I

Name of Student:-Deepesh Rajak

Enroll. No:-0613ME131024

Affiliated to Rajiv Gandhi Proudyogiki Vishwavidyalaya Bhopal (M.P)

JULY- DECEMBER-2016 DEPARTMENT OF MECHANICAL ENGINEERING

A

Industrial Training Report

On

“BHILAI STEEL PLANT”

Mr. Abdul Kadir

Head of Department

Mechanical Department

MR. RITUL SARAF

Principal/Director

ASST. PROF R.K.RAJAK

Industrial training Coordinator

II

ACKNOWLEDGEMENT

Training is one of the most important aspects for an engineering

student’s career. It is to strength the theoretical concepts. Through

training a student is acquainted with the latest technology and recent

development.

Firstly I convey my sincere thanks to all the BSP Employees.

Their guidance was omnipotent and incompatible throughout the

training period.

I also convey our special thank to Mr. ADHIKARI SAHU

(Training officer) for providing us this opportunity to undergo this

training. We also express our regards to all member of H.R.D in BSP

I would like to express my thanks to all departments for

valuable suggestion, guidance, support encouragement and providing

necessary information for the project.

Name of Student:-Deepesh Rajak

Enrollment No:-0613ME131024

III

PREFACE

Vocational training is one of the important part of the

curriculum for the engineering student. Its basic idea is to strength the

theoretical concept of the student through practical training of making

them acquainted with the latest technology and development.

The philosophy of this report is to emphasize the practical

understanding of basic concept, which has been studied in the class.

I do sincerely hope that this project will the ………………….

In formulating its theory and. I tried my best to cover, even if there is

any acutance surface, I regret for that.

Name of Student:-Deepesh Rajak

Enrollment No.:-0613ME131024

IV

About Company

Eleven times winner of Prime Minister's Trophy for Best Integrated Steel Plant in the

country, Bhilai Steel Plant (BSP) is India's sole producer & supplier of world class rails for

Indian Railways including 260 metre long rails, and a major producer of large variety of wide

and heavy steel plates and structural steel. With an annual production capacity of 3.153 MT

of saleable steel, the plant also specializes in other products such as wire rods and merchant

products. The entire range of TMT products (Bars & Rods) produced by the Plant is of

earthquake-resistant grade and superior quality. The plant also produces heavy structural

including channels and beams.

Since BSP is accredited with ISO 9001:2000 Quality Management System Standard, all

saleable products of Plant come under the ISO umbrella. The Plant's HR Deptt is also

certified with ISO 9001:2000 QMS Standard. IS0:14001 has been awarded for Environment

Management System in the Plant, Township and Dalli Mines. The Plant is accredited with

SA: 8000 certification for social accountability and the OHSAS-18001 certification for

Occupational Health & Safety.

BSP has received Integrated Management System (IMS) Certificate by a single certifying

agency (M/s DNV), integrating QMS, EMS, OHSAS & SAMS - becoming the first SAIL

unit and among few corporate houses in India to achieve this unique distinction.

Among the long list of national awards it has won, Bhilai has bagged the CII-ITC

Sustainability award for three consecutive years. BSP won 1st prize in National Energy

Conservation Award 2013 in Integrated Steel Sector in recognition of major energy saving

initiatives in 2011-12 and '12-13. The Plant again won this award for Year 2014 for

achieving a 5% saving in thermal energy consumption and savings of 2% in electrical energy

consumption over the previous year.

V

Summary:-

s.no. week shop Learn skill

1 1st week Document

verification & safety

class

Learn All

information about

safety in plant

2 2st week Sintering plant-II Learn which material

use in plant

3 3st week BBM Learn about bloom

and blade mill

4 3st week FORGE SHOP Laser welding

cutting CNC

VI

TABLE OF CONTENT:-

Subject page

Table of Content…………………………………………..……….01

Table of Figure…………………………………………..…………02

List of Table………………………………………...………….03

Chapter 1: Introduction of plant and training outline

Chapter 2 Practical Training

2.1 Safety class before plant visit

2.2 Sintering plant - II

2.3 Forecasting shop

2.4 Blooming & Blade mill

Chapter 3: Impact of learned skills in training

Chapter 5: conclusion

VII

Chapter 1: Introduction of Plant

1.1 SAIL:-

Steel Authority of India Limited (SAIL) is the largest steel-making company in India

and one of the seven Maharatna’s of the country’s Central Public Sector Enterprises.

