SAIL Summer Internship Report- Braj Kishor Sah

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A

SUMMER INTERN PROJECT REPORTSubmitted by

BRAJ KISHOR SAH

Roll No – 112CR0126

In partial fulfilment of Summer Internship for the award of the degree

Of

BACHELOR OF TECHNOLOGY

IN

CERAMIC ENGINEERING

Steel Authority of India Limited

SAIL Refractory Unit Ranchi Road

Ramgarh (Dist), Jharkhand-829117

July 2015

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Steel Authority of India LimitedSAIL Refractory Unit Ranchi RoadRamgarh (Dist), Jharkhand-829117

CERTIFICATE

To Whom so ever It May Concern

This is to certify that Mr. Braj Kishor Sah is student of B.Tech – CeramicEngineering, National Institute of Technology, Rourkela. He has undergone hisIndustrial training at our organization for 8 weeks from May 11, 2015 to July 10,2015.

We wish him good luck for a bright and prosperous future.

(A.K. Sinha)Sr. Manager (Pres. and Admn)

Steel Authority of India LimitedSAIL Refractory Unit Ranchi RoadRamgarh (Dist), Jharkhand-829117

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ABSTRACT

The B.Tech programme is well structured and integrated course of technical studies. The mainobjective of Summer Training at B.Tech level is to develop skill in student by supplement tothe theoretical study of technical work field in general. Industrial training helps to gain real lifeknowledge about the industrial environment. In every professional course, training is animportant factor. Professors gives us theoretical knowledge of various subject in the collegebut we are practically exposed of such subjects when we get training in the organization. It isonly the training through which I came to know that what an industry is and how it works. Ican learn about various departmental operations being performed in the industry, which would,in return, help me in the future when I will enter the practical field. In today’s globalize world,where cutthroat competition is prevailing in the market, theoretical knowledge is not sufficient.Beside this one need to have practical knowledge, which would help in individual in his/hercarrier activities and it is true that “EXPERIENCE IS BEST TEACHER”.

Braj Kishor Sah

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ACOKNOWLEDGEMENT

The summer internship opportunity I had with SAIL REFRACTORY UNIT, RAMGARH,RANCHI ROAD, JHARKHAND-829117 was a great chance for learning and professionaldevelopment. Therefore, I consider myself as a very lucky individual as I was provide with anopportunity to be a part of it. I am also grateful for having a chance to meet so many wonderfulpeople and professionals who lead me though this internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude andspecial thanks to the Manager (P&A) Mr. Anand Kumar Sinha of SAIL REFRACTORYUNIT, RAMGARH, RANCHI ROAD, JHARKHAND-829117 who in spite of beingextraordinarily busy with his duties, took time out to hear, guide and keep me on the correctpath and allowing me to carry out my project at their esteemed organization and extendingduring training.

I express my deepest thanks to Mr. Ujjal Kumar Pal, Asstt. General Manager Production/ IClab for taking part in useful decision and giving necessary advices and guidance and arrangedall facilities to make life easier. I choose this moment to acknowledge his contributiongratefully.

It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to Mr.Dinesh Prasad, Shri Keshari Nandan Gupta, Sr. Manager (Production), Shri A.KumarAsstt. Manager (Production), Shri P.K. Gupta, Sr. Manager (Maintenance), Shri R.L. Tiwari,Sr. Manager (Electrical), Dr. R.C. Pandey Sr. Manager (MM), Shri J.K. Singh Asstt.Manager (F&A), Mr. Prasanta Baidya, Mr. Ajaz Ahmed, Mr. Shakil Khan for their carefuland precious guidance which were extremely valuable for my study both theoretical andpractically.

I perceive as this opportunity as a big milestone in my carrier development. I will strive to usegained skills and knowledge in the best possible way, and I will continue to work on theirimprovement, in order to attain desired career objectives. Hope to continue cooperation withall of you in the future.

Sincerely,Braj Kishor SahDate: 06/07/2015

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ContentsCertificate…………………………………………………………………………...…………2

Abstract……………………………………………………………………………………..…3

Acknowledgement……………………………………………………………………….…….4

1. INTRODUCTION ..............................................................................................................................7

1.1. CAPACITY OF PLANT................................................................................................................8

1.2. AREA........................................................................................................................................8

1.3. MAN POWER OF PLANT ..........................................................................................................8

1.4. FACILITIES PROVIDED BY COMPANY.......................................................................................8

2. RAW MATERIALS..........................................................................................................................9

2.1. INDEDEGINES ...............................................................................................................................9

Materials come from India..................................................................................................................9

2.2. IMPORTED....................................................................................................................................9

2.3. Raw Materials ..............................................................................................................................9

2.3.1. Fused Magnesia ...................................................................................................................9

2.3.2. Refractory Grade Fused Magnesia..................................................................................10

2.3.4. Sea Water Magnesia .........................................................................................................11

2.3.5. Graphite .............................................................................................................................12

2.3.6. Resin ...................................................................................................................................14

2.3.7. Aluminium Powder ...........................................................................................................14

2.3.8. Pitch Power........................................................................................................................14

2.3.9. Dead Burnt Magnesia .......................................................................................................15

