A study report on mel

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A study report on

MAHARASHTRA ELEKTROSMELT LIMITED

(A SUBSIDIARY OF STEEL AUTHORITY OF INDIA LIMITED.)

By: Anita G. Tirkey

Management trainee (Tech.)

Department: PH Yard Empnumber:1338



COMPANY PROFILE

Chandrapur Ferro Alloy Plant is Ferro Alloy unit of SAIL. Earlier it was

known as Maharashtra Elektrosmelt Limited (MEL), a subsidiary of Steel Authority

of India Ltd. It is one of the largest producers of bulk ferro alloys in India.

The plant is situated in Chandrapur, Maharashtra State. Chandrapur is well

connected to all major cities in India by road and rail. The plant has a total

capacity of about 100,000 tons per annum of High Carbon Ferro Manganese and

Silico Manganese.

MEL has rich experience of more than three decades in the field of ferro

alloys and is considered to be a leader. Its high quality ferro alloys have earned a

name for themselves in the market. Its operational practices have become a

benchmark in the industry.

By supporting various ancillary industries, MEL is quickening the pace of

industrialisation of the region having abundant natural resources.

MEL, having become a leader in the field of Manganese based ferro alloys,

has made lot of technological developments in this field some of which are even

first in the country.

MEL was promoted by SICOM and DCLV and was set up in an area of 550

acres at Chandrapur during 1974.The setting of MEL was the first major

industrial venture of SICOM and Maharashtra Govt.The plant is located about 5

Km from Chandrapur railway station, connected by rail and road to major cities of

India.

MEL has been taken over by SAIL in June 1986.Today MEL isperforming very well in all spheres of its activities and is one of the largest

producer of manganese based Ferroalloys in the country.



MAJOR EVENTS IN THE HISTORY OF MEL

MEL promoted by SICOM Apr-74

Commissioning of SAF-1 Feb-77

Commercial production of HC FeMn Feb-77

Commissioning of cupolas of melting pig-iron Dec-79

Commercial production of steel Feb-80

Use of Mn Ore sinter in SAF Apr-81Commissioning of SAF-2 Aug-81

Production of pig-iron in Saf Nov-81

SAIL takeover of MEL Jun-81

Conversion of SAF from prod. Of pig-iron to

prod. Of HC FeMn Feb-86

Starting production of SiMn Dec-87

Commissioning of CLV converter Feb-88

Starting production of medium FeMn Nov-90

Commissioning of 1 MVA direct Arc furnace for

prod. Of MC FeMn Nov-90

Medium carbon FeMn prod. Started Apr-90

Inauguration of High pressure sintering unit Jul-91

Lime conversion started Jun-94



PRODUCT PROFILE

The major products of MEL are:

1. High carbon FeMn

2. SiMn

3. Medium carbon FeMn

High Carbon Ferro Manganese (64,000 tons per annum)

Size: 25-100 mm, 12-25 mm, 3-12 mm, 0-3 mm

Chemical Specification:

Manganese : 70 – 74 %

Carbon : 6 – 8 %

Silica : 1.5 % max

Phosphorous : 0.43 % max

Silico Manganese (46,000 tonnes per annum)

Size: 12-50 mm, 3-12 mm, 0-3 mm



Carbon : 2 % max

Silica : 15 – 20 %




Medium Carbon Ferro Manganese (2,500 tonnes per annum)

Size: 10-50 mm



Carbon : 1 – 3 %

Silica : 2 % max


The bi-products of MEL are:

1. Ferro alloys khad

2. High MnO slag

3. Low MnO slag

4. Gas cleaning plant sludge

Chemical specifications:

Name of product Mn %

Ferro alloys khad 25-45%

Gas cleaning plant sludge 26-30%

High MnO slag 30-40%

Low MnO slag 25-30%



PLANT FACILITIES

Two 33 MVA Sub-Merged Arc furnaces equipped with gas cleaning plants for

the production of HC FeMn and SiMn.

One 1 MVA Electric Arc Furnace for production of MC FeMn.

Raw material handling , screening and conveying facilities.

Two manganese ore fines Sinter Plants – one conventional and the other

being high pressure sintering unit.

Supporting facilities like workshop, utility, laboratory, transport etc.

BG railway siding to handle incoming raw materials and outgoing finished

products

Furnace gas based 4.2 MW Power Plant.

Two Lime Kilns (7 tpd and 4 tpd).

Product handling yard with railway siding for handling processing and

dispatches of finished product.

PH Crusher system for breaking of Ferro Alloy.





PERSONNEL AND ADMINISRATION DEPARTMENT



Personnel and administration department

INTRODUCTION:

Personnel and administration department may be defined as the planning,

organizing, directing & controlling of resources & maintenance of employees for the

purpose of attaining organizational goals.

