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QUALITY

Growth
through Sustainability
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

01
Total Quality Management Vision
Customer Satisfaction
=
Organizational Performance
=
Manufacturing Excellence
=
Employee Contentment
=
Social Responsibility

02
Quality Policy
Shyam 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 Policy


As 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 Policy


At 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

03
Total Quality Management
The P-D-C-A Cycle

Management
Responsibility

PLAN

Resource Measurement Analysis


Management and Improvement

DO ACT

Product
Realization

CHECK

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.

04
Total Quality Management
TQM 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
Electric ARC Furnace

The TQM System


Objective

Continuous Improvement
Principles

Process Total
Customer Focus
Improvement Involvement
Elements

Leadership Education and Training Supportive Structure


Communications Reward and Recognition Measurement

05
Total Quality Management
TQM 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 8402


Management 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 Management
Quality 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

06
Certificates & Licenses
Certificates
1. ISO 9001 : 2008 Quality Management System

2. ISO 14001 : 2004 Environmental management System

3. OHSAS 18001 : 2007 Occupational Health and Safety Management


Control Room - DRI Plant System

4. TUV approved Total Management System

BIS Licenses
1. 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

Spectrometer

Universal Testing Machine

07
Universal Testing Machine
Production Flow Chart

Integrated Steel Plant

Iron ore Coal Dolomite (Flux)

DRI

Sponge Iron

Electric Arc Furnace (EAF)

Continuous Casting Unit

Billet

Reheating Furnace

Heated Billet

Rolling Mill

Thermex Unit (QST)

Cooling bed

Finished Stock Yard for


TMT Bars

08
DRI Plant
Ground hopper Iron Ore Ground hopper
(5 to 40mm)+Dolomite Coal (0-150mm)

Crusher house Transfer house

Return for crushing Return for screening


Dolomite
(5-18mm)
Ore Size

F/C (4 -18 mm) I/C (0-8 mm)

Stock house

Kiln (reduction)

Cooler

Product separation bin

Lumps Fines
(5-20 mm) (0-5 mm)

Sponge Iron
Char Char
(stored with heat Sponge Iron
(unburned coal) (unburned coal)
No. marking)

09
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

No
Conforms?
Yes
Deslagging
CRS grade addition
of Cu (Copper) and Hot material transferred from furnace to ladle (Tapping)
Cr (Chromium)

Concast plant

Sizing in required length


Billet
Cooling bed

Visual Inspection & Testing

Batch number wise stocking at finish stockyard

10
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

11
Production Process
Shyam Steel's Durgapur unit is a automated integrated The basic reactions involved are as follows:
steel plant comprising of: 3Fe2O3 + CO = 2Fe3O4 + CO2 (1)
= DRI Unit. Fe3O4 + CO = 3FeO + CO2 (2)
= Steel Melting Shop equipped with Electric Arc Furnace. FeO + CO = Fe + CO2 (3)
= Continuous Billet Casting Unit; and
2) Electric Arc Furnace: Steps involved in an Arc
= Rolling Mill with Thermex system.
Furnace can be summarized as follows:
It has been setup in Collaboration with World-
a) Charging: The charge is prepared according to
renowned companies viz; Concast AG-Zurich and HSE
the proposed chemistry for the targeted grade.
Germany. Sponge Iron and other ingredients along with
lime in a close requisite ratio is charged in the
1) DRI Unit: In the Direct Reduced Iron (DRI) plant,
Arc Furnace.
production of sponge iron using a solid reductant
involves reducing iron ore (lumps/pellets) with a b) Melting: Melting is accomplished by injecting
carbonaceous material such as coal. The reduction energy to the charge materials in the form of
electrical energy through three graphite
is carried out in a rotary kiln (which is inclined and
electrodes. Carbon injected inside the furnace
rotates at a pre-determined range of speeds) at a
reacts with oxygen producing CO, which
stipulated temperature (8500C -10,500C). The
bubbles through the bath creating foamy slag.
inclination and the rotary motion of the kiln ensures
The excess CO reacts with oxygen, converting
that the raw materials moves from the feed end to
to CO2 again generating heat. Oxygen will
the discharge end of the kiln and during this react with several components present in the
movement the actual reduction of iron ore to iron bath including silicon; manganese; phosphorus
takes place. The material discharged from the kiln and sulphur. The oxides thus formed will end up
is taken to a rotary cooler for cooling and the in the slag. In arc furnace charged materials gets
cooled product is separated from the coal char. melted at about 1800C.