1. Refractory Industry for manufacture of Basic Refractory Bricks .........................................16

2. Manufacture of Ramming Mass composition, Fettling material and Magnesite Mortar ......16

3. It is used in SLAG beneficiation and in SLAG splashing in Arc Furnaces ..........................16

4. It is also used as a coating material in Steel Industry. ..........................................................16

3. PRODUCTION ...........................................................................................................................17

3.1. Selection of raw materials .........................................................................................................17

3.2. Grinding.................................................................................................................................17

3.3. Mixing.........................................................................................................................................18

3.4. Ageing ........................................................................................................................................20

3.5. Pressing ......................................................................................................................................21

3.6. Curing .........................................................................................................................................22

3.7. Checking & Packing ....................................................................................................................22

3.8. Transportation ...........................................................................................................................23

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4. MAINTANENCE ........................................................................................................................24

4.1 TYPES OF MAINTANCE SYSTEMS.................................................................................................24

4.2 MAINTENANCE OBJECTIVES........................................................................................................24

4.4. Mechanical Maintenance Engineer ...........................................................................................25

4.5. Electrical Maintenance Engineer ...............................................................................................26

4.6. Civil Maintenance Engineer .......................................................................................................26

5. HYDRAULICS............................................................................................................................29

5.1 Hydraulic Press (BRAMAH PRESS)...............................................................................................29

5.2 ADVANTAGES OF HYDRAULIC SYSYEMS .....................................................................................30

6. PURCHASE.................................................................................................................................33

6.1. Types of Tenders........................................................................................................................33

6.2. NEGOTIATIONS......................................................................................................................33

7. LABORATORY ..........................................................................................................................36

7.1. Pyro metric Cone Equivalence (PCE)..........................................................................................36

Machine is for testing of melting capacity of taken specimen. Test is based on comparison. Meltingpoint of component which is to be tested is compared by standard material with pre-determinedmelting point.....................................................................................................................................36

7.2. Refractory under Load (RUL).................................................................................................36

7.3. Cold Crushing Strength (CCS) ................................................................................................36

7.4. Types of Test Which Performed Here...................................................................................36

8. ELECTRICAL DEPARTMENT...............................................................................................38

9. STORES.......................................................................................................................................39

9.1. Store Department normally divided inti Following Various Section..........................................39

9.2. Task of Store .........................................................................................................................40

9.3. Functions of Stores ...............................................................................................................40

9.4. Store function deals with three major activities...................................................................40

9.5. Methods of Issues of Materials in SAIL Refractory Unit .......................................................40

10. SIZE OF BRICKS WHICH IS MANUFACTURED HERE ..............................................41

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1. INTRODUCTIONSAIL Refractory Unit is situated at the edge of Ranchi-Patna highway (NH-33), just besidethe Ranchi Road Railway Station of Eastern railway at RANCHI ROAD, POST-MARAR,RAMGARH (JHARKHAND)-829117. The place is well connected by road linking, in theSouth of the state capital Ranchi and Hazaribagh in the North by a distance of 45 km on theeither side.

The company previously known as “ASSAM SILLIMANITE LTD.” in the private sector. Itwas commissioned on July 15, 1961 vide factory registration no. 8745/HBG having itsproduction in plant no.-1 commenced in the year 1962 and in plant no.-2 in the year 1965. Themain product at that time was Sillimanite based high refractory. The company had a captivelease-hold mines located in the state of ASSAM KNOWN AS N.M. MINES SONAPAHAR,ASSAM.The management of the company was taken over by “HINDUSTAN STEEL LTD.” as an“Authorized Person” on 2nd November, 1972 under the industries (Development andRegulation Act, 1951), which was taken over by the Government of INDIA on 2nd November1976 under the central legislation act.In year 1978 for the restriction of iron and steel companies, a legislation was passed by theparliament under public sector iron and steel companies restructuring Act 1978.M/SHINDUSTAN STEEL LTD (Refractory Plant) was merged into BHARAT REFRACTORYLTD., Ranchi road refractory plant, vide order number. So 1847(E) DT. 28/07/2009 issuedfrom this GOVT. OF INDIA, MINISTRY OF CORPERATE AFFAIRS. BRL has been mergedwith SAIL as SAIL REFRACTORY UNIT, RANCHI ROAD.

Plant

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1.1. CAPACITY OF PLANT

The re-assessed capacity of plant is 12200 Tonne production for the year 2014-15 consistingof 12000 Tonne of Magnesite Carbon Brick and 1200 Tonne of various masses.

1.2. AREA

The plant is spread over land of 72.65 acres.

1.3. MAN POWER OF PLANT

Man power position in SRU Ranchi road total no. of workers are 173, in which there are 23executive and 150 non- executive workers including 20 SC and 15 ST worker.

1.4. FACILITIES PROVIDED BY COMPANY

A canteen, School bus facility, Hospital, School, etc.

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2. RAW MATERIALSTwo categories of raw materials used in this plant:-

2.1. INDEDEGINES

Materials come from India.

2.2. IMPORTED

Materials come from abroad like Ireland and China.