The personnel and administration department is concerned with all of the

human relationship among workers. It tends to attain maximum individual employee

development, desirable working relationship between employees & employer and

effective molding of human resources.

OBJECTIVES AND FUNCTION OF PERSONNEL AND ADMINISTRATION

DEPARTMENT

Procurement and management of adequate workforce.

Education and training of present employees.

Maintaining satisfactory personnel contracts and employee relationship.

Maintaining employee’s health.

Maintaining employee’s safety.

Maintaining employees service activities (employee’s welfare).

Maintain an employee favorable attitude towards his work and work

environment.

In order to achieve the aforesaid objectives the personnel and administration

in MEL is divided in different sections as

Time office

Security

Fire-fighting

Welfare



Human resource development

Establishment

TIME OFFICE:-

MEL’s time office is provided with various kinds of functions i. e. keeping up-to-

date records of attendance, leaves, overtime, provident funds, night shifts, late

coming , salary and wages etc.

It maintains the following information:

Attendance of employees

Leave records of employees

Over time record

Provident fund record

Night shift allowance record

Late coming employees record

Salary and wages register

Under enquiry suspended signature book

Tokens

SECURITY DEPARTMENT:-

Security department is meant for security of man, material and property of the

plant. It is the backbone of the management. Besides the security main functions

of security department is to maintain discipline inside the plant premises.

Working/operation:

Security department watches and keeps track of man and material

movement with the help of some registers & passes as follows:

Material inward note

Raw material register

Store material register

Dispatch register

Exit register for executives



Returnable good register

General vehicle register

Visitor entry pass

FIRE FIGHTING DEPARTMENT:-

Fire is an enthusiastic destroyer of life and property. The fore triangle

heat, fuel, & oxygen are the clue as to how fire starts & how it can be

extinguished. When a flammable material & sufficient heat come together in the

presence of oxygen, we have a dangerous situation. But the removal of one limb of

the triangle will either prevent the fire or extinguish it completely.

Fire prevention is being a matter of awareness of the factors which cause

fire to start then taking steps to prevent before possibly becoming reality. Itneeds

Regular program of education for supervisors of workforce

A plan for proper & regular maintenance of plant & equipment

Proper location of fire fighting equipments which also needs to be kept

properly maintained and provided with unobstructed access

Routine inspection of the site

HUMAN RESOURCE DEVELOPMENT AND GENERAL ADMINISRATION:-

The various functions & activities performed by this department are as

follows:

Human resource development & training:-

Training classes are conducted once in every month keeping in mind the aim

of modernizing the minds of employees, skill development, making them familiar

with technology up gradation & change in concepts of management with the

changing technology inculcating in them leadership qualities, motivating them for

higher productivity, conducting refreshing courses on safety and fire fighting,

computer training & appraised of environmental & pollution control programs. The

various types of training include:



PURCAHSE DEPARTMENT



PURCAHSE DEPARTMENT

Introduction:-

Purchasing is nothing but procurement of materials, supplies, machinery and

services needed for production and maintenance of the company. The purchase

department occupies a vital and unique position in the organization because

purchasing is one of the main functions in the organizations.

Objectives of purchase department:-

To procure right material of standard quality in right quantities.

To procure from right and reliable source of vendor.

To procure material economically.

To receive & deliver material at right place & at right time.

Following are the functions & activities of purchase department:-

Maintain records of reliable source of supply & prices of material required.

Keep records that indicate materials and substitutes available.

Making contacts with right sources of supply.

Procure and analyze quotation & plan & follow up the procedure.

To keep records of all purchases & to make sure through inspector thatright kind of material has been purchased.

To keep the uninterrupted supply of materials so that production continues

with least capital tied in inventories.



Purchase procedure:-

For the stock items registered with the stores, the store department raises

the purchase indent. The indent after having been approved from senior

manager stores and finance department is sent to the purchase department.

For non-stock items the user department raises the indent, the indent after

having routed through manager DMP cell AGM (MS & FAD), DGM (works),

AGM (F&A), & stores it is sent to the purchase department.

The purchase department after receiving the indents scrutinizes them

to make sure whether they are complete in all respects with the required

enclosures and certificates. If the indent found incomplete, then it is

returned to the concerned department for review. The indents complete in

all respects are entered in to the indent register & case file. Then the

enquiry proposal is initiated for the approval of the issue of enquiry & put to

the competent authority. Enquiries generally issued within 10days from the

date of receipt of indents complete in all respects, after having approved

the enquiry proposal from the competent authority.

Tendering:-

A tender or quotation is nothing but a document. The aim of which is

to find the price for procuring certain material. Tendering is done keeping in

view the indenters recommendations, nature of item, value involved, and

prevailing market conditions.

Modes of tendering:-

1. Advertized or open tendering

2. Limited tender enquiry

3. Single tender enquiry



Repeat tenders:-

These are called without calling any new tenders against an existing

original order or within one year from the date of original order or within 6

months from the date of completion of last supplies against the original

order whichever is earlier.