SAIL produces iron and steel at five integrated plants and three special steel plants,

located principally in the eastern and central regions of India and situated close to

domestic sources of raw materials. SAIL manufactures and sells a broad range of steel

products. Steel Authority of India Limited (SAIL) is one of the largest state-owned

steel making company based in New Delhi, India and one of the top steel makers in

world. With an annual turnover of ₹43,337 crore (US$6.4 billion) (FY 2015-16). It is a

public sector undertaking which trades publicly in the market is largely owned

by Government of India and acts like an operating company. Incorporated on 24 January

1973, SAIL has 93,352 employees (as of 31-Mar-2015).[With an annual production of

13.9 million metric tons, SAIL is the 24th largest steel producer in the world. The Hot

Metal capacity of the Company will further increase and is expected to reach a level of

23.5 million tons per annum by the end of the Financial Year 2015-16. Shri P.K Singh is

the current Chairman of SAIL.

VIII

Table no. 01:-

Type State owned enterprise public

Industry Steel

Founded 1954

Headquarters New Delhi, India

Products Steel, flat steel products, long steel

products, Wire Products, plates

Employees 131,910 (2006)

Website www.sail.co.in

IX

SAIL UNIT’S :-

BHILAI STEEL PLANT

BOKARO STEEL PLANT

DURGAPUR STEEL PLANT

ROURKELA STEEL PLANT

IISCO STEEL PLANT

FERRO STEEL PLANT

SPECIAL STEEL PLANT

OTHEAR STEEL PLANT

X

BHILAI STEEL PLANT :-

Bhilai steel plant is first unit of SAIL. The Bhilai Steel Plant (BSP), located in Bhilai, in

the Indian state of Chhattisgarh, is India's first and main producer of steel rails, as well as a

major producer of wide steel plates and other steel products. The plant also produces and

markets various chemical by-products from its coke ovens and coal chemical plant. It was set

up with the help of the USSR in 1955.

The eleven-time winner of the Prime Minister's Trophy for best integrated steel plant in the

country, Bhilai Steel Plant ( BSP), has been India's sole producer of rails and heavy steel

plates and major producer of structural steel. The plant is the sole supplier of the country's

longest rail tracks, which measure 260 meters (850 ft.).

Bhilai Steel Plant - a symbol of Indo-Soviet techno-economic collaboration, is one of the

first three integrated steel plants set up by Government of India to build up a sound base for

the industrial growth of the country, The agreement for setting up the plant with a capacity of

1 MT of Ingot steel was signed between the Government of erstwhile U.S.S.R. and India on

2nd February, 1955, and only after a short period of 4 years, India entered the main stream of

the steel producers with the commissioning of its first Blast Furnace on 4th February, 1959

by the then President of India, Dr Rajendra Prasad. Commissioning of all the units of 1 MT

stage was completed in 1961. A dream came true-the massive rocks from the virgin terrains

of Rajhara were converted into valuable iron & steel.

In the initial phase the plant had to face many teething problems, mostly unknown to the

workforce at the time, But by meticulous efforts and team-sprit, these problems were

surmounted and the rated capacity production was achieved only within a year of integrated

operation of the plant.

Thereafter, the plant was expanded to 2.5 MT capacity per year, and then to 4 MT of crude

steel per year, with Soviet assistance.

All the units of the plant have been laid out in sequential formation according to

technological inter-relationship so as to ensure uninterrupted flow of in-process materials like

Coke, Sinter, Molten Iron, Hot Ingots, as well as disposal of metallurgical wastages and slag

etc., minimizing the length of various inter-plant communications, utilities and services.

XI

BSP is the sole manufacturer of rails and producer of the widest and heaviest plates in India.

