Large Group Interactive Webinar

SAILing through COVID-19

Turbulence
Initiatives Taken for Safety of
Employees Against Covid 19:
The Global Pandemic
 Amid COVID-19 Pandemic, Distribution of PPEs viz. Nose Masks,
Gloves, Hand Sanitizers are done regularly. Quantity distributed to
various departments during Lockdown till date is as follows:

 Sanitization work done at Plant, Township, Hospital, Executive

Hostels, Schools and it is being regularly carried out.

S.No. Particulars of PPE No.

Distributed
1. Nose Mask 21667 nos.+
 
2. Nylon Knitted Hand Gloves 8331 pairs +
 
3. Rubber Hand Gloves 2144 pairs +
 
4. 100 ml bottles of Hand Sanitizers 14303 bottles+
 
5. Disinfectant spraying gun 10 nos.
 THERMAL SCREENING

Thermal screening of all individuals entering the plant through

Tunnel Gate, Sanmara Gate, Vehicle Gate and SCOB Gate.
 PERSONAL VEHICLE SANITIZATION

Vehicle sanitization of personal vehicles entering the plant from SCOB

Gate & Tunnel Gate is being done regularly by the Safety Engineering
Department.
 COMMERCIAL VEHICLE SANITIZATION

As per the guidelines, sanitization of all heavy/ commercial vehicles entering

the plant from Vehicle Gate & Sanmara Gate is being done regularly by the
Safety Engineering & Civil Maintenance Department.
 HELPING HAND INITIATIVES
 Distribution of food grain
 Contribution to PM care fund & CM relief fund
 Steps taken at our hospital
 Quarantine facility created at ISP
COVID-19 :Guidelines
The New Normal
 Guidelines for Maintaining Workplace
Health & Safety
While at the Workplace
• Rigorously follow established SOPs/safety guidelines.
• Ensure use of PPE by self and colleagues
• Helmets, gloves, aprons and other PPE should be used
without exception
• Maintain social distancing. Don’t socialize. Don’t
unnecessarily roam about at the workplace
• Frequent hand washing is advised. Social distancing in all
meetings
 Guidelines for Maintaining Workplace
Health & Safety
While at the Workplace

• Insist co-workers to wear mask and follow social distancing.

• Wait for your turn for using toilets and wash hands
thoroughly.
• Maintain social distancing in all restrooms.
• Employees should not consume Gutkha, tobacco and all
such items and should not spit in the open.
• Unnecessary visit to Canteens should be avoided.
 Guidelines for Maintaining Workplace
Health & Safety
While Leaving for Home

• Ensure keeping all your safety PPEs under lock and key.
• Wash hands thoroughly.
• Use own vehicle / shared vehicle with proper social distancing
and face mask on.

After Reaching Home

• Keep all your clothes, mobile, wallet, keys, other belongings in a

separate tray/ basket for washing/ sanitization.
• Take full bath applying soap.
• Usable masks are to be washed and use-and-throw masks are
to be disposed of in covered bins

Use Aarogya Setu app to keep yourself updated

Production Performance
2019-20
&
ABP 2020-21

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 Major Highlights 2019-20

 SAIL SeQR Launched and 2.3 lakh Tonnes

dispatched in 2019-20

 Alternate Gas System made operational in mills

during BF Shutdown. Both the Mills (Bar Mill &
WR Mill were able to run without BF gas on 26th
March)

 ERP implemented in July 2019 and Primary sales

successfully started through SAP in Dec’2019
 Major Highlights 2019-20
 Development of New Grades:
MIG Casting done on 02.03.20
8200 Tonnes High carbon WR Coils produced.
CHQ Boron
EN8D
SAE1006

 Successful trial rolling done for profile of 150x150

billet from 200x280 blooms on 11.03.20
 Production Highlights 2019-20
 All Major Units except mills reached rated capacity on
monthly basis . WRM achieved 90 % Capacity in Nov’19
and Bar Mill achieved 82 % capacity in Feb’20

