Industrial Training Presentation

Eliminating chances of accident and reduction in breakdown of an induction furnace

Under guidance of:

Mr. Anurag GuptaMr. Ranjay Kumar Singh

Submitted by:

Aaradhya Poddar0902949001

B.Tech 4th year

SIDHBALI INDUSTRIESKOTDWAR

INTRODUCTION

• This group today, stands among the leading manufacturers in the Indian Steel Market and is primarily known for providing supreme quality TMT STEEL BARS and allied products.

• The Group consists of three core companies:

• Shree Sidhbali Industries Limited, Kotdwar• Shree Sidhbali Ispat Limited, chandrapura• Shree Sidhbali steels, Muzaffarnagar

• Product range by the group:

TMT bars from 8 mm to 32 mm Angles and channels Mild Steel billets and ingots High quality, environment-friendly fine textured papers from Sugarcane Pulp Power generation

• Among all other, “SIDHBALI SARIA” is one of the most popular brand in TMT Steel, which is presently manufactured by Sidhbali Group.

SIDHBALI GROUP has been consisting presently three core companies as:

• Shree Sidhbali Industries Shree Sidhbali Industries Limited at Kotdwar Unit in Uttrakhand State having installed capacity of 75000 MT P.A. and the input raw material i.e. M.S. Ingot is also produced by the Melting Division of this Unit having installed capacity of 30000 MT P.A. This Unit is situated in Kotdwar.

• Shree Sidhbali Ispat Limited:-After marking an inerasable imprint of its trust and quality in the Northern India, Sidhbali has eventually moved towards the Western and Southern parts also. Rolling Mill having production capacity of 100000 MT P.A., which cater to the construction requirements of South and West of India. The raw materials used in the manufacture of Sidhbali TMT Steel are not imported, instead are made in Sidhbali’s own “Melting Division” having production capacity of 36000 MT P.A. It’s this inspiring growth that motivated the company to set up a “Sponge Iron Unit” having production capacity of 105000 MT P.A. in this Plant. Yet again in Chandrapur, Sidhbali has set up the “Captive Power Generation Unit” having capacity of 20 MW, which generates energy through high grade technologies. Today, this is the biggest and most hi-tech unit of entire Maharashtra.

• Shree Sidhbali Steels Limited:-The quality of Sidhbali Steel has over the time fetched incredibly high demands in the Northern India. To fulfill the same, just recently, the Group started their third steel manufacturing plant in Muzaffarnagar of Uttar Pradesh State, having production capacity of 60000 MT P.A. TMT Bars with Melting Division having capacity of 15000 MT P.A.

Group Profile

• Sidhbali Group is standard certified ISI : 1786-2008, ISO 2001 & ISO 14001 Accreditations

• Group have an annual turnover of about Rs 300 crores.

• Some of the awards recieved by Sidhbali group are

• Udyog Patra & Udyog Vibhushan Awards

• Star Category Award By The State Government

Company Profile

Year of commencement: 1996

Plant Area: 5 acres

Number of employees: 500

Divisions: Melting division Rolling division

Capacity: 30,000 MT P.A 75,000 MT P.A

Shree Sidhbali Industries Limited (KOTDWAR PLANT)

• Shree Sidhbali Industries Limited is the first manufacturing unit of Sidhbali Group

• There are two divisions in Shree Sidhbali industries Kotdwar

• Rolling division• Melting division

• Rolling division consists of a reheating furnace.

• Melting division consists of a induction furnace

Induction furnace

• Capacity can vary in a big range from less than one kilogram to one hundred tones

• Highest chemical durability

• Lowest alloy losses.

• Leading to highest metal quality with respect to impurities.

• High refractoriness.

• Available in various sizes.

• Comes in different capabilities

• Induction furnace is a clean, energy-efficient and well-controllable melting process compared to most other means of metal melting.

Induction Furnace

MS scrap

Sponge iron

Cast iron

Cool Water Inlet

Hot Water Outlet

Ladle

Ingot Moulds

Ingots to Rolling division

Flow diagram

Flow of work

Some of the induction hazard are 

Lack of operator skill during temperature taking, sampling or the addition of alloying compounds, causing metal splash

The introduction of wet or damp metal into the furnace, causing a water/molten metal explosion

Dropping large pieces of charge material into a molten bath causing metal splash Improper attention to charging causing bridging condition Failure to stand behind safety lines, causing a trapping situation Coming into contact with electrical conductors, overriding safety interlock

switches or coming in contact with incompletely discharged capacitors causing electric shock or electrocution• Lack of operator training

Hazards of Induction Furnace

Eliminating chances of molten metal splash

5W & 1H Analysis

Date 08/06/2012

What One person was injured molten metal splash

Where Near the furnace surface

When During metal charging

Who Melter

Why Unknown reason

How Eliminate all possible causes

Analysis

Reasons•Wet or damp charge material•Sealed containers in scrap•Centrifugally-cast scrap rolls•Dropping heavy charge into molten bath•Wet or damp tool or additives

Recommended solutions

• To use compressed air to remove dampness and dust or other impurities from the charge

• Sealed containers should be first drilled and cleaned and then should be used as charge in the furnace

• Remote charging system should be used i.e. all workers are kept away from furnace so they are safe from splash

• To save people from injury the workers should be provided with primary protective equipment

• There should be proper barriers to keep workers and visitors at a proper distance from the furnace thus keeping them safe

Benefits • Most common reason for molten metal splash eliminated

• By air cleaning even dust or impurities being added to furnace were reduced thus better quality and less wastage

• Scrap not wasted even if it consists of sealed containers

• Money saved as scrap and labours are saved

• No separate investment as both the solution has everything from within the division 

Observations

• Steel sheets covering the industry should be replaced by transparent sheet in order to insure better light in the industry

 • The furnace should have an opening at the top so that the slag can come out

automatically and no worker is required for the same purpose. • The furnace wall presently made up of refractory material can be used 10 to 15 times

should be replaced by an alloy comprising of niobium, hafnium and titanium.

• Proper neatness should be maintained in the industry • The furnace should be equipped with ground and leak detection system • Should be upgraded in technology because that upgrade can reduce the specific power

consumption per unit tonne by around 25% • Electromagnet on crane should be used to collect iron and steel particles from the floor

to get most and save money out of scrap 

Conclusion

The project holds a brief description about the working of the Induction Furnace and how the problems arising in the plant are tackled. In melting division safety and maintenance has an active work to do and has to maintain healthy relation with the employees. 

Accidents are part of the melting shop and they cannot be completely removed but safety people try to minimize the accidents and thus save industry from damage and injury to workers. First the cause is detected and then by data collection and idea implementation the problem is tried to be removed. If all the causes are removed one by one and like this causes of accidents are reduced. 

Breakdowns are also very damaging for industry as the production stops there is a complete stop over income. First analysis is done to understand the problem and causes. Then all possible prevention measures are taken so that there are no further breakdowns in industry. 

It was a nice experience being a part of the SIDHBALI INDUSTRIES for six weeks. This training has enhanced my knowledge and provided me an experience of working in an industry. It also helped to understand how an industry runs and even what all barriers one face in its growth, I also learned a systematic and refined way of tackling problems and understood that one has to think out of the box for once growth and growth of industry as a whole.

THANK YOU !!