Organization Structure Training report which is required for joining into christ university. This is an 1 Credit project and management takes it seriously. My OST Company was in Chandrapur, Maharashtra, which is an SAIL company.

1. Christ University Institute of Management(CUIM)
Kengari Campus, Bangalore
Masters of Business Administration, 2016-18
Organization Structure Training (OST)
ReportOn
Chandrapur Ferro Alloy Plant(SAIL)
-By Rohit Debnath

2. Acknowledgement
I thank Chandapur Ferro Alloy Plant and
it‘s Human Resource Department for providing this amazing
opportunity.
I am grateful to Mr. Partho Chakraborthy, General Manager (Human
Resource) for his valuable feedback and guidance throughout the
training period.I would also like to thank everyone in Chandapur
Ferro Alloy Plant for their immense support duringthe whole tenure.
I owe a huge debt of gratitude to Christ University Institute of
Management for designing this training module, without which I
could have never known the functioning fundamentals of all the
departments in a large scale organisation.
My special thanks to Prof G. M. Divakar, who has been my mentor
throughout the training tenure and without his guidance and feedbacks
this could have been an impossible task.
Finally, this project would not have been possible without the whole
hearted co-operation and support of my friends and family. They
showed understanding and patience wherever needed.
Rohit Debnath

3. INTRODUCTION
Chandrapur Ferro Alloy Plant, (CFP) erstwhile Maharashtra Elektrosmelt
Ltd. (MEL)became a Unit of SAIL w.e.f. 12/7/2011. Chandrapur Ferro Alloy
Plant is the only Public sector Unit engaged in production
of Manganese based Ferro Alloys in the Country
CFP has an installed capacity of 1,00,000 TPY Ferro Manganese. The
product range of CFP includes High Carbon Ferro Manganese, Silico
Manganese and Medium Carbon Ferro Manganese. The Plant is accredited
with Quality Assurance Certificate ISO 9001:2008.
CFP's major production facilities include two nos. of 33 MVA
Submerged Electric Arc Furnaces for the production of Ferro alloys, two
nos. Manganese Ore Sintering Plants, Furnace gas based Power Plant,
Mechanized Crushing and Screening System for Ferro Alloys and 1 MVA
Electric ArcFurnace for the production of Medium Carbon and Low Carbon
Ferro Manganese with Lime Calcination and Manganese Ore Roasting Unit.
The plant is a leader in ferroalloy technology. Activities for technological
developments are taken up in areas like raw material preparation, raw
material substitution, furnace operation, ferroalloy casting and processing
etc. One example of the latest technological development is the state of the
art ‘Layer Casting Technology’ for casting molten Ferro Alloys and Ferro
Alloy Processing Unit (Crusher) which is the first of its kind in India.

4. FIRE & SAFETY DEPARTMENT
The main aim of safety department is the removal of unsafe activites &
unsafe conditions because these are the two main reasons for accidents in
industries.
To ensure safety the ASK principle is to be followed.
Attitude: A person should have proper attitude to execute skill and
knowledge in such adverse and high risky conditions.
Skill: the knowledge is necessary but a person should have enough skill to
execute that knowledge.
Knowledge: A person should have proper knowledge of equipments.
To mitigate Unsafe Act, Standard Operating Practices (SOP) and Standard
Maintenance Practices (SMP) are to be followed. Warnings and penalties
are issued to private contractors if these practices are being breached.
As it’s not possible to eliminate Unsafe Conditions completely, to reduce its
severity Personal Protective Equipment (PPE) should be used.
Accidents are categorized as:
1. Non Reportable Accidents (victim reports to duty within 48 hours)
2. Reportable Accidents (this needs attention and information report
must be sent to Factory Inspector or Deputy Director Industrial
Safety and Health)
3. Fatal Accident or Disability(Immediately report to Factory Inspector
or Deputy Director Industrial Safety and Health)
CFP does not have designated personnel for fire fighting so it is the
responsibility of each and every employee to help out in case of a fire. For

5. this it is necessary that the employees must know how to use the fire safety
equipments like fire extinguishers. It is the responsibility of the fire &
safety department to educate all employees with regards to fire safety.
Dry powder fireextinguishers are to be used for any machine related fires.
However in control room fires CO2 extinguishers should be used. In case of
electrical fires it is necessary to ensurethat the main power supply iscut
off before usingwater extinguishers.
HEALTH HAZARDS in MANGANESE Based Industry
 Manganese Fumes
As CFP is primarily engaged in Manganese based Ferro Alloys
production; there is always a concern for Manganese based occupational
health diseases.
As per current OSHA standard Permissible Exposure Limit for
manganese is 5mg/m3 of air.
 Carbon Monoxide Gas
Carbon Monoxide gas is primarily present in the Submerged Gas
Furnace effluent output. As CO gas has viable calorific value nearly 45 % of
total CO produced is consumed in power plant boiler. Remaining is
consumed in lime kiln, Sinter plant I & II.
‘CO’ Becomes Lethal Because Of These Properties:
 Colourless
 Odourless
 Heavier than air