From China- Fused Magnesia (FM) and Graphite

From Ireland- Sea Water Magnesia (SWM)

From Australia- Carbon Mag

Landed cost of imported raw materials as on 07.01.2014

Name of various raw materials and chemicals which is used here are-

2.3. Raw Materials

2.3.1. Fused MagnesiaFused magnesia is produced from natural magnesite or high purity calcined magnesite grain,which is fused in arc furnaces. The product has high purity, crystal grain, compact structured,strong slag resistance and good thermal shock stability. It is a kind of excellent hightemperature electrical insulation material and is also used to make high quality magnesitebricks, magnesia carbon brick and the important raw materials for amorphous refractory.Fused magnesia of the highest quality with a crystal size of > 1,200 µm.

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It is an extremely resistant base material for the production of converter bricks thanks to itsvery low SiO2 content of 0.26% and Fe2O3 content of 0.19%.

Crystal Fused Magnesia 99.99% Fused Magnesia

High Purity Crystallized Fused Magnesia .High Purity Low SiO2 and Low Fe2O3

Fused Magnesia

Fused magnesia is superior to deadburned magnesia in strength, abrasion resistance andchemical stability. Major applications are in refractory and electrical insulating markets.Producers of fused magnesia commonly fall into one of two categories: those producingrefractory grades and those producing electrical grades. Few producers serve both markets ona mainstream basis.

2.3.2. Refractory Grade Fused MagnesiaThe addition of fused magnesia grains can greatly enhance the performance and durability ofbasic refractories such as magcarbon bricks. This is a function of a higher bulk specific gravityand large periclase crystal size, plus realignment of accessory silicates. Refractory grade fusedmagnesia has exacting specifications and is normally characterised by the following:

Generally high magnesia content (minimum 96 per cent MgO and up to/exceeding 99per cent MgO)

Low silica; lime: silica ratios of 2:1 Densities of 3.50 g/cm3 or more Large periclase crystal sizes (>1000 microns)

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Due to its excellent corrosion resistance, refractory grade fused magnesia is used in high wearareas in steel making, e.g., basic oxygen and electric arc furnaces, converters and ladles.

Ultra high purity (>99 per cent MgO) grades have been used in high-tech applications such asoptical equipment, nuclear reactors and rocket nozzles.

In fused magnesia production, the main constraints on capacity are the size and number ofelectric arc furnaces, and the cost of energy. The manufacture of fused magnesia is very powerintensive with electricity consumption varying between 3500-4500 kWh/tonne; fusedmagnesia producers often quote total capacity based on utilising off peak power.

2.3.4. Sea Water Magnesia

Seawater contains approximately 3.5% dissolved salts, of which about 0.5% are solubleMagnesium Chloride (MgCl2) and Magnesium Sulphate (MgSO4) salts. Approximately 500Tonnes of seawater are required to produce 1 Tonne of Magnesium Oxide (MgO).

Seawater is collected from the sea and stored in a large reservoir (below) from where it ispumped to the factory, located a couple of kilometres upstream. Once in the factory, theseawater is degassed to remove hardness before being transferred to the reactor.

Sea Water Reservoir

High Purity Limestone comes from local mines to the plant. The limestone is crushed, gradedand transported to the production plant, where it is calcined (high temperature firing) atapproximately 1600°C in a rotary kiln to convert it to quicklime (Calcium Oxide, CaO). Thechemical reaction is given by the following equation:

The resulting quicklime is then mixed with freshwater and converted to lime slurry (CalciumHydroxide, Ca (OH) 2) in a highly exothermic reaction known as hydration or slaking:

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Lime Slurry

Precipitation of Magnesium HydroxideAfter slaking, the lime slurry is pumped to the reactor where it reacts with the degassedseawater. Precipitation of Magnesium Hydroxide (Mg (OH)2) occurs instantaneously and isdescribed by the following equation:

After the reactor, the Magnesium Hydroxide crystals are settled and thickened.

Filtration and WashingThe settled Magnesium Hydroxide slurry is pumped and filters in the multiple hearth furnace(MHF). The slurry is filtered and washed with freshwater and the filter cake is sent to twopressure filters, which squeeze more water from the cake to increase the solids content furtherand reduce the amount of water going onto the next stage of the process – magnesia calcination.

SinteringGreen pellets are fed to the shaft kilns, where they are heated to temperatures in the region of2300°C. The intense heat encourages the Magnesia crystals to grow and the briquettes beginto shrink as the bulk density increases. The final product, Periclase (also known asSintermagnesia or Deadburned Magnesia), is a very dense, chemically inert, refractory gradesintermagnesia.2.3.5. GraphiteGraphite archaically referred to as Plumbago, is a crystalline form of carbon, a semimetal,a native element mineral, and one of the allotropes of carbon, amongthem diamond and graphene. Graphite is the most stable form of carbon under standardconditions. Therefore, it is used in thermochemistry as the standard state for defining the heatof formation of carbon compounds. Graphite may be considered the highest grade of coal, justabove anthracite and alternatively called meta-anthracite, although it is not normally used asfuel because it is difficult to ignite.

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Rock Graphite Graphite Powder

It is used to manufacture the refractories. This end-use began before 1900 with the

graphite crucible used to hold molten metal; this is now a minor part of refractories. In the mid-

1980s, the carbon-magnesite brick became important, and a bit later the alumina-graphite

shape. Currently the order of importance is alumina-graphite shapes, carbon-magnesite brick,

monolithics (gunning and ramming mixes), and then crucibles.

