WATER MANAGEMENT DEPARTMENT

Water is one of the most important inputs for steel making, as are iron ore, limestone, coal, power and transport. In Bhilai Steel Plant, water is used for cooling, quenching, dust collection scale breaking, steam raising, lubrication, fire fighting etc. Bhilai Steel Plant gets its water requirement from the reservoirs which are now under the jurisdiction of Chhattisgarh State Irrigation Department. To meet the requirement of BSP at 1.0 MT stage, Gondli Reservoir of 3.4 TMC capacity was developed in 1956 by the State (MP) Irrigation Department. In order to meet the increased requirement of water at 2.5 MT stage , Kharkhara Reservoir of 4. 9 TMC capacity was constructed in 1966-67. With the commencement of 4.0 MT Expansion of the Plant in late seventies, necessity for additional source of water was felt and this additional water requirement of BSP was assured from Mahanadi Reservoir complex. Raw water is conveyed to BSP by open lined Tandula Main Canal which is 69 kms. from Tandula Head Works. Tandula canal is connected to Kharkhara and MRP by respective feeder canals. Water released from irrigation reservoirs (Tandula & MRP complex) is received and stored in a site storage reservoir, having a capacity of 36 million cubic meters, and is called Maroda-II. The storage capacities of Reservoirs: A. State Government Irrigation Department : 1. Kharkhara 2. Tandula 3. Gondli 144.95 Million Cubic Meters. 302.27 Million Cubic Meters. 96.56 Million Cubic Meters. 767.00 Million Cubic Meters. 284.00 Million Cubic Meters.
Water Management Department (WMD)

4. Ravi Shankar 5. Dudhawa 6. Murrom Silli 7. Sondhur -

162.00 Million Cubic Meters. 162.00 Million Cubic Meters.

B. Bhilai Steel Plant : 1. Maroda-I 2. Maroda-II 9.09 35.90

The annual requirement of water for BSP is 110 MM3 (3.8 TMC). This includes drinking water for plant & Township (60 %) and industrial make-up water (40%). For drinking water, raw water from Maroda-II is supplied to Raw Water Pump House. After prechlorination raw water is pumped to Maroda Treatment Plant, having maximum capacity of 6700 M3/hr. At Treatment Plant, alum is added to accelerate the process of settlement of suspended solids. Then water is filtered through rapid gravity sand filters / pressure filters and is supplied to Township and Plant after (post) chlorination. Industrial water supply to the Plant has two distinct different systems viz, I. "Once through system" "Re-circulating system". Industrial water supply to 2.5 M T area is "once through" system (except to THF 1,2,3 (SMS-I) and CAS-II). It is a centralized supply system where water is drawn from Maroda -I through incomingchannel and travels to main pumping station known as Pump House-1, Pump House-2 & Pump House-11 complex. The chlorinated water is filtered through Rotary Screens(4 Nos.) and is pumped to all the consumers of 2.5 MT area. The major consumers are BF- 1 to 6, Rolling Mills (L.P.), SMS-I, OP-I, PBS (PP-I) , PCM,CO & CCD (Bat. 1 to 8) & SP-II. After use, wherever necessary, the return water is treated in settling tanks; where oil, sludge, scale etc. is removed and water flows back to Maroda-I for recirculation. II. Industrial water supply to 4.0MT area is recirculating system consisting of cooling towers, settling tanks, filters etc. The water lost in the process is made up by tapping from make-up water line which is originating from Make-up water Pump House (PH-31) which draws water directly from Maroda-I.

The major units of water supply department are :

Water Management Department (WMD)

1. Pump Houses 2. Cooling towers 3. Radial Settling Tanks 4. Horizontal Settling tanks 5. Filter Houses 6. Oxidation Ponds 7. Water Chemical Treatment Plant 8. Chlorine Stations 9. Over Head Tanks 10. Ash Pond

70 Nos. 85 Nos. 22 Nos. 96 Nos. 02 Nos. 04 Nos. 02 Nos. 03 Nos. 12 Nos. 01 No.

11. Testing Laboratory 12. Rotary Screens 13. Fire Hydrants

02 Nos. 10 Nos. 270 Nos.

FLOW DIAGRAM OF WATER SUPPLY SYSTEM

Water Management Department (WMD)

There are three major outlets for storm water and waste water :-

I. Outlet "A" near Sector-4. (Zero Discharge) II. Outlet "B" near RSM & Disposal store. III. Outlet "C" near Somani Village joining Purena Nallah.