Rate contracts:-

For the proprietary items or items which are procured repetitively &

regularly, it is advantageous to go for rate contracts. For entering in to ratecontracts the mode of tendering followed may be of open tendering or

limited tendering or single tendering.

Emergency purchase:-

Emergency or cash purchase can be made in case of non-availability of

any item & if there is an urgent requirement for the same. No financial

concurrence is required if the purchase value doesn’t exceed Rs. 1000/-. The

emergency is required to be certified by the competent authority of thedepartment not below the rank of DGM.

Invitation of tenders:-

Tender invitation is issued in prescribed Performa. The invitation to tender

is covered by general terms & condition of contract. The following method

for calling of tenders is adopted.

1. Single part tendering

2. Receipt and opening of offer

3. Evaluation of tender

4. Tender notification & tender committee

5. Issue of purchase order



6. Receipt of material

7. Raw material purchase procedure



RAW MATERIAL YARD



RAW MATERIAL YARD

Being the largest producer of FeMn, MEL requires various raw materials in large

quantities to meet its production demand. These materials are brought from

various places and suppliers. Raw materials yard deals with receipt pf materials

such as Mn ore, coke, dolomite, lime-stone coming from various mines throughout

India.

A very large open space comes under RM yard. The area occupied by RM yard is

about 45000 square meters.

The work responsibility of RM yard starts with receipt of raw material at sidings,

its blending, and stacking at proper locations, charging at ground hopper and

finishes with controlling. Feeding of raw material and feeding system till bunkers.

OFFICE FUNCTIONS OF RM YARD

1. Maintenance of records of raw material’s daily position

2. Making work order (labour engagement through contract)

3. Preparing statement of materials rejected from screen house and sending the

same to accounts department

4. keeping records of correspondence with other internal dept. such as mechanical

maintenance, electrical dept. etc.

5. Contractors bill making

6. Keeping correspondent with railways.

7. Collection of orders of raw materials



OFFICE PROCEDURES:

Whenever raw material comes by road transport or railways its quantity , quality,

supplier name, transporter name or number (in case of road transport0, date of

receipt, chalan number and in case of rail transport type of wagon , again number,

engine number are recorded in registers meant for this work. There is also a

mention of time by which unloading states and finishes. These details are recorded

inward nodes, weightiest slips, involves and other document.

After having received the raw material it is unloaded and stacked at proper

;location. Maintenance of log book is one of the important functional of the RM

yard. Logbook contains information about bunker

position and charging report which is prepared on shift basis. It records bunker

position at the starting of shift , material charged and bunker position at the end

of the shift, workforce allocated and its requirement for next shift, chargingprogram or material required for next shift.

Official work also includes the maintenance of vehicle report book. Details of the

vehicles engaged in each shift are noted in this register which includes date and

shift , driver’s name , vehicle number, reporting time, place of work , total working

hours, breakdown time, idle period(with reason) , number of trips etc.



PROCEDURES AND OPERATIONS IN RM HANDLING

1. STACKING OF MATERIAL

Stacking of raw material at yard is very important from raw material handling

viewpoint as it avoids mixing and minimizes handling expanses and provides ease in

handling. Depending upon the grade and the constituent the ore are stand in a

fixed place at yard called dumps. Capacity of each stack is around is 1000-5000

tonnes.

The composition of each blended stack is fixed by production dept. and informed

to RM dept. before the stacking starts. The stacking is done with the help of pay

loaders and dumpers and dozers.

2. FEEDING SYSTEMS

The pay loaders put the raw materials to be charged to the feeding system in the

dumper. The dumper then unloads the same on net mesh fixed at the top of groundhopper. The ground hopper has different accommodate capacity for different

materials.

With the help of operating systems raw material is conveyed to crusher house,

first via belt no. 1, where cone crusher is provided with a bypass arrangement so

that the raw material which is not to be crushed can be directly conveyed to belt

no 2.Belt no. 2 feeds the raw material to screening house. Where two single

vibrating screens are provided for screening material. the dust separated after

screening and gets corrected at the bottom is transported in dust yard with the

help of trolleys or dumpers. The raw material then goes to bunker house through

junction tower and from bunker house, this is carried to furnace bins via belt

conveyor.



3. SCREENING AND SALVAGING

Before sending the raw material to bunker house it is screened at screen house.

Belt no. 2 feeds the raw material to screen house where two single vibratingscreens of size 6mm x 6mm are provided. During operation screens vibrates

mechanically and the screened raw material is fed to belt no. 3 & 4 as the case may

be. The under size particles gets collected in chute. chutes are periodically cleared

off .the screened material (Mn ore) dust is sent to the sintering plant for making

sinters where as dust of dolomites and lime stones is disposed off by dumping in

low laying area or dust yard with the help of trolleys or dumpers.

