
ecke
dTe
stin
gno
rms
Rec
ord
1.
Raw
mat
eria
l-Su
rfac
e fin
ish/
Vis
ual /
Rev
iew
IS
: 28
30D
oc. N
o.: Q
S/Q
A/B
3/00
bille
tC
hem
ical
of B
illet
Cer
tific
ate
IS :
2062
com
posi
tion
2A.
Ang
les,
Cha
nnel
, Su
rfac
e Fi
nish
/ V
isua
l / M
easu
rem
ent
IS :
2062
, IS
: 185
2D
oc. N
o : Q
S/Q
A/G
1/00
Jois
tD
imen
sion
2B.
Do
Stan
dard
Wei
ght p
er m
eter
leng
th b
yIS
: 80
8
wei
ght
el
ectr
onic
bal
ance
2C.
Do
Mat
eria
l com
posi
tion
Che
mic
al A
naly
sts
IS :
2062
Doc
. No
: QS/
QA
/G1/
00
2DD
oM
echa
nica
lTe
nsile
test
ing
Y
.S, U
TS,
IS :
2062
Doc
. No
: QS/
QA
/G1/
00
prop
ertie
s%
Elo
ng &
Ben
ding
2ED
oId
entif
icat
ion
&V
isua
lEa
ch b
undl
e of
item
Doc
. No
: QS/
QA
/G1/
00
Mar
king
mus
t hav
e m
etal
tag
indi
catin
g Lo
t no,
grad
er, s
ize,
spec
ifica
tion
No.
,
Man
ufac
ture
r N
ame.
Prep
ared
by
Issu
ed b
yA
ppro
ved
by
GM
- Q
.A.
Man
agin
g D
irec
tor
Prof
esso
r
S. D
asgu
pta
P. B
eriw
ala
Dr.
T.K
. Pal
SSIL
SSIL
JU, K
olka
ta
25
Qua
lity
Ass
uran
ce P
lan
for
Stru
ctur
al S
ectio
n (R
ound
, Squ
are
bar
and
Flat
)
Sl.
Type
of P
rodu
cts
Cha
ract
eris
tics
Type
of I
nspe
ctio
nA
ccep
tanc
eFo
rmat
of
No.
Ope
ratio
nch
ecke
dTe
stin
gno
rms
Rec
ord
1.
Raw
mat
eria
l-Su
rfac
e fin
ish/
Vis
ual /
Rev
iew
IS
: 28
30D
oc. N
o.: Q
S/Q
A/B
3/00
bille
tC
hem
ical
of B
illet
Cer
tific
ate
IS :
2062
com
posi
tion
2A.
Rou
nd, S
quar
e
Surf
ace
Fini
sh/
Vis
ual /
Mea
sure
men
tIS
: 20
62, I
S : 1
148
Doc
. No
: QS/
QA
/G1/
00
bar
and
Flat
Dim
ensi
on
2B.
Do
Stan
dard
Wei
ght p
er m
eter
leng
th b
yIS
: 17
30, I
S : 1
732
wei
ght
el
ectr
onic
bal
ance
2C.
Do
Mat
eria
l com
posi
tion
Che
mic
al A
naly
sts
IS :
2062
Doc
. No
: QS/
QA
/G1/
00
2DD
oM
echa
nica
l pro
perti
esTe
nsile
test
ing
Y
.S, U
TS,
IS :
2062
Doc
. No
: QS/
QA
/G1/
00
% E
long
& B
endi
ng
2ED
oId
entif
icat
ion
&V
isua
lEa
ch b
undl
e of
item
Doc
. No
: QS/
QA
/G1/
00
Mar
king
mus
t hav
e m
etal
tag
indi
catin
g Lo
t no,
grad
er, s
ize,
spec
ifica
tion
No.
,
Man
ufac
ture
r N
ame.
Prep
ared
by
Issu
ed b
yA
ppro
ved
by
GM
- Q
.A.
Man
agin
g D
irec
tor
Prof
esso
r
S. D
asgu
pta
P. B
eriw
ala
Dr.