Bhilai specializes in the high strength UTS 90 rails, high tensile and boiler quality plates,

TMT bars, and electrode quality wire rods. It is a major exporter of steel products with over

70% of total exports from the Steel Authority of India Limited being from Bhilai. The

distinction of being the first integrated steel plant with all major production units and

marketable products covered under ISO 9002 Quality Certification belongs to BSP. The

includes manufacture of blast furnace coke and coal chemicals, production of hot metal and

pig iron, steel making through twin hearth and basic oxygen processes, manufacture of steel

slabs and blooms by continuous casting, and production of hot rolled steel blooms, billets and

rails, structural, plates, steel sections and wire rods. The plant's Quality Assurance System

has subsequently been awarded ISO 9001:2000. Not content with the Quality Assurance

system for production processes, Bhilai has one in for ISO 14001 certification for its

Environment Management System and its Dalli Mines. Besides environment-friendly

technology like Coal Dust Injection System in the Blast Furnaces, de-dusting units and

electrostatic precipitators in other units, BSP has continued a vigorous afforestation drive,

planting trees each year averaging an impressive 1000 trees per day in the steel township and

mines. A leader in terms of profitability, productivity and energy conservation, BSP has

maintained growth despite recent difficult market conditions. Bhilai is the only steel plant to

have been awarded the Prime Minister's Trophy for the best integrated steel plant in the

country seven times. Bhilai Steel Plant, today, is a panorama of sky-scraping chimneys and

blazing furnaces as a modern integrated steel plant, working round the clock, to produce steel

for the nation. Bhilai has its own captive mines spread over 10929.80 acres. We get our iron

ore from Rajhara group of mines, 85 kms south-west of Bhilai. Limestone requirements are

met by Nandini mines, 20 kms north of Bhilai and dolomite comes from Hirri in Bilaspur

district, 135 kms east of the plant. To meet the future requirement of iron ore, another mining

site Rowghat , situated about 100 km south of Rajhara, is being developed; as theore reserves

at Rajhara are depleting. Bhilai expanded its production capacity in two phases - first to 2.5

MT which was completed on Sept. 1, 1967 and then on to 4 MT which was completed in the

year 1988. The plant now consists of ten coke oven batteries. Six of them are 4.4 metres tall.

The 7 metre tall fully automated Batteries No 9 & 10 are among the most modern in India. Of

Bhilai's seven blast furnaces, three are of 1033 cu. metre capacity each, three of 1719 cu.

metre and one is 2000 cu. metre capacity. Most of them have been modernised incorporating

state-of-the-art technology.

XII

HUMAN PROFILE:-

More than the machinery and processes, it is the men i.e. the engineers, Technicians, skilled

and unskilled workers behind them that constitute the flesh and blood of this steel plant.

Bhilai at present has around 34000 persons to run this pulsating giant. The culture which has

today become the hallmark of Bhilai is a result oriented approach to work. It is their effective

and co-operative working relation ship nurtured in a spirit of dedication and enthusiasm that

has shaped Bhilai's image today. Adjoining the plant, a modern township - Bhilai Nagar,

having the spaciousness of a village and the cleanliness of a modern town is spread - over

in 17 self-sufficient sectors with schools, markets, parks and other facilities. Free Medical aid

is given to all the employees and their dependents through a network of health centres,

dispensaries and hospitals. Medical facilities are Extended to retired employees & their

spouses also. The Education Department runs a number of higher secondary, middle,

primary, and pre-primary schools in Bhilai and also in the mines townships at Rajhara,

Nandini and Hirri.

XIII

Awards & Accolades To Bhilai Steel Plant:-

JANUARY 28, 2008 Golden Peacock Award for Corporate Social Responsibility – 2007

Bhilai Steel Plant has been adjudged winner of the "Golden Peacock Award for

Corporate Social Responsibility for the year 2007" by the Golden Peacock Award

Jury, under the Chairmanship of Justice PN Bhagwati, former Chief Justice of India

and member UN Human of Rights Commission and Co-Chairmanship of Justice MN

Venkatchaliah , former Chief Justice of India. The award received by Shri Sunil Jain,

Deputy General Manager (Corporate Social Responsibility) at Vilamoura, Portugal on

15th February 2008, was formally handed over to MD BSP Shri Ramaraju by Shri

P.K.Agrawal, ED(P&A) in the presence of Shri TK Gupta, ED (F&A) and Shri NK

Mayson, ED (Mines).