4. BUNKER HOUSE

Raw material is conveyed to bunker house through junction tower via belt no. 5.belt

no 5 has a moving trolley arrangement called moving trippler,which feeds the raw

material to desired bunkers. From these bunkers necessary amount of raw material

s can be drawn to furnace.



P RODUCTION PLANNING AND CONTROL DEPARTMENT



Production planning and control department

Production: it is the transformation of raw material into finished products.

Planning: it is the looking ahead anticipating possible difficulties and problems

that may arise during production and deciding in advance after trading into

consideration the difficulties that how the production in a best way be carried out.

Control: this phase makes sure that the planned production is constantly

maintained.

The PPC department in MEL has a very vital and unique position in the company

organisation, as the PPC function is the most important function in achieving thegoals of the company.

It keeps the management of the ongoing plant activities which in turn helps the

management in having firm control over the management functions.

Functions and activities:

The various functions of ppc department:

1. Forecasting: it is the estimation and determining the type of work, volume orquantity of work, nature and quality of work to be carried out in future.

2. Material control: it involves determining the requirement and control of

materials for production

3. Process planning: it is finding out the most economical way of carrying out the

work.

4. Assigning the work to the manpower.

5. Progress reporting: in progress reporting the information or data regarduibg

the work progress, is collected by the department and it is interpreted by

comparison with the preset level of performance.



6. Corrective actions and replan: action is taken if the progess indicates the

deviations from the set target and if the corrective actions taken fail to bring out

the desired results, replanning is essentially done.

Activities:

1. It provides the daily production reported to ED DGM works AGM (personnel)

AGM (finance and accounts), C.S. & AGM (Law), AGM (Marketing and Management),

AGM (MS & FAD) Nagpur office and corporate office.

2. It gives periodic information regarding plan status, plan activities, breakdowns,

and shutdowns, major works and problems related to industrial relation to ED and

DGM (Works)

3. It provides the statistical information regarding raw material and maintenance

areas.

4. It prepares fortnightly monthly reports for corporate office.

5. Preparation of annual production plan.

6. Preparation of emergency plans, contingency plan and disaster plans.

It coordinates between production department and services department for

maintenance of system during breakdowns and shutdowns.

It provides budget information

It coordinates between production/service department and commercial/finance

department to ensure timely delivery of goods.

It provides information regarding accidents if occurred.

It also prepares material flowchart of HC FeMn, MC FeMn and SiMn.

It prepares equipment performance plans environment management plan and annual

training plans.

It prepares by-products sales budget and keeps information regarding production

dispatcher, stock at plant and raw material requirement for production.



Responsibilities of PPC department:

The PPC dept. for its smooth running and proper functioning has to depend on

information provided by the other departments

Other dept. must cooperate with PPC to carry out its daily functions. The

responsibilities of other departments: Towards PPC are as follows……

A. FAD/EAF/Sinter Plants

Providing

1. The morning reports of products daily before 8 a.m.

2 raw material consumption

3. Final production report daily

4. Performance highlights and breakdown/shutdown analysis

5. Information regarding activities in shifts and at the end of the shifts.

6. Information for the budget preparation and annual production plan

7. Information for the management information system as and when required by

outside agencies

8. Reporting breakdowns/shutdown time to time.

B. Laboratory:

Providing analysis reports of finished products and raw materials daily.

C. Maintenance

Providing information regarding shutdown/breakdown planning and its progress,

jobs to be carried out, resource availability etc.



D. Yard

1. Reports regarding raw material receipt, dispatcher, stock position of finished

product of raw material on daily basis.

2. Information regarding activities in yards about loading/unloading makes

availability etc.

E. Transport:

Information on availability of vehicle for production activities

F. General Stores

1. Information regarding orders booked for raw materials source wise and status

of raw materials receipt and movement

2. Information on budget preparation

G: Safety:

Providing accidental statistics periodically and highlights of safety activities

H: Finance:

1. Stock positions of raw materials month-wise

2. Information regarding financial for management information system on routine

basis vis. Capitability/profitability

3. Information for bidet preparation

I: Marketing:

Information regarding in hand dispatch schedule for main products and by-

products

J: Personnel and Administration department:

Report on training and HRD, manpower supply of stationeries, dispatches of

reports through courier



S INTERING P LANT 1 AND S INTERING PLANT 2



Sintering Plant 1 and Sintering plant 2

In 1978 Mel decided to reutilise Mn ore fines in the form of sinters for improved

economy.

Paramount sinters private limited set up a sintering plant 1. the problems of generation

of Mn ore in large quantities and the constraints faced in conventional enforced MEL to

set up a high pressure sintering unit of capacity 100 ton/day designed by RDCIS ,SAIL

,Ranchi in 1991.

With the continuous generation of undersized Mn ore fines from RM yard and PH yard,

the importance of sintering plant is increasing very fast. The fine of Mn ore in

agglomerated form is used for the production of FeMn and SiMn.

