A

VOCATIONAL TRAINING REPORT

AT

“BHILAI STEEL PLANT”

Submitted to

CHHATTISHGARH SWAMI VIVEKANAND TECHNICAL UNIVERSITY, BHILAI

(C.G.)

Diploma

In

Mechanical Engineering

By

NITISH SAW
ROLL NO. 200603718004

Department of Mechanical Engineering

Rungta College of Engineering and Technology
Durg, C.G.
Pin: 490023

Session - 2020-2021
 DECLARATION

I the undersigned solemnly declare that the report of the training work entitled “BHILAI
STEEL PLANT” is based on my own work carried out during the course of my study.

I assert that the statements made & conclusions drawn are an outcome of training work. I
further declare that to the best of our knowledge & belief that the report does not contain any
part of any work which has been submitted for the award of any other degree in this
university.

(Signature of the student)

Name: Nitish saw

Roll No: 200603718004

Enrollment No: BF1824

2
 ACKNOWLWDEMENT
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.

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.

3
 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.

4
 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.

5
 Summary:-

Sr.no. week Duration shop Learn skill

1. 1st week 27/06/17 30/06/17 Document verification Learn all
& safety class information
about safety in
plant
2. 2nd week 01/07/17 04/07/17 Foundry & pattern shop Learn about this
shope
3. 2nd week 05/07/17 05/07/17 Forge & steel shop Laser welding
cutting CNC
4. 3rd week 10/07/17 13/07/17 Plate mill Learn about
How to
producing a
plate
5. 3rd- 4th 14/07/17 18/07/17 CRM learn about tool
week of CRM
6. 4th week 19/07/17 22/07/17
MARS-1 Learn about
machining
process

6
 CONTENTS
ITEMS PAGE NO.

CHAPTER 1: INTRODUCTION.....................................................................................01

1.1 INTRODUCTION OF SAIL...................................................................01

1.2 SAIL UNIT’S…………………………………………………………
1.3 INTRODUCTION OF B.S.P…………………………………………
1.4 AWARDS OF B.S.P………………………………………………….
1.5 MINES AND QUARRIES…………………………………………….
1.6 IRON ORE GROUP OF MINES………………………………………
1.7 FLOW CHART OF B.S.P…………………………………………….

CHAPTER 2: FOUNDRY AND PATTERN SHOP…………………………………..

2.1 INTRODUCTION OF FOUNDRY………………………………….

2.2 PRODUCTION SEQUENCE IN SAND CASTING……………….
2.3 SAND MOULD MAKING PROCEDURE………………………….
2.4 TYPE OF SAND MOULD…..……………………………………..
2.5 MOULDING SAND PROPERTIES………………………………...
2.6 INTRODUCTION OF PATTERN …………………………………

CHAPTER 3 : FORGE AND STEEL STRUCTURE SHOPE……

3.1 INTRODUCTION OF FORGE SHOPE……………………

3.2 TYPE OF FORGING………………………………………………….
3.3 FORGING PROCESS………………………………………………….
3.4 STEEL STRUCTURAL SHOPE………………………………………

CHAPTER 4 : PLATE MILL………………………………….

4.1 INTRODUCTION OF PLATE MILL……………………..

4.2 THE SEQUENCE OF OPPERATION…………….

CHAPTER 5 : CAPITAL REPAIR AND MODIFICATION (C.R.M.)………………

5.1 INTRODUCTION OF C.R.M………………………………………..

5.2 SOME SPACIAL ACHIEVMENT………………………………….
5.3 CORE COMPETENEIES…………………………………………..

CHAPTER 6 : MARS-1 SHOPE……………………………………………………….

6.1 INTRODUCTION OF MARS-1…………………………………………..

6.2 MAIN ACTIVITIES OF MARS 1…………………………………………
6.3 FLOW PROCESS…………………………………………………………
6.4 SECTIONS OF MARS-1………………………………………………..

7
 CHAPTER 7: CONCLUSION…………………………………………………………….

CHAPTER 8: REFERANCES……………………………………………………………….

LIST OF FIGURES
FIGURES PAGE NO.

FIGURE 1: LAYOUT OF B.S.P. …………………………………………..

FIGURE 2: SHOWEL………………………………………………………
FIGURE 3: TROWEL ……………………………………………………….
FIGURE 4: LIFTER …………………………………………………………
FIGURE 5: FLOW CHART OF PRODUCION OF SAND CASTING……….
FIGURE 6.1: SINGLE PIECE PATTERN……………………………………
FIGURE 6.2: TWO PIECE PATTERN……………………………………..
FIGURE 6.3: LOOSE PIECE PATTERN…………………………………….
FIGURE 7 : HOT FORGING …………………………………………………
FIGURE 8 : PLATE MILL …………………………………………………….
FIGURE 9 : PRODUCTION OF PLATE ………………………………………
FIGURE 10 : VERTICAL AND HORIZONTAL LATH MACHINE………

LIST OF TABLES
TABLES PAGE NO.