Crucibles began using very large flake graphite, and carbon-magnesite brick requiring not quite

so large flake graphite; for these and others there is now much more flexibility in size of flake

required, and amorphous graphite is no longer restricted to low-end refractories. Alumina-

graphite shapes are used as continuous casting ware, such as nozzles and troughs, to convey

the molten steel from ladle to mold, and carbon magnesite bricks line steel converters and

electric arc furnaces to withstand extreme temperatures. Graphite Blocks are also used in parts

of blast furnace linings where the high thermal conductivity of the graphite is critical. High

purity monolithics are often used as a continuous furnace lining instead of the carbon-

magnesite bricks.

The US and European refractories industry had a crisis in 2000–2003, with an indifferent

market for steel and a declining refractory consumption per tonne of steel underlying firm

buyouts and many plant closures. Many of the plant closures resulted from the acquisition of

Harbison-Walker Refractories by RHI AG and some plants had their equipment auctioned off.

Since much of the lost capacity was for carbon-magnesite brick, graphite consumption within

refractories area moved towards alumina-graphite shapes and monolithics, and away from the

brick. The major source of carbon-magnesite brick is now imports from China. Almost all of

the above refractories are used to make steel and account for 75% of refractory consumption;

the rest is used by a variety of industries, such as cement.

According to the USGS, US natural graphite consumption in refractories was 12,500 tonnes in

2010

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2.3.6. ResinResin is used as a binder to manufacture the refractory. It provides strength to the refractory.

2.3.7. Aluminium PowderAluminium powder is powdered aluminium. This was originally produced by mechanicalmeans using a stamp mill to create flakes. Subsequently, a process of spraying moltenaluminium to create a powder of droplets was developed by E. J. Hall in the 1920s. Theresulting powder might then be processed further in a ball mill to flatten it into flakes for useas a coating or pigment.This is used as an antioxidant in magnesia carbon refractory.

Aluminium Pigment Powder Aluminum Powder 20 micron

2.3.8. Pitch PowerPitch powder is one of the carbonaceous facing material used in the foundry for mixing in greenmould composition. When molten matter comes in contact with mould surface containing pitchpowder, gaseous envelop is formed which resists the fusion of sand to the metal. Being a Tarit has got a binding effect and green strength of the mould is increased considerably. The ashcontents being low as 0.8% to 0.4%, it improves casting finish and increases dry and greenstrength, it also reduces expansion.The volatile matter being about 5’0 percent and ash less than 1.0 percent will improve thequality of castings to a considerable extent.

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The softening point of the pitch powder should be as high as practicable and it is proposed thatit should be 120 to 130°C.

Binder Pitch Pitch Powder

2.3.9. Dead Burnt MagnesiaDead Burnt Magnesite (DBM) is produced in a vertical shaft by sintering raw magnesite at acontrolled high temperature of 1750 degree centigrade. It is chemically inactive and extremelyheat resistant. It is mainly used in the manufacture of basic refractories. The finished productis low in Silica and high in Iron which is suitable for hot fettling of Furnaces and ideal formanufacturing Monolithic which helps in quick sintering because of high Iron content. Thesebasic refractories are used by the iron & steel industry in electric arc furnaces and differentkind of kilns for lining purpose. We provide various sizes of DBM as per consumer'sspecifications at a very competitive rate.

Dead Burnt Magnesite

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Normal Magnesia Dead burnt Magnesia

SPECIFICATIONS

MgO 84-87%

SiO2 5.5% (max)

CaO 3% (max)

Fe2O3 5.5% (max)

LOI 1% (max)

SIZE0-1mm, 0-2mm, 0-3mm, 0-6mm, 1-2mm, 1-6mm, 2-6mm, 200 mesh or as required

APPLICATIONS :

1. Refractory Industry for manufacture of Basic RefractoryBricks

2. Manufacture of Ramming Mass composition, Fettlingmaterial and Magnesite Mortar

3. It is used in SLAG beneficiation and in SLAG splashingin Arc Furnaces

4. It is also used as a coating material in Steel Industry.

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3. PRODUCTIONDepartment involve in production of high heat resistance magnesia carbon bricks which is usedin blast furnace in steel plants. Fused magnesia which comes from China and sea watermagnesia from Ireland are the main raw material in production of these high heat resistancebricks.

Steps involve in production of Magnesia Carbon Bricks

3.1. Selection of raw materials

For the production of the magnesia carbon bricks, the first step is to select the raw materials.For production of magnesia carbon bricks, the selected raw materials are sea water magnesia,fused magnesia, carbon mag, aluminium powder, resin, pitch powder. The selected rawmaterials are tested in the plant laboratory and if these are found ok, then these raw materialsare used for manufacturing of bricks as per required quantity.

3.2. Grinding

The selected raw materials are taken as per required amount and put in to the ball mill forgrinding. Ball mill is used for size reduction of the raw materials. The plant has two ball mill,which is to reduce the size of raw materials.One of them produced the final product coarse, medium, and fine whereas another ball millproduced only coarse and fine particles.