DRI Plant EAF

12
Once sufficient charge has been melted and d) De-slagging: De-slagging is the process by
enough space has been created, second charge which the slag layer above the steel is removed
can be taken and the process is repeated. Once from the furnace. This process is important for
the final charge has been melted and is reached removing impurities from the molten material.
at melt stage, temperature measurement is taken The furnace is tilted towards the slag door for
and sample is drawn for determining the slag removal. Phosphorus is transferred to the
amount of oxygen to be blown during refining. slag, during the early stage of the heating while
c) Refining: Refining means reduction of the temperature is relatively low. The first de-
undesirable elements in steel like sulphur, slagging (at the beginning of refining) removes
phosphorous etc and also bringing down the a substantial portion of the phosphorous as
carbon to required levels. P2O5, thus preventing phosphorous reversal to

Phosphorus and sulphur which cannot be the metal. Typically during the refining stage,
removed in Induction Furnace, can be easily the furnace may be de-slagged several times.
removed in EAF. Phosphorous is removed in the e) Tapping: After reaching the required
early stage of refining. Sulphur is removed as temperature and composition, the tap hole is
sulphides in slag and is better achieved during opened and metal is tapped into the ladle and
reducing stage. sent to continuous casting unit for casting of
Aluminium, silicon and manganese react with billets. During the tapping process bulk alloys
oxygen before carbon to form oxides which are added based on the bath analysis for the
goes into the slag. CO, which is produced due desired steel grade. De-oxidizers may be added
to the reaction of carbon with oxygen, bubbles to the steel to control the oxygen content, prior
through the bath causing the slag to foam and to further processing. This is commonly referred
has many beneficial effects. The foaming also to as killing of steel. This is done by adding
helps in bringing down nitrogen and hydrogen aluminum or silicon in the form of ferrosilicon
levels in steel. At the end of refining stage or silicon manganese.
temperature measurement is done and sample A typical construction of Arc Furnace has shown
is drawn for analysis. below:

EAF - Electrodes Concast

13
Production Process
3) Continuous Billet Casting: Molten steel from This rapid quenching hardens the surface of the
EAF is tapped into a ladle and taken to the TMT Re-bars to a depth optimized for each section,
continuous casting machine. Liquid steel flows out forming a Martensitic rim while the core remains
of the ladle into the tundish and then into a water- hot & Austenitic.
cooled mold. Solidification begins in the mold. The Self Tempering: After Re-bars leave the quenching
continuous billets coming out from the CCM is box, the core remains hot compared to the surface
sized according to the length required. allowing heat to flow from the core to the surface
4) Rolling Mill with Thermex Technology: The causing Tempering of the outer Martensite layer thus
billets manufactured are re-heated at a temp. of forming a structure called 'Tempered Martensite'.
1200C in the re-heating furnace and are rolled Atmospheric Cooling: This takes place on the
into specific sections of finished material in the cooling bed, where the Austenitic core is
Rolling Mill Unit. In the case of manufacturing TMT transformed into ductile Ferrite-Perlite structure.
Re-bars, from the finishing stand of the rolling Mill, Thus the final structure consists of stronger outer
the Re-Bars are guided through a specially designed layer (Tempered Martensite) with ductile core
proprietary Thermex pipes to obtain special (Ferrite-Pearlite). This process increases the tensile
property 'Thermex Process' as explained below: strength of the material while keeping high ductility
Quenching: The hot rolled bar from the finished and weldability. This whole process is a patented
mill stand enters into the 'Thermex System' and is technology from HSE, Germany under the brand
rapidly quenched by a special water spray system. name of 'Thermex'.