TABLE 1: PROFILE OF SAIL. ……………………………………………...

TABLE 2 : PROFILE OF PLATE MILL …………………………………….

8
 CHAPTER 1: INTRODUCTION
1.1 INTRODUCTION OF 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.

9
Table no. 01.:-Profile of sail
Type State owned enterprise public

Industry Steel

Founded 1954

Headquaters New Delhi, India

Products Steel, flate steel products,long steel products,

Wire products, plates...etc
Employees 131,910 (2006)
Website www.sail.co.in

10
1.2 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

11
1.3 INTRODUCTION OF BHILAI STEEL PLANT (B.S.P.)
The beginning
This Leadership of free, India took a visionary decision to set up integrated steel plants under
the exclusive responsibility of the state owing to the massive investment needed for creating
additional Steel capacity, which private industry would not be able to mobilize and the
cardinal role steel would play in rapid economic advancement as a major step towards this
goal, government of INDIA and USSR entered into an agreement signed at New Delhi on 2 nd
march 1955, for the establishment of an integrated Iron and Steel works at Bhilai with an
initial capacity of one million tonnes of ingot steel.

The main consideration which responsible for setting up the plant at Bhilai, was the
availability of Iron ore at Delhi-Rajhara at a distance of about 90 Km from the site limestone
from Nandini at 22 km and dolomite at HIRRI at 41 km. the plant was commissioned with
the inauguration of the first blast furnace by the then president of India. Dr. Rajendra Prasad
on 4th Febraury 1959. The plant was soon expanded to 2.5 Million tonnes in September 1967
and in further expansion to 4 MT was completed in 1988. The main focus in the 4 MT stage
was on the continuous casting unit and the plate mill, a new technology in steel casting and
shaping for any integrated steel plant to India during those times. As of FY16(1), SAIL was
the leader in India’s steel sector with the company accounting for 13 per cent of country’s
finished steel production and 15.8 per cent of country’s crude steel production.

Arcelor Mittal SA is looking to set up a joint venture (JV) factory in India with state-owned
Steel Authority of India Ltd (SAIL), to manufacture high-end steel products which could be
used in defence and satellite industries.

The organization
Bhilai Steel Plant functions as a unit of SAIL with its corporate office at New Delhi. SAIL is
governed by a Board consisting of function Directors, Managing Directors and government
nominee Directors, 85.62% of the shares of SAIL are with Indian Government and balance
are with financial institutions, mutual funds, Indian Public and others, corporate office
formulate Policies, strategies and overall guidelines for its unit, central organization like
CMO ( Central Marketing Organization ) RDCIS ( Research and Development Centre for

12
Iron & Steel ) CET ( Centre for engineering and Technology ) look after the relevant
activities for the plates under SAIL.
Over the years, Bhilai Steel Plant has developed an organizational culture that run forces its
commitment to values and stimulates continuous improvements and higher levels of
performance. the chief executives at Bhilai is the Managing director (MD) who is in overall
control of the operations of the plant, township and the mines, Managing Director is assisted
by his DRO’S i.e. the functional heads (Executive directors/General Manager) concept of
Zonal heads and HOD’S helps in integrating various functions with clear accountability for
achieving corporate vision, company goals and objectives

1.4 AWARDS & ACCOLADES WON DURING THE YEAR 2015-2016

Company level
• Steel Authority of India Limited has won 4 Prime Minister's Shram Awards
(involving 23 employees) for the year 2014.
• Steel Authority of India Limited has won 15 Vishwakarma Rashtriya Puraskar
Awards (involving 86 employees) for the performance year 2013.
• Bhilai Steel Plant (BSP), bagged the Prime Minister's Trophy for the Best Performing
Integrated Steel Plant in the Country for the year 2011-12, declared in 2014-15, for a
record 11th time. Chairman, SAIL and Chief Executive Officer, BSP received the
trophy from Hon'ble Prime Minister Shri Narendra Modi at Rourkela on 1st April,
2015.
• Steel Authority of India Limited won Dainik Bhaskar India Pride Award 2015-16
under Corporate Social Responsibility award category.
• Steel Authority of India Limited won CII-ITC Sustainability 2015 Award for
'Corporate Excellence - Commendation for Significant Achievement' in recognition of
its exemplary performance and contribution in the economic, social and
environmental segment.
• Steel Authority of India Limited won India Today - MDRA CPSE Best HR
Excellence Award - 2015.
• Steel Authority of India Limited was awarded with the prestigious EEPC India
National Awards for Engineering Export Excellence as the Star Performer for the year
2013-14 in the Basic Iron and Steel - Large Enterprise product group category.
• Town Official Language Implementation Committee (PSU), Delhi under the
Chairmanship of SAIL was been adjudged 3rd in Northern Region for commendable

13
 performance in implementing the Official Language Policy of the Union during the
year 2014-15.
• BOM - 1st Prize in Publicity & Propaganda, 1st Prize in Survey & Mining Software,
1st Prize in First Aid Trade Test, 1st Prize in Mechanical Trade Test, 2nd Prize in
Illumination, 3rd Prize in General Working.
• GOM - 1st Prize in Mechanical Trade Test, 2nd Prize in Dozer Operator Trade Test,
2nd Prize in Survey & Scientific Study, 2nd Prize in Workshop Facilities, 2nd Prize in
Statutory Provision & Compliances, 3rd Prize in Overall Performance, 3rd Prize in
Publicity & Propaganda.
• 2nd Prize for "Best IT Practices of Govt. organizations for the citizens/ employees
and students" in Digital India Week - 2015, Ranchi.