Ball Mill

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Ball Mill

A ball mill works on the principle of impact: size reduction is done by impact as the balls dropfrom near the top of the shell.A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis of the shellmay be either horizontal or at a small angle to the horizontal. it is partially filled with balls.The grinding media is the balls, which may be made of steel (chrome steel), stainless steel orrubber. The inner surface of the cylindrical shell is usually lined with an abrasion-resistantmaterial such as manganese steel or rubber. Less wear takes place in rubber lined mills, suchas the Sepro tyre drive Grinding Mill. The length of the mill is approximately equal to itsdiameter.

3.3. Mixing

There are four mixture in plant which is used to mix the sea water magnesia, fused magnesia,carbon mag, aluminium powder, resin, pitch powder in proper ratio. The mixture named as E-1, W-3, Hari and ICC.

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STEEL AUTHORITY OF INDIA LIMITEDSAIL Refractory unit Ranchi Road

PLANT No. – 01

MIXTURE

Sl. No. Name of Motor KW R.P.M. Full L.A. Over L. ContactorSize

01. Mixture MotorMake-AGE

24 720 43 25 to 100 3 TF 47

02. Gate MotorMake-SIEMENS

1.5 1440 3.45 2.8 to 4 3 TF 34

03. VOIST Motor 3.7 1440 8 5 to 8 3 TF 34

04. Gudgudiya Motor-01 18.5 980 30.5 12.5 to 15 3 TF 44

05. Gudgudiya Motor-02 18.5 980 30.5 12.5 to 15 3 TF 44

Mixture Machine

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Plant also have a tube mill which is used to produce the pre-mix of aluminium powder.

A tube mill consists of a horizontal rotating cylinder, up to three diameters in length, containing

a charge of tumbling or cascading steel balls, pebbles, or rods. Both types of mill include liners

that protect the cylindrical structure of the mill from wear. Thus the main wear parts in these

mills are the balls themselves, and the liners. The balls are simply "consumed" by the wear

process and must be re-stocked, whereas the liners must be periodically replaced. The ball and

tube mills are low-speed machines that grind the coal with steel balls in a rotating horizontal

cylinder. Due to its shape, it is called a tube mill and due to use of grinding balls for crushing,

it is called a ball mill, or both terms as a ball tube mill.

The grinding in the ball and tube mill is produced by the rotating quantity of steel balls by their

fall and lift due to tube rotation. The ball charge may occupy one third to half of the total

internal volume of the shell. The significant feature incorporated in the BBD mills is its double

end operation, each end catering to one elevation of a boiler. The system facilitated entry of

raw coal and exit of pulverized fuel from same end simultaneously. This helps in reducing the

number of installations per unit.

Tube Mill

3.4. Ageing

Aging of mixed powder is done on the basis of moisture content in the materials. To ageing themixture powder filled into the rectangular bucket and it is placed in open atmosphere within ashaded building. Mixture take time 1-10 days for ageing.

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Ageing

3.5. Pressing

After mixing the raw materials, mixture goes for pressing. Plant have EP-800 tonne andSACMI-2500 tonne capacity hydraulic machines. SACMI press having a capacity of 15ton/shift is imported from Italy at accost of Rs 7.53 crore. Plant have one EP-800 tonne presswith a capacity of 8 ton/shift. SACMI-2500 tonne press is fully automated.

EP-800 Tonne Pressing Machine

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EP-800


01. Main Pump Motor-01 45 1000 78 45 to 63 3 TF 48



04. Control Pump Motor 5.5 1500 11 9 to 12.5 3 TF 32

05. Filter Pump Motor 7.5 2900 14 11 to 16 3 TF 34

06. Grease Pump Motor 0.18 1420 0.36 0.45 to 0.63 3 TF 34

07. Feed Belt Motor 0.75 1440 1.5 0.45 to 0.63 3 TF 34

08. Take off Belt Motor 0.55 1440 1.10 0.45 to 0.63 3 TF 34

3.6. Curing

After completion of pressing process, bricks goes in chamber kiln for curing. Curing inchamber kiln is done at 200oC in order to harden the bricks. Plants have five chamber kiln inwhich three are running. The time period for curing is 40-48 hours.

3.7. Checking & Packing

After curing the final product is verified by inspection body and if it is found ok, then it ispacked. If any problem found in the final product then the effected item is removed.

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3.8. Transportation

Packed bricks are transported to the truck via fork lift, plant have 5 fork lift.

Fork Lift

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4. MAINTANENCEFunction of maintenance department of SAIL are entrusted with the maintenance of plants tocare of a regular, through supervision of the conditions and functions of all operationalequipments in the right time so that the effect of deterioration can be spotted early enoughbefore major costly breakdowns and damage to the equipments.The justification for a maintenance organization group lies in its use to ensure availability ofequipment and services for performance of their functions at optimum return on investmentswhether this investment be in MACHINARY, MATERIAL, PEOPLE and MONEY.