 Eqv. Pushing: 273 Ovens/Day (99% ABP, 4 % CPLY)

 Sinter : 3.71 Million Tonnes (95 % ABP, 13 % CPLY)

 Hot Metal : 2.505 Million Tonnes ( 93% ABP, 14 % CPLY)

 Crude Steel : 2.083 Million Tonnes (83% ABP, 10% CPLY)

 Production Highlights 2019-20

 Saleable Steel : 2.094 Million Tonnes (87% ABP, 10 %

CPLY)

 WRM : 4.12 lakh ton ( 82% ABP , 21% CPLY )

 Bar Mill : 6.32 lakh Ton ( 79% ABP , 18 % CPLY )

 USM : 1.72 lakh Ton ( 32% ABP , -30 % CPLY)

 Constraints : 2019-20

 Blast Furnace was down in April 2019

 Converter Health was an issue during May – June

 Unfavorable Market conditions forced us to restrict

our production during Aug- Oct

 COVID-19 outbreak in March 2020

 Dispatch Highlights 2019-20
 Highest ever annual dispatch of 2.05 Million
Tonnes of Saleable Steel which is 12 % above
CPLY

 Direct dispatch was 55.5 % of total saleable steel

dispatch against 46.6 % in CPLY

 Export component was 136% higher than CPLY

and was major contributor in higher Direct
Dispatch quotient .
 Dispatch Highlights 2019-20
 Record export dispatch of 5.37 lakh tonnes of
saleable steel .

 1.84 Lakh tonnes of Pig Iron Equivalent was

dispatched

 8.95 Lakh tonnes of Granulated slag was

dispatched
 Techno Economic Highlights 2019-20
 Coke yield was improved by screen bypass and was
67.5 % as compared to 67 % CPLY

 BF fuel rate : 548 Kg/THM (CPLY 541 Norm 535)

 BF Coke rate : 384 Kg/THM (CPLY 388.Norm 370)

 Nut Coke : 45 Kg/THM (CPLY 29, Norm 25 )

 CDI : 119 Kg/THM (CPLY 123, Norm 140)

 BF productivity : 2.006 T/m3/day (CPLY1.742 Norm

2.159 )
Techno Economic Highlights 2019-20

 Coal to Hot Metal : 932 (CPLY 906 Norm 886)

 TMI : 1119 Kg/THM (CPLY 1119 Norm 1115 )

 Specific Energy : 6.19 Gcal/TCS (CPLY 6.312,

Norm 5.95)

 Power Consumption : 525.3 Kwh/TSS (CPLY 552

Norm 483 )
ABP 2020-21: Salient Features
 ISP committed to implement the Safety
Culture Survey report

 ISP has planned the targets beyond its rated

capacity in Sinter Plant, BF and SMS.

 To develop new sections and grades such as

8 mm TMT in Bar Mill and production of
EWNR Grade.
 ABP 2020-21
Growth over
2019-20
ITEMS Unit 2020-21 2019-20
ACT
Actual

COB #10 OP/ day 99 2% 97

COB #11 OP/ day 99 3% 96

All COB Eq. OP/ day 281 3% 273

Sinter 000 Mt 3957 7% 3710

Hot Metal 000 Mt 2800 12% 2505

Pig Iron 000 Mt 29 -83% 168

Crude Steel 000 Mt 2600 25% 2083

 ABP 2020-21
Growth over
2019-20
ITEMS Unit 2020-21 2019-20
ACT
Actual

SALEABLE STEEL      
WR Mill 000 Mt 550 33% 412
Bar Mill 000 Mt 840 33% 632
US Mill 000 Mt 400 133% 172
Finished Steel 000 Mt 1790 47% 1216
Saleable Semis 000 Mt 722 -18% 878
Saleable Steel 000 Mt 2512 20% 2094
Power Generation MW 49.1   44
Power Import MW 110   100
 April’20 Highlights