6.  Spontaneously combines with Haemoglobin in the blood reducing its
oxygen carrying capacity.
RAW MATERIALYARD
The raw material yard is responsible for handling and maintenance of
all raw materials arriving at CFP. All raw materials required for production
like Manganese Ore, Iron Ore, Manganese Ore Sinter, Dolomite, Limestone,
Charcoal are received by road or rail mode.
RM YARD FUNCTIONS AND PROCESS FLOW
75.78%
13.20%
4.43%
0.18%
2.22%
0.75%
3.4%
Typical Annual Raw Material Contribution
Mn Ore
Coke
Dolomite
Limestone
Charcoal
Carbon Paste
Quartzite

7. RAW MATERIAL FEED SYSTEM
We have two bunker houses with 10 bunkers each. Capacity of each
bunker is 200 m3. A single bunker can hold;
Raw Material Single Bunker holding capacity
(tonne)
ManganeseOre 400-405
Coke 120-140
Dolomite/Quartzite 280-300
On the basis of chemical analysis of available ores, charge burden is
calculated for 1MT of liquid metal (HCFeMn or SiMn)
Accordingly, various raw materials are drawn with help of
vibrofeeder attached to each bunker and collected in the weighing scale
hoppers. The weighted materials is drawn on the conveyor belt at the
bottom of the weighing scale thereby blending the material and raw
material to be charged is elevated to top of the furnace building through
conveyor.
Compositions of various raw materials:
Weighment
of raw
material
Unloading
at RMyard
Stacking
Feed into
ground
hopper
Screen
house
Supplyvia
conveyors

8. Manganese Ore:
1. High Grade – Mn: 40-50%
2. Low Grade Low Phos – Mn: 36-42% ; P: 0.03-0.06%
3. Low Grade High Sulphur – Mn: 28-32% ; S : 28-32%
Dolomite :
SiO2 : 2.5-3.5% ; CaO : 28-32% ; MgO : 18-22% ; R2O3 : 2% max
Limestone :
SiO2 : 3-4% ; CaO : 48-52% ; MgO : 2-5 % ; R2O3 : 2% max
Quartzite :
SiO2 : 96-98% ; Fe : 0.5-1% ; Al2O3 : 0.8-1.5% ; P : 0.02% max
SINTER PLANT
Ore below 6 mm size cannotbe charged into the furnacebecause it leads to
choking of the furnace. Butthe undersized orecannotbe rejected because
it will causehuge losses. So in order to make this undersized oreusefulitis
subjected to sintering processwhich is doneat sinter plantI & II .
In Sinter Plantwe make ManganeseOre sinter through sintering process.
Sintering is the process of compacting and forminga solid mass of material
by incipientfusion..
At CFP we have two sinter plants of 100 tonneper day capacity. We
make sinter cakes in our Sinter Plants at a temperatureof around 1000⁰C.
Sinter so produced iscooled and sent to crusher to get desired chargeable
size. The fines generated after crushingare sent back for sintering. At
presentwe are producing30 tonnesof sinter per day through each sinter
plant

9. Safety aspects
Gas masks should be worn dueto useof CO gas in combustion. Ear plugs
should be worn by personnelworkingnear crusher. Helmet & safety shoes
are compulsory.
0
5000
10000
15000
20000
25000
30000
2009-10 2010-11 2011-12 2012-13 2013-14 2014-15
Production(intonnes)
PLANT SHUT
DOWN
10%
MECH. MAINTT
35%
ELEC MAINTT
22%
OPERATIONAL &
OTHER
2%
SAF GAS NOT
AVAILABLE
31%
SP-II Delay Analysis : Apr '09 to Mar '14

10. FERRO ALLOYS DIVISION
1 .FURNACE OPERATIONS
Production facility involves 2 Submerged Arc Furnace (SAF) of 33 MVA
rated capacity and 1 Electric Arc Furnace (EAF) of 1 MVA rated capacity.
a) Two SAF of 33 MVA rated capacity with 3 Electrode (3 Phase) of 1.5
m diameter each
These furnaces are state of the art furnaces which can be used
to produce either HCFeMn or SiMn. In these furnaces the electrodes
are submerged inside the raw material for better and effective
utilization of heat hence called Submerged Arc Furnace.
Raw Material HCFeMn SiMn
Mn ore + Sinter 2430 kg 1885 kg
Iron Ore 20 kg 15 kg
Dolomite & Limestone 325 kg 0 kg
ReducingAgent- Coke 600 kg 600 kg
ReducingAgent-
Charcoal
0 kg 220 kg
FeMn Slag 0 kg 1050 kg
Quartzite 0 kg 250 kg