Rolling Mill

Thermex Plant

14
Quality Check flow chart
Schematic Diagram of QC

HOLD PT (1)
Irone Ore Coal Dolomite
HOLD PT(2) Sponge Iron

Ferro
HOLD PT(3) Alloys Sponge Hold Point Activity
& Other Iron
Elements 1. Chemical analysis of iron ore,
coal, dolomite
HOLD PT(4) EAF 2. Final chemical analysis of
LADLE sponge iron
HOLD PT(5) BILLET CASTER 3. Chemical analysis of sponge iron,
ferro alloys & other elements
HOLD PT(6) COOLING BED 4. Refining and deslagging
5. Chemical analysis and visual
BILLET YARD
inspection of billets
6. Final chemical analysis of billets
HOLD PT(7) REHEATING FURNACE
7. Re-heating furnace temperature
check
Roughing Mill
8. Splitting tendency check

HOLD PT(8) Intermediate Mill 9a. Incoming material temperature


check
Finishing Mill 9b. Water temperature and pressure
HOLD PT(9A) check

HOLD PT(9B) THERMEX PLANT 9c. Outgoing material temperature


HOLD PT(9C) check
HOLD PT(9D) COOLING BED 9d. Equalising temperature check
10. Final physical and chemical
FINAL PRODUCT analysis of finished product

HOLD PT(10) LAB

15
Inspection Process
Purpose: To conduct inspection, testing, identification composition required, various ferro alloys are added to
and traceability of materials and products in various it. Then the molten steel with requisite chemical
stages of production in accordance with the applicable composition from Electric Arc Furnace is sent to the
IS specifications and customer requirements. continuous casting unit for casting billet.
Scope: The process covers inspection, testing, Continuous Casting Machine (CCM): The billets thus
identification and traceability of the product from produced are first visually inspected for the surface
receipt stage, in process inspection and final inspection condition and then tested for its chemical composition.
till desptach.
If any surface discontinuity is observed in the material
Procedure it is then sent to SMS unit for recycling. The tested billet
Direct Reduced Iron Unit (D.R.I.): The sized iron-ore is then sent to the Rolling Mill raw material yard with
is tested for its Fe content and coal for its ash content a proper batch number.
and is then charged to D.R.I plant. The finished product Rolling Mill: The billets are then taken for production
of DRI plant i.e. sponge iron is then tested for its Fe
in the Rolling Mill. During the production process,
content and chemical composition and is identified by
inspection is done at various stages. The non-
day wise production.
conforming products are identified and segregated
The conforming material is taken to SMS plant for
properly for recycling. The finished product is then
charging and in case of non-conformation, material is
subjected to final inspection (visual inspection &
sent to rejection yard.
physical property) and a Lot Number is allotted to it
Steel Melting Shop (SMS): In the SMS plant the material
before being stored in the finished product yard.
is melted at about 18,000C in an Electric Arc Furnace.
The finished product is properly tagged which carries
The slag is removed automatically in the Arc furnace
to achieve precision control of chemistry of the following information:
the molten metal. The hot molten metal is checked for I. Name of the Company II. Lot No.
its chemical composition. Depending upon the III. Size of the product IV. Grade