1.5 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".

1.6 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
(iii) Jharandalli Mechanised Mine

(iv) Dalli Manual Mine and

(v) Mahamaya Manual Mine

14
1.7 Flow chart of bhilai steel plant:-

Fig 1 : plant layout of BSP

15
 CHAPTER 2 : FOUNDRY AND PATTERN SHOP
2.1 Introduction of Foundry:
Foundry practice deals with the process of making castings in moulds,
formed in either sand or either material. This is found to be the cheapest method of metal
shaping. Further, castings may be made to fairly close dimensional tolerances by
choosing proper moulding and casting process.

1.casting terms:
In the following chapters the details of sand-casting, which represents the basic process
of casting would be seen. Before going into the details of the process, defining a number
of casting vocabulary words would be appropriate.

Flask: A moulding flask is one which holds the sand mould intact. Depending upon the
position of the flask in the mould structure, it is referred by various names such as drag,
cope and cheek. It is made up of wood for temporary applications or more generally of
metal for long-term use.

Drag: Lower moulding flask.

Cope: Upper moulding flask.

Cheek: Intermediate moulding flask used in three-piece moulding.

Pattern: Pattern is a replica of the final object to be made with some modifications. The
mould cavity is made with the help of the pattern.

Parting Line: This is the dividing line between the two moulding flasks that makes up
the sand mould. In split pattern it is also the dividing line between the two halves of the
pattern.

Bottom Board: This is a board normally made of wood, which is used at the start of the
mould making. The pattern is first kept on the bottom board, sand is sprinkled on it and
then the ramming is done in the drag.

Facing Sand: The small amount of carbonaceous material sprinkled on the inner surface
finish to the castings.

Core: It is used for making hollow cavities in castings.

Pouring Basin: A small funnel-shaped cavity at the top of the mould into which the
molten metal is poured.

Sprue: The passage through which the molten metal from the pouring basin reaches the
mould cavity. In many cases it controls the flow of metal into the mould.

16
 Runner: The passageways in the parting plane through which molten metal flow is
regulated before they reach the mould cavity.

Gate: The actual entry point through which molten metal enters the mould cavity.
Chaplet: Chaplets are used to support cores inside the mould cavity to take care of its
own weight over-come the metallostatic forces.

Chill: Chills are metallic objects, which are placed in the mould to increase the cooling
rate of castings to provide uniform or desired cooling rate.

Riser: It is a reservoir of molten metal provided in the casting so that hot metal can flow
back into the mould cavity when there is a reduction in volume of metal due to
solidification.

2. TOOLS:
The tools and equipment needed for moulding are: Moulding board, moulding flasks
(boxes), shovel and moulders tools.

Moulding Tools: It is a wooden with smooth surface. It supports the flasks and the
pattern, while the mould is being made.

Moulding Flask: It is a box, made of wood or metal, open at both ends. The sand is
rammed in after placing the pattern to produce a mould. Usually, it is made of two parts.
Cope is the top half of the flask, having guides or the aligning pins to enter. Drag is the
bottom half of the flask having aligning pins.

Showel: It is used for mixing and tempering moulding sand and for transferring the sand
into the flask. It is made of steel blade with a wooden handle.

Fig 2: showel

Hammer: It is used or packing or ramming the sand around the pattern. One of its end, called
peen end, is wedge shaped and is used for packing sand in spaces, pockets and corners, in
early stages of ramming. The other end, called the butt end, has a flat surface and is used for
compacting the sand towards the end of moulding.

. Strike off Edge: It is a piece of metal or wood with straight edge. It is used to remove the
excess sand from the mould after ramming, to provide a level surface.

Sprue Pin: It is tapered wooden pin used to make a hole in the cope sand through which the
molten metal is poured into the mould.

17
RiserPin: It is straight wooden pin used to make a hole in the cope sand, over the mould
cavity or the molten metal to rise and feed the casting to compensate the shrinkage that take
place during solidification.

Trowel: It is used to smoothen the surface of the mould. It may also be used for repairing the
damaged portion of the mould. Trowels are made in many different styles and sizes, each one
suitable for a particular job.