Sintering plant 1:

Sinter plant 1 has a capacity of 50 ton sinter per day. It utilizes fines of Mn ore and

coke collected from screen house. It is a mechanized plant consisting of raw material

loading elevators ,conveyer belts ,mixing drums, vibrating feeders, continuous travelling

grade type sinter strand, ignition hood with oil burner ,sinter breaker ,sinter cooler,

sinter screens ,suction fans, cooling arrangement ,finished sinter hoppers.

Process: sintering is to heat a mass of fine particles for a proloinge4d time below the

melting point to cause agglomeration. The ore fines, fuel fines, return fines and water

are mixed in a definite proportion. This mix is rolled in drums top from micro

pellets/nodules. Mix is fed to sinter strands top layer of fuel is ignited while

maintaining vaccume below sinter belt. Ignition is continued till top layer reaches

incandescence. Under vacume air is drawn from sinter belts. Heat generated by fuel

fines causes surface fusion of grains. Ore fines are thus fused together. The entire

bed is converted into to sinter cake.



Sinter plant II

With the production capacity of 100 ton sinters per day was commissioned on 1991. High

pressure sintering is carried out with the supply of compressed air from top of the bed.

The pressure drop is created by the surplus above the bed under high pressure which

helps in intensification of sintering process and overcomes most of the constraints

faced in conventional sintering with appreciably high vertical speed of sintering.

System and process:

HPSU comprises of six main units viz. raw material receiving and handling unit, crushing

and screening unit, raw material storage, proportioning and mixing units, sintering unit,

sinter braking and cooling units and sinter dispatch unit. Raw materials are Mn ore, Lime

stone and Coke breeze taken from the ground hopper and proportionating section with

the help of belt conveyer. After required crushing, screening and proportioning the

materials are fed to drum mixer. This mix is fed to sintering pots. The sinter pot after

receiving the charge from the drum mixer moves to sintering station with the help of

motorized trolley. The bed height is about 650 mm. at sintering station the motorized

trolley is loaded on to the vacuum chamber and suction is applied. After that ignition is

done with the help of flue gas for about 25-30 minutes. Then sinter pot is taken to

discharge position where sinter cake is discharge and then crushed to primary and

secondary breakers. Crussed sinter is then taken sinter cooler with the help of deep

bucket conveyer and after cooling and a\screening the same is carried to the product

bunker.



T RANSPORT DEPARTMENT



Transport department

Functions of transport department:

The main functions of this department are allotment of vehicle to various departments

and their maintenance. There are 67 employees in this department. The maintenance

and operation of transport is the responsibility of this department. According to the

requirement of various departments, transport department provides its services.

Vehicles are allotted to the following departments according to their requirement and

the availability:

1. RM yard

2. FAD

3. HPSU

4. Sintering Plant 1

5. Lime Kiln

6. Arc Furnace

7. Workshop

8. Stores

9. Civil Department.

In addition to the allotment of vehicle to the above departments this department also

manages the repairing and maintenance of the vehicles. Under maintenance work both

preventive and breakdown maintenance are taken up.



Vehicles available to the transport:

The following vehicles are available to the transport department:

Name No. of vehicles

Loaders 6

Dumpers 12

Hippo Dumpers 3

Buses 2

Ambulance 2

Firetender 1

Porclain 1

Tractors 2

DG sets 2

Loco Engine 1

Jeeps and cars 4

As a part of preventive maintenance every day a vehicle is attended for regular

checking, engine oil level, gear oil level, gearing, nuts and bolts are checked.

Despite of the above maintenance schedule if any breakdown occurs it is immediately

attended by the maintenance team. For painting of vehicle and other works which are

beyond the scope of transport department, vehicles are sent to the outside agencies.





MECHANICAL MAINTENANCE DEPARTMENT



MECHANICAL MAINTANACE DEPARTMENT

INTRODUCTION

In any industries equipment and machinery plays a vital role I the total production

process. Machines and equipments costs a lot more money and therefore their

damages are very expensive. Again in the process of production if any damages or

down time occurs it becomes much more expensive as it hampers the production

for this reason it is vitally important.

Mech. Maintenance Dept. in MEL looks after the maintenance the mechanicalequipments and system associated with two 33 MVA SAFs and 1 MVA EAF in FAD.

high pressure sintering unit and workshop maintenance of some important

mechanical equipments and mech. Equipment associate s with systems like furnace

shell and roof cooling system, furnace charging system, electrode holding and

sleeping system, furnace tilting etc.

OBJECTIVES AND FUNCTIONS OF MECHANICAL MAINTENANCE DEPT.

1. To achieve min. breakdowns and to keep the equipments in good working

conditions.

2. To ensure availability of machines and services for continuous running of

furnaces.