T.K
. Pal
SSIL
SSIL
JU, K
olka
ta
26
Responsibility MatrixShyam Steel Industries Ltd Quality System Manual IOCL NO. # 5.5
DOC. NO. #QSM/ SSIL /5.5/00
Title: Management Responsibility Authority & Communication Page: A5
Legend DR - Direct ResponsibilityCR - Contributory Responsibility
Approved by : CMD Issued by : MR Issue : # 01Issue Date : 15.10.05
Sl. No. ACTIVITY MD GM MR WM MKT PUR PROD QA STORE MNT
1. Quality System DR DR DR DR CR CR CR DR CR CR
2. Control of Documents DR DR DR DR CR CR CR CR CR CR
3. Control of Records DR DR DR DR DR DR DR DR DR CR
4. Management Responsibility DR DR DR DR CR CR CR CR CR CR
5. Resource Management DR DR DR CR CR CR - - - -
6. Complete Awareness Training DR DR DR DR CR CR CR DR CR CR
7. Customer Related Processes DR DR CR CR DR - CR CR - -
8. Purchase DR CR - CR CR DR CR CR CR -
9. Production CR DR - DR - - DR CR CR -
10. Maintenance - CR - CR - CR CR CR - DR
11. Identification & Traceability - CR - DR - - DR DR DR -
12. Preservation of Products - CR - - - - DR DR CR -
13. Control of Monitoring - DR - DR - DR DR DR CR -
& Measuring Devices
14. Monitoring & Measuring - - - - - CR DR DR CR -
15. Internal Audit CR CR DR CR CR CR CR CR CR CR
16. Control of Non- DR DR CR DR DR DR DR DR CR CR
Conforming Products
17. Data Analysis CR CR - - - DR DR DR CR -
18. Corrective Action CR CR CR CR - DR DR DR CR -
19. Preventive Action DR DR DR DR CR DR DR DR CR -
27
Joint Inspection Process
During any client visit for approval of our brand or any third party inspection of material before despatch, the
testing of physical and chemical properties of any ready lot is done again and witnessed by the client/third party
inspector. During this inspection process a joint inspection report of finish product testing is prepared and signed
by both the parties.
The following Third Party inspection Agency doing inspection of material at our plants:
1. Lloyds Register Asia. (LRA) 2. Bureau Veritas (I) Pvt. Ltd. 3. Rites Ltd.
4. Det Norske Veritas As (DNV) 5. TUV India Pvt. Ltd. 6. SGS India Pvt. Ltd
Activities:
Policy: Inspection and testing shall be carried out at different stages to verify that the specified requirements for
the products are met.
Scope: These procedures cover the inspection and testing of purchased products, semi-finished products and
finished goods, right from the raw material to the finished product stage.
Responsibility: Quality Assurance Manager is responsible for implementation of these procedures.
Scope & Responsibility of Quality Management Department
Type of Inspection & Testing Responsibility Reference Document
Raw material inspection & testing Quality control manager Receiving inspection report
In-process inspection Lab/inspection in-charge In-process inspection report
Final inspection Quality Control Manager Final inspection report
Joint inspection Quality Control & third party Joint inspection report
inspection authority or
client representative
28
Product Realisation Process and Interaction
Cus
tom
er R
equi
rem
ent
Management Responsibility
Resource Management
Marketing
Manufacturing
Quality Assurance Purchase Store
Control of document Control of
& record NC product
Corrective & Analysis
Preventive action of Data
Prod
uct r
equi
rem
ent
Req
uire
men
t bas
ed o
n pu
rcha
se o
rder
(if a
ny)
Custom
er Satisfaction
General feedback report
Product feedback reporC
ustomer com
plaintC
ustomer visit report
29
Control of Non-conforming ProductProducts that do not conform to specified requirements are identified and controlled to prevent unintended use
or delivery. The control and related responsibility and authority for dealing with non-conforming product are
described in documented procedure QP/SSIL/8.3/00.
1. Identified
nonconforming
products
2. Identified non-
conformity and
action
Disposition
action taken
Summary report
for corrective &
preventive action
taken
Key Tasks/
(Responsibility)
a) Inspection & Identification of non-conforming
products (inspection/lab in-charge)
b) Review and Disposition of non-conforming
products (Q.C. Manager)
a) Take corrective action against the Identified
nonconformity
b) Take preventive action against the non-
conformity, compiling and presentation of
summary report for management review meeting
(Q.A. Manager)
Process Map - Quality Management Process
INPUTS OUTPUTS
30
Shyam Steel Industries LimitedAngadpur, Durgapur, West Bengal
Inspection Check list for an Integrated Steel Plant
1. Inspection of manufacturing Process flow chart from basic raw material to finish product (DRI EAF
CCM RM TMT Plant) including technical specification.
2. Checking of approved QAP & inspection of Quality Control Process flow chart from raw material to finish
product.
3. Inspection of Steel Billets and their certification from Bureau of Indian Standard.
4. Inspection of finish product such as TMT Re-bars and their certification from Bureau of Indian Standard.
5. Inspection of Identification mark at every stage of Quality Control and stockyard.
6. Inspection of Laboratory and testing facilities available in Lab. Calibration certificates verification of testing
equipments.