Control Panel - Universal Testing Machine Control Panel - Electric ARC Furnace

16
Glossary of Terms/ Definitions Commonly used in Iron & Steel Industry
MISCELLANEOUS TERMS:
Steel Melting Scrap: Steel waste/scrap not usable as such in its existing form which are further re-melted
to produce liquid steel to produce various products. Depending on their form/type, they are classified as
Heavy Melting Scrap, Light Melting Scrap, Turnings/borings etc.
Re-rollable Scrap: Seconds & defective products, cuttings/end cuttings, used steel products like used rails
etc which could be directly used for re-rolling (without resorting to re-melting) into finished products for
specified applications. These are substitutes of steel billets /pencil ingots. Ship breaking generates substantial
quantity of re-rollable steel scrap.
Integrated Steel Plants: Steel plants using iron ore as the basic raw material for production of crude steel
which is further rolled into finished shapes in-house. Conventionally, these plants have captive coke ovens
also and the sensible heat of the outgoing gases from iron/coke making are utilised as fuel for various
applications. It therefore, includes units with in-house coke making (optional), iron making followed by
production of liquid steel & crude steel and finished steel. So all ISPs adopting BF- BOF route and Major
producers adopting Corex-BOF or DRI-EAFor MBF-EOF technology would technically, fall under this
category.
Mini Steel Plants: Conventionally, EAF/IF based steel plants with/ without captive rolling mills were covered
under this category. However, now all steel plants (based on any technology) of capacity upto 5 lakh tpa
are covered under this category.
Primary Steel Producers: Steel (crude and/or finished steel) producers using iron ore as the basic raw
material/input. It therefore, includes in-house iron making followed by production of liquid steel & crude
steel with/without in-house rolling. So, all ISPs adopting BF- BOF route and Major producers adopting
Corex - 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) to
produce Hot Rolled Long products/Flat Products from semis. Ingots are also hot rolled to get semis. At
times blloms are also hot rolled to produce billets. Rolling Mills used for hot rolling are known as Hot
Rolling 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 are
called 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 on
Number of Rolls used in the arrangement/configuration of rolls in single stand. For example, a 2 Hi mill
consist of 2 rolls one above the other known as upper roll and the lower roll. In a 4 Hi mill, there are 4
rolls in a stand2 upper rolls one above the other and 2 lower rolls one above the other.

17
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 center
defect 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. for
guaranteed 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 & mill
personnel are not fully trained in quenching &
tempering technology.

18
Induction Furnace VS Electric Arc Furnace
Sl No. Characteristic Arc Furnace Induction Furnace

Power Cables Electrodes


1 Operating Principle Hatch for iron ore,
Cover

lime and other material


Oxygen inlet
Copper induction coils
Tapping spout
Door for
for molten iron Molten metal
removing slag
(arrows indicate
mixing action)

Refractory material
Iron ore

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 Electro
temperature electric arc to melt raw magnetic Induction where eddy
materials current is generated within the
metal and resistance leads to Joule
Heating of the metal. An Induction
Furnace uses induction to heat
metal 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 lower
Temperature 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 Induction
Furnace
6 Starting or stopping Arc Furnace can rapidly start and stop, Induction Furnace cannot start
the 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 comparatively
lining than Induction Furnace lower than Arc Furnace
8 Variety of Steels Possibility of producing variety Variety of steels cannot be
of steels produced

19
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 solidifies
in Ingot leading to rolling defect into equiaxed crystals

The liquid steel during the solidification process The gas in liquid steel escapes during solidification
releases 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

20
Quality Assurance
Plan for Sponge Iron
Sl. Types of Product Characteristics Types of Inspection Frequency of Acceptance Format of
No. Operations checked Testing checking norms Record

1. Iron Ore Fe content & Review of Test As per IS: 5842 Raw material receiving
size of Iron Ore Certificate, Size acceptance IS: 5843 inspection Report
Measurement & norms (DOC. No. QS/OA/S1/00)
Chemical analysis

2. Non-coking Coal Ash content Review of Test As per IS : 1350 Raw material receiving
& size of coal Certificate, Size acceptance inspection Report
Measurement &. norms (DOC. No. QS/QA/SC/00)
Chemical analysis

3. Dolomite Chemical Review of Test As per IS: 1760 Raw material receiving
composition & Certificate, Size acceptance inspection Report
size of dolomite Measurement & norms (DOC. No.QS/QA/SD/00)
Chemical analysis

4. Sponge Iron Chemical Chemical Analysts As per IS: 10812 final Inspection Report
composition acceptance (Doc. No.QS/QA/S1/00)
norms