11. Electric Power 2660 kW-hr 3900 kW-hr
Broader Requirement of Raw Material for Producing 1 MT of HCFeMn and
SiMn
ProductionProcess ofSAF
 Normally at full load each SAF is operated at 20-21MW load.
Electrical energy is supplied by 22kV single three phase transformer
to the three graphite electrode of diameter 1.5 m each. Now, voltage
is stepped down so that operated secondary current is around 90kA
and operating secondary voltage around 120-140V. High kA current
is desired mainly to use electricity to produce more heat by I2R. Thus,
in this process fuel is electrical energy. The arcing temperature is
around 2800⁰C
 This heat is used for smelting of Manganese Ore. Smelting is
carbothermic reduction of oxides in Manganese ore and Iron ore into
metal form, i.e. MO + C = M + CO Where coke and coal are used a
reducingagent and dolomite and limestone are used as fluxing agent.
The process temperature is around 1350⁰ to 1450⁰C
 Smelted ore is subsequently melted in the process to form molten
metal and slag, which are accumulated in hearth portion of SAF.
 Each SAF is provided with taphole during tapping, molten metal and
slag comes out in mixed form along the launder and gets separated
by gravity separation method using skimmer block (buffle). Metal
being heavier takes under path of buffle and slag being lighter takes
over path of buffle.
 Separated molten metal and slag are cast in separate Layer Casting
pits. In one pit normally 7-9 tappingsare cast layer by layer.
 After cooling, the cast metal and slag are scooped and lifted with pay
loaders and transported via dumpers to mechanised crushing and

12. screening unit for sizing. After confirming the analysis, finished
product is supplied to customer by rail or road.
0
10000
20000
30000
40000
50000
60000
70000
80000
2011-12 2012-13 2013-14 2014-15
Productionintonnes(SAFI+II)
Year-Wise Production Of SiMN
0
10000
20000
30000
40000
50000
60000
70000
80000
90000
2011-12 2012-13 2013-14 2014-15
Productionintonnes(SAFI+II)
Year Wise Production Of HCFeMn

13. SAF-I
MONTH
2008-
09
2009-
10
2010-
11
2011-
12
2012-
13
2013-
14
2014-
15
APRIL 91.97 98.66 96.83 93.23 95.05 95.62 95.30
MAY 98.50 98.15 97.43 97.06 91.32 93.26 95.65
JUNE 80.61 97.34 97.73 96.02 88.07 97.60 92.23
JULY 98.56 95.50 93.33 92.23 76.11 76.20 75.43
AUGUST 94.75 98.71 97.89 87.29 91.96 97.91 95.57
SEPTEMBER 98.20 99.21 95.30 95.16 95.13 94.55 92.70
OCTOBER 88.83 98.45 93.72 95.24 92.20 97.52 93.65
NOVEMBER 83.69 94.27 92.59 75.21 98.92 88.80 90.29
DECEMBER 92.46 98.43 97.10 89.92 98.00 93.23 96.52
JANUARY 91.92 98.51 95.28 92.49 46.57 90.04 95.67
FEBRUARY 98.23 95.93 99.54 93.47 99.14 90.56 98.37
MARCH 98.47 99.33 98.49 93.36 99.22 95.30 91.90
Monthwise Furnace availability for SAF-I
SAF-II
MONTH
2008-
09
2009-
10
2010-
11
2011-
12
2012-
13
2013-
14
2014-
15
APRIL 93.08 96.74 95.91 96.66 95.11 94.77 89.98
MAY 94.82 96.88 96.64 97.75 89.66 93.31 85.66
0
20000
40000
60000
80000
100000
120000
140000
2011-12 2012-13 2013-14 2014-15
Productionintonnes Year Wise Production of Equivalent HCFeMn