Fig 3 : Trowels

Spike or Draw Pin: It is a steel rod with a loop at the other end. It is used to remove the
pattern from the mould. A draw Screw, with a threaded end may also be used for the purpose
to draw metal patterns.

Silk: It is a small double ended tool having a flat on one end and a spoon on the other. It is
used for mending and finishing small surfaces of the mould.

Lifters: Lifters are made of thin sections of steel of various widths and lengths, with one end
bent at right angles. These are used for cleaning and finishing the bottom and sides of the
deep and narrow pockets of the mould.

Fig 4 : Lifter

Gate Cutter: It is a semi- circular piece of tin sheet, used to cut gates in the mould. Gates are
meant for easy flow of molten metal into the mould.

Bellows: It is a hand tool, used to blow air to remove the loose sand particles from the mould
cavity.

Vent Rod: It is a thin rod used for making vents or holes in the sand mould to allow the
escape of mould gases generated during the pouring of molten metal.

Core Box: A core box is designed to mould cores. It is made of either wood or metal, into
which core sand is packed to form the core. Wood is commonly used for making a core box,

18
but metal boxes are used when cores are to be made in large numbers. Specially prepared
core sand is used in making cores.

2.2 Production sequence in sand casting

Fig 5 : flow chart of production of sand casting

2.3 Sand mould making procedure:

The procedure for making a typical sand mould is described in the following steps First, a
bottom board is placed either on the moulding platform or on the floor, making the surface
even. The drag moulding flask is kept upside down on the bottom board along with the drag
part of the pattern at the centre of the flask on the board. There should be enough clearance
between the pattern and the walls of the flask which should be of the order of 50 to 100mm.
Dry facing sand is sprinkled over the board and pattern to provide a non-sticky layer. Freshly
prepared moulding sand of requisite quality is now poured into the drag and on the pattern to
a thickness of 30 to 50mm. The rest of the drag flask is completely filled with the backup
sand and uniformly rammed to compact the sand. The ramming of the sand should be done
properly so as not to compact it too hard, which makes the escape of gases difficult, nor too
loose, so that the mould would not have enough strength. After the ramming is over, the
excess sand in the flask is completely scraped using a flat bar to the level of the flask edges.

Now, with a vent wire, which is a wire of 1- to 2-mm diameter with a pointed end,
vent holes are made in the drag to the full depth of the flask as well as to the pattern to
facilitate the removal of gases during casting solidification. This completes the preparation of
the drag.

19
 The finished drag flask is now rolled over to the bottom board exposing the pattern. Using a
slick, the edges of sand around the pattern is repaired and the cope half of the pattern is
placed over the drag pattern, aligning it with the help of dowel pins. The cope flask on top of
the drag is located aligning again with the help of the pins. The dry parting sand is sprinkled
all over the drag and on the pattern.

A sprue pin for making the sprue passage is located at a small distance of about 50 mm from
the pattern. Also, a riser pin if required is kept at an appropriate place and freshly prepared
moulding sand similar to that of the drag along with the backing sand is sprinkled. The sand
is thoroughly rammed, excess and scraped and vent holes are made all over in the cope as in
the drag.

The sprue pin and riser pin are carefully withdrawn from the flask. Later, the pouring basin
is cut near the top of the sprue. The cope is separated from the drag and any loose sand on
the cope and drag interface of the drag is blown off with the help of bellows. Now, the cope
and the drag pattern halves are withdrawn by using the draw spikes and rapping the pattern
all around to slightly enlarge the mould cavity so that the mould walls are not spoiled by the
withdrawing pattern. The runners and the gates are cut in the mould care-fully without
spoiling the mould. Any excess or loose sand found in the runners and mould cavity is blown
away the bellows. Now, the facing sand in the form of a paste is applied all over the mould
cavity and runners, which would give the finished casting a good surface finish

2.4 TYPES OF SAND MOULDS:

In order to produce sound castings, moulds are required to have some specific properties.

Some of them are the following:

1.It must be strong enough to withstand the temperature and weight of the molten metal.

2.It must resist the erosive action of the flowing hot metal.

3.It should generate minimum amount of gases as a result of the temperature of the
molten metal.

4.It should have good venting capacity to allow the generated gases to completely escape
from it.

Moulds that are used for sand casting may broadly be classified as

1. Green sand moulds

2.Dry sand moulds

3.Skin dried moulds

Green SAND MOULDS:

20
 Green sand is the moulding sand which has been freshly prepared from silica grains, clay
and moisture. In a green sand mould, metal is poured immediately and the castings taken
out. These are most commonly used and are adapted for rapid production, whereas the
moulding flasks are released quickly.

Dry SAND MOULDS:

These are the green sand moulds which are completely dried by keeping in an oven
between 150 to 350c for 8 to 48 hours depending on the binders in the moulding sand. These
moulds generally have higher strengths than the green sand mould and are preferred because
they are less likely to be damaged during handling.