4.1 TYPES OF MAINTANCE SYSTEMS

Any organization which is machinery, plant, equipments and facilities must have a clear-cutmaintenance policy. In SAIL broadly the following methods are used for carrying outmaintenance activities.

a) Breakdown MaintenanceThis is event based and carried out when breakdown of equipment takes place bringing downproduction. This is firefighting and should be avoided at all cost.

b) Preventive MaintenanceIt consists of planned and co-ordination inspection, adjustment, repair and replacements inmaintaining equipments. Preventive maintenance of a machine can be carried out both duringoperation as well as shut down.

c) Planned MaintenanceIt has to be centred on the original recommendation made and prescribed by the originalequipment manufacturer. The maintenance manager has to use all his experience and expertiseto super impose refinements and improvements on manufacturer recommendation.

d) Predictive MaintenanceMost predictive maintenance are performed while the equipment is in services, therebyminimizing disruption of normal system operations. Adoption of predictive maintenance(PDM) in the maintenance of equipments can result in substantial cost and higher systemreliability.

4.2 MAINTENANCE OBJECTIVES

a) Ensure maximum equipment availability for meeting annual production planningtargets.

b) Maintain plant equipments and facilities at economic level of repairs at all times toconserve these and increase their span.

c) Provide desired services to operating departments at optimum level.d) Ensure reliability and safety of equipments for uninterrupted production.e) Ensure operational readiness of all stand by equipments.

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4.3. Entire Maintenance department can be categorized as:-

4.4. Mechanical Maintenance Engineer

Works Manager

ChiefMaintenance

Engineer

MechanicalMaintenance

Engineer

ElectricalMaintenance

Engineer

CivilMaintenance

Engineer

MechanicalMaintenance Engineer

Supted. PlantMaintenance

Maintenance of cranes,hoist, lifts, etc.

Maintenance of plantNew installation

Supted. Repair ShopMachine Shop

Fitting ShopWelding Shop

Automobile Shop

Supted. Power HouseMaintenance Repair

Checking of mechanicalequipments in power

house

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4.5. Electrical Maintenance Engineer

4.6. Civil Maintenance Engineer

Electrical MaintenanceEngineer

Phone SupervisorRepair,

Maintenance andInstallation of internal

phone system

Supted. Power Hose(Electrical)Repair and

Maintenance ofelectrical equipments of

power house.

Supted. ElectricalMaintenance

Maintenance ofdistribution line. Repair

shop Maintenance ofelectrical lining for

lighting and machinery.

Civil MaintenanceEngineer

Supted. BuildingMaintenance

Supted. RoadMaintenance

Supted. Sanitation andWater supplyMaintenance

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The plant has a well-organized work shop where machines are repaired by maintenanceworkers. Work shop have these machines:-

1) Lathe Machine-1

2) Shaper-2

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3) Grinder Machine-24) Welding Shop5) Drilling Machine-26) Auto Garage

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5. HYDRAULICSThe science which deals with flow of fluids (under pressure) is called Hydraulics. Principal ofoperation of pneumatics and hydraulics are almost same. Pneumatics can do same job with lessefficiency, less accuracy, less reliability due to compressibility, water condensation, and noiseand dust pollution. Load capacities are also due to low pressure involved. Hence hydraulics isslowly replacing pneumatics. Due to these reasons hydraulics are widely used in most oforganization including SAIL.Ball Mill and SACMI are few examples of hydraulics which is used in SAIL.

5.1 Hydraulic Press (BRAMAH PRESS)

Since pressure in the confined fluid is uniform throughout and by applying this pressure onlarge area large forces can be developed. This is the starting point for development ofhydraulics.


SACMI PRESS

Power-2500 T

Sl. No. Name of Motor KW R.P.M. FullL.A.

Over L. ContactorSize

01. Main Pump Motor 55 1470 100 100 to 160 3 TF 45



04. Control Pump Motor 15 1440 28 28 to 40 3 TF 34

05. Filter Pump Motor 7.5 1450 14 10 to 16 3 TF 34

06. Lubrication Motor 0.18 1350 0.36 0.6 to 1 3 TF 30

07. Power Pule Cooling Motor 0.25 1440 0.50 0.6 to 1 3 TF 30

08. Conveyor Belt Motor 5.5 1440 11.05 9 to 12.5 3 TF 30

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SACMI-2500 Tonne Pressing Machine

5.2 ADVANTAGES OF HYDRAULIC SYSYEMS

1) Precise control-depending on different requirements one can get exact speed, force andposition of user.

2) Over load protection-in case there is over load in pipe line or user, there is provision ofrelief value set at a certain maximum pressure to take cares of it.

3) Suspension of load for long period.4) Easy maintenance only oil contamination control will fulfil major portion of

maintenance work.5) Variable speed controls.6) Flexibility in design as per need of production, scheme of hydraulic circuit may be

changed easily only with addition of a few components.7) Stalling of loads, the loads can be stalled to zero speed without any damage to the

equipments.

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Hydraulic Pressure Pump


AIR COMPRESSOR 1 & 2

Air Compressor- 1


01. Compressor Motor-01 90 1460 158 0.63 t0 0.9 3 TF 63

02. Compressor Motor-02 90 1460 160 0.63 t0 0.9 3 TF 63

03. Pump Motor-01 2.2 2850 4.7 3 to 5 3 TF 30

04. Pump Motor-02 2.2 2850 4.7 3 to 5 3 TF 30

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Air Compressor- 2


01. Compressor Motor-01 30 730 58 50 to 200 3 TF 47

02. Compressor Motor-01 30 730 62 25 to 100 3 TF 47

03. Water Pump-01 2.2 2800 4.7 3 to 5 3 TF 30

04. Water Pump-02 2.2 2800 4.7 3 to 5 3 TF 30

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6. PURCHASEAs the name indicate purchase department deals with purchase of required equipments ormaterials for organization. For this department issue a tender. Tender means an invitation tooffer for item/items or work. All public sector purchase/contracts in India, over a certain valuehas to be publicly notified through Tender Notices which are advertised through All IndiaNewspapers, Trade Journals, Departmental Publications and Notice Boards, and now onInternet.

