Industrial Training Report

In

Company Name

Submitted in partial fulfillment of the requirement for the award of the diploma

In

Mechanical Engineering

Submitted To:-

SUKHJINDER SINGH (HOD)

NAVDEEP SINGH (INCHARGE)

Submitted by:-

Name:-SUJIT KUMAR

University Roll No: -140765348106

Trade / Sem:-ME/B/5th

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STEEL AUTHORITY OF INDIA LIMITED

A PROJECT REPORT OF

VACATIONAL TRAINING

(JULY04, 2016 – JULY30,2016)

Submitted By

NAME: - SUJIT KR. MAHATO

BSL URN:-5903222

BHAI GURDAS POLYTECHNIC COLLEGE

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BOKARO STEEL PLANT

ACKNOWLEDGEMENT

An endeavour is not accomplished and successful till the people who have made it possible are given due credit for making it possible. I take this opportunity to thank all those who have made the endeavour of mine successful.First and foremost, I am very thankful to all the officers of Bokaro steel plant who really helped a lot and guided me throughout my training session, without their help I would have been unable to complete my project. These people have really been kind enough in providingme with all kinds of contextual information.I would like to thank Mr Prabhat Kumar, for letting me enjoy this experience of

I am also thankful to technicians and field operators and other staff of training department who spared their valuable time and took effort explaining the working of various units of the plant.

I am greatly thankful to for their co-operation. I was thoroughly guided by them throughout my training .The information provided to me by them have helped me a lot and would also help me in my long run too .The tremendous effort put by them have motivated me and made me gain confidence in completing this report.

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SR NO:- CONTENT PAGE NO:-

1. INTRODUCTION 5

2. HISTORY 6

3. COMPANY PROFILE 7

4. WORKSHOP ATTENDED 8

5. C.B.R.S 9

6. MACHINE SHOP 10

7. FOUNDARIES 11

8. WATER MANAGEMENT DEPARTMENT 12

9. RAW MATERIAL HANDLING PLANT 13

10. COKE OVEN & BY PRODUCT PLANT 14

11. SINTER PLANT 15

12. OPERATION GARAGE 16

13. FLOW CHART 17

14. FINISHED PRODUCTS 18

15. SHEET MELTING SHOP 19

16. COLD ROLLING MILL 20

17. BLAST FURNACE 21

18. CONCLUSION 22

19. REFERENCES 23

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INTRODUCTION

OF

STEEL AUTHORITY OF INDIA LIMITED

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).[2] With an annual production of 13.9 million metric tons, SAIL is the 24th largest steel producer

in the world.[4] The Hot Metal capacity of the Company will further increase and is expected to

reach a level of 23.5 million tonnes per annum by the end of the Financial Year 2015-16. P.K

Singh is the current chairman of SAIL.

SAIL operates and owns 5 integrated steel plants

at Rourkela, Bhilai, Durgapur, Bokaro and Burnpur and 3 special steel plants

atSalem, Durgapur and Bhadravathi. It also owns a Ferro Alloy plant at Chandrapur. As part of

its global ambition, the company is undergoing a massive expansion and modernisation

programme involving upgrading and building new facilities with emphasis on state of the art

green technology. SAIL is a public sector company, owned and operated by the Government of

India. According to a recent survey, SAIL is one of India's fastest growing Public Sector

Units.Besides, it has R&D centre for Iron & Steel (RDCIS), Centre for Engineering and

Technology (CET), Management Training Institute (MTI) and SAIL Safety Organisation (SSO)

located at Ranchicapital of Jharkhand.

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HISTORY

The Ministry of Steel and Mines drafted a policy statement to evolve a new model for managing

industry. The policy statement was presented to the Parliament on 2 December 1972. On this

basis the concept of creating a holding company to manage inputs and outputs under one

umbrella was mooted. This led to the formation of Steel Authority of India Ltd. The company,

incorporated on 24 January 1973 with an authorised capital of ₹2,000 crore (US$300 million),

was made responsible for managing five integrated steel plants at Bhilai, Bokaro, Durgapur,

Rourkela and Burnpur, the Alloy Steel Plant and the Salem Steel Plant. In 1978 SAIL was

restructured as an operating company.[7]

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COMPANY PROFILE

TOTAL AREA 33,045,35 ACRES.

CAPACITY

FIRST PHASE:- 1.7 MT of INGOT STEEL

SECOND PHASE:- 4.0 MT of INGOT STEEL

AFTER MODERNIZATION:- 4.5 MT of LIQUID STEEL

INOUGH SCOPE FOR FURTHER EXPANTION(PLAN FOR 7 MT)

TYPES OF PRODUCTS

FLAT PRODUCT

ROUNDED PRODUCT

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WORKSHOP ATTENDED

CENTRAL BASE REPAIRING SHOP(CBRS)

MACHINE SHOP

FOUNDARIES

WATER MANAGEMENT DEPARTMENT (WMD)

TRAFFIC

RAW MATERIAL HANDELLING PLANT (RMHP)

SINTER PLANT (SP)

OPERATION GARAGE (OG)

COKE OVEN & BY-PRODUCT PLANT (CO&BPP)

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CENTRAL BASE REPAIRING SHOP (CBRS)

Central Base Repairing Shop, one of the importand division of sail where the big dumper like HD-27 and many more.

Here the vehicle which are completely damaged are repaired.