Skin dried mould:

Though the dry sand mould is preferable for large moulds because of the expense involved, a
compromise is achieved by drying only the skin of the mould cavity with which the molten
metal comes into contact, instead of the full mould. The skin is normally dried to a depth of
15 to 25 mm, using either torches or by simply allowing them to dry in atmosphere.

Other sands:

Though moulding sands are the prime mould materials used in a foundry, there are a number
of other materials, which are also used for a number of specific properties

Facing sand:.

This sand is used next to the pattern to obtain cleaner and smoother casting surfaces.
Generally, sea coal or coal dust(finely divided bituminous coal of 2 to 8%) is mixed with the
system sand to improve the mould ability and surface finish. The sea coal being
carbonaceous, will slowly burn due to heat from the molten metal and give off small amounts
of reducing gases.

Mould wash:

Purely carbonaceous materials such as sea coal, finely powdered graphite or proprietary
compounds are also applied on to the mould cavity after the pattern is withdrawn. This is
called the mould wash and is done by spraying, swabbing or painting in the form of a wet
paste. These are used essentially for the following reasons:

1. To metal penetration into the sand grains and thus ensure a good casting finish

2.To avoid mould-metal interaction and prevent sand fusion.

For deposing the mould wash, either water or alcohol can be used as a carrier. But
because of the problem of getting the water out of the mould, alcohol is preferred as a carrier.
The proprietary washes are available in powder, paste or liquid form. The powder needs to be
first prepared and applied whereas the paste and liquid can be straightaway applied.

Backing sand:

21
 This is normally the reconditioned foundry sand is used for ramming the bulk of the
moulding flask. The moulding flask is completely filled with backing sand after the pattern is
covered with a thin layer of facing sand. Since the casting is not affected to any great extent
by the backing sand, it usually contains the burnt facing sand, moulding sand and clay.

Parting sand:

This is the material, which is sprinkled on the pattern and to the parting surfaces of the
mould halves before they are prepared, to prevent the adherence of the moulding sand. This
helps in easy withdrawal of the pattern and easier separation of the cope and drag flasks at
parting surface. It is essentially a non-sticky material such as washed silica grains.

2.5 Moulding sand properties:

The properties of moulding sand are dependent to a great extent on a number of
variables. The important among them are

• Sand grain shape and size,

• Clay type and amount,

• Moisture content, and

• Method of preparing sand mould.

2.6 Introduction of Pattern:

A pattern is the replica of the desired casting, which when packed in a suitable
material, produces a cavity called the mould. This cavity when filled with molten metal,
produces the desired casting after solidification.

1. Types of pattern:
These are various types of patterns depending upon the complexity of the job, the
number of castings required and the moulding procedure adopted.

Single piece pattern:

These are inexpensive and the simplest type of patterns. As the name indicates, they
are made of a single piece as shown in fig. This type of pattern is used only in cases where
the job is very simple and does not create any withdrawal problems. This pattern is expected
to be entirely in the drag.

fig 6.1 : single piece pattern

22
Split pattern or two piece pattern:

This is the most widely used type of pattern for intricate castings. When the contour
of the casting makes its withdrawal from the mould difficult, or when the depth of the casting
is too high, then the pattern is split into two parts so that one part is in the drag and other in
the cope.

Gated pattern:

This is an improvement over the simple pattern where the gating and runner system are
integral with the pattern. This would eliminate the hand cutting of the runners and gates and
help in improving the productivity of a moulder..

Cope and drag pattern:

These are similar to split patterns. In addition to splitting the pattern, the cope and drag halves
of the pattern along with the gating and risering systems are attached separately to the metal
or wooden plates along with the alignment pins. They are called the cope and drag patterns.

Match plate pattern:

These are extensions of the previous type. Here, the cope and drag patterns along with the
gating and the risering and mounted on a single matching metal or wooden plate on either
side.

Loose piece pattern:

This type of pattern is also used when the contour of the part is such that withdrawing the
pattern from the mould is not possible. Hence during moulding, the obstructing part of the
contour is held as a loose piece by a wire.

23
Follow board pattern:

This type of pattern is adopted for those castings where there are some portions, which are
structurally weak and if not supported properly are likely to break under the force of
ramming.

Sweep pattern:

It is used to sweep the complete casting by means of a plane sweep. These are used for
generating large shapes, which are axi-symmetrical or prismatic in nature such as bell-shaped
or cylindrical.

Skeleton pattern:

A skeleton of the pattern made of strips of wood is used for building and final pattern by
packing sand around the skeleton.

1. Pattern design:

While designing a pattern, the following must be considered.

1. Avoid abrupt changes in cross section.

2. Avoid sharp corners and edges, to enable smooth flow of molten metal.
3. Provide the following pattern allowances.

a. Shrinkage allowance, to allow for shrinkage when casting cools in the mould.
b. Slight taper or draft, to allow easy withdrawal of the pattern from the mould.
c. Machining allowance, to take care of the machining on these surfaces.