Rolling of 8 TMT in Bar Mill & 6 mm TMTC in WR Mill

8 TMT : 6930 T produced and 6448 T dispatched.
6 mm TMTC : 117 T made & 32 T Dispatched
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 April’20 Highlights
 Coke Oven Gas was introduced for the first time
in Mills Gas Mixing Station on 23rd April
 Mills operated without CBM gas during BF
Shutdown on 27th April.
 The initiative will give a direct saving of Rs.34.8
Cr.(With three mills operation) and Rs.17.0 Cr.
(With two mills operation)
 The equivalent savings of CBM gas is 1700
Nm3/Hr
 April’20 Highlights
 ICC Blend reduced to 90 % in both the
batteries after discussions with RDCIS
regarding Coke Properties and Ash Content.

 Running of single Sinter plant in order to

reduce power consumption resulting in
average saving of Rs. 8 lakh / Day (Average
Running Cost of 2 machine : Rs.18 Lakhs /
Day , Single Machine : Rs. 10 Lakhs/ Day )
 Production : April’20
 Coke oven pushing @ 78 ovens/day from each battery.

 Hot Metal production was reduced to 5000 TPD. The Hot

metal production for the month is 1,43,766T, crude steel :
1,29,292 and saleable steel : 1,17,248 T

 Finished Steel Production: 22440 T (19% of Saleable);

(WRM: 14366 T & Bar Mill: 8073 T)
 Mills were down for maintenance and repair jobs
WRM : 7th –18th
Bar Mill : 29th Mar-6th Apr & 19th Apr- 30th Apr

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 April’20 Dispatch & Stock
 Saleable Steel Dispatch : 70,006 T; Export: 48,880 T (WR Coil:
9014 T and Semis : 40,972 T ).
 Road dispatch was highly restricted; only 1240 T has been
dispatched by Road.
 Saleable Steel Stock accretion for this month is about 45,800 T.
85,200 T during Lockdown period (25th March-3rd May)

 Stock as on 01.05.20
• Total Saleable Steel: 1,47,000 T
• Finished Steel: 27,000 T
WRM: 7500 T
Bar Mill: 4835 T
USM: 14,715 T
• Saleable Semis: 1,19,942 T (150 Billets :100550 T, 200 Blooms :
19392 T)
• In Process Semis: 36550 T
• Total Steel (Saleable+ In process): 1,83,541 T 29
 May’20 Plan
 Hot metal has been restricted to around 5000
TPD. Hence Hot metal plan is 1.5 Lac T.
 Crude Steel: 1.38 Lac T and Saleable Steel:
1.33 Lac T
 However depending upon market condition
production can be ramped up to normal levels
within one week (time required by Coke Ovens
and Blast Furnace to ramp up).
 Imperatives for Liquidity
and Cash Management,
Cost Reduction Strategies
 Challenges Ahead

1. Cash Conservation & Generation

2. Cost Reduction
 Steps taken
• A Committee constituted with specific terms of reference:
 Review all open purchase orders for deferment of delivery
period wherever possible, foreclosure of Non-essential
purchase orders.
 Review all contracts for deferment / curtailment of services
wherever possible, foreclosure of Non-essential contracts.
 Re-negotiate purchase orders and contracts in view of
expected slowdown in the economy. If sufficient rebates
are not forthcoming, such purchase orders and contracts
may be considered for closure and fresh tender may be
floated to capture the benefit of reduced prices in the
market.
 Review and defer all fresh indents for material and/ or
services unless absolutely necessary.
 Liquidity Position
 Borrowings of SAIL touched all time high at
Rs.52,200 Cr.
 Cash Collection of SAIL in Apr-20 is Rs 2635 Cr
as against requirement of more than Rs 5700 Cr
Per month.
 ISP Local Cash Generation is Rs 12 Cr in Apr-20
as against Avg Collection of Rs 45 Cr. (2019-20)
 Avg Monthly Cash outflow of Rs 300 Cr. (Salary
& wages Cash out flow Rs 60 Cr.)
Cash Conservation & Generation
– Steps Required
 Rationalisation of Contractual Manpower
 Bare minimum procurement of Stores and
spares for plant operation.
 Monitoring the drawl of power and CBM
 Minimum operation of assets
 Maximizing sales of secondary products
 Recovery of dues from Township Debtors
 Cost Reduction – Steps Required
 Improvement in Techno-economic Parameters
especially Coal to Hot Metal Ratio, Specific Power -
CBM Consumption etc.
 Reduction in Fuel rate
 Increasing the usage of Indigenous coal to the extent
possible.
 Reduction in consumption of Stores & Spares, Repairs
& Maintenance and Administrative expenses.
Will to Win
Tale of a Ship
 The Story of Sankalp
 In the olden days there was a kingdom called Samridhi.
 Samridhi wanted to be prosperous.
 The kingdom decided to explore treasures and riches
across the globe and prepared for grand voyage in the
sea. It prepared a state of the art ship called Sankalp.

Sankalp
 Ship par Excellence
 The ship was world class and equipped with
best of available technologies in rowing, sailing
and navigating.
 It was loaded with food, drinks, heating oil and
all the best of amenities for comfort
 There were sailors, navigators, artisans, singers,
dancers, doctors, geologists, cook, waiters on
board to meet each others requirements and
ultimately achieve the purpose.
 Smooth Sailing
 The sailing was smooth and enjoyable.
 The team members enjoyed the voyage, there were
parties, there were fun on board every day.
 They landed on few islands, did some business, earned
some profit, replenished their stocks and moved on.
 There were intermittent hiccups due to bad weather
conditions but the crew was smart enough to overcome
those
 The Storm
• One day there was a storm and it was a very big one.
• Captain was experienced, he knew that the storm was
different from the normal ones. This time it is going to be
long lasting and more turbulent.
• He called every individual on board in his ship and conveyed
his concerns.
 Captains’ Concerns and Appeal
 Ladies and Gentlemen we are in a big trouble
 The storm this time is going to be longer and very
turbulent
 We have to row harder
 We have to hold the Mast and the sail stronger to
avoid getting into the eye of the storm
 We have to save our foods for longer time
 We have to save the oil for heating
 We have to catch more fish for ourselves
 Please help us in achieving this
Response from the Members in Sankalp
There was silence for some time. After some
hesitation, every member stood up including the
Doctor and his group, Singing troupe, Dance Group,
Cook and his team and voiced their thought in a
chorus.
 We will cut down our rest time by two hours
every day and join with you to row harder and
hold the mast and sail stronger
 We will reduce our food intake during every
meal by a quarter and help the group survive
longer
 We will tolerate the cold and burn less oil and
make everyone survive longer
 We will eat more raw food and less cooked and
save more oil
 Tell us Captain what else we can do to survive
and achieve our mission.
 How they Acted

The members did exactly what

they said
• Sankalp Members exerted
themselves. Took less rest, ate
less, sacrificed comfort. They
Helped in rowing and holding
the mast. They went beyond
the assigned job and braved
the storm.
 Fate and Fortune
Their efforts paid off .The storm got over after 7 days.
They had still some food and oil left with them.
They continued sailing and after two days reached an
island. Lo and behold it was the treasure island. They
rejoiced, danced, celebrated.
They filled their ship with lots of treasure and made
their kingdom (Samridhi) the richest on planet.
Treasure Island is Ahead of us...
India is going to be the next steel hub and there is
going to be lot of demand for steel
Possible policy framework for supporting domestic
steel producers
Govt. spending in projects likely to increase

……………but till then we have to withstand the

market storm.

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 Our Pledge
We, the employees of SAIL, as family members of this
great organisation, commit ourselves to do everything
to fight against COVID-19 and ensure corona free
work environment.
We will keep ourselves vigilant in our actions with
regard to maintaining physical distancing norms and
wearing masks with the best personal sanitization
practices at work-place.
We pledge to stretch ourselves in this challenging
scenario beyond the assigned job and accept any
personal discomfort for the sake of the future of SAIL,
which is the source of our pride and prosperity.

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Thank You

SAIL - ISP