vocational trainning

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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
BOKARO STEEL PLANT

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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 BASEREPAIRING SHOP(CBRS)
 MACHINESHOP
 FOUNDARIES
 WATER MANAGEMENTDEPARTMENT (WMD)
 TRAFFIC
 RAWMATERIAL HANDELLING PLANT (RMHP)
 SINTER PLANT(SP)
 OPERATION GARAGE(OG)
 COKE OVEN & BY-PRODUCTPLANT(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

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COKE OVEN & BY PRODUCT PLANT (C0&BPP)
 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.

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SINTER PLANT (SP)
 Sinter is porous agglomerate ofmineral fines formed after incept fusion.
Sintering is a process ofpreparing sinter in which a high temperature is
maintained for two basic purposes:
 Waste management
Advantageous properties of sinter
 Sintering as a process uses allwastes generatedin the mines site,
handling and the mill zone, so it is a goodsource ofwaste management.
Now days, 70% of BlastFurnace burden is sinter.
 Ore Fines
 Flux (limestone+Dolomite)
 Coke
 Additives

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OPERATION GARAGE (OG)
 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.

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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.

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CONCLUSION
 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.

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REFERENCES
www.sail.co.in
www.google.co.images
THANK YOU

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