ANUARY 4, 2008 BHILAI STEEL PLANT QUALITY CIRCLE TEAMS EXEL AT NATIONAL CONVENTION:-

Quality Circle teams representing Bhilai Steel Plant participated in the National

Convention of Quality Cycles (NCQC) - 2007 at Jadhavpur University, Kolkata from

December 27-30, 2007 and won 8 par excellence awards, 13 excellent awards and

3 distinguished awards. 24 QC teams had been sponsored by Bhilai Steel Plant. Thus

33 % of BSP teams received "Par Excellence Award" against the national average of

11.6 % (77 out of the total 661 participating teams).

AUGUST 14, 2007 Dr. Gopichand Narayan Das Chandwani awarded the Shri Gajanan Madhavs Muktibodh Smriti award:-

Dr. Gopichand Narayan Das Chandwani, Sr. Lecturer at BSP's Sr. Secondary

school, Sector-10 was awarded the Shri Gajanan Madhav Muktibodh Smriti award

for his technical papers on Binomial theorem and trignometrical equation, Symposium

on Roll theorem, academic achievements and excellent work rendered by him.

Chhatisgarh's Governor Shri E S L Narasimhan gave away the 'Rastriya Shikshak

Samman Puraskar 2006' instituted by Rastriya Shikshak Kalyan Pratishthan,

Chhattisgarh unit and 50,000 Rs. to Dr. Chandwani on August 13, 2007 at Raj

bhavan, Raipur. Shri Ajay Chandrakar, Education Minister, Chhattisgarh was present

on the occasion

XIV

MINES & QUARRIES

Bhilai Steel Plant is an ore based plant. The location of the plant at Bhilai was based on the

fact that three basic and important raw materials required for steel making i.e. Iron Ore,

Limestone and Dolomite are available in close proximity to Bhilai. The total iron ore

requirement of BSP is met from a group of mines at Dalli Rajhara known as Iron Ore

Complex. Except for some quantity of high grade limestone being procured from Rajasthan,

the total limestone requirement of BSP is met from captive mines at Nandini. A major portion

of dolomite requirement is procured from captive mine at Hirri. The limestone mine at

Nandini and dolomite mine at Hirri together are known as Flux Group of Mines. where as

Iron ore mines at Dalli Rajhara is named as "Iron Ore Complex Mines".

IRON ORE GROUP OF MINES:-

Dalli Rajhara is situated approximately 90 Kms south-west of Bhilai. There are five

working mines, :-

(i) Rajhara Mechanised Mine

(ii) Dalli Mechanised Mine

(ii) Jharandalli Mechanised Mine

(iv) Dalli Manual Mine and

(v) Mahamaya Manual Mine.

Aridongri deposit has beeen surrendered & handed over to state

government.

Ore deposit at Kokan has been exhausted while Dulki Mine is yet to be started.

The initial reserve, and reserve position as on 01.04.2007 for iron ore, is as follows:-

XV

Fig . 01 Plant layout

XVI

2.1 Safety class before visit:-

INTRODUCTION:-

Accidents in a plant affect productivity and morale of workforce. All accidents,regardless of

their consequences are symptoms of production inefficiency. Accident free production is

regarded as an efficient production. Many activities and processes in a steel plant can present

situations which involve risk to Safety and Health of employees and risk of damage and loss

to plant equipment and product. Hence, it is a moral, economic as welll as legal duty of all

especially the front line executives – to prevent, control or guard against such risks and their

possible ill effects with an objective to achieve elimination of human suffering, damage to

material and equipment and resultant loss of production, the Hindustan Steel Limited (HSL)

laid a policy for accident prevention which was adopted by the committee of management in

the meeting held at Durgapur on 25th August, 1972. Based on the principles expressed in that

policy, the organisation of Safety activities and programme for accident prevention in the

plants of Hindustan Steel Limited and at the Head office were outlined. It was stated that

there should be a dynamic Safety Department in each plant and a suitable organisation at the

head office to implement the Safety policy and programmes and that the Safety department

should have the status necessary for effective discharge of its functions

XVII

OCCUPATIONAL HEALTH & SAFETY POLICY

Bhilai Steel Plant is committed to:

1. ☯ Create worksite free from Occupational Health & Safety Hazards for its employees,

2. ☯ The Safety of the people associated with it, those living in the neighbourhood of its

plants, mines and units.

3. ☯ Pursue the Safety efforts by adhering to Occupational Health & Safety Management

System based on the requirements of internationally recognize OHSAS-18001 standard

and its periodic review at works.