3. To keep machines and other facilities ready to be used at their optimum

capacity without any interruption.

To achieve these objectives

Routine scheduled check ups of all mechanical equip. And facilities arecarries out by this dept. to examine their conditions and to check for

needed repairs which ensures the safe and efficient operation of the

equipments and machinery.

To carry out the maint. Replacement and minor installations work of

equipments.



Preventive maint. Of equipments by proper inspection, lubriacation,

adjustment and repairs is carried out.

To avoid unsatisfactory condition corrective repairs and reconditioning

and reassembling of equipments is carried out as per the situation.

PROCEDURE OF MAINTANCE OF MECH. EUIPQMENTS OF SAFs AND EAF

This procedure is for the maintenance of the following equips.

1. GCP of SAF 1.

2. Water cooling system of both SAFs.

3. EOT cranes of SAFs and EAF.

4. Conveyor belt charging system from bunkers house to both SAFs.

5. All other equips. Of SAFs and EAF.

PREVENTIVE MAINTENCE PROCEDURE

This procedure is to adapt for major and minor defects and rectifications of the

above equipments. Major and minor defects in mech. equip. are identified by mech.

maint. Deptt. Executives or staffs in regular checkups during shifts but if the

defect is of major nature then it is informed to Sr. executives of maint. Deptt.

And as per the nature of the defect it is attained by planned shutdown. Shutdownof equips. And its duration is informed to shift in charge of SAF or EAF and a Line

clearance is obtained from relevant departments shift in charge for attending the

defects and all the necessary details are entered in the log book maintained in this

(mm) department.

BREAKDOWN MAINTENCE PROCEDURE

The procedure for breakdown maint. Or breakdown repairs of above critical

equipments maintained in the list is for minor breakdowns and major breakdowns.

Shift in charge. of mech maint. Deptt acknowledges the breakdown and

takes line clearance from shift in charge of relevant deprts.The breakdown is

visualised for its nature and if it is of minor nature where additional manpower long

duration, materials etc. are not needed. It is attended immediately by engaging the



shift staff and after rectification the line clearance is returned by shift in charge

Mech maint to concerned shift in charge of other departments

If the breakdown is of major nature then it is informed toSAF In charge , Sr.

Executive for their information and advice ,if any ,getting additional man power,material, deciding the activity scheduled, duration for attending the breakdown &

above for taking up some other area development for utilisation of shutdown period

.

After completion of repair work & other associated job, the line clearance is

returned by shift in charge. Mech-maintaince to the other associated department

shift in charge and the nature of the defect and corrective action taken are

entered in the log book.

CRITICAL EQUIPMENT CHECK LIST FOR MATERIAL EQUIPMENT FOR SAF

AND EAF

Check points

Gas cleaning plants

1. Foundation bolts 2. Greasing 3. Impellor noise 4. Spray noise

Water cooling system

1. Flow of water 2. Temp. of water 3.pressure of water 4.leakages

EOT Cranes

1. Foundation bolts 2.coupling bolts 3.condition of wire ropes

4. Oil level in gear boxes 5.brakes 6.crane wheels 7.stopper

Conveyor belts

1. gear boxes 2.coupling 3.head drums 4.tail drums



Maintenance of associates equipments at SAF and EAF

1. Hydraulic System 2.Mud gun 3.Gas shield rope 4.electrode holder

assembly 5.electrode casing position 6.tilting arrangement 7.water cooling

bus tubes 8.cooling system

FACILITIES AVAILABLE AT WORKSHOP

Workshop is equipped with following facilities

1. Lathe machine

2. universal milling machine

3.

shaping machine4. pillar drilling machine

5. power hack Saw

6. pedestal grinder

7. shearing machine

8. bending machine

9. rolling machine

10. punch press

11. hydraulic pipe bending machine

12. 3 T crane

13. mini welding machine





CIVIL MAINTAINANCE DEPARTMENT



CIVIL MAINTAINANCE DEPARTMENT

CIVIL TENDERING PROCESS

A tender is nothing but a written or published document, the aim of which

is to find the price to get a particular work done within the desired period and

under specified condition.

In civil dept. tenders invited for various civil worked can be divided into

following types.

1. Single tender:-It is invited from one reliable supplier or contractor.

Sometimes a specific type of work is to be carried out for such workstender from the single contractor who has experience and skill in carrying

out these works is invited. Works that are repeated in nature generally falls

in that group.

2. Limited tender: - in this type of tender the quotation are invited from the

limited number of reliable contractors. These contractors are approved by

or registered by the company. A quotation form is used for calling the

quotation.

3. Open tenders: - open tenders are published in newspapers. It is also called

as press tenders who are open to everybody. Any contractors reliable or

unreliable can furnish the quotation. Whenever any new civil project work is

to be taken up open tenders are invited from competent contractors in civil

works. Based on the competency of the contractor related to work such as

project in hand, project completed earlier, workmanship, quality of work, his

quoted in agreeable rates, and the contracts are aborted to the contractors.