Prepared by Issued by Approved by

GM- Q.A. Managing Director Professor


S. Dasgupta P. Beriwala Dr. T.K. Pal
SSIL SSIL JU, Kolkata

21
22
Quality Assurance Plan for M.S / CRS / Special Grade Billet
Sl. Type of Products Characteristics Type of Inspection Frequency of Acceptance Format of
No. Operation checked Testing checking norms Record

1. Sponge Iron, CPC/ Material Review of Test As per IS : 13839 Raw material receiving
Silico Manganese/ Composition Certificate acceptance IS : 10812 inspection Report (DOC.
Ferro Manganese norms IS : 13502 No. QS/QA/S1/00 or
IS : 1171 QS/QA/P1/00 or
IS : 1470 QS/QA/M1/00)
2A. Electric Arc Furnace Chemical Chemical As per IS : 2830/2831 (DOC No.
(Melting / bath composition Analysis acceptance QS/QA/B2/00)
sample norms
2B. Chemical Addition Chemical Chemical As per IS : 2830/2831 (DOC No.
composition Analysis acceptance QS/QA/B2/00)
norms
2C. Final sample Chemical Chemical As per IS : 2830/2831 (DOC No.
(After adding) composition Analysis acceptance QS/QA/B2/00)
norms
3A. Concast billet Surface finish & Visual inspection & As per IS : 2830/2831 Final Inspection Report
dimension of measurement of acceptance (Doc. No. QS/QA/B3/00)
finish Product finish Product norms
3B. Concast billet Chemical Chemical Analysis As per IS : 2830/2831 Final Inspection Report
composition acceptance (Doc. No. QS/QA/B3/00)
norms

Prepared by Issued by Approved by

GM- Q.A. Managing Director Professor


S. Dasgupta P. Beriwala Dr. T.K. Pal
SSIL SSIL JU, Kolkata
Quality Assurance Plan for Thermo Mechanically Treated (TMT) Rebars
Sl. Type of Products Characteristics Type of Inspection Acceptance Format of
No. Operation checked Testing norms Record

1. Raw material- Surface finish / Visual / Review IS : 2830 Doc. No. QS/QA/B3/00
billet Chemical composition of Billet Certificate IS : 1786
2A. TMT Rebar Surface Visual / IS : 1786
Finish/Surface Measurement Doc. No.QS/QA/T3/00
Characteristics &
2B. Do Standard Weight per meter length by IS : 1786 Doc. No : QS/QA/T4/00
weight electronic balance
2C. Do Material Chemical Analysts IS : 1786 Doc. No : QS/QA/T3/00
composition %C, %S & %P and other
for low alloy steel (CRE)
2D Do Mechanical properties Tensile testing 0.2% P.S. / Y.S, IS : 1786 Doc. No : QS/QA/T3/00
(Normal &. D garde UTS, % Elong and % Total
TMT Rebar) Elongation at Maximum force
2E Do Bendability & Bend test & Rebend test IS : 1786 Doc. No : QS/QA/T3/00
Rebendability
2F Do Identification & Visual Each bundle of bar must Doc. No : QS/QA/T3/00
Marking have metal tag indicating
Lot no, grader, size,
specification No.,
Trade mark.

Prepared by Issued by Approved by

GM- Q.A. Managing Director Professor


S. Dasgupta P. Beriwala Dr. T.K. Pal
SSIL SSIL JU, Kolkata

23
24
Quality Assurance Plan for Structural Section (Angle, Chennel & Joist)
Sl. Type of Products Characteristics Type of Inspection Acceptance Format of
No. Operation checked Testing norms Record

1. Raw material- Surface finish/ Visual / Review IS : 2830 Doc. No.: QS/QA/B3/00
billet Chemical of Billet Certificate IS : 2062
composition

2A. Angles, Channel, Surface Finish/ Visual / Measurement IS : 2062, IS : 1852 Doc. No : QS/QA/G1/00
Joist Dimension

2B. Do Standard Weight per meter length by IS : 808


weight electronic balance

2C. Do Material composition Chemical Analysts IS : 2062 Doc. No : QS/QA/G1/00

2D Do Mechanical Tensile testing Y.S, UTS, IS : 2062 Doc. No : QS/QA/G1/00


properties % Elong & Bending

2E Do Identification & Visual Each bundle of item Doc. No : QS/QA/G1/00


Marking must have metal tag
indicating Lot no,
grader, size,
specification No.,
Manufacturer Name.

Prepared by Issued by Approved by

GM- Q.A. Managing Director Professor


S. Dasgupta P. Beriwala Dr. T.K. Pal
SSIL SSIL JU, Kolkata
Quality Assurance Plan for Structural Section (Round, Square bar and Flat)
Sl. Type of Products Characteristics Type of Inspection Acceptance Format of
No. Operation checked Testing norms Record

1. Raw material- Surface finish/ Visual / Review IS : 2830 Doc. No.: QS/QA/B3/00
billet Chemical of Billet Certificate IS : 2062
composition

2A. Round, Square Surface Finish/ Visual / Measurement IS : 2062, IS : 1148 Doc. No : QS/QA/G1/00
bar and Flat Dimension

2B. Do Standard Weight per meter length by IS : 1730, IS : 1732


weight electronic balance

2C. Do Material composition Chemical Analysts IS : 2062 Doc. No : QS/QA/G1/00

2D Do Mechanical properties Tensile testing Y.S, UTS, IS : 2062 Doc. No : QS/QA/G1/00


% Elong & Bending

2E Do Identification & Visual Each bundle of item Doc. No : QS/QA/G1/00


Marking must have metal tag
indicating Lot no,
grader, size,
specification No.,
Manufacturer Name.

Prepared by Issued by Approved by

GM- Q.A. Managing Director Professor


S. Dasgupta P. Beriwala Dr. T.K. Pal
SSIL SSIL JU, Kolkata

25
Responsibility Matrix
Shyam Steel Industries Ltd Quality System Manual IOCL NO. # 5.5
DOC. NO. #
QSM/ SSIL /5.5/00

Title: Management Responsibility Authority & Communication Page: A5

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 -

Legend DR - Direct Responsibility


CR - Contributory Responsibility

Approved by : CMD Issued by : MR Issue : # 01


Issue Date : 15.10.05

26
Scope & Responsibility of Quality
Management Department
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.

Activities:
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

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

27
Product Realisation Process and Interaction

Management Responsibility

General feedback report


Requirement based on purchase order (if any)

Resource Management

Marketing

Product feedback repor


Customer Requirement

Customer Satisfaction
Manufacturing

Quality Assurance Purchase Store Customer complaint

Control of document Control of


Product requirement

& record NC product


Customer visit report

Corrective & Analysis


Preventive action of Data

28
Control of Non-conforming Product
Products 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.

Process Map - Quality Management Process

INPUTS OUTPUTS

Key Tasks/
(Responsibility)

a) Inspection & Identification of non-conforming

1. Identified products (inspection/lab in-charge)


Disposition
nonconforming
b) Review and Disposition of non-conforming action taken
products
products (Q.C. Manager)

a) Take corrective action against the Identified

nonconformity
Summary report
2. Identified non-
b) Take preventive action against the non- for corrective &
conformity and
preventive action
action conformity, compiling and presentation of
taken
summary report for management review meeting

(Q.A. Manager)

29
Shyam Steel Industries Limited
Angadpur, 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. Professor


S. Dasgupta S. S. Beriwala Dr. T. K. Pal
SSIL SSIL Metallurgical Dept.
J. U. Kolkata

30
Lab and Test Equipments
Sl.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

31
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.

32
Shyam Steel Industries Ltd
Shyam Towers, EN 32, Sector V, Salt Lake, Kolkata 700091
Tel + 91 33 4007 4007 Fax + 91 33 4007 4010
www.shyamsteel.com