4. ☯ Demand accountability for Safety performance and provide the resource to make

safety program work.

5. ☯ Involve all employees for continual improvement in OH&S.

XVIII

The following three aspects are important for progress of safety in a steel

plant.:-

1.The condition of the work place environment e.g. means of access, physical plant safety,

housekeeping, and safe place of work etc.

2.The training and competence of the employees which include ability to understand apply

and respond to safe systems of work.

3. The development of motivational and behavioral influences of employees. This includes

the use of more direct strategies to identify unsafe behavior and attitudes and to motivate

employees.

4 protecting workers in the iron and steel industry from workplace hazards and to preventing

or reducing work-related injuries and diseases, ill health and incidents;

5. TO assisting and facilitating the improved management of occupational safety and health

(OSH) issues at the workplace;

6 To promoting effective consultation and cooperation between governments and employers’

and workers’ organizations in the improvement of OSH in the production of iron and steel. 1

7 . Improving knowledge and competence; (d) promoting the implementation and integration

of consistent OSH management systems with a view to improving working conditions.

XIX

A steel plant is full of hazards at every step of its operation. These hazards

are to be tackled for the sake of safety in the steel plant. Major amongst

these hazards are enumerated below:-

1. Road hazards – Road hazards are high because of heavy concentration and heterogeneous

nature of the road traffic. This hazard is having maximum intensity during the shift

change timings.

2. Coke oven and byproduct plant – Here the main hazards are heat, dust, smoke, moving

equipment, chemicals, fire and explosion etc.

3. Sinter plant – In sinter plant main hazard are moving equipment, dust and smoke etc.

4. Blast furnace – The main hazards at blast furnace are heat, dust, noise, liquid metal and

slag, gas poisoning, moving equipment’s, moving locomotives, fire and explosion and

working at heights etc.

5. Steel melting shop – The main hazard in this shop are heat, dust, noise, liquid metal and

slag, moving equipment, suspended loads, working at heights and fire and explosion etc.

6. Rolling mills – The main hazards at rolling mills are heat, noise, moving equipment,

splinters, cobbles, suspended loads and slippery floors etc.

7. Power plant – The main hazards are heat, working at height, noise, vibrations and gas and

steam lines etc.

8. Material handling – The main hazards are posture, excess loads, moving equipment,

improper signaling and suspended overhead loads etc.

9. Other major hazards which are common to most of the places are working in confined

space, working with improper tools, poor illumination, poor ventilation, electrical hazards,

loco movements, unmanned crossings, unpreparedness for emergencies, unsafe

scaffoldings, over confidence and working without safety appliances, personal protective

equipment’s (PPEs), written clearances, and shutdown clearances etc. Violation of safety

protocols and shut down procedures etc. are also cause of hazards.

XX

chapter 02 Practical Training:-

2.1 SINTERING PLANT-II:-

Sintering Plant-II (SP-II) was set up during 6th BF stage;

started on 1st August 1979 with one inter machine of 75 M2 sintering area with rated

capacity of o. 75 MT/ YR Subsequently, three more machines were added to it,

making the total capacity of SP-II as 3.137 MT/YR. Initially, the acceptability of sinter

was very poor at blast furnaces, and the sinter process was basically for utilization of

metallurgical waste of mines and plant, viz. iron ore fines, lime stone chips, flue dust,

mill scale etc. Later on the importance of Sinter gained momentum and it was

accepted as a major raw material in BF burden due to its good metallurgical

properties. The requirement of sinter went up necessitating the setting up of second

Sintering Plant.

(Subsequently Sintering Plant-III has also been set up).

GENERAL:

Sinter now is the major component in BF burden. Sintering process originally

started as a process of agglomeration of iron ore fines. Later on, it was advanced to

utilise not only fine ore, but also other in-plant metallurgical waste materials such as

flue dust, mill scale, converter slag etc. It has also become a source for introducing

all the required flux into the BF. The following are the major advantages of sintering

process of agglomeration :

1. Simplicity of unit.

2. High specific productivity of unit.

3. Less conversion cost.

4. Better metallurgical properties of sinter.

RAW MATERIALS :

The various raw material used at SP-II for producing sinter are as follows:

1. Iron ore fines 0 - 8 mm

2. Lime stone 10 - 50 mm

3. Raw Dolomite 0 - 50 mm

4. Coke Breeze 0 - 16 mm

5. Lime Dust 0 - 5 mm

XXI

6. Mill Scale 0 - 3 mm

7. Sinter Return 0 - 5 mm

8. Settling Tank Dust 0 - 3 mm

9. LD slag 0 - 10 mm

The SP-II is located South-East of Coke Ovens. It comprises following main

sections :

A. Raw Material Section.

B. Mixing and proportioning section.

C. Sintering Building.

D. Priority Route.

A. RAW MATERIAL SECTION :

The Raw Material section has following sub sections :

a) Raw Material Receiving Bins.

b) Raw Material Preparation Section.

c) Flux crushing section.

d) Fuel Receiving Bins.

e) Fuel & Flux Preparation Section.

a) RAW MATERIAL RECEIVING BINS :-

There are 24 Nos. bins of 85 cum volume each, in two rows, 12 in each row;

where various raw materials are being received from different sources. On one side

of bins, flux materials are being received, and on the other side iron bearing materials

are received.

The flux side bins, bins/bunker nos. 1 to 10 and 21 & 22 are located over

conveyor RB-2; and the iron bearing side bins, bins/bunker nos. 11 to 20 and 23 & 24

are located over conveyor RB-1. All the bins, except bins no. 11, 21 & 22 are having

disc feeder discharge system of 2400 mm diameter and the bins no. 11, 21 & 22 are

equipped with variable speed belt feeder discharge system.

Installation of Raw Material Screen

In the existing layout, Iron ore mix, contains Iron ore fines, Sinter Return from

BFs, lime, mill scale etc. Removal of +8 mm fraction of ore mix by 1.5 to 2 % leads

to better homogenization of ore mix and reduced sinter return generation.

XXII

XXIII

XXIV

SINTER SCREENING BUILDING :-

The cold sinter undergoes a two stage screening in a 3100 X 7500 mm double deck screen of

capacity 600 T/Hr. The cold sinter of size +6 mm is transported by SS-9 and SS-10 conveyor,

which feed to a system of conveyor belts, carrying the sinter to sinter loadings bins and sinter

storage bunker of JH-44. The -6 mm size sinter return from this building is carried by SS-5

and SS-6 conveyor belt which feeds this return to conveyor belts SB-8 and SB-9. The Sinter

return is finally transported to the four bunkers in mixing bins by conveyors M-13, M-14, M-

15 and M-16. The sludge from the disc feeder of the settling tank is fed by conveyor ST-1 to

conveyors SB-8 and SB-9.

D. PRIORITY ROUTE :-

Priority route is the section which transports the finished sinter, coke

and ironore etc.to BFs. Sinter from Conveyors SS-9 and SS-10 is unloaded on Conveyors

J17C4, J17C5 in junction houses-15, there after via JH-20 the sinter is sent JH-27. From JH

27 sinter is either filled in loading bins or it is conveyed to Jh-44 for BF-7. In loading bins

there are four bunkers of 200 Cu.M each. Each bunker is fitted a the bottom with the

pneumatically operated tilting chutes. The bins are filled one by one and the sinter is

discharged into a transfer car by means of pneumati gate in each bin. There are two gates and

both of them can be opened simultaneously for loading the transfer car. When it is to be

despatched to BF-7, the sinter is conveyed to JH-44 by conveyor belt from JH-27. In JH-44

sinter is stored in four bins; from there it is charged to BF-7. At JH-20 to JH 27 a new

conveyor belt is commissioned, by which SP-III sinter is transported to BFs.

XXV

Chapter FORGE SHOP:-

Forge Shop is housed in a single bay building with an area of 120m x

21m, and an open gantry of size 12m x 11m is provided to stock raw materials required for

the shop. It has been designed to produce semi-finished and finished jobs. The finished

products are subjected to close inspection by :-

a. Engineering Shops Inspection Department : for dimensional accuracy.

b. R & C Lab process control : for metallurgical quality. Setup at 2.5 MT stage, the shop is

designed to produce 3200 tonnes of forgings, 300 T Balls and 50 T of non-standard items.

