SAIL Summer Internship Report- Braj Kishor Sah

1
A
SUMMER INTERN PROJECT REPORT
Submitted by
BRAJ KISHOR SAH
Roll No – 112CR0126
In partial fulfilment of Summer Internship for the award of the degree
Of
BACHELOR OF TECHNOLOGY
IN
CERAMIC ENGINEERING
Steel Authority of India Limited
SAIL Refractory Unit Ranchi Road
Ramgarh (Dist), Jharkhand-829117
July 2015

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CERTIFICATE
To Whom so ever It May Concern
This is to certify that Mr. Braj Kishor Sah is student of B.Tech – Ceramic
Engineering, National Institute of Technology, Rourkela. He has undergone his
Industrial training at our organization for 8 weeks from May 11, 2015 to July 10,
2015.
We wish him good luck for a bright and prosperous future.
(A.K. Sinha)
Sr. Manager (Pres. and Admn)

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ABSTRACT
The B.Tech programme is well structured and integrated course of technical studies. The main
objective of Summer Training at B.Tech level is to develop skill in student by supplement to
the theoretical study of technical work field in general. Industrial training helps to gain real life
knowledge about the industrial environment. In every professional course, training is an
important factor. Professors gives us theoretical knowledge of various subject in the college
but we are practically exposed of such subjects when we get training in the organization. It is
only the training through which I came to know that what an industry is and how it works. I
can learn about various departmental operations being performed in the industry, which would,
in return, help me in the future when I will enter the practical field. In today’s globalize world,
where cutthroat competition is prevailing in the market, theoretical knowledge is not sufficient.
Beside this one need to have practical knowledge, which would help in individual in his/her
carrier activities and it is true that “EXPERIENCE IS BEST TEACHER”.
Braj Kishor Sah

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ACOKNOWLEDGEMENT
The summer internship opportunity I had with SAIL REFRACTORY UNIT, RAMGARH,
RANCHI ROAD, JHARKHAND-829117 was a great chance for learning and professional
development. Therefore, I consider myself as a very lucky individual as I was provide with an
opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful
people and professionals who lead me though this internship period.
Bearing in mind previous I am using this opportunity to express my deepest gratitude and
special thanks to the Manager (P&A) Mr. Anand Kumar Sinha of SAIL REFRACTORY
UNIT, RAMGARH, RANCHI ROAD, JHARKHAND-829117 who in spite of being
extraordinarily busy with his duties, took time out to hear, guide and keep me on the correct
path and allowing me to carry out my project at their esteemed organization and extending
during training.
I express my deepest thanks to Mr. Ujjal Kumar Pal, Asstt. General Manager Production/ IC
lab for taking part in useful decision and giving necessary advices and guidance and arranged
all facilities to make life easier. I choose this moment to acknowledge his contribution
gratefully.
It is my radiant sentiment to place on record my best regards, deepest sense of gratitude to Mr.
Dinesh Prasad, Shri Keshari Nandan Gupta, Sr. Manager (Production), Shri A.Kumar
Asstt. Manager (Production), Shri P.K. Gupta, Sr. Manager (Maintenance), Shri R.L. Tiwari,
Sr. Manager (Electrical), Dr. R.C. Pandey Sr. Manager (MM), Shri J.K. Singh Asstt.
Manager (F&A), Mr. Prasanta Baidya, Mr. Ajaz Ahmed, Mr. Shakil Khan for their careful
and precious guidance which were extremely valuable for my study both theoretical and
practically.
I perceive as this opportunity as a big milestone in my carrier development. I will strive to use
gained skills and knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives. Hope to continue cooperation with
all of you in the future.
Sincerely,
Braj Kishor Sah
Date: 06/07/2015

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Contents
Certificate…………………………………………………………………………...…………2
Abstract……………………………………………………………………………………..…3
Acknowledgement……………………………………………………………………….…….4
1. INTRODUCTION ..............................................................................................................................7
1.1. CAPACITY OF PLANT................................................................................................................8
1.2. AREA........................................................................................................................................8
1.3. MAN POWER OF PLANT..........................................................................................................8
1.4. FACILITIES PROVIDED BY COMPANY.......................................................................................8
2. RAW MATERIALS..........................................................................................................................9
2.1. INDEDEGINES ...............................................................................................................................9
Materials come from India..................................................................................................................9
2.2. IMPORTED....................................................................................................................................9
2.3. Raw Materials ..............................................................................................................................9
2.3.1. Fused Magnesia...................................................................................................................9
2.3.2. Refractory Grade Fused Magnesia..................................................................................10
2.3.4. Sea Water Magnesia .........................................................................................................11
2.3.5. Graphite.............................................................................................................................12
2.3.6. Resin...................................................................................................................................14
2.3.7. Aluminium Powder...........................................................................................................14
2.3.8. Pitch Power........................................................................................................................14
2.3.9. Dead Burnt Magnesia.......................................................................................................15
1. Refractory Industry for manufacture of Basic Refractory Bricks.........................................16
2. Manufacture of Ramming Mass composition, Fettling material and Magnesite Mortar......16
3. It is used in SLAG beneficiation and in SLAG splashing in Arc Furnaces..........................16
4. It is also used as a coating material in Steel Industry. ..........................................................16
3. PRODUCTION ...........................................................................................................................17
3.1. Selection of raw materials .........................................................................................................17
3.2. Grinding.................................................................................................................................17
3.3. Mixing.........................................................................................................................................18
3.4. Ageing ........................................................................................................................................20
3.5. Pressing......................................................................................................................................21
3.6. Curing.........................................................................................................................................22
3.7. Checking & Packing....................................................................................................................22
3.8. Transportation ...........................................................................................................................23