6.1. Types of Tenders

1. Limited TenderingThis involves issuing tender to few selected tenders only. It is for specific brand or company.

2. Open TenderingThis means that the tender is open to any suppliers who can quote for the materials as perrequirements. This is usually done by publishing the tender notice in Newspapers/TradeJournals/Internet and other bulletins.

3. Global TenderingThis involves issuing tender to global tenderers (outside the country).

4. Single TenderingIt means sending the tender to one particular party. These are also sent for items of proprietarynature.Example- Samsung Phones, Crympton Motors, etc.After collection of bid document and submission of offers representative of tenderers areallowed to attend Tender opening. The comparative statement (C.S.) of all rated offers andother terms like freight forwarding, quality assurance, taxes, identifying the lowest cost (L1,L2,L3) offers are listed.

6.2. NEGOTIATIONS

If for some reasons, the party is not able to comply with the terms of the order, an amendmentto the order needs to be issued. The order may not necessarily be placed on L1 since, variousother criteria like past performance of the party, urgency of requirement etc. are also consideredbefore decision taken.In some cases orders are divided between two or three parties. At times L2 is asked towork/supply at L1 rates. In these situations, negotiation plays an important role especially incase where multiple technology, high value items/work are involved.These are the format of forms which is used by purchase department to purchasegoods/materials/instruments/machines etc.

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Indent Form 1

Recommendation of Screening Committee :

TO BE FILLED BY PURCHASE SECTION

Indent Received on Indent Received By Indent Registration No.D D M M Y Y

Signature

Name

Indent Form 2

Suggested Name of Suppliers with Address :

Suggest Mode of Tendering Suggested Number of Vendors on Whom to Place Order

Consumption Pattern for Last 3 Years (Quantity & Value)

Stock-in-Hand Pending Purchase Order Nos Consumption Norm

Signature of Indenter : Signature of Section Head : Signature of Finance (Budget Section):

FINANCE ONLYA/C HEAD : Capital/Revenue (Pl TICK) Budget Clearance

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Indent Form 3

SAIL,SRU,HO/UNIT:RANCHI ROAD MATERIAL INDENT FORM INDENTOR

Indent No. D D M M Y Y Proprietary Item YES/NO

Proprietary CertificateAttached

YES/NO

SL. No. MaterialCode

Material Description with FullSpecification

Unit Quantity EstimatedUnit Rate

EstimatedTotal Price

DeliverySchedule

1.

2.

3.

4.

Special Instructions/Clauses (if any like inspection Guidelines, Complementary/Matching Items etc.)

Justification of Purchase/Basis of Estimates : Last Purchase Price/Budgetary Offer references etc.

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7. LABORATORYUnit has a well-equipped lab in which metal’s characteristics, nature and its suitability for workis done.

7.1. Pyro metric Cone Equivalence (PCE)

Machine is for testing of melting capacity of taken specimen. Test is based on comparison.Melting point of component which is to be tested is compared by standard material with pre-determined melting point.

7.2. Refractory under Load (RUL)

In this test load bearing capacity of material is tested and result is taken by the help ofparameter.

7.3. Cold Crushing Strength (CCS)

SAIL Refractory Unit have 2 cold crushing strength machine. One is of 40 tonnes and anotheris of 300 tonnes.Apart from these, unit also have a well-equipped chemical laboratory for testing of chemicalcharacteristics of materials.The brick size for CCS test is 100*100*100 mm3.

7.4. Types of Test Which Performed Here

1. Resin TestThere are four types of test which is performed on resin:-

I. Specific Gravity1. Take 70-80ml resin.2. Put it into hydrometer.3. The temperature should be 25oC.4. The recommended range of specific gravity is 1.17-1.21.

II. Non Volatile Matter1. Take 2gm resin.2. Put it into dredger for 1 hour.3. The temperature should be 135oC.4. Now cooled resin and weight5. The recommended range of solid content in resin is 70-75 wt. %.

III. Viscosity1. Take 250-300ml resin.2. Put it into viscometer.

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3. Temperature should be 25oC.

IV. Water Miscibility1. Take 20ml resin.2. Add water dropwise till the colour of resin is change.

2. Aluminium Power TestTo know the composition of aluminium powder, this test is performed. The recommendedcomposition of aluminium powder given below:-

Composition Wt. Percentage (%)

Alumina 99.5

Fe 0.4

Si 0.1

3. Graphite TestGraphite test is performed to know the % of following parameters present in graphite.

Moisture Volatile Matter Fixed Carbon

The gain size of aluminium powder should be in the range (-0.044, min 40%)-(+0.074, max10%MgO, Silica and iron are main materials for chemical test. Department plays a very importantrole in the company production. Different kind of raw materials comes here are tested first inits laboratory in the presence of member of concerned department.