Major Pump Houses of Water Supply Department

A. 2.5 MT Area :
PUMP HOUSE NO.1

It feeds PBS (PP-I) and Chilled Water Plant-I. There are 4 pumps of capacity of 12,000 to 15,000 Cu.M/hr. Normally three working and one reserve/ standby.
PUMP HOUSE NO.2

There are 5 groups of pumps in this pump house. Group I : This group supplies water to SMS-I, OP-I, PCM, BBM, RSM, MM, WRM, CO&CCD and various auxiliary shops of 2.5 MT area. There are 6 pumps of capacity 6000 Cu.M/hr. each. Normally 3 pumps work and 3 are kept in reserve. It is known as GPG group. Group II : This group supplies water to BF- 1 to 6. There are 5 pumps of capacity 6000Cu.M/hr. each. Normally 2 pumps work and 3 are kept in reserve. It is known as BF group. Group III : This group supplies water to GCPs of BF-1 to 6. There are 5 pumps of capacity 3420 Cu.M/hr. each. Normally 2 pumps work, and 3 are kept in reserve. It is known as GCP group. Group IV : This group supplies BF-GCP return clarified water to cooling towers for cooling purpose. It is known as CT group. Group V : This group supplies water to GCPs & BF 1 to 6, this group of pumps are run asand when required during Capital Repair. There are 2 pumps in this group of capacity 85 Cu.M/hr. It is known as High Pressure group.
PUMP HOUSE NO. 11

There are two group of pumps. Group-I is for GPG and connected to group-I of PH-2 system for boosting purpose. Group-I is having 2 pumps of capacity 6000 Cu.M/hr. each. Normally one pump works in this group. Group-II is for PBS (PP-I) and is connected to PH-1 system for boosting purpose. This group of pumps works as per requirement. This group-II is having 2 pumps of capacity 12500 Cu.M/hr. each.

Water Management Department (WMD)

PUMP HOUSE NO. 3 & 3A :

This handles the return water, from all the Mills, contaminated with oil and mill scale. It delivers water to horizontal settling tanks. There are 11 pumps of capacity 2000 Cu.M/hr. each.
PUMP HOUSE NO. 26 :

It supplies water to Wire Rod Mill main motor coolers and oil coolers. There are 3 pumps of capacity 190 Cu.M/hr.
PUMP HOUSE NO. 27 :

It supplies water to CAS-II for air and oil coolers. There are 5 pumps of capacity 600 Cu.M/hr. each.
PUMP HOUSE NO. 56 :

There are two group of pumps. Group "A" : Having pumps of capacity 400 Cu.M/hr. each for THF-I furnace, burner, lance & door cooling. Group "B" : Having 2 pumps of capacity 500 Cu.M/hr.each for GCP of THF-I.
PUMP HOUSE NO. 59 :

There are two group of pumps. Group-I : Having 2 pumps of capacity 1500 Cu.M/hr. each supplying cold water to THF- 2 for furnace, burner, lance & door cooling. Group-II : Is for supplying hot water to cooling towers for cooling purpose.
PUMP HOUSE NO. 62 :

There are two group of pumps. Group-I : Having 2 pumps of capacity 1500 Cu.M/hr. each supplying cold water to THF- 3 for furnace, burner, lance & door cooling. Group-II : Is for supplying hot water to cooling towers for cooling purpose .
PUMP HOUSE NO. 67 : Water Management Department (WMD)

2 Pumps of 1000 Cu.M/hr for recycling of SP-II water.

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B . 4.0 MT Area :
PUMP HOUSE NO. 31 : ( Make-up water PH)

There are two group of pumps. Group-I : Having 6 pumps of capacity 2500 Cu.M/hr. for supplying water to spray cooling devices of Plate Mill. Normally two pumps work. Group-II : Having 6 pumps of capacity 2000 Cu.M/hr. for supplying chlorinated water to 4.0 MT area mainly for Make-Up purpose. Normally three pumps work. There are 6 Rotary Screens also in this Pump House.
PUMP HOUSE NO. 33 :

There are two group of pumps. (Group-I: clear water Gr and Group-II : conatminated water Gr.) Group-I : Having 5 pumps of capacity 1600 Cu.M/hr. each for supplying water to coolers of motor of main stand, re-heating furnace, descaling unit, oil coolers and ventilation chambers of Plate Mill. Group-II : Having 6 pumps of capacity 1600 Cu.M/hr. for supplying water to Roll cooling.
PUMP HOUSE NO. 34 :