14. JUNE 97.65 97.91 90.23 97.91 86.05 80.93 93.33
JULY 84.39 94.07 82.82 99.08 92.54 83.07 87.36
AUGUST 88.85 98.84 92.05 93.81 93.58 88.75 89.20
SEPTEMBER 95.06 99.77 86.5 95.62 95.45 97.94 75.22
OCTOBER 98.02 97.17 90.46 97.41 96.40 72.96 98.23
NOVEMBER 96.97 90.70 94.46 97.17 94.81 96.64 84.76
DECEMBER 97.42 97.15 90.83 93.49 96.12 91.26 96.83
JANUARY 93.28 95.37 97.43 97.34 97.00 96.97 89.40
FEBRUARY 90.08 97.69 97.24 94.01 96.29 96.15 93.77
MARCH 98.83 96.96 97.96 94.32 91.57 96.03 95.89
Furnace availability fo SAF-II
Safety aspects
Dueto close proximity to CO gas all personnelmustwear gas masks. 100%
cotton clothes should be worn which are less susceptible to catching fire.
Helmet & safety shoes are compulsory.
b) 1 Electric Arc Furnace (EAF) of 1 MVA rated capacity
This is a small furnace primarily being used for production of
MCFeMn through silicothermic reduction route.
Raw Material Requirement
Roasted Mn Ore 880 kg
SiMn (3-12 mm) 760 kg
HCFeMn (3-12 mm) 250 kg
Lime 725 kg
Electric Power 1200 kW-hr
Broader Requirement of Raw Material for Producing 1 MT of MCFeMn

15. ProductionProcess ofEAF
 Limestone is calcined in 7 TPD shaft typekiln usingfurnacegases
 High gradeManganeseore from MOIL Balaghat mine (49%
Manganese)is roasted in the 4 TPD country kiln using furnacegases
 First part of mixtureis fed to the furnacemanually.
 Electric arcing is madebetween the electrode tip and charge so as to
produceheat, thereby creating molten poll inside the furnace.
 Then manually second and third lots are charged into the furnacefor
complete melting of charge.
 Duringthe process silicothermic reduction of Manganeseore takes
place.
 It is a batch type processand it takes around 2 hoursfor completion
of a heat.
 Furnacetap-hole is opened by oxygen lancing. Then furnaceis tilted
to cast molten metal and slag in the sand pans
 After sufficientcooling, the cast cakes are lifted and keptseparately
 Metal and slag is separated manually.

16. 2. ELECTRODE SLIPPINGDEVICE
Electrodes are held in position by electrode holder assembly. The
electrode movement hydraulically controlled and provided with on-load
slipping device.
The slipping device consists of two rings mounted one above the other.
The lower ring is stationary, mounted on the suspension frame of the
electrode column, while the upper ring can be moved up and down by
means of cylinders connecting the two rings.
Each ring assembly consists of friction ring segments and a pressure
ring. The friction ring segments are pressed against the electrode by
applying compressed air to rubber membranes fitted in the pressure ring.
The electrode control panel houses the various valves and switches
required for the operation of the slipping device. The control valves are of
the solenoid type. The slipping operation can be carried out manually and
semi-automatically from the electrode panel, and semi-automatically and
automatically from the control room panel. Automatic slipping is governed
by the timer in the control room panel.
0
500
1000
1500
2000
2500
3000
2010-11 2011-12 2012-13 2013-14 2014-15
ProductioninTonnes Year-Wise Production Of MCFeMn

17. In the rest position both rings are inflated and the upper ring is in the
lower position. The slipping device provides a holding force in addition to
the one of the contact clamps at the lower part of the electrode holder.
Pressure switches ensure that only one ring can be deflated at a time.
In the feed cycle the upper ring is deflated, then raised the desired feed
length and inflated in this position. When the pressure has built up, the
lower ring is in turn deflated and hydraulic pressure applied to the top of
the cylinders. The electrode is hereby forced down through the electrode
holder. The velocity of the downward movement is controlled by an
adjustable flow regulator in the cylinder manifold pipeline.
The feed length is controlled by the limit switches on the slipping device.
These switches are normally adjusted for a feed length of 20 mm (3/4”).
3. GAS CLEANINGPLANT
During the production process due to chemical reactions in the furnace
exhaust gas at high temperature is released, which needs to be cleaned
prior to exhaust to atmosphere. Wet Gas Cleaning Plant is installed in order
to carry out the cleaning process.
In the process, furnace gases (flue gases) are taken out and routed
through gas cleaning plant (GCP). At GCP, wet venture are provided, where
dust laden flue gases are brought in maximum contact of water so that dust
is collected as slurry and cleaned gas is distributed via booster house to
power plant and sintering units.
The gas cleaning plant consists of two stage venturi scrubber system
followed by centrifugal separator, l.D.Fan, and flaring system.
Hot fumes are converged from the furnace top through a water cooled
duct to the inlet of scrubbing system. Water cooled duct is jacketed type
wherein water flows in the annular area between two ducts. Hot gas flows
inside the inner duct and gets cooled due to heat transfer to the water in
annular area.

18. The scrubbing system consists of a quencher, two stage Kinpactor
system followed by a centrifugal separator. Hot fumes are quenched in the
quencher. In the first stage Kinpactor coarser particles are collected due to
the venturi action. The quenched, partially clean gas is then passed on the
second stage Kinpactor where the fine particles are collected due to the
shearing action of gases with water by the principles of impaction,
interception and diffