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Revision No.: 0 Date:18-05-2019
PROJECT MICROPLAN DOCUMENT
A. PROJECT PROFILE
A.1 PROJECT TITLE : Development of Fe-500D/Fe-550DTMT rebars with low carbon equivalent
at DSP
A.2 CATEGORY : PPI PD BR SID TS
A.3 BACKGROUND & JUSTIFICATION : TMT rebar is one of the integral part of RCC construction. The
strength of rebar is determined by carbon equivalent (CE) and
thermo-mechanical processing parameters of the rebars.
Deciding the percentage of carbon content in steel has been a
major challenge for engineers. While a minimum level of carbon
content in steel is essential to achieve the required strength,
excess carbon threatens its weld ability. CE mainly depends on
carbon and manganese content. Reducing the CE, effectively
reduces the alloying content (C and Mn) there by decreasing the
cost of production of TMT rebars.
Hence, it is proposed to develop Fe-500D/Fe-550Dgrade TMT
rebar with lower CE at DSP.
A.4 OBJECTIVE : Development of Fe-500D/Fe-550DTMT rebars with low carbon
equivalent at DSP
A.5 APPROACH : Alloy design and processing parameters for Fe-500D/Fe-550Dgrade
TMT rebar
Preparation of process chart for production of Fe-500D/Fe-550Dgrade
TMT rebar
Heat making as per designed chemistry
Hot rolling and water cooling as per designed process parameters.
Microstructural examination
Tensile properties evaluation
Formulation of SOP for regular commercial production
Submission of report.
A.6 PROPOSED DATE OF COMMENCEMENT A.7 PROPOSED DATE OF COMPLETION
0 1 0 6 1 9 3 1 0 1 2 0
Format No. RD-PR-B01-FR01 Issue Status : 0 Effective Date: 30.06.18
REVIEWED BY: APPROVED BY:
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A.8 ENGINEER DAYS REQUIRED
PARTICIPATING GROUPS
YEAR TOTAL
LP&ML
2019 - 20 200 200
GRAND TOTAL 200 200
A.9 ESTIMATED COST OF PROJECT (Rs in lakhs)
YEAR CAPITAL REVENUE COST (R) GRAND TOTAL
COST
(C) DIRECT ENGINEER TOTAL (C + R)
REVENUE DAYS COST REVENUE
2019 – 20 Nil 5.00 58.80 63.80 63.80
GRAND TOTAL Nil 5.00 58.80 63.80 63.80
* Fabrication of samples, transportation, and Lab consumables.
A. 10 ANTICIPATED PROJECT OUTPUTS (Please tick mark the appropriate boxes) :
Publication : ; Patent : ; Copyright :
Economic Benefit : Transfer of : ; Social Benefit :
Know-how
A. 11 EXPECTED BENEFITS :
11.1 Please tick mark the appropriate boxes:
Cost Value Quality New
Reduction Addition Improvement Product
Yield Energy Environment Other
Improvement Conservation Control (Specify)
11.2 Technological Benefits (Please specify in quantifiable terms): The above measures will help in cost
reduction of TMT rebars.
11.3 Estimated Annual Benefit (EAB) : Rs. 160.00 Lakhs
Format No. RD-PR-B01-FR01 Issue Status : 0 Effective Date: 30.06.18
REVIEWED BY: APPROVED BY:
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Format No. RD-PR-B01-FR01 Issue Status : 0 Effective Date: 30.06.18
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B QUALITY PLAN & RESPONSIBILITY
B.1 ACTION PLAN:
SL. Milestones with activities Time Schedule Action by Monitore Estimated
NO. d by Engg.
Days
From To
1.0 Alloy design and processing parameters for Fe- 01.06.19 31.08.19 PS, DK, AKB VK 20
500D/Fe-550DTMT rebar
2.0 Preparation of process chart according to TDC 01.07.19 31.08.19 PS, DK, AKB, VK 20
3.0 Heat making Fe-500D/Fe-550Dgrade steel as per 01.08.18 31.09.19 PS, DK, AKB VK 40
designed chemistry
4.0 Hot rolling and water cooling of Fe-500D/Fe- 01.10.19 31.11.19 PS, DK, MK, VK 40
550Dgrade TMT rebar as per designed process AKB
parameters.
5.0 Microstructural examination of Fe-500D/Fe- 01.12.18 31.12.19 PS, DK, MK VK 20
550Dgrade TMT rebar
6.0 Tensile properties evaluation Fe-500D/Fe-550Dgrade 01.12.19 31.12.19 PS, DK, MK VK 20
TMT rebar
7.0 Formulation of SOP for commercial production of Fe- 01.12.19 31.01.20 PS, DK, AKB VK 20
500D/Fe-550D
8.0 Preparation and submission of report 01.01.20 31.01.20 PS, DK VK 20
VK: Vinod Kumar; AKB: A. Bandyopadhyay; MK: M Kalet PS: P Sarvanan, DK: CH S S Dharma Kowshik
Format No. RD-PR-B01-FR01 Issue Status : 0 Effective Date: 30.06.18
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B.2 PROJECT BAR CHART :
PROJECT TITLE : Plant/ Unit
Development of Fe-500D/Fe-550DTMT rebars with low carbon equivalent at DSP
DSP
PROPOSED DATE OF COMMENCEMENT: 01-06-2019 PROPOSED DATE OF
COMPLETION: 31-01-2020
SL. MILESTONES TIME SCHEDULE
NO.
2019 – 20
J J A S O N D J
1.0 Alloy design and processing parameters for Fe-500D/Fe-
550DTMT rebar
2.0 Preparation of process chart according to TDC
3.0 Heat making Fe-500D/Fe-550Dgrade steel as per
designed chemistry
4.0 Hot rolling and water cooling of Fe-500D/Fe-550Dgrade
TMT rebar as per designed process parameters.
5.0 Microstructural examination of Fe-500D/Fe-550Dgrade
TMT rebar
6.0 Tensile properties evaluation Fe-500D/Fe-550Dgrade
TMT rebar
7.0 Formulation of SOP for commercial production of Fe-
500D/Fe-550D
8.0 Preparation and submission of report
Format No. RD-PR-B01-FR01 Issue Status : 0 Effective Date: 30.06.18
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C. PROJECT OUTLAY
C.1 CAPITAL COST (Rs in Lakhs)
SL. DESCRIPTION ESTIMATED COST
NO. 2019 – 20 TOTAL
TC FE TC FE TC FE
1 Equipment - - - - - -
2 Spares along with Equipment - - - - - -
3 Prototype, if required - - - - - -
4 Civil works - - - - - -
5 Structural works - - - - - -
6 Erection/ Commissioning - - - - - -
7 Know-how - - - - - -
8 Contingency - - - - - -
9 Interest during construction - - - - - -
10 Others - - - - - -
TOTAL
C.2 LIST OF EQUIPMENT TO BE PURCHASED NA
SL. Name of the Indigenous/ Expected cost (CIF) Basis of Planned date of Expected date of
NO. Equipment & Quantity Imported Total FE Estimate Indent Delivery
Format No. RD-PR-B01-FR01 Issue Status : 0 Effective Date: 30.06.18
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C.3 REVENUE COST (Rs in Lakhs)
SL. DESCRIPTION ESTIMATED COST
NO.
2019 – 20 TOTAL
TC FE TC FE TC FE
1 Material, Spares & Consumable for laboratory 4.00 4.00
(Chemicals and Glasswares)
2 Equipment costing less than 5000/- each - -
3 Fabrication / Machining from out side 1.00 1.00
4 *Consultancy / Sponsored Research -
5 Lab. Investigation / Testing from out side
6 Cost of Engineer-days 58.80 58.80
7 Others (specify) -
63.80 63.80
TOTAL
TC : Total cost ; FE ; Foreign Exchange Component ; TC to include FE component also
* Details of Consultancy / Sponsored Research to be filled up as per Annexure to C .3 of PMD
D. MAJOR RESOURCES & CONSTRAINTS
The analysis of major resources is to be carried out as per the guidelines (RD-PR-B01-AX01) and the same
is to be kept in the project file. In PMD, under this section a statement is to be given to this effect that
analysis of major resources and constraints has been carried out as per the guidelines.
Format No. RD-PR-B01-FR01 Issue Status : 0 Effective Date: 30.06.18
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E. ESTIMATED ANNUAL BENEFIT (EAB)
Project Title : Development of Fe-500D/Fe-550DTMT rebars with low carbon equivalent at DSP
Plant : DSP
Start: 1 19-20 Completion: 4 19-20 Certification: 4 19-20
Qtr Year Qtr Year Qtr Year
Note : Year & Qtr refers to Financial Year
1. DATA (Report in the following sequences along with the sources of data)
1.1 Basic Plant Data
1.2 Plant Operating Data (Before Innovation)
Annual Production of Fe-500D/Fe-550D TMT rebars 40,000t
1.3 Plant Operating Data (After Innovation)
Annual Production of Fe-500D/Fe-550D TMT rebars [A] 40,000t
1.4 Extent of Utilisation
1.5 Cost Data
Cost saving per ton after innovation (alloy saving) [B] 400Rs
2. PROCEDURE OF CALCULATIONS
(Consult Manual on the working of Standing Committees on Benefit Calculation )
Total cost saving A*B 16000000
3. Estimated Annual Benefit (EAB) : Rs. 160.00 lakhs
Format No. RD-PR-B01-FR01 Issue Status : 0 Effective Date: 30.06.18
REVIEWED BY: APPROVED BY:
