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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.