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8. ELECTRICAL DEPARTMENTPlant has a well maintained electrical department which provide the current to the plant anddifferent motors which runs to manufacture the bricks. It has a 33KV sub station and two powertransformer of capacity 15 MVA.

Electrical department also has two generator DG-1 and DG-2 which is works when there is noelectricity.

The work of electrical department is to provide electricity to the plant continuously withoutany interruption.

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9. STORESThe term stores refer to the physical place be it a building or a room where materials of allvariety are kept. The function of stores is to receive, store and issue materials.

9.1. Store Department normally divided inti Following Various Section

1) Receiving Section.2) Tool Stores.3) General Stores.4) Raw Materials Stores.5) Finished part Stores.

Store function as an element of materials department, has an interface with many usersdepartments in its daily operations. The basic purpose served by stores is the provision ofuninterrupted services to manufacturing divisions. Store acts as a cushion between purchaseand manufacturing on one hand and manufacturing and marketing on the other

Storage of Raw Materials

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9.2. Task of Store

Safe custody and stocking of materials, their receipts, issues and accounting with the objectiveof efficiently and economically providing the right material at the right time whenever requiredin the right condition to all user departments.

9.3. Functions of Stores

1) To receive raw materials, components tools, spares, supplies, equipments and otheritems and account for them.

2) To provide adequate, proper and efficient storage and preservation for all the items.3) Physical checking of all incoming materials as per the delivery CHALLAN and

proper maintenance of daily goods receipt register or records.4) Arrange for inspection of incoming materials.5) Issue the materials to the consuming department against authorized requisitions and

account for the same.6) Maintain accurate and up-to-date records of materials received, issued, rejected,

disposed and quality on hand of all the items.7) To ensure good housekeeping so as to minimize the need for material handling.8) To accept a store scrap and other discarded materials.

9.4. Store function deals with three major activities

1. ReceiptThis deals with the function of receiving an physical handling delivered materials, andverifying that the deliveries correspond exactly as to the nature and quantity as per specified inpurchase order. Inspection of incoming materials ranges from simple counting to elaboratelaboratory testing and statistical tests. This section is also called as GOOD INWARDSECTION.

2. Stocking3. Issue

Normal supply of materials from stores to various user department.

9.5. Methods of Issues of Materials in SAIL Refractory Unit

a) First-in-First-Out (FIFO Method)b) Last-in-First-Out (LIFO Method)c) Average cost methodd) Replacement price methode) Actual price method

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10. SIZE OF BRICKS WHICH IS MANUFACTURED HEREAlmost 50 different types of bricks are manufactured. The table given below shows theparameters of bricks.

Different Bricks Size with E/A in mmSl. No. Items Name Size of Bricks in mm E/A in each Plate

1. 150*100*160/140 10+102. 150*100*154/146 4+43. 150*100*160/120 20+204. 178*100*165/135 15+155. 178*100*154/146 4+46. MC-1 350*125*150 Std.7. MC-2 350*125*150/125 12.5+12.58. 1A 230*125*75 Std.9. 3A 230*125*75/65 5+510. BLOCK 250*100*150 Std.11. 11A 460*125*75 Std.12. 12A 460*125*75/60 5+513. 13C 460*125*75/55 10+1014. MC-3 550*125*150 Std.15. MC-4 550*125*150/120 15+1516. MC-9 600*125*100/92 4+417. MC-10 600*125*100/78 11+1118. MC-11 600*125*100/60 20+2019. MC-11A 600*125*105/80 12.5+12.520. MC-9A 600*125*60 Std.21. MC-5 700*125*110/95 7.5+7.522. MC-6 700*125*110/75 17.5+17.523. MC-12 700*125*110/60 25+2524. TUYER BRICK 700*125*125 Std.25. MC-7 800*125*110/100 5+526. MC-8 800*125*110/80 15+1527. MC-13C SPLIT 800*125*110/60 25+2528. MC-14 900*125*104/96 4+429. MC-15 900*100*120/112 4+430. MC-16 900*100*150/110 20+2031. 900*100*130/100 15+1532. 900*100*120/104 8+833. 900*100*130/83 23.5+13.534. 900*100*125 Std.35. 200*100*165/135 15+1536. 200*100*154/146 4+437. 200*100*165/130 17.5+17.538. 200*100*160/140 10+1039. A1 450*100*150/125 12.5+12.540. A2 450*100*150/130 10+1041. B1 500*150*100/108 21+21

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42. B2 500*150*100/124 13+1343. C1 600*100*100/67 16.5+16.544. C2 600*100*100/85 7.5+7.545. D1 700*100*110/76 17+1746. D2 700*100*110/92 9+947. E1 800*100*120/80 20+2048. E2 800*100*120/100 10+1049. 250*100*150 Std.50. 250*100*150/128 11+11

In last, I would like to thank all the HOD’s and workers of SAIL Refractory Unit, Ramgarh,Ranchi Road for giving me valuable suggestion and information which helps me to understandthe working and management of entire plant.

Documents

SAIL Summer Internship Report- Braj Kishor Sah