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NMDC IRON & STEEL PLANT NAGARNAR. A Journey from Mineral to. Metal. NMDC IRON & STEEL PLANT NAGARNAR, CHHATTISGARH. A case study of execution of a Mega Steel Plant Presented by- Prasant Dash Executive Director NMDC Iron & Steel Plant , Nagarnar.
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NMDC IRON & STEEL PLANTNAGARNAR A Journey from Mineralto Metal
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARH A case study of execution of a Mega Steel Plant Presented by- Prasant Dash Executive Director NMDC Iron & Steel Plant, Nagarnar.
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARHv • NMDC Limited is a “Navratna” Public sector company under the Ministry of Steel, Government of India Incorporated in the year 1958. • NMDC is pioneer in exploration of minerals and is primarily engaged in the business of developing mines to produce raw materials for the industry. • NMDC Ltd is setting up an Integrated steel plant of 3.0 MTPA at Nagarnar, in the tribal district of Bastar, Chhattisgarh which will boost the socio- economic stature & standard of living in this tribal belt.
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARH • NMDC being a mining company was not having any expertise in steel. The estimated time period for the project was about four years which is already overrun by one and half years. NMDC has hired MECON as our Engineering consultant & as well as PMC contractor and awarded all the major packages on EPC basis. • An attempt is being made in this case study to identify the major challenges and learning’s of project execution in steel industry in order to complete future projects with zero cost and time overrun.
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARH CHHATTISGARH STATE Raipur Nagarnar Bailadila Mines Visakhapatnam
Salient features of the Plant • Capacity (Liquid Steel) : 3 MTPA • Cost of Project : 15525 Crores • Land Acquired : 1900 acres • Capacity (HR coils/sheets/plates) : 2.89 MT/yr. • Coke Oven & CDCP : 7 mtr Tall Batteries, 2 Nos. • Sinter Plant : 460 Sqm, 1 No. • Blast furnace : 4506 Cum • Pig Casting Machine : 1700 tpd, 3 machines • Steel Melting Shop : 2 x175 T BOF Converters • Thin Slab Caster + HSM : 2 Strand CC and HSM 2RM+4FM+2 Down Coiler • Other Units : By Product Plant, RMHS
NISP Packages • Major Technological Packages • RMHS • CO &CDCP • By-Product Plant • Sinter Plant • Blast Furnace • Steel Melting Shop • TC-HSMTSC Final RM • Lime & Dolo Plant • Oxygen Plant With 56 Auxiliary and 11 Enabling Packages
TOTAL SCOPE OF WORK NAGARNAR, CHHATTISGARH Total scope of work
PROCESS-CUM-MATERIAL FLOW SHEET RMHS COKING COAL 2,289,300 COKE BREEZE 295,000 IRON ORE FINES 3,826,900 IRON ORE LUMP 1,052,800 BURDEN SINTER 4,214,600 BURDEN COKE 1,195,600 SP : 1 x 460 m2 CO : 2 x 67, 7m tall BF : 1 x 4500 m3 3,321,200 GHM 282,000 HM 3,039,200 HM PCM SMS : 2 x 175 T 3,000,000 LS RH-OB : 175 T LF : 2 x 175 T 3,000,000 Liq Steel TSC coupled with HSM 2,896,000 T HR COILS 9
PRODUCT MIX HR Plates HR Plates API - 5L Quality Plates
PRODUCT MIX HR Sheets LPG Cylinders HR COILS
PRODUCT MIX High Carbon Steel Silicon steel Automotive steel
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARH General challenges faced by NMDC for setting up a green field project are: • Land Acquisition. • Environmental & Forest clearances. • Resettlement & Rehabilitation policy of displaced persons. • Poor logistics for transportation by Rail and Road. • Scarcity of skilled and trained manpower in the area. • Limited availability of quality education and medical facilities • Delay in getting statutory clearance and permission
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARH Constraint due to Employer • Time lag between awarding of major contract for major as well as auxiliary packages. • Recruitment and retention of manpower by NMDC.
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARH Constraint due to consultant • Delay in finalization of design & engineering by consultant. • Lack of coordination between consultant’s engineering, inspection and site supervision team. • Incorrect assessment (increase) in scope of work by consultant and contractor while tendering. • Outdated Vendor list in contract.
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARH Constraint due to consultant • Difference arising due interpretation of contract by Client, consultant and contractor. • Price escalation due to delay in execution and non-availability of adequate provision in contract for paying price variation before contract closing. • Lack of foresight for planning essential facilities for starting of plant. (Sand Pit, ZLD, Coal Storage area etc.)
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARH Constraint due to Consortium: • Lack of Coordination among the consortium members of various packages • Financial problem of contractor and its sub-contractor has caused delay in execution of ordering to vendor and reduced rate of progress at site. • Different pace of work by various contractors in respective packages • Ambiguity in plan during contingency ( non- availability of construction water/permanent water, emergency power and island facility) • Sub-contracting of jobs to in-competent contractors by main contractors.
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARH Constraint due to ambiguity of contract • Inter consortium disputes between contractors due to non clarity in scope of work. • Technical contract prepared by MECON having lot of discrepancies causing delay in execution.
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARH Constraint due to Employer and Consultant • Integration and interfacing of different plants/packages.
NMDC IRON & STEEL PLANTNAGARNAR, CHHATTISGARH Constraint due to Location • Availability and retention of skilled labour by contractor in Bastar region. • Poor infrastructural and logistic facility in region.