There is no change in the capacity under 4 MT expansion of the plant. Maximum single

weight that can be forged is 4.5 tonnes.

MAIN EQUIPMENT

Forge Shop has been equipped with the following machines:

3 Tonne Pneumatic Hammer : 1 No

2 Tonne Pneumatic Hammer : 1 No

1 Tonne Pneumatic Hammer : 1 No

0.4 Tonne Pneumatic Hammer : 2 Nos

250 Tonne Friction Press : 1 No

160 Tonne Electric Press : 1 No

100 Tonne Eccentric Press : 1 No

1 Tonne Forging Manipulator : 1 No

250 Tonne Bar Cropper : 1 No

CO Gas Fired Furnaces

a. Annealing Furnace 6 x 1.5m (car bottom) : 1 No

b. Reheating Furnace (Batch type) : 9 Nos

c. Band saw machine (max. dia. 400 mm) : 1 No

MATERIAL HANDLING EQUIPMENT

3 Overhead Travelling Cranes of 5 T capacity each 4 cantilever Cranes of 3 T

capacity each

1 cantilever Crane of 1.5 T capacity and

1 Transfer Car of 10 T capacity are provided for handling of materials.

XXVI

STEEL STRUCTURAL SHOP:-

Steel Structural Shop (SSS ) is one of the major

engineering shops in the plant for manufacturing spares through the process of fabrication. It

was expanded in 2 stages. From 1 MT to 2.5 MT stage and from 2.5 MT to 4 MT stage. At

present the shop has an open gantry for material storage and 3 bays parallel to it. One 30 M

bay perpendicular to the existing bays was added during 4 MT stage. Total working area

at present is 12960 M2.

SSS has the following roles to play :

1. Caters to all the departments / shops of the plant for :

a) Capital Repairs jobs.

b) Schedule maintenance jobs (fabricated and gas cut items)

c) Break down jobs.

d) Modification and addition of new facilities as and when required in plant.

2. It also acts as a blanking shop for machine shops.

Infrastructure / facilities provided are :

i) EOT Cranes with capacities ranging from 5 T to 50 T

ii) Transfer Cars, connecting different bays.

iii) Radial drilling machines

iv) 63 T Crank press

v) 80 T Punching machine

vi) 200 T Vertical press .

vii) 200 T Capacity hydraulic press brake

viii) Shearing machines various capacities

ix) Combination Shear (punching machine)

x) Profile gas cutting machine (Photo tracer type)

xi) Welding Transformer & Rectifier

xii) MIG / MAG Welding machines

xiii) CNC Oxy-fuel Profile Gas Cutting machine

xiv) Plate Straightening machine ( up-to 25 mm Capacity)

xv) Plate Bending machine ( up-to 32 mm Capacity )

xvi) Heavy Plate bending machine (up-to 70 mm Capacity)

XXVII

BLOOMING & BILLET MILL :-

Blooming & Billet Mill popularly known as "Mother

Mill", is a primary mill designed to roll 2.5 MT/ Annum of ingots into semies in the form of

blooms & billets. A two high reversing blooming mill and 12 stands continuous billet mill are

part of this department. The 1150mm two high reversing Blooming Mill is designed to roll

steel ingots into blooms for Continuous Billet Mill and Rail & Structural Mill. Average

weight of steel ingots which are used for rolling is 8 to 9 Ton. Major sections are described

below :

SOAKING PITS

Heating of the ingots and soaking at a particular temperature is done in the soaking pits.

There are 14 groups of recuperative type soaking pits. Each group consists of 2 pits. Each pit

is heated by two burners situated diagonally opposite in the upper part of the lateral wall of

the pit. The fuel burnt is mixture of coke oven gas and blast furnace gas with a calorific value

of 1600 KCal./Cu.M. Air is preheated in ceramic recuperators and the gas in the metallic

recuperators. The ingots are placed in the pits in such a way so that proper circulation of the

flame around the ingot is ensured. Generally 16 ingots are placed in one chamber at a time.

Strict records are maintained to avoid mix-up. After 4th to 5th round of rolling, cleaning of

the pit is done by scrapper bar held by the tongs crane and bottom is made with two buckets

of Coke Breeze. Out of the 28 pits (14x2), 25 to 26 pits are under operation depending on

requirement and the balance are under repair/reserve. Operational data of Soaking Pits

Dimensions of the pit

Length : 6.7m

Width : 4.2m

Depth : 4.5m

Soaking temp. : 1300 °C

Pit pressure : + 0.2/0.3mm w.c.