Major work is done here like opening engine, hydraulic, gear box etc..,

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MACHINE SHOP

A   machine shop   is a room, building, or company where   machining   is done. In a machine shop,   machinists   use   machine tools   and   cutting tools   to make parts, usually of   metal  or   plastic  (but sometimes of other materials such as   glass  or   wood).

A machine shop can be a   small business  (such as a   job shop) or a portion of a   factory, whether a   toolroom  or a production area for   manufacturing .

The parts produced can be the   end product  of the factory, to be sold to customers in the   machine industry, the   car industry, the   aircraft industry, or others.

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FOUNDARIES

Foundaries act as a maintenance department for sail.In case of any break downs or

any and mechanical problems the foundries produce spare parts internally and help

plant to become self dependent..

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WATER MANAGEMENT DEPARTMENT

This department is responsible for supplying the various departments of the plant

with proper water supply for various purposes including washing and cleaning…

The department uses horizontal centrifugal pumps to pump water which it receives

from the tenughat canal directly from damodar river.

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RAW MATERIAL HANDLING PLANT (RMHP)

It is the primary and most important department of plant, it transports the raw

material to different zone of plant of further process.

Raw Material Handling Plant is meant for transporting materials from Raw

material yard/Base mix yard to various process units of the plant.

The Major Raw materials required for Iron and Steel making are iron ore lump,

iron ore fines, sized iron ore, flux limestone / dolomite, manganese, quartzite coking

coal, non-coking coal (for Boiler operation & For Pulverized coal injection ) and

coke.

WAGON TIPPLER & TRANSPORTATION

COKE OVEN & BY PRODUCT PLANT (C0&BPP)Page 13

Coke is a fuel with few impurities and a high carbon content, usually made from coal. It is the solid carbonaceous material derived from destructive distillation of low-ash, low-sulfur bituminous coal.

Cokes made from coal are grey, hard, and porous. While coke can be formed naturally, the commonly used form is man-made.

SINTER PLANT (SP)

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Sinter is porous agglomerate of mineral fines formed after incept fusion.

Sintering is a process of preparing sinter in which a high temperature is

maintained     for two basic purposes:

Waste management

Advantageous properties of sinter

Sintering as a process uses all wastes generated in the mines site,

handling and the mill zone, so it is a good source of waste management.

Now days, 70% of Blast Furnace burden is sinter.

Ore Fines

Flux (limestone+Dolomite)

Coke

Additives

OPERATION GARAGE (OG)Page 15

Operational Garage, Central department of vehicle repair and maintainance of

SAIL.

C.B.R.S. is sub department of O.G.

In O.G., running vehicle are repaired in which minor faults are present.

FLOW CHART

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FINISHED PRODUCTS

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SHEET MELTING SHOP

Hot Metal from the Blast Furnaces is converted into steel by blowing 99.5% pure Oxygen through it in the LD converter. Suitable alloying elements are added to produce different grades of steel.Bokaro has two Steel Melting Shops - SMS-I and SMS-II. SMS-I has 5 LD converters of 130T capacity each. It is capable of producing Rimming steel through the ingot route. SMS-II has 2 LD converters, each of 300 T capacity, with suppressed combustion system and Continuous Casting facility. It produces various Killed and Semi-Killed steels.

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COLD ROLLING MILL

The Cold Rolling Mill at Bokaro uses state-of-the-art technology to produce high quality sheet

gauge material, Tin Mill Black Plate and Galvanised Products. Cold rolling is done to produce

thinner gauge strips of very smooth and dense finish, with better mechanical properties than hot

rolling strips. Rolling is done well below re-crystallization temperature without any prior heating

of the material. The products of CRM are used for deep drawing purposes, automobile bodies,

steel furnitures, drums and barrels, railway coaches, other bending and shaping jobs and coated

steels. The CRM complex comprises of two Pickling Lines (including a high speed Hydrochloric

Acid Pickling Line with re-generation facilities), two Tandem Mills, an Electrolytic Cleaning

Line, a Continuous Annealing Line, Bell Annealing Furnaces, two Skin-Pass Mills, a Double

Cold Reduction Mill (DCR), Shearing Lines, Slitting Lines and a packaging and despatch

section. The 5-stand Tandem Mill is capable of rolling sheet gauges upto 0.15 mm thickness. It

has sophisticated Hydraulic Automatic Gauge Control, computerised mill regulation and

optimisation control.

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BLAST FURNACE

Bokaro has five 2000-cubic metre Blast Furnaces that produce molten iron - Hot Metal - for steel

making. Bell-less Top Charging, modernised double Cast Houses, Coal Dust Injection and Cast

House Slag Granulation technologies have been deployed in the furnaces. The process of iroin-

making is automated, using PLC Charging System and Computer Controlled Supervision

System. The wastes products like Blast Furnace slag and gas are either used directly within plant

or processed for recycling / re-use.

CONCLUSION

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As we have been there we have experienced and gained the knowledge about the

proper and such a big industry. In books we acquire only theoretical knowledge, but

in actual, the pragmatic implementation of the same, can be grasped only by visiting

an industry, which SAIL has provided us.

We have learned that how team work can handle and run such a big industry.

We come to know that how we implement our ideas in practical way.

With experience, knowledge & skills acquired during industrial training we will be

better prepared to face working world.

REFERENCES

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www.sail.co.in

www.google.co.images

THANK YOU

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