24
 CHAPTER 3 : FORGE AND STEEL SRUCTURE SHOPE
3.1 INTRODUCTION FORGE SHOPE
Forging is a manufacturing process involving the shaping of metal using localized
compressive forces. Forging is often classified according to the temperature at which it is
performed: "cold", "warm", or "hot" forging. Forged parts can range in weight from less than
a kilogram to 580 metric tons.Forged parts usually require further processing to achieve a
finished part.

Fig 7: hot forging

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.

3.2 TYPE OF FORGING:

1. Hot Forging
2. Cold forging
3. Warm forging

25
1.HOT FORGING:

It is the controlled plastic deformation of metals at elevated temperature by using the external
pressure. The pressure may be applied by hand hammers or power hammers .So in this
,pressure apllied is not continuous but intermittent.

Following are some of the examples of hot forging:

1.HAMMER OR SMITH FORGING

2.DROP OR DIE FORGING

3.PRESS FORGING

4.UPSET FORGING

5.ROLL FORGING

6. SWAGGING HOT FORGING

2.COLD FORGING:

Cold Forging is a cold working process where the material is squeezed into a die and the
finished parts assume the shape of the die. This process is also known as Cold Heading.

3.3 FORGING PROCESS:

Cold Forging - Starts at room temperature (RT to 600-800 F)

Warm Forging - Below or near recrystallization temperature (900 F - 1800 F for steel)

Hot Forging - Above recrystallization temperature (1800 F - 2200 F for steel, 800 F for Al)

MAIN EQUIPMENT

Forge Shop has been equipped with the following machines:

3 Tonne Pneumatic Hammer

2 Tonne Pneumatic Hammer

1 Tonne Pneumatic Hammer

0.4 Tonne Pneumatic Hammer

250 Tonne Friction Press

160 Tonne Electric Press

26
100 Tonne Eccentric Press

1 Tonne Forging Manipulator

250 Tonne Bar Cropper

CO Gas Fired Furnaces

a. Annealing Furnace 6 x 1.5m (car bottom)

b. Reheating Furnace (Batch type)

c. Band saw machine (max. dia. 400 mm)

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

3.4 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

27
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)

28
 CHAPTER 4 : PLATE MILL
4.1 INTRODUCTION OF PLATE MILL
With the commissioning of 3600 mm Plate Mill under 4 MT expansion programme,
Bhilai has entered into the area of flat products in a big way. This giant rolling mill complex
which extends to over a kilometer in length has an overall covered area of about 15680 m². It
consists of six main bays; 1-3 bays of span 36 meters each, 2 bays of span 30 meters each and
one bay of 18 meters span, also, two open gantries for scrap removal. The mill is intended for
an annual production of 0.95 million tonnes of finished plates in 5600 operating hours. The
thickness of the plates range from 5120 mm. It is called 3600 mm Plate Mill because the
barrel length of the work roll is 3600 mm.

Continuously cast slabs in the length range of 5.6-10.2 M are delivered in hot condition to
the slab yard. These slabs are cut to smaller lengths in 3 non flame cutting machines as per
requirement. Inspection and conditioning is carried out after cutting of the slabs to the
required sizes. Inspected slabs with proper identification are supplied to Plate Mill.

Fig 8 : plate mill shope

4.2 The sequence of operations are :

Slab heating, descaling, rolling, levelling, cooling, inspection and shearing to required
size. Heating of slabs is done in three continuous double row pusher type furnaces with an
estimated capacity of 120 T/hr each. These furnaces have five heating zones : Soaking Zone,
top and bottom preheating zone, top and bottom heating zone. The soaking zone has a flat
roof with sixteen small capacity vertical burners through the roof. The other four zones have
six burners each. Mixed gas of calorific value 2500 K cal/cum is used as a fuel. In time of gas

29
shortage, provision for oil firing is also there in the four zones, heating and preheating zones.
Air for combustion is supplied by individual blowers. This is preheated in multicellular cross
parallel flow type of metallic recuperators. The slabs move on skid pipes in the heating and
preheating zones and over a solid hearth in the soaking zone. The skid pipes are cooled by
evaporative cooling system instead of the conventional water cooling system. The solid
hearth in the soaking zone is made of electro cast corundum blocks.

Programmed slabs from the slab yard are placed by the means of overhead crane of the
lifting and lowering table. The slabs are pushed one by one on the charging side roller table.
The slabs are positioned with respect to the furnace skids with the help of movable hydraulic
stopper. They are pushed in to the furnace in cold condition for heating up to the required
temperature. The first slab on the delivery side is pushed to pre-determined position by the
pusher and then it is extracted by shock free slab extractors.