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4. MAINTANENCE........................................................................................................................24
4.1 TYPES OF MAINTANCE SYSTEMS.................................................................................................24
4.2 MAINTENANCE OBJECTIVES........................................................................................................24
4.4. Mechanical Maintenance Engineer ...........................................................................................25
4.5. Electrical Maintenance Engineer ...............................................................................................26
4.6. Civil Maintenance Engineer .......................................................................................................26
5. HYDRAULICS............................................................................................................................29
5.1 Hydraulic Press (BRAMAH PRESS)...............................................................................................29
5.2 ADVANTAGES OF HYDRAULIC SYSYEMS .....................................................................................30
6. PURCHASE.................................................................................................................................33
6.1. Types of Tenders........................................................................................................................33
6.2. NEGOTIATIONS......................................................................................................................33
7. LABORATORY..........................................................................................................................36
7.1. Pyro metric Cone Equivalence (PCE)..........................................................................................36
Machine is for testing of melting capacity of taken specimen. Test is based on comparison. Melting
point of component which is to be tested is compared by standard material with pre-determined
melting point.....................................................................................................................................36
7.2. Refractory under Load (RUL).................................................................................................36
7.3. Cold Crushing Strength (CCS)................................................................................................36
7.4. Types of Test Which Performed Here...................................................................................36
8. ELECTRICAL DEPARTMENT...............................................................................................38
9. STORES.......................................................................................................................................39
9.1. Store Department normally divided inti Following Various Section..........................................39
9.2. Task of Store .........................................................................................................................40
9.3. Functions of Stores ...............................................................................................................40
9.4. Store function deals with three major activities...................................................................40
9.5. Methods of Issues of Materials in SAIL Refractory Unit .......................................................40
10. SIZE OF BRICKS WHICH IS MANUFACTURED HERE ..............................................41

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1. INTRODUCTION
SAIL Refractory Unit is situated at the edge of Ranchi-Patna highway (NH-33), just beside
the Ranchi Road Railway Station of Eastern railway at RANCHI ROAD, POST-MARAR,
RAMGARH (JHARKHAND)-829117. The place is well connected by road linking, in the
South of the state capital Ranchi and Hazaribagh in the North by a distance of 45 km on the
either side.
The company previously known as “ASSAM SILLIMANITE LTD.” in the private sector. It
was commissioned on July 15, 1961 vide factory registration no. 8745/HBG having its
production in plant no.-1 commenced in the year 1962 and in plant no.-2 in the year 1965. The
main product at that time was Sillimanite based high refractory. The company had a captive
lease-hold mines located in the state of ASSAM KNOWN AS N.M. MINES SONAPAHAR,
ASSAM.
The management of the company was taken over by “HINDUSTAN STEEL LTD.” as an
“Authorized Person” on 2nd
November, 1972 under the industries (Development and
Regulation Act, 1951), which was taken over by the Government of INDIA on 2nd
November
1976 under the central legislation act.
In year 1978 for the restriction of iron and steel companies, a legislation was passed by the
parliament under public sector iron and steel companies restructuring Act 1978.M/S
HINDUSTAN STEEL LTD (Refractory Plant) was merged into BHARAT REFRACTORY
LTD., Ranchi road refractory plant, vide order number. So 1847(E) DT. 28/07/2009 issued
from this GOVT. OF INDIA, MINISTRY OF CORPERATE AFFAIRS. BRL has been merged
with SAIL as SAIL REFRACTORY UNIT, RANCHI ROAD.
Plant

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1.1. CAPACITY OF PLANT
The re-assessed capacity of plant is 12200 Tonne production for the year 2014-15 consisting
of 12000 Tonne of Magnesite Carbon Brick and 1200 Tonne of various masses.
1.2. AREA
The plant is spread over land of 72.65 acres.
1.3. MAN POWER OF PLANT
Man power position in SRU Ranchi road total no. of workers are 173, in which there are 23
executive and 150 non- executive workers including 20 SC and 15 ST worker.
1.4. FACILITIES PROVIDED BY COMPANY
A canteen, School bus facility, Hospital, School, etc.

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2. RAW MATERIALS
Two categories of raw materials used in this plant:-
2.1. INDEDEGINES
Materials come from India.
2.2. IMPORTED
Materials come from abroad like Ireland and China.
From China- Fused Magnesia (FM) and Graphite
From Ireland- Sea Water Magnesia (SWM)
From Australia- Carbon Mag
Landed cost of imported raw materials as on 07.01.2014
Name of various raw materials and chemicals which is used here are-
2.3. Raw Materials
2.3.1. Fused Magnesia
Fused magnesia is produced from natural magnesite or high purity calcined magnesite grain,
which is fused in arc furnaces. The product has high purity, crystal grain, compact structured,
strong slag resistance and good thermal shock stability. It is a kind of excellent high
temperature electrical insulation material and is also used to make high quality magnesite
bricks, magnesia carbon brick and the important raw materials for amorphous refractory.
Fused magnesia of the highest quality with a crystal size of > 1,200 µm.

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It is an extremely resistant base material for the production of converter bricks thanks to its
very low SiO2 content of 0.26% and Fe2O3 content of 0.19%.
Crystal Fused Magnesia 99.99% Fused Magnesia
High Purity Crystallized Fused Magnesia .High Purity Low SiO2 and Low Fe2O3
Fused Magnesia
Fused magnesia is superior to deadburned magnesia in strength, abrasion resistance and
chemical stability. Major applications are in refractory and electrical insulating markets.
Producers of fused magnesia commonly fall into one of two categories: those producing
refractory grades and those producing electrical grades. Few producers serve both markets on
a mainstream basis.
2.3.2. Refractory Grade Fused Magnesia
The addition of fused magnesia grains can greatly enhance the performance and durability of
basic refractories such as magcarbon bricks. This is a function of a higher bulk specific gravity
and large periclase crystal size, plus realignment of accessory silicates. Refractory grade fused
magnesia has exacting specifications and is normally characterised by the following:
 Generally high magnesia content (minimum 96 per cent MgO and up to/exceeding 99
per cent MgO)
 Low silica; lime: silica ratios of 2:1
 Densities of 3.50 g/cm3
or more
 Large periclase crystal sizes (>1000 microns)

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Due to its excellent corrosion resistance, refractory grade fused magnesia is used in high wear
areas in steel making, e.g., basic oxygen and electric arc furnaces, converters and ladles.
Ultra high purity (>99 per cent MgO) grades have been used in high-tech applications such as
optical equipment, nuclear reactors and rocket nozzles.
In fused magnesia production, the main constraints on capacity are the size and number of
electric arc furnaces, and the cost of energy. The manufacture of fused magnesia is very power
intensive with electricity consumption varying between 3500-4500 kWh/tonne; fused
magnesia producers often quote total capacity based on utilising off peak power.
2.3.4. Sea Water Magnesia
Seawater contains approximately 3.5% dissolved salts, of which about 0.5% are soluble
Magnesium Chloride (MgCl2) and Magnesium Sulphate (MgSO4) salts. Approximately 500
Tonnes of seawater are required to produce 1 Tonne of Magnesium Oxide (MgO).
Seawater is collected from the sea and stored in a large reservoir (below) from where it is
pumped to the factory, located a couple of kilometres upstream. Once in the factory, the
seawater is degassed to remove hardness before being transferred to the reactor.
Sea Water Reservoir
High Purity Limestone comes from local mines to the plant. The limestone is crushed, graded
and transported to the production plant, where it is calcined (high temperature firing) at
approximately 1600°C in a rotary kiln to convert it to quicklime (Calcium Oxide, CaO). The
chemical reaction is given by the following equation:
The resulting quicklime is then mixed with freshwater and converted to lime slurry (Calcium
Hydroxide, Ca (OH) 2) in a highly exothermic reaction known as hydration or slaking:

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Lime Slurry
Precipitation of Magnesium Hydroxide
After slaking, the lime slurry is pumped to the reactor where it reacts with the degassed
seawater. Precipitation of Magnesium Hydroxide (Mg (OH)2) occurs instantaneously and is
described by the following equation:
After the reactor, the Magnesium Hydroxide crystals are settled and thickened.
Filtration and Washing
The settled Magnesium Hydroxide slurry is pumped and filters in the multiple hearth furnace
(MHF). The slurry is filtered and washed with freshwater and the filter cake is sent to two
pressure filters, which squeeze more water from the cake to increase the solids content further
and reduce the amount of water going onto the next stage of the process – magnesia calcination.
Sintering
Green pellets are fed to the shaft kilns, where they are heated to temperatures in the region of
2300°C. The intense heat encourages the Magnesia crystals to grow and the briquettes begin
to shrink as the bulk density increases. The final product, Periclase (also known as
Sintermagnesia or Deadburned Magnesia), is a very dense, chemically inert, refractory grade
sintermagnesia.
2.3.5. Graphite
Graphite archaically referred to as Plumbago, is a crystalline form of carbon, a semimetal,
a native element mineral, and one of the allotropes of carbon, among
them diamond and graphene. Graphite is the most stable form of carbon under standard
conditions. Therefore, it is used in thermochemistry as the standard state for defining the heat
of formation of carbon compounds. Graphite may be considered the highest grade of coal, just
above anthracite and alternatively called meta-anthracite, although it is not normally used as
fuel because it is difficult to ignite.

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Rock Graphite Graphite Powder
It is used to manufacture the refractories. This end-use began before 1900 with the
graphite crucible used to hold molten metal; this is now a minor part of refractories. In the mid-
1980s, the carbon-magnesite brick became important, and a bit later the alumina-graphite
shape. Currently the order of importance is alumina-graphite shapes, carbon-magnesite brick,
monolithics (gunning and ramming mixes), and then crucibles.
Crucibles began using very large flake graphite, and carbon-magnesite brick requiring not quite
so large flake graphite; for these and others there is now much more flexibility in size of flake
required, and amorphous graphite is no longer restricted to low-end refractories. Alumina-
graphite shapes are used as continuous casting ware, such as nozzles and troughs, to convey
the molten steel from ladle to mold, and carbon magnesite bricks line steel converters and
electric arc furnaces to withstand extreme temperatures. Graphite Blocks are also used in parts
of blast furnace linings where the high thermal conductivity of the graphite is critical. High
purity monolithics are often used as a continuous furnace lining instead of the carbon-
magnesite bricks.
The US and European refractories industry had a crisis in 2000–2003, with an indifferent
market for steel and a declining refractory consumption per tonne of steel underlying firm
buyouts and many plant closures. Many of the plant closures resulted from the acquisition of
Harbison-Walker Refractories by RHI AG and some plants had their equipment auctioned off.
Since much of the lost capacity was for carbon-magnesite brick, graphite consumption within
refractories area moved towards alumina-graphite shapes and monolithics, and away from the
brick. The major source of carbon-magnesite brick is now imports from China. Almost all of
the above refractories are used to make steel and account for 75% of refractory consumption;
the rest is used by a variety of industries, such as cement.
According to the USGS, US natural graphite consumption in refractories was 12,500 tonnes in
2010

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2.3.6. Resin
Resin is used as a binder to manufacture the refractory. It provides strength to the refractory.
2.3.7. Aluminium Powder
Aluminium powder is powdered aluminium. This was originally produced by mechanical
means using a stamp mill to create flakes. Subsequently, a process of spraying molten
aluminium to create a powder of droplets was developed by E. J. Hall in the 1920s. The
resulting powder might then be processed further in a ball mill to flatten it into flakes for use
as a coating or pigment.
This is used as an antioxidant in magnesia carbon refractory.
Aluminium Pigment Powder Aluminum Powder 20 micron
2.3.8. Pitch Power
Pitch powder is one of the carbonaceous facing material used in the foundry for mixing in green
mould composition. When molten matter comes in contact with mould surface containing pitch
powder, gaseous envelop is formed which resists the fusion of sand to the metal. Being a Tar
it has got a binding effect and green strength of the mould is increased considerably. The ash
contents being low as 0.8% to 0.4%, it improves casting finish and increases dry and green
strength, it also reduces expansion.
The volatile matter being about 5’0 percent and ash less than 1.0 percent will improve the
quality of castings to a considerable extent.

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The softening point of the pitch powder should be as high as practicable and it is proposed that
it should be 120 to 130°C.
Binder Pitch Pitch Powder
2.3.9. Dead Burnt Magnesia
Dead Burnt Magnesite (DBM) is produced in a vertical shaft by sintering raw magnesite at a
controlled high temperature of 1750 degree centigrade. It is chemically inactive and extremely
heat resistant. It is mainly used in the manufacture of basic refractories. The finished product
is low in Silica and high in Iron which is suitable for hot fettling of Furnaces and ideal for
manufacturing Monolithic which helps in quick sintering because of high Iron content. These
basic refractories are used by the iron & steel industry in electric arc furnaces and different
kind of kilns for lining purpose. We provide various sizes of DBM as per consumer's
specifications at a very competitive rate.
Dead Burnt Magnesite

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Normal Magnesia Dead burnt Magnesia
SPECIFICATIONS
MgO 84-87%
SiO2 5.5% (max)
CaO 3% (max)
Fe2O3 5.5% (max)
LOI 1% (max)
SIZE
0-1mm, 0-2mm, 0-3mm, 0-6mm, 1-2mm, 1-6mm, 2-6mm, 200 mesh or as required
APPLICATIONS :
1. Refractory Industry for manufacture of Basic Refractory
Bricks
2. Manufacture of Ramming Mass composition, Fettling
material and Magnesite Mortar
3. It is used in SLAG beneficiation and in SLAG splashing
in Arc Furnaces
4. It is also used as a coating material in Steel Industry.

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3. PRODUCTION
Department involve in production of high heat resistance magnesia carbon bricks which is used
in blast furnace in steel plants. Fused magnesia which comes from China and sea water
magnesia from Ireland are the main raw material in production of these high heat resistance
bricks.
Steps involve in production of Magnesia Carbon Bricks
3.1. Selection of raw materials
For the production of the magnesia carbon bricks, the first step is to select the raw materials.
For production of magnesia carbon bricks, the selected raw materials are sea water magnesia,
fused magnesia, carbon mag, aluminium powder, resin, pitch powder. The selected raw
materials are tested in the plant laboratory and if these are found ok, then these raw materials
are used for manufacturing of bricks as per required quantity.
3.2. Grinding
The selected raw materials are taken as per required amount and put in to the ball mill for
grinding. Ball mill is used for size reduction of the raw materials. The plant has two ball mill,
which is to reduce the size of raw materials.
One of them produced the final product coarse, medium, and fine whereas another ball mill
produced only coarse and fine particles.
Ball Mill

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Ball Mill
A ball mill works on the principle of impact: size reduction is done by impact as the balls drop
from near the top of the shell.
A ball mill consists of a hollow cylindrical shell rotating about its axis. The axis of the shell
may be either horizontal or at a small angle to the horizontal. it is partially filled with balls.
The grinding media is the balls, which may be made of steel (chrome steel), stainless steel or
rubber. The inner surface of the cylindrical shell is usually lined with an abrasion-resistant
material such as manganese steel or rubber. Less wear takes place in rubber lined mills, such
as the Sepro tyre drive Grinding Mill. The length of the mill is approximately equal to its
diameter.
3.3. Mixing
There are four mixture in plant which is used to mix the sea water magnesia, fused magnesia,
carbon mag, aluminium powder, resin, pitch powder in proper ratio. The mixture named as E-
1, W-3, Hari and ICC.

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STEEL AUTHORITY OF INDIA LIMITED
SAIL Refractory unit Ranchi Road
PLANT No. – 01
MIXTURE
Sl. No. Name of Motor KW R.P.M. Full L.A. Over L. Contactor
Size
01. Mixture Motor
Make-AGE
24 720 43 25 to 100 3 TF 47
02. Gate Motor
Make-SIEMENS
1.5 1440 3.45 2.8 to 4 3 TF 34
03. VOIST Motor 3.7 1440 8 5 to 8 3 TF 34
04. Gudgudiya Motor-01 18.5 980 30.5 12.5 to 15 3 TF 44
05. Gudgudiya Motor-02 18.5 980 30.5 12.5 to 15 3 TF 44
Mixture Machine

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Plant also have a tube mill which is used to produce the pre-mix of aluminium powder.
A tube mill consists of a horizontal rotating cylinder, up to three diameters in length, containing
a charge of tumbling or cascading steel balls, pebbles, or rods. Both types of mill include liners
that protect the cylindrical structure of the mill from wear. Thus the main wear parts in these
mills are the balls themselves, and the liners. The balls are simply "consumed" by the wear
process and must be re-stocked, whereas the liners must be periodically replaced. The ball and
tube mills are low-speed machines that grind the coal with steel balls in a rotating horizontal
cylinder. Due to its shape, it is called a tube mill and due to use of grinding balls for crushing,
it is called a ball mill, or both terms as a ball tube mill.
The grinding in the ball and tube mill is produced by the rotating quantity of steel balls by their
fall and lift due to tube rotation. The ball charge may occupy one third to half of the total
internal volume of the shell. The significant feature incorporated in the BBD mills is its double
end operation, each end catering to one elevation of a boiler. The system facilitated entry of
raw coal and exit of pulverized fuel from same end simultaneously. This helps in reducing the
number of installations per unit.
Tube Mill
3.4. Ageing
Aging of mixed powder is done on the basis of moisture content in the materials. To ageing the
mixture powder filled into the rectangular bucket and it is placed in open atmosphere within a
shaded building. Mixture take time 1-10 days for ageing.

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Ageing
3.5. Pressing
After mixing the raw materials, mixture goes for pressing. Plant have EP-800 tonne and
SACMI-2500 tonne capacity hydraulic machines. SACMI press having a capacity of 15
ton/shift is imported from Italy at accost of Rs 7.53 crore. Plant have one EP-800 tonne press
with a capacity of 8 ton/shift. SACMI-2500 tonne press is fully automated.
EP-800 Tonne Pressing Machine

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EP-800
Size
01. Main Pump Motor-01 45 1000 78 45 to 63 3 TF 48
04. Control Pump Motor 5.5 1500 11 9 to 12.5 3 TF 32
05. Filter Pump Motor 7.5 2900 14 11 to 16 3 TF 34
06. Grease Pump Motor 0.18 1420 0.36 0.45 to 0.63 3 TF 34
07. Feed Belt Motor 0.75 1440 1.5 0.45 to 0.63 3 TF 34
08. Take off Belt Motor 0.55 1440 1.10 0.45 to 0.63 3 TF 34
3.6. Curing
After completion of pressing process, bricks goes in chamber kiln for curing. Curing in
chamber kiln is done at 200o
C in order to harden the bricks. Plants have five chamber kiln in
which three are running. The time period for curing is 40-48 hours.
3.7. Checking & Packing
After curing the final product is verified by inspection body and if it is found ok, then it is
packed. If any problem found in the final product then the effected item is removed.

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3.8. Transportation
Packed bricks are transported to the truck via fork lift, plant have 5 fork lift.
Fork Lift

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4. MAINTANENCE
Function of maintenance department of SAIL are entrusted with the maintenance of plants to
care of a regular, through supervision of the conditions and functions of all operational
equipments in the right time so that the effect of deterioration can be spotted early enough
before major costly breakdowns and damage to the equipments.
The justification for a maintenance organization group lies in its use to ensure availability of
equipment and services for performance of their functions at optimum return on investments
whether this investment be in MACHINARY, MATERIAL, PEOPLE and MONEY.
4.1 TYPES OF MAINTANCE SYSTEMS
Any organization which is machinery, plant, equipments and facilities must have a clear-cut
maintenance policy. In SAIL broadly the following methods are used for carrying out
maintenance activities.
a) Breakdown Maintenance
This is event based and carried out when breakdown of equipment takes place bringing down
production. This is firefighting and should be avoided at all cost.
b) Preventive Maintenance
It consists of planned and co-ordination inspection, adjustment, repair and replacements in
maintaining equipments. Preventive maintenance of a machine can be carried out both during
operation as well as shut down.
c) Planned Maintenance
It has to be centred on the original recommendation made and prescribed by the original
equipment manufacturer. The maintenance manager has to use all his experience and expertise
to super impose refinements and improvements on manufacturer recommendation.
d) Predictive Maintenance
Most predictive maintenance are performed while the equipment is in services, thereby
minimizing disruption of normal system operations. Adoption of predictive maintenance
(PDM) in the maintenance of equipments can result in substantial cost and higher system
reliability.
4.2 MAINTENANCE OBJECTIVES
a) Ensure maximum equipment availability for meeting annual production planning
targets.
b) Maintain plant equipments and facilities at economic level of repairs at all times to
conserve these and increase their span.
c) Provide desired services to operating departments at optimum level.
d) Ensure reliability and safety of equipments for uninterrupted production.
e) Ensure operational readiness of all stand by equipments.

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4.3. Entire Maintenance department can be categorized as:-
4.4. Mechanical Maintenance Engineer
Works Manager
Chief
Maintenance
Engineer
Mechanical
Maintenance
Engineer
Electrical
Maintenance
Engineer
Civil
Maintenance
Engineer
Mechanical
Maintenance Engineer
Supted. Plant
Maintenance
Maintenance of cranes,
hoist, lifts, etc.
Maintenance of plant
New installation
Supted. Repair Shop
Machine Shop
Fitting Shop
Welding Shop
Automobile Shop
Supted. Power House
Maintenance Repair
Checking of mechanical
equipments in power
house

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4.5. Electrical Maintenance Engineer
4.6. Civil Maintenance Engineer
Electrical Maintenance
Engineer
Phone Supervisor
Repair,
Maintenance and
Installation of internal
phone system
Supted. Power Hose
(Electrical)
Repair and
Maintenance of
electrical equipments of
power house.
Supted. Electrical
Maintenance
Maintenance of
distribution line. Repair
shop Maintenance of
electrical lining for
lighting and machinery.
Civil Maintenance
Engineer
Supted. Building
Maintenance
Supted. Road
Maintenance
Supted. Sanitation and
Water supply
Maintenance

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The plant has a well-organized work shop where machines are repaired by maintenance
workers. Work shop have these machines:-
1) Lathe Machine-1
2) Shaper-2

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3) Grinder Machine-2
4) Welding Shop
5) Drilling Machine-2
6) Auto Garage

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5. HYDRAULICS
The science which deals with flow of fluids (under pressure) is called Hydraulics. Principal of
operation of pneumatics and hydraulics are almost same. Pneumatics can do same job with less
efficiency, less accuracy, less reliability due to compressibility, water condensation, and noise
and dust pollution. Load capacities are also due to low pressure involved. Hence hydraulics is
slowly replacing pneumatics. Due to these reasons hydraulics are widely used in most of
organization including SAIL.
Ball Mill and SACMI are few examples of hydraulics which is used in SAIL.
5.1 Hydraulic Press (BRAMAH PRESS)
Since pressure in the confined fluid is uniform throughout and by applying this pressure on
large area large forces can be developed. This is the starting point for development of
hydraulics.
SACMI PRESS
Power-2500 T
Sl. No. Name of Motor KW R.P.M. Full
L.A.
Over L. Contactor
Size
01. Main Pump Motor 55 1470 100 100 to 160 3 TF 45
04. Control Pump Motor 15 1440 28 28 to 40 3 TF 34
05. Filter Pump Motor 7.5 1450 14 10 to 16 3 TF 34
06. Lubrication Motor 0.18 1350 0.36 0.6 to 1 3 TF 30
07. Power Pule Cooling Motor 0.25 1440 0.50 0.6 to 1 3 TF 30
08. Conveyor Belt Motor 5.5 1440 11.05 9 to 12.5 3 TF 30

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SACMI-2500 Tonne Pressing Machine
5.2 ADVANTAGES OF HYDRAULIC SYSYEMS
1) Precise control-depending on different requirements one can get exact speed, force and
position of user.
2) Over load protection-in case there is over load in pipe line or user, there is provision of
relief value set at a certain maximum pressure to take cares of it.
3) Suspension of load for long period.
4) Easy maintenance only oil contamination control will fulfil major portion of
maintenance work.
5) Variable speed controls.
6) Flexibility in design as per need of production, scheme of hydraulic circuit may be
changed easily only with addition of a few components.
7) Stalling of loads, the loads can be stalled to zero speed without any damage to the
equipments.

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Hydraulic Pressure Pump
AIR COMPRESSOR 1 & 2
Air Compressor- 1
Size
01. Compressor Motor-01 90 1460 158 0.63 t0 0.9 3 TF 63
02. Compressor Motor-02 90 1460 160 0.63 t0 0.9 3 TF 63
03. Pump Motor-01 2.2 2850 4.7 3 to 5 3 TF 30
04. Pump Motor-02 2.2 2850 4.7 3 to 5 3 TF 30

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Air Compressor- 2
Size
01. Compressor Motor-01 30 730 58 50 to 200 3 TF 47
02. Compressor Motor-01 30 730 62 25 to 100 3 TF 47
03. Water Pump-01 2.2 2800 4.7 3 to 5 3 TF 30
04. Water Pump-02 2.2 2800 4.7 3 to 5 3 TF 30

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6. PURCHASE
As the name indicate purchase department deals with purchase of required equipments or
materials for organization. For this department issue a tender. Tender means an invitation to
offer for item/items or work. All public sector purchase/contracts in India, over a certain value
has to be publicly notified through Tender Notices which are advertised through All India
Newspapers, Trade Journals, Departmental Publications and Notice Boards, and now on
Internet.
6.1. Types of Tenders
1. Limited Tendering
This involves issuing tender to few selected tenders only. It is for specific brand or company.
2. Open Tendering
This means that the tender is open to any suppliers who can quote for the materials as per
requirements. This is usually done by publishing the tender notice in Newspapers/Trade
Journals/Internet and other bulletins.
3. Global Tendering
This involves issuing tender to global tenderers (outside the country).
4. Single Tendering
It means sending the tender to one particular party. These are also sent for items of proprietary
nature.
Example- Samsung Phones, Crympton Motors, etc.
After collection of bid document and submission of offers representative of tenderers are
allowed to attend Tender opening. The comparative statement (C.S.) of all rated offers and
other terms like freight forwarding, quality assurance, taxes, identifying the lowest cost (L1,
L2,L3) offers are listed.
6.2. NEGOTIATIONS
If for some reasons, the party is not able to comply with the terms of the order, an amendment
to the order needs to be issued. The order may not necessarily be placed on L1 since, various
other criteria like past performance of the party, urgency of requirement etc. are also considered
before decision taken.
In some cases orders are divided between two or three parties. At times L2 is asked to
work/supply at L1 rates. In these situations, negotiation plays an important role especially in
case where multiple technology, high value items/work are involved.
These are the format of forms which is used by purchase department to purchase
goods/materials/instruments/machines etc.

34
Indent Form 1
Recommendation of Screening Committee :
TO BE FILLED BY PURCHASE SECTION
Indent Received on Indent Received By Indent Registration No.
D D M M Y Y
Signature
Name
Indent Form 2
Suggested Name of Suppliers with Address :
Suggest Mode of Tendering Suggested Number of Vendors on Whom to Place Order
Consumption Pattern for Last 3 Years (Quantity & Value)
Stock-in-Hand Pending Purchase Order Nos Consumption Norm
Signature of Indenter : Signature of Section Head : Signature of Finance (Budget Section)
:
FINANCE ONLY
A/C HEAD : Capital/Revenue (Pl TICK) Budget Clearance

35
Indent Form 3
SAIL,SRU,HO/UNIT:RANCHI ROAD MATERIAL INDENT FORM INDENTOR
Indent No. D D M M Y Y Proprietary Item YES/NO
Proprietary Certificate
Attached
YES/NO
SL. No. Material
Code
Material Description with Full
Specification
Unit Quantity Estimated
Unit Rate
Estimated
Total Price
Delivery
Schedule
1.
2.
3.
4.
Special Instructions/Clauses (if any like inspection Guidelines, Complementary/Matching Items etc.)
Justification of Purchase/Basis of Estimates : Last Purchase Price/Budgetary Offer references etc.

36
7. LABORATORY
Unit has a well-equipped lab in which metal’s characteristics, nature and its suitability for work
is done.
7.1. Pyro metric Cone Equivalence (PCE)
Machine is for testing of melting capacity of taken specimen. Test is based on comparison.
Melting point of component which is to be tested is compared by standard material with pre-
determined melting point.
7.2. Refractory under Load (RUL)
In this test load bearing capacity of material is tested and result is taken by the help of
parameter.
7.3. Cold Crushing Strength (CCS)
SAIL Refractory Unit have 2 cold crushing strength machine. One is of 40 tonnes and another
is of 300 tonnes.
Apart from these, unit also have a well-equipped chemical laboratory for testing of chemical
characteristics of materials.
The brick size for CCS test is 100*100*100 mm3
.
7.4. Types of Test Which Performed Here
1. Resin Test
There are four types of test which is performed on resin:-
I. Specific Gravity
1. Take 70-80ml resin.
2. Put it into hydrometer.
3. The temperature should be 25o
C.
4. The recommended range of specific gravity is 1.17-1.21.
II. Non Volatile Matter
1. Take 2gm resin.
2. Put it into dredger for 1 hour.
3. The temperature should be 135o
C.
4. Now cooled resin and weight
5. The recommended range of solid content in resin is 70-75 wt. %.
III. Viscosity
1. Take 250-300ml resin.
2. Put it into viscometer.

37
3. Temperature should be 25o
C.
IV. Water Miscibility
1. Take 20ml resin.
2. Add water dropwise till the colour of resin is change.
2. Aluminium Power Test
To know the composition of aluminium powder, this test is performed. The recommended
composition of aluminium powder given below:-
Composition Wt. Percentage (%)
Alumina 99.5
Fe 0.4
Si 0.1
3. Graphite Test
Graphite test is performed to know the % of following parameters present in graphite.
 Moisture
 Volatile Matter
 Fixed Carbon
The gain size of aluminium powder should be in the range (-0.044, min 40%)-(+0.074, max
10%
MgO, Silica and iron are main materials for chemical test. Department plays a very important
role in the company production. Different kind of raw materials comes here are tested first in
its laboratory in the presence of member of concerned department.

