in this presentation of plate and foundry and pattern shope. which is expaline in simple way.....

2. Department of Mechanical Engineering
Bharti college of Engineering and Technology
Pulgaon Chowk Durg, C.G.
Pin: 491001
VOCATIONAL TRAINING PRESENTATION
ON
“BHILAI STEEL PLANT”
Submitted to
CHHATTISHGARH SWAMI VIVEKANAND TECHNICAL
UNIVERSITY, BHILAI
in the partial fulfillment of the requirements for the award of Degree
of
Bachelor of Engineering
In
Mechanical Engineering
By
SURENDRA KUMAR
3433714028
a

3. CONTENTS
 INTRODUCTION OF SAIL
PROFILE OF SAIL
B.S.P. OVERVIEW
INTRODUCTION OF B.S.P.
FLOW CHART OF B.S.P.
RAW MATERIALS FROM MINES
DO’S & DONT’S IN THE INDUSTRY
PLATE MILL
PRODUCTION OF PLATE MILL
OPERATION IN PLATE MILL
PROCESS FLOW IN MAKING PLATE
MAJOR PRODUCTION
FOUNDRY SH0PE.

4. INTODUCTION OF SAIL
o Steel Authority Of India Limited
o Largest steel making company in India
o An annual turnover of ₹ 51866 crore.
o One of the seven Maharatnas of the country's Central Public
Sector Enterprises.
o SAIL traces its origin to the Hindustan Steel Limited (HSL)
which was set up on 19 January 1954
o Annual production of 13.5 million metric tons
o 24th largest steel producer in the world

5. 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
Profile of SAIL

6. SAIL integrated Steel Plants
oBhilai Steel Plant (BSP) in Chhattisgarh setup with Soviet Collaboration
oRourkela Steel Plant (RSP) in Orissa setup with German Collaboration
oDurgapur Steel Plant (DSP) in West Bengal setup with British Collaboration
oBokaro Steel Plant (BSL) in Jharkhand setup with Soviet Collaboration
oIISCO Steel Plant (ISP) at Burnpur, West Bengal
Special Steel Plants
oSteel Authority of India Limited (SAIL), Kanpur, Uttar Pradesh
oAlloy Steels Plants (ASP), Durgapur, West Bengal
oSalem Steel Plant (SSP), Tamil Nadu
oVisvesvaraya Iron and Steel Limited (VISL), at Karnataka
Ferro Alloy Plant
oChandrapur Ferro Alloy Plant (CFP) in Maharastra

7. BHILAI STEEL PLANT OVERVIEW

8. INTRODUCTION OF B.S.P.
o Bhilai Steel Plant is located in Bhilai in the Indian state of Chhattisgarh
o a unit of Steel Authority of India Ltd.
o Bhilai steel plant is India’s largest steel producing plant which was
stablished in 4 Feb,1959 in collaboration with USSR.
o Bhilai steel plant steel producing capacity of more than 4 million tones of
steel per year.
o Bhilai Steel Plant has been India's sole producer of rails and heavy steel
plates
o eleven-times winner of the Prime Minister's Trophy for best integrated steel
plant in the country
o Sole supplier of the country's longest rail tracks, which measure 260 metres (850 ft)
o Total Rail track inside – 365 KM
o Annual production capacity of 3.153 MT of saleable steel
o Covers an area of about 36 sq.kms

9. Flow chart of B.S.P.

10. RAW MATERIAL FROM MINES
Iron-Ore
- Dalli-Rajhara Iron Ore Complex,
80 kms from Bhilai
Limestone - Nandini, 23 kms from Bhilai
Dolomite - Hirri, 150 kms from Bhilai

11. Do’s and Dont’s in the Industry
 Do’s-
Punctuality (timeliness),
Maintaining healthy and cordial relationship with the people in
organization.
Understanding the work culture.
Obeying direct orders from the seniors.
 understanding and note down the importante point.
Maintaining proper Line and Staff Relationship with the
seniors and subordinates (If Any).
11

12. Do’s and Don’ts in the Industry
 Don’ts
Do not take the training lightly and casually.
Do not involve in internal politics.
Do not reveal you weaknesses.
Do not lie to your seniors.
Do not waste your time.
Do not ask for favours.
12

14. PLATE MILL
 Plates of wide variety, in any required size,
and strength, chemical and physical
properties, can be produced here
 capacity to produce high pressure, boiler
quality and high tensile steels
 Bhilai has the widest plate mill in the
country, and it uses continuously cast slabs as
input.
 On 29th March,1983 , First Plate was
produced from this Mill
 it has three Reheating furnace