7. Checking of certificates, Licenses and quality control documents.
8. Verification of supply of material at nationally important infrastructural projects.
9. Details of new product development and development reports.
10. Witnessing of sample testing in the Laboratory.
11. Verification of quality assurance system documents,
12. Sign off all inspection reports.
Prepared by Issued by Approved by
GM- Q.A. Chairman cum M.D. ProfessorS. Dasgupta S. S. Beriwala Dr. T. K. Pal
SSIL SSIL Metallurgical Dept.
J. U. Kolkata
31
Lab and Test EquipmentsSl.No. Name of Equipment Make Range/L.C Idft. no. Status of
Calibration no.
1. Universal testing Krystal Elmec 1000.0 KN, 0.2 KN, UT/01 Yes
Machine 0.5 KN, 1.0 KN & 2 KN
2. Microscope Apollo 10x, 15x MS/01 Not Required
3. Spectrometer Spectro Analysis Module for Spectro/01 Yes
Analytical Fe with Low Alloy, Cast
Instrument Iron, Stainless Steel &
Gmbh & Co. Kg Manganese Steel
4. Impact type portable Dietmar System, Scale - HV, HB, PH/01 Yes
hardness tester Khedekar Sadan, HRB, HRC, HSD
Killa Miraj
5. Double pan balance Rohtar 0-5000 gm./1 gm. DPB/01 Yes
6. A set of weight range A.Bhatta & Co 0.030-100 gm./0.03 gm. W/01 Yes
7. Mandrel for bend & Blue Star 6-32 mm SSIL Not Required
rebend test
8. Strohlein apparatus Banner & Co. 1.5c.c burr at SP Yes
i) Tube furnace 0-1350c
ii) Auto transformer
9. Muffle furnace with A.Bhatta & Co 0-1200c MF/01 Yes
temp. control box.
Size: (1200x1200x2700) mm
10. Hot Plate (Size:275mmx125mm) A.Bhatti & co HP/01 Not Required
11. Chain-o-matic balance Kercy & co 200gm/0.001 CB/01 Yes
12. Fortein barometer Banner & Co. Max.635mm of hg. FB/01 Yes
13. Vernier caliper Mitutoyo 0-200mm/0.02mm VC/01 Yes
14. Vernier caliper Mitutoyo 0-300mm/0.02mm VC/02 Yes
15. Outside micrometer Mitutoyo 0-25mm/0.01mm M/01 Yes
16. Steel scale Kristeel 0-1000mm/0.5mm SC/01 Yes
17. Steel scale Kristeel 0-300mm/0.5mm SC/02 Yes
18. Steel tape Freemans 0-3000mm/1mm ST/01 Yes
19. Radius gauge Mitutoyo 0-7mm/0.25mm RG/01 Yes
20. Spring caliper Kristeel 150mm SPC/01 Not Required
21. Sample polishing machine A.Bhatta & Co PC/01 Not Required
32
Manufacturing and Testing Codes & Standards
Details of different Codes and Standards of rolling product for various
requirements are as follows:
A. Raw Material
IS 2830/1992 : Carbon steel cast billet, ingots, blooms and slabs for rerolling into steel for general
structural purpose.
IS 2831/2001 : Carbon steel cast billet, ingots, blooms and slabs for rerolling into low Tensile Structural
steel for general structural purpose.
IS 10812/1992 : Specification for Sponge iron.
B. TMT Re-Bars / HYSD Bars
IS 1786 / 2008 (Fe 415 / Fe 415D / Fe 500 / Fe 500D /Fe 550 / Fe 550D / Fe 600):
Specifications for High Strength Deformed Steel Bars (TMT Bars) & Wires for concrete re-enforcements.
C. Angle, Channel, Flat, Bar & Structural Steel Section.
IS 2062 / 2006 : Hot Rolled Low, Medium and High Tensile Structural Steel.
D. Door, Window & Ventilator Section
IS 7452 / 90 : Specification for hot rolled steel sections for doors, windows and ventilations.
E. Dimension and Testing Codes & Standards
IS 228 / 87 : Method for chemical analysis of steels.
IS 808 /1989 : Specification for Dimensions for Hot Rolled Steel Beam, Column, Channel and Angle
Sections.
IS 1599 / 85 : Method for Bend Test.
IS 1608 / 2005 : Specification for Mechanical testing of metals.
IS 1730 / 89 : Steel Plates, Sheets, Strips and flats for Structural and general Engineering purpose.
IS 1731 / 71 : Dimensions for steel flats for structural & General Engineering purpose.
IS 1732 / 89 : Dimensions for round and square steel bars for Structural purpose.
IS 1852 / 85 : Specification for Rolling & cutting tolerances for hot-rolled steel products.
Shyam Steel Industries LtdShyam Towers, EN 32, Sector V, Salt Lake, Kolkata 700091
Tel +91 33 4007 4007 Fax +91 33 4007 4010
www.shyamsteel.com
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