38
8. ELECTRICAL DEPARTMENT
Plant has a well maintained electrical department which provide the current to the plant and
different motors which runs to manufacture the bricks. It has a 33KV sub station and two power
transformer of capacity 15 MVA.
Electrical department also has two generator DG-1 and DG-2 which is works when there is no
electricity.
The work of electrical department is to provide electricity to the plant continuously without
any interruption.

39
9. STORES
The term stores refer to the physical place be it a building or a room where materials of all
variety are kept. The function of stores is to receive, store and issue materials.
9.1. Store Department normally divided inti Following Various Section
1) Receiving Section.
2) Tool Stores.
3) General Stores.
4) Raw Materials Stores.
5) Finished part Stores.
Store function as an element of materials department, has an interface with many users
departments in its daily operations. The basic purpose served by stores is the provision of
uninterrupted services to manufacturing divisions. Store acts as a cushion between purchase
and manufacturing on one hand and manufacturing and marketing on the other
Storage of Raw Materials

40
9.2. Task of Store
Safe custody and stocking of materials, their receipts, issues and accounting with the objective
of efficiently and economically providing the right material at the right time whenever required
in the right condition to all user departments.
9.3. Functions of Stores
1) To receive raw materials, components tools, spares, supplies, equipments and other
items and account for them.
2) To provide adequate, proper and efficient storage and preservation for all the items.
3) Physical checking of all incoming materials as per the delivery CHALLAN and
proper maintenance of daily goods receipt register or records.
4) Arrange for inspection of incoming materials.
5) Issue the materials to the consuming department against authorized requisitions and
account for the same.
6) Maintain accurate and up-to-date records of materials received, issued, rejected,
disposed and quality on hand of all the items.
7) To ensure good housekeeping so as to minimize the need for material handling.
8) To accept a store scrap and other discarded materials.
9.4. Store function deals with three major activities
1. Receipt
This deals with the function of receiving an physical handling delivered materials, and
verifying that the deliveries correspond exactly as to the nature and quantity as per specified in
purchase order. Inspection of incoming materials ranges from simple counting to elaborate
laboratory testing and statistical tests. This section is also called as GOOD INWARD
SECTION.
2. Stocking
3. Issue
Normal supply of materials from stores to various user department.
9.5. Methods of Issues of Materials in SAIL Refractory Unit
a) First-in-First-Out (FIFO Method)
b) Last-in-First-Out (LIFO Method)
c) Average cost method
d) Replacement price method
e) Actual price method

41
10. SIZE OF BRICKS WHICH IS MANUFACTURED HERE
Almost 50 different types of bricks are manufactured. The table given below shows the
parameters of bricks.
Different Bricks Size with E/A in mm
Sl. No. Items Name Size of Bricks in mm E/A in each Plate
1. 150*100*160/140 10+10
2. 150*100*154/146 4+4
3. 150*100*160/120 20+20
4. 178*100*165/135 15+15
5. 178*100*154/146 4+4
6. MC-1 350*125*150 Std.
7. MC-2 350*125*150/125 12.5+12.5
8. 1A 230*125*75 Std.
9. 3A 230*125*75/65 5+5
10. BLOCK 250*100*150 Std.
11. 11A 460*125*75 Std.
12. 12A 460*125*75/60 5+5
13. 13C 460*125*75/55 10+10
14. MC-3 550*125*150 Std.
15. MC-4 550*125*150/120 15+15
16. MC-9 600*125*100/92 4+4
17. MC-10 600*125*100/78 11+11
18. MC-11 600*125*100/60 20+20
19. MC-11A 600*125*105/80 12.5+12.5
20. MC-9A 600*125*60 Std.
21. MC-5 700*125*110/95 7.5+7.5
22. MC-6 700*125*110/75 17.5+17.5
23. MC-12 700*125*110/60 25+25
24. TUYER BRICK 700*125*125 Std.
25. MC-7 800*125*110/100 5+5
26. MC-8 800*125*110/80 15+15
27. MC-13C SPLIT 800*125*110/60 25+25
28. MC-14 900*125*104/96 4+4
29. MC-15 900*100*120/112 4+4
30. MC-16 900*100*150/110 20+20
31. 900*100*130/100 15+15
32. 900*100*120/104 8+8
33. 900*100*130/83 23.5+13.5
34. 900*100*125 Std.
35. 200*100*165/135 15+15
36. 200*100*154/146 4+4
37. 200*100*165/130 17.5+17.5
38. 200*100*160/140 10+10
39. A1 450*100*150/125 12.5+12.5
40. A2 450*100*150/130 10+10
41. B1 500*150*100/108 21+21

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42. B2 500*150*100/124 13+13
43. C1 600*100*100/67 16.5+16.5
44. C2 600*100*100/85 7.5+7.5
45. D1 700*100*110/76 17+17
46. D2 700*100*110/92 9+9
47. E1 800*100*120/80 20+20
48. E2 800*100*120/100 10+10
49. 250*100*150 Std.
50. 250*100*150/128 11+11
In last, I would like to thank all the HOD’s and workers of SAIL Refractory Unit, Ramgarh,
Ranchi Road for giving me valuable suggestion and information which helps me to understand
the working and management of entire plant.

SAIL Summer Internship Report- Braj Kishor Sah

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