XXVIII

BLOOMING MILL:-

The heated ingot are placed on the ingot buggy (two ingots at a time)

by means of tongs crane which delivers it on to the receiving roller table of Blooming Mill.

The Blooming Mill is a 2-High horizontal stand, equipped with individually driven rolls.

Each roll of the Blooming Mill is driven by 930 V, 8000 KW, 0-20-80 rpm motor. Length of

Roll - 2800 mm Dia. of Roll - 1150 mm (Min.1100mm & Max.1180mm) Rolls are used in

pairs. Each roll set is ground with the required pass design (4 including the shaped beam

pass). After rolling of about 1 lakh ton, the rolls are charged. The used rolls are sent for

redressing in Roll Turning Shop. After redressing they are assembled and reused. The Top

Roll is balanced by counter weights. It is moved up and down by screw down mechanism

driven by two motors mounted on the top of the stand. There are manipulator side guards on

both sides of the Roll stand. This is to manipulate the rolling stock on to the required pass

section of the roll. Tilters are fitted in the front manipulator for tilting the rolling stock

whenever required. The total rolls from ingot to bloom is done in 11 - 17 passes. After

rolling, the bloom proceeds to the shea where the front and back ends are cropped off to

eliminate defects and the bloom is cut into required length. Blooms intended for further

rolling in Billet Mill are sent directly after cutting the front and back end. The shear is of the

up-cut crank shaft type with maximum cutting force of 1000 Ton and operating speed of upto

10 cuts per minute. Crop ends are pushed down and conveyed to crop pit for cooling. The

Mill can roll square and rectangular blooms and also narrow width slab. Common Sizes of

Blooms and Narrow Width Slabs

i) 320 x 320 mm

ii) 265 x 340 mm

iii) 260 x 300 mm

iv) Shaped blooms for Beam-450mm & Beam-600mm

v) Narrow Width Slab 200 x 320 mm

vi) Narrow Width Slab 200 x 420 mm

XXIX

BLOOM STORAGE:-

Blooms assigned for Rolling in the Rail & Structural Mill and requiring inspection

and conditioning are transported hot, by 15 ton over-head cranes and stacked in

specified areas depending on quality of steel.

BILLET MILL:-

The Billet Mill has been designed to roll billets from blooms of cross section

325x325 sq.mm in 6 to 12 passes depending on cross section of billets to be produced

in the Mill. The capacity of the Mill was designed to roll 15,01,000 Tons/Year.

The Mill consists of 12 working stands arranged in three groups.

a. The First group contains Two 2-High Horizontal stands with a 90 deg. tilted in

Between. These stands are equipped with rolls of diameter 1000mm and length

1200mm.

b. The Second group called the roughing group contains 4 stand - 2 each of

Horizontal and vertical stands arranged alternately. These stands are equipped

With rolls of diameter 700mm.

c. The Third group called the finishing group located after the transfer table contains

6 stands - 3 horizontal and 3 vertical stands arranged alternately. These stands

are equipped with rolls of diameter 500mm.

SECTION OF BILLETS ROLLED ARE

1. 150 x 150 mm

2. 110 x 110 mm

3. 105 x 105 mm

4.100x100mm

XXX

chapter 5 conclusion:-

One of the primary objectives of the industries is to develop a well-knit personnel policy and

a comprehensive personnel programmer that will be result-oriented and to develop

organizational objectives .The Company has an exclusive Training and Development Centre

to take care of the training requirements of the officers and workmen as well as the newly

recruited Management Trainees etc. The training initiative includes special need based

Programs and orientation programs catering to the requirements of various departments of the

company..

The training at BHILAI STEEL PLANT was very helpful. It has improved my theoretical

concepts of material making and production . Protection of various apparatus was a great

thing. I was observable many machining process like grinding, turning , cutting , laser

welding cutting as well as hydraulic machine.

I had a chance to see RAIL MILL and steel melting shop where the main working of steel

plant is being done and also I saw the working of various shops of the plant, which was very

interesting. So the training was more than hope to me and helped me to understand about

power system more.