15. PRODUCTION
Capacity 9,50,000 T
Plates thickness 6-120 mm
Width 1500-3270 mm
Length 5-12.5 M
 On 29th March,1983 , First Plate was produced
from this Mill

16. OPERATION IN PLATE MILL
 Slab heating
 Descaling
 Rolling
 Punching
 Levelling
 Cooling
 Inspection
 Shearing to required size
 Normalized
 Dispatch

17. PROCESS FLOW IN MAKING OF PLATES

18. MAJOR PRODUCTION
Wheels and Axles
Rails

19. Galvanised sheets
Pipes

20. Wire Rods
SAIL TMT

21. FOUNDRY & PATTERN SHOP
Foundry & Pattern shop is an important Engineering Shop, set up to
meet the requirement of various ferrous and non-ferrous castings and cast
blanks required for the plant and other Engineering Shops especially machine
shops, for manufacture of spares. It comprises two major parts, the Pattern
Shop and the Foundry Shop.
THE PATTERN SHOP:
The pattern shop is designed to produce patterns for foundry needs.
The annual output is rated at 220 Cu. meters. The shop works in G shift. It is
equipped with modern set of working machine tools. Handling of heavy
patterns at the shop and storage is carried out by overhead travelling crane
operated from floor level. The patterns are painted according to a code,
ticked, labelled and stored, to enable the patterns to be issued to foundry as
and when required, according to a well-laid out procedure. The pattern

22. FOUNDRY SHOP:
The foundry shop is laid out in five bays, each of length 270 meters.
Various types of castings and their usage is as follows :
Iron Castings : ( Capacity 79000 T/year)
i) Spare parts for machines / equipments.
ii) Ingot moulds.
iii) Bottom Stools.
Steel Castings : ( Capacity 6500 T/ year)
i) Spare parts for machines/equipments.
ii) Twin hearth-charging boxes.
iii) Skull cracker balls.
iv) Spares for Mould bogie.
v) Ladle covers for SMS, Lip ring for CCS.
vi) Pig casting moulds.
vii) Alloy steel Ingots.

23. Non - Ferrous Castings : ( Capacity 515 T/ Year)
i) Bushings, slide blocks for machines/ equipments.
ii) Monkey for BF & Hollow shaft for SMS.
iii) L.N. body & covers.
iv) Al. Cubes & Al. Shots for SMS-I & SMS-II.

24. Main Sections of Foundry Shop :
1)Charging and Moulding Material Store :
The charging and moulding material storage is designed to hold 15 days supply of all
raw material used in foundry. The storage bay is served by overhead travelling cranes with
removable magnets. With the help of electric grabs, all the raw materials are stored in bins &
bunkers.
2) Sand Preparation Section :
In this section, preparation of moulding sands and core sand mixture for all types of
castings is done. The raw silica sand is received from Sambalpur and Allahabad. Quartzite sand
is supplied by Crushing Plant. The new sand, if wet, is dried in a rotary dryer in which sand is
heated to 200-250 deg.C. The dried sand is fed in the feeding hoppers, over the sand mixers of
20 cu.m/hr capacity.
In the sand mixer ; various moulding materials like fire clay, bentonite, molasses, saw dust
etc. are added and mixed. The sand so prepared is distributed by the system of conveyor belts
throughout the cast-iron, steel and core section. 130 T of mixed sand is produced by sand
mixers for preparing different types of sand mixtures for core section (about 5 T per day).

25. 3) Iron Foundry :
The Iron foundry can be divided in to the following sub-sections.
i) Cast Iron section.
ii) Mixer section
iii) Moulding section
iv) Ingot Moulds
v) Mould drying chambers.
The estimated annual requirement of the metal is about 1,00,000 tons and the
daily requirements is 270 tons. The moulding section prepares moulds for all types of
castings required under the schedule or special work requiring upto 30 tons liquid metal.
The Ingot Mould section produces the Ingot Moulds required by the plant. Each Ingot
Mould weights 8.8. T or 9.3 T and the daily production of Ingot Moulds are 17 nos. on
average. Ingot Moulds are rammed on two 30 tones jolting machines in the Ingot Mould
section. Top box is prepared for using at top of Ingot Mould for pouring. The mould drying
chambers are used for drying the moulds in the chamber type drying ovens at the
temperature of 300-350 degree cel. There are 6 drying ovens. The 4 drying ovens are of
130 Cu.m. capacity and the other 2 of 60 cu.m. capacity for drying small castings. These
ovens have been provided with an arrangement for the re-circulation of the products of
combustion. Coke oven gas is used for heating purpose.