Profile of plate mill: table no.2

Capacity 9,50,000T
Plate thickness 8-120 mm
Width 1500-3270 mm
Lenth 5-12.5 M

 The modern Plate Mill rolls out heavy and medium plates, as well as those for pipe
manufacturers. Plates of wide variety, in any required size, and strength, chemical and
physical properties, can be produced here.
 It has capacity to produce high pressure, boiler quality and high tensile steels.
 Shipbuilding plates, conforming to Lloyds specifications, and pressure vessel boiler
plates, conforming to various ASTM, ASME standards, have withstood the challenges
of nature and time. Some of the unique features of the mill are on-line finishing
facilities and off-line normalising facilities.

Fig 9 : production of plate

30
 CHAPTER 5 : CAPITAL REPAIR AND
MODIFICATION(C.R.M.)
5.1 INTRODUCTION OF C.R.M.
This department was established in 1971 primarily to carry out capital repairs of
Blast Furnaces and Open Hearth Furnaces. Later on it got involved in capital repair
ofother units also, like Rolling Mills, RMP-1, Coal Chemicals Department etc.
Presentlythe department is primarily made responsible for organising capital repairs of
Blast Furnaces. Jobs are executed partly through contractual agencies, while carrying
outvarious assignments during all preventive maintenance shutdowns in different units by
central maintenance organisation as also for carrying out riveting jobs at site.At present
the department is having three sections namely Mech.-1, Mech.-II and Planning.
Manpower of the department is 175, including 9 executives.

5.2 SOME SPECIAL ACHIEVEMENTS:

 Replacement of Converter-A, B&C vessel at SMS-2.

 Installation of Hanging Platform Insertion arrangement in Bell -less Top of Blast
faenece
 Replacement of well of stripper Crane-3.
 Capital Repair of BF-4 and BF-3
 Major repair of RH Degasser, VAD and Ladle Furnace of SMS-II

5.3 CORE COMPETENCIES :

 Planning organising and executing the various categories of capital repair of BFs
 Fabrication & Erection of technological structures like, girders, beams column
etc in various work areas.
 Capacity to complete replacement of various units of 1000T shear of BBM, 800
pinion stand of R&S Mill
 Ability to meet the maintainance and major repair needs of various E.O.T. cranes.
 Provision of technological solution to some of the critical problems of BFcs
 Repair and upkeep of enabling equipment like winches, pulleys etc.

31
 CHAPTER 6 : MACHINING ASSEMBLY &
RE-ENGINEERING SERVICES-1 (MARS-1)
6.1 INTRODUCTION OF MARS-1
MARS-1 has a vital role to play in maintaining the plant equipment so for as it
supplies the bulk of spare parts required by the various units. It acquires an added
significance by virtue of the finishing line of manufacturing activities of engineering shop
. The product mix so arranged so as to meet the demand of both heavy and small spares.
The shop is housed in three machining bays, 21 meters x182 meters each with an
assembly bay of 24 meters x 96 meters .A total of 196 machine –tools are engaged in
direct production of spares, where- as the remaining contribute indirectly towards shop
production. Apart from these, there are 12 Heat Treatment / Heating furnaces 22 material
handling equipment (cranes,jib cranes transfer cars). The Annual production plan for
MARS-1 during 2007-2008 is 6,40,000 credit hours.

Fig 10: vertical and horizontal lathe machine

6.2 MAIN ACTIVITIES:-

Functionwise MARS-1 carries out the following activities:

1. Manufacture of spares, changables, tools, tackles etc. Required for maintenance and
operation of various departments.

2. Overhauling and repair of equipment sub - assemblies to the extent of those that can be
transported to MARS-1.

3. Reclamation of worn-out spares .

4. Repair of certain equipment at site-especially where machining at site is required.

32
5. Manufacturing and modification of equipment / spares for development work from the
point of view of import substitution,cost reduction ,etc.

6.3 FLOW PROCESS:-

A brief description of process for spares manufacture from the order stage to the
despatch stage is given below:-

Work order for a group of jobs is placed on the shop by the cental planning
department(CPD). The CPD prepares a monthly plan ,enlisting the jobs to be carried out
in a particular month , after necessary discussion ,review of previous month's plan ,
requirement of new item etc; with the help of shop planning section and ordering
departments. Jobs are categorised in the order of priorities . This plan is processed for
execution by the shop planning section. The technology prepares calculations, tooling is
prepared in advance by tool room . These mastercards are numbered and stored by
planning section for future reference , and copiesmade out for execution taking into
account priorities if any , blank availability etc Simultaneously the blanks (forgings ,
castings or fabrications ) stored in an open gantry storage (controlled by CPD ) are taken
in and after preparatory work, if any , are supplied to the concerned machines . The route
card, drawing and job card are issued to the machine when the job is taken up . After
completion, inspection is carried out by the inspection department for quality control .
The completed jobs are collected by the ordering department.

6.4 SECTIONS :-

MARS-1 is divided in to following sections:-

1. Machining Section:-

The machning section carries out the following function :-

(i) Manufacture of various spares of a wide variety, out of forged , casting and
fabricated blanks.
(ii) Finishing of reclamed parts.
(iii) Modisfication of various spares by machining.