There are two group of pumps. Group-I : Having 5 pumps of capacity 1250 Cu.M/hr. each for supplying water for scale flushing purpose in Plate Mill. Group-II : Having 6 pumps of capacity 1800 Cu.M/hr. for supplying oil & Mill scale contaminated water to settling tanks , which in turn returns to PH - 33 contaminated water group-II suction chamber.
PUMP HOUSE NO. 39 :

Water Management Department (WMD)

There are four groups of pumps. Group-I : Having 5 pumps capacity 1250 Cu .M /hr. each for supplying water to equipments of Concast. Group-II : Having 5 pumps capacity 770 Cu.M/hr. each for supplying soft water to moulds of Concast. Make up water is drawn from WCTP-3 soft water system. Group-III : Having 5 pumps of capacity 225 Cu.M/hr. for supplying water to secondary spray cooling devices of Concast. Make up water is drawn from WCTP-4 soft water system. It is a once through system. Group-IV : Having 5 pumps of capacity 1000 Cu.M/hr. for supplying return hot water to cooling towers.

PUMP HOUSE NO. 40 :

There are two groups of pumps. Group-I : Having 7 pumps of capacity 900 Cu.M/hr. each for supplying oil and scale laden water to settling tank which in turn comes to PH-39/ Gr.-IV suction chambers via gravity sand filters. Group-II : Having 3 pumps of capacity 450 Cu.M/hr. each for supplying water to cooling tower.
PUMP HOUSE NO. 41 :

There are 6 pumps of capacity 780 Cu.M/hr. for supplying water to GCPs of Converter in SMS-II.
PUMP HOUSE NO. 42 :

There are 5 pumps of capacity 170 Cu.M/hr. for supplying water to Lance of Converter in SMS-II.
PUMP HOUSE NO. 44 :

There are two groups of pumps. Group-I : Having 5 pumps of capacity 1650 Cu.M/hr each for supplying to CAS-III and Chilled water Plant-II. Group-II : Having 3 pumps of capacity 200 Cu.M/hr. for supplying drinking water to 4.0 MT area for boosting purpose.
PUMP HOUSE NO. 45 :

There are six pumps of capacity 4000 Cu.M/hr. each for supplying water to Power Plant-II.
PUMP HOUSE NO. 46 :

There are two groups of pumps . Group-I : Having 6 pumps capacity 1350 Cu.M/hr. each for supplying water to OP-II. Make up water is drawn from WCTP-4 soft water system. Group-II : Having 6 pumps for supplying hot return water to cooling towers for cooling purpose.
PUMP HOUSE NO. 46 A :

It is an additional pump house for OP-II. It is having six pumps capacity 1250 Cu.M/hr. each. Make up water is drawn from WCTP-4 soft water system.

Water Management Department (WMD)

PUMP HOUSE NO. 53 :

There are five groups of pumps. Primary : Having 4 pumps of capacity 2100 Cu.M/hr. each for supplying water to BF-7. Having 4 pumps of capacity 1600 Cu.M/hr. each for supplying water to BF-7. Having 4 pumps of capacity 800 Cu.M/hr. each for supplyingto GCP of BF-7 Having 4 pumps of capacity 800 Cu.M each for supplying hot return water from GCP-7 to cooling tower for cooling purpose. Capacity !5 Cu.M/hr. Supply 5 CuM DM Water to BF-7 in a day or as per requirement.

Secondary : GCP Supply : GCP Return : DM Water :

L.F. PUMP HOUSE :

There are two groups in this pump house. Group I : Having 2 pumps of capacity 450 Cu.M/hr. each for supplying industrial water to Ladle furnace Group II : Having 2 pumps of capacity 90 Cu.M/hr. each for supplying soft water to Ladle furnace.
R.H. DEGASSING PUMP HOUSE :

There are two groups in this pump house. Group I : Having 2 pumps of capacity 696 Cu.M/hr. each for supplying clarified water to Degasser unit. Group II : Having 2 pumps of capacity 30 Cu.M/hr. each for disposal of sludge settled in suction chamber of the pump house.

DRINKING WATER PUMP HOUSES PUMP HOUSE NO. 4 :

PUMP HOUSE NO. 32 :

It receives water from Water Treatment Plant Maroda, and supplies to 4.0 MT area. In this pump house there are 4 pumps of capacity 200 Cu.M/hr. each.

Water Management Department (WMD)

It receives water from Water Treatment Plant Maroda, and supplies to 2.5 MT area. In this pump house there are 2 UGRs and 5 pumps of capacity 250-360 Cu.M/hr.

WATER CHEMICAL TREATMENT PLANT-3

The Plant is designed to supply 140 Cu.M/hr. softned water to continuous casting shop (PH-39 Mould Group [group-II]), 60 Cu.M/hr. deaerated soft water to Plate Mill ( Reheating furnace) 40 Cu.M/hr. deaerated soft water to Converter Shop for skirt and hood cooling and 6 Cu.M/hr. deaerated soft water to BF-7 ( At present it is not in operation). Raw water is drawn from the make up water grid of 4.0 MT area . Additional source of raw water is also made as second source from new raw water pump house. The treatment given at this Plant is as follows : i. Filtration through pressure sand filters. (4 Nos.) ii. Major cation exchanging is done by weekly hydrogen based resin (acidic cation) in the exchangers (3 Nos.). Here, all the carbonate & bye- carbonate hardness is removed by exchange with RH type resin. iii. Breaking the carbonic acid in the degasser (2 Nos.) into water and carbondioxide and removing carbon dioxide. iv. Making the degassed water alkaline to 9 pH, by addition of sodium hydroxide. v. To remove the rest of the cations linked to strong acid, radicals like Cl--, SO4++ with sodium based resin, thus converting all the harder salts into Sodium salts. The resultant water is soft water coming out from softeners (3 Nos.). vi. The soft water is deaerated by spraying against the flow of steam in Deaerator (2 Nos.) which carries away the dissolved oxygen along with it, leaving the collected water free from oxygen. The soft and deaerated water is pumped to Plate Mill, Concast and Converter shops as per requirement.

WATER CHEMICAL TREATMENT PLANT-4 Water Management Department (WMD)

The Plant is designed to supply 850 Cu.M/hr. of soft water. Raw water is drawn from the make up water system of 4.0 MT area. The raw water is filtered through Automatic valve-less gravity filters (AVGF - 7 Nos.) . The filtered water is passed through softeners (7 Nos.) having sodium base resin. In the softener, hardness of water is removed and water becomes soft. Softened water is supplied to the consumers through two different groups, 700 Cu.M/hr. of soft water is supplied to Concast through secondary cooling group ( group-III) of pump house-39 and 150 Cu.M/hr. to Oxygen Plant-II Pump House, PH-46 & PH-46 A as make up water.

Different types of water & their consumers :

1. Drinking water (Throughout the Plant & Township) 2. Industrial water (Through out the Plant) 3. Raw water 4. Soft water 5. Deaerated water 6. DM Water -

For Drinking and Fire-Fighting. For Industrial use and Fire Fighting. WCTP-1 (PBS), WCTP-2 (PP-II) & WCTP-3 (PM, Concast, Converter) Concast, Converter- 130T ladle furnace & Oxygen Plant-II. Plate Mill and Converter. BF-7

W M D : SOME HIGHLIGHTS

Recycling of high Fe content sludge arising from GCP of SMS-I, ETP of Converter, RST of BFs, and Settling Tanks of SP-I&II to RMP-I and SP-II. Desiltation of Maroda-I Reservoir (Cooling Pond), to improve the quality of waters being recycled back for plant operation. Commissioning and stabilizing of Ladle furnace & RH degasser water supply system including pump houses, cooling towers and associated facilities at SMS-II. Reduction in arising of scale in the secondary settling tanks and the suction chamber of PH-3&3A, thereby improving the life of return water pumps, by strict monitoring for cleaning of scale pits at the Rolling Mills. Direct supply of soft water to CCS under system pressure and stoppage of pump operation at WCTP-3, thereby saving electricity. Recycling of wastewater from storm water Outlet No.7 to Maroda-I and hence saving of make-up water consumption for plant operation. Achieved Zero discharge at outlet 'A'. Conservation of wastewater of the bed drainage PH of Plate Mill by diverting the drainage system to Maroda-I. Removal & recycling of scale (100%) arising at the settling tanks of Rolling Mills, CCS, Plate Mill and ETP of Converter shop. Rain water harvesting of plate mill area and collecting it in Maroda - I.

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Water Management Department (WMD)