4. Term tenders or term contracts: - when any work is to be completed to be

urgently or in a very short period the contract is given to a single contractor

approved by the company without inviting tenders from other contractors.



Tendering procedure:

1. The user department who want to take up any civil work make request to civil

department seeking the details of the estimates of proposed work.

2. After having set the estimate to the user department, user department gets

the proposed work approved from ED through the head of user department

,DGM(works) and AGM(F/A).

3. The user department after seeking the approval of the work communicates the

same to civil department.

4. The civil department then prepares a note sheet which consists of request for

floating tenders regarding the proposed work or for inviting the quotation and

forming the committee which comprises of each member from (1) user department

(2) finance department (3) civil department.

5. After having the approved the above requtition by head of user department,

DGM (works), AGM (F/A) and ED, contractor are informed to fill up the quotation

and submit them in sealed envelops.

6. The quotation are open in the presence of acting committee and the contractors

on the dates fixed in advance and about which contractors are already informed.

After having examined the quotation on critical and on economical basis the

quotation having the lowest rates is accepted.

7. The work order is then prepared and gets signed by the representative of the

civil department



Work Order

The work order contains the following terms and conditions:

1. The contractors has to continue the contract irrespective of any variations in

quantum of work, item, duties, taxes etc. no extra rate will be paid on such

account.

2. If the work is found unsatisfactory the work will be rejected and the

contractor has to re-execute the work to the satisfaction of civil engineer.

3. In case the contractor give up the work it will be get executed by any other

agency departmentally at this cost.

4. The company will deduct 5% of the estimated cost as security deposit from

contractor bill toward the assurance of the quality of their work.

5. The security deposit can be refunded to the contractor after one year from

the date of handling over the work, if no complain about the standard or thequality of work is encountered.



Function and works carried out by civil maintenance department:

Work carried out by this department can broadly be categorised into the

following types:

1. Project works

New projects related to construction of residential, official, plant buildings,

shopping complex, recreation hall, construction of roads etc. are assumed as per

the provision made for the same in annual budget of the company.

2. Maintenance of existing structures

Structural inspection of all the existing structures is done every year for the

assessment of maintenance work volume. The various maintenance works includes

paintings and colour-washing building, sanitary works, repairs of roads, paintings

of structures, sheet roofs repair, wooden-door repairs etc.

3. Modification of existing structures

Modification includes constructing additional rooms in house, space distribution,

changing the design of structures etc.

Distribution of work:

Civil maintenance work is to be carried out, as per the schedule prepared for the

day, are distributed among the workers everyday in the morning. Complaints

received from residential houses in township regarding structural or other

defaults are attended in a sequence as per the complain received on first come

first serve basis. When maintenance works are of large volume it is to be carried

through contractors.



LABORATORY, POLLUTION CONTROL &

ENVIROMENT



LABORATORY, POLLUTION CONTROL & ENVIROMENT

Functions: The main functions of this department are

1. Inspection and analysis of incoming raw materials

2. Inspection and analysis of finished product

3. Inspection and analysis of by product.

Under analysis both physical and chemical analysis is done.

The environment division for pollution control following function are carried

out.

1. Plantation in plant premises and near by suburbs .

2. environmental monitoring with the help o f private agency.

3. Cleaning of slurry from gas cleaning plant.

In addition to this it gives certification of the product to the

customer and ensures them the quality of product.

Sampling: is carried out for the physical & chemical analysis. As the large quantity

of finished product &raw materials are put in big stacks and it is not possible to

each piece of material, stack sampling is done. it is done in two ways .

Pit sampling: in this process pits are made at number of places throughout the

stack. Samples are collected from the pits randomly and sent to laboratory.

T trenches sampling: in this process samples are into pieces of different shapes,

like H,T,+, X etc. in physical analysis of sample proper size samples are collected

by seeving through seeves. For chemical analysis sample spread in circle and

divided into four quadrants.



QUALITY CONTROL OF FINISHED PRODUCTS

To keep consistency on the quality of finished products sampling is done

at various stages such as during tapping,stacking, & despatching.Samples taken

after tapping are collected and analysed for its verification.At the time ofdispatch the product sames are taken from wagons for its physical & chemical

analysis.

POLLUTION CONTROL

WATER POLLUTION CONTROL

Waste water coming out from thickness plant is treated in pond

with chemical like Alum.lime & bleaching powder so as to brig pollution level below

permissible limit as per the norms of environmental standard by Maharashtra

pollution control board.These are given as below

Ph:-5.5 to 9

Suspended solids:-100 ppm

Biochemical Oxygen demand(BOD) 20 ppm

COD 250 mg/l

Oil and Greece 10 mg/l

Iron 5 mg/l

Mn

5 mg/l

Cyanide 0.2 mg/l

Modified Bio assay test on fish (for 96 hrs) 90% survival

The sludge formed during waste water treatment is taken out periodically

and is used for filling up low lying areas whereas suspended liquid is supplied to

plantation



AIR POLLUTON CONTROL

The maharashtra pollution control board has given standard norms for

1. tack emmissino

2. Ambient air quality3. industrial effluents

To keep the air pollution under control,furnace stack monitering & ambient air

quality analysis is carried out.