For performing the above , apart from the general purpose machine tool ranging
from extra heavy duty to light duty nature are used which are :

a) Lathes (Max dia -2000mm,length 12000mm)

b) Shapers (Max stroke 1000mm)

c) Planning M/cs (Max table size 6000x2000mm)

d) Slotter (Max stroke 1000mm)

e) Vertical Boring M/cs (Max dia -5000mm)

33
f) Pillar & Radial Drilling M/cs (Max drill size 80mm)

g) Horizontal boring M/cs (Max spindl dia 175mm)

h) Plano milling M/cs (Max table size 6300x2000mm)

The section is provided with a versatile gear cutting group comprising Gear Hobblers
(max. Module 36 ,dia 3000mm), gear slotter (max, module 8, dia 500), a MAAG Gear
shapers with rack cutting unit (Max module 15, dia 1450) , straight level gear generators
(Max. Module 24) , and a spiral bevel gear generators (Max. Module 1, dia 500). Other
machines of special intrest are a ROD Threading Machine and vertical Boring machine
with copying attachment.

The section is housed in three bays Heavy Machine Bay, Lihgt & Medium MachineBay
and Expansion Bay. Handling equipments are provided in all the three bays which include
8 EOT cranes ( Max. Capacity 30T/5T), 6 Electrical transfer cars (Max. Capacity 20T)
connecting the three bays to open gantry and assembly section. T rollys of 2T capacity are
also provided for material transfer , stores collection etc.

2. Planning Section

Guided by the monthly plan given by CPD , the shop planning section proceeds with
various steps in processing the jobs . The functions of planning section are:

(i) Receipt , document and storage of work- orders received and master cards
department-wise.
(ii) Collection preparation of finished products . A sub - section called
production control group (PCG) executes these jobs .
(iii) Scheduling of jobs operation-wise with a view to take up the various work on
different machines as per sequence of operation specified , and to distribute
the workload on machine in optimum manner
(iv) Issue and receipt of jobs cards for each operation .
(v) Assessment of progress of jobs , maintaining statistics of production and othe
relevant data.
(vi) Advance preparation of co-ordination with tool room.
(vii) Co-ordination with CPD and maintenance/ planning section of various
ordering department for assemblies etc. The section has been provided with
PCs for storage of master carde and copies preparation .

The preparation of blanks machining includes and cutting of shafts , riser

cutting on casting , marking out jobs etc. For these P.C.G. Is provided with 4 circular saw
machining and 2 power back saws , layout tables for marking etc.

34
 3.Technology Section : -
The section is responsible for working out the technological processing of jobs to be
manufactured . The responsibilities of the section are .
1. Preparation of master card , detailing sequence of operations , type of machine tool to
be employed , sequence of machining on eatch machine , cutting tools to be used
necessary shop calculations , tooling required etc. Along with all other relevant and
special instruction .
2. Design, manifacture in co- ordination with tool room and try out of jigs and fixtures
where - ever applicable

4. Assembly Section :-
1. Planned manufacture of new assemblies i.e. Crane wheels of various types and
size for different department . Hammer crusher rotors for coke oven and sintering
plant, peel assembly for SMS , transfer chains for Mill etc.
2. Planned periodcal repair/overhauling of equipment like B.F.Top
equipments(charge distributor , bells , hoppers etc.) skip cars , mud gun ,OBC
trolley travel axle for SMS , stripper yard crane traverse , charging machine
spindle , crusher roters for coke ovens , various transmission shofts and rollers for
mill etc.

5. Tool Room & Treatment Section :-

The Tool Room is intended to

i. produce & Recondition various metal cutting tools & cutters

ii. Repair measuring instruments/ tools , hand tools etc.

iii. Manufacture jigs , fixtures , gauges , templates ,and special cutters.

iv. Manufacture of machine tool accessories , and various other tackles.

v. Manufacture precision where high accuracy is demanded .

Also, tool room controls all the grinding operations carried out on various produced in
MARS-1.

6. Maintenance Section
The upkeep & maintenance of machine tools and all other installations of MARS-1 is as
vital to the shop performance as the production itself. This is carried out by electrical &
mechanical maintenance section which have the following responsibilities.

1. Regular check up of condition of machine tools.

2. Planned preventive maint. Of machine tools , with the objective of minimizing
breakdowns by rectifying possible defects in advance .

35
 3. Attending day to day minor breakdowns.
4. Attending to major breakdowns in such way so as to curtail the down time of
machines to minimum.

7. Store Section
Controlled by the Incharge tool room, this section ensures the supply of tool items &
consumable required by MARS-1. These are normally collected from various centralized
store of plant & stocked as per requirement . This section is also responsibilefor
procurement of all items specially required by MARS-1.

36
 CHAPTER 7 : 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 PLATE MILL,and
MARS-1 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.

37
 CHAPTER 8 : REFERANCE
 www.google.com
 www.wikipedia.com
 www.sail.bhilaisteel.com
 www.studymafia.com

38