The ambient air quality should be as follows

1. NO2 & SO2 each 120 µgm/N m3

2. Suspended particles mattere 500 µgm/N m3

Air quality of stock emission (furnace) should have following limits

1. SPM:-150 µgm/N m3

2. SO2 :-297 kg/day

To achieve the above standards the various measures taken are

1. periodically maintaing & analysing ambient air quality & stack gas quality

by agencies like pollution and Ecology control laboratory ,Nagpur

2. plantation throughout the campus3. In case of industrial effluents to meet required standards monitoring

facilities are made available and chemical treatment is given to the industrial

effluents to keep various parameters without limit.

Solid waste recovery the

biggest problem for any processing unit is solid waste disposal.the innovative step

taken by MEL in this regard is the use of granulator slag for brick manufacturing in

addition to this the use of granulator slag for road construction in peri pheralarea.the slag brics are used in the construction of wall around the plant filling up

low lying areas by using dried sludge proved to be the suitable alternative for solid

waste disposal.





P RODUCT H ANDLING Y ARD



Product Handling Yard

The product handling yard is situated along one side of broad-gauge railway siding.

The product that is FeMn and SiMn is dumped and stacked date wise and size wise

in the product handling yard. The various operation carried out during the

handling of Ferro alloys right from tapping to the PH yard and then loading in to

the wagons are as follows:

1. conveyance of product from tapping bay of furnace to ferro plot.

2. weighing of metals and slags.

3. dumping at fero plot

4. cooling

5. breaking in to sizes.

6. picking

7. stacking ,packing in bags and loading in wagons and trucks

Conveyance of product from furnace and its weighment :

Metals and slag are carried to product handling yard by hot body dumpers which is

weighed at weigh bridge of 20 tonnes capacity.this indicates thje gross weight of

prduct released from the furnace. Net weight of product is determined by

subtracting tare weight from the gross weight.

Breaking of cakes after its dumping and cooling:

After weighment of meatls and slags ,slag are dumped at slag dumping place while

the products are dumped at particular place marked for that day according to

date. The product dump is too hot and it requires 2-3 dayas to cool before its

breaking begins.



Slag cakes which are dumped at slag dumping place contains some amount of metals

in the slag. This cake is crushed into to min. 25 mm size. The 25-40 mm size metals

siis recovered by handpicking. Remaining undersized mix having size below 25 mm is

send to screening and jigging unit from where we get recovery of sizes of 12-25mm

, 3-12 mm ,-3mm. from slag mix we get metals around 30-35 %. Rest ungranulated

slag is further crushed and treated in the same way as the slag mix to get the

recovery of 1-2 % metal.

The product which is dumped requires -23 days to cool it before its breaking

begins. The breaking of the cakes in the specified size is allotted to the labour

contractors. The prime sizes specified is as under:

Product Size

HC FeMn 10-50 mm

MC FeMn 50-150 mm,25-80 mm

SiMn 25-50 mm

This breaking in saleable size is as per the dispatch program.

During breaking of the cakes some undersized products are also generated along

the prime sized products which are grouped in sizes viz. 25-40 mm, 12-25 mm.

product size below 12 mm is subjected to screening and jigging to get sizes such as

12-6 mm, 6-3mm,-3mm.

The quantity of finished product of prime sizes recovered is 85-90 % of the weigh

of the Ferro alloy cakes.



Separation of product size and picking:

Separation of metal product is done by manual picking up to the size of 25 mm.

product below 25 mm that is 25-12 mm size is obtained by screening the remains

through 12 mm size screens.

Disposal of slag:

High MnO slag is used for SiMn production while granulated slag is disposed at the

slag disposal site.

Stacking packing and loading of Product:

After metal dressing is over the FeMn are brought onto the cemented platforms

and staked there as per the sizes and dispatch schedule.

The loading and dispatching of the product is the most important work to be

carried out in the product handling yard. The loading is done in the trucks or

wagons. Before the loading starts the products are checked visually and put aside

in case of serious damage. The wagons are loaded up to carrying capacity +2 ton

weight. Each wagon is specified with charged weight capacity over which we can’t

load. Before loading the load line is marked on each wagon.

The load line depends upon the bulk density of product ,size , cross sectional area

of wagon and carrying capacity of wagon.

It is given by the formula as:

Area*hight*bulk density of product=charged weight of wagon(cc+2t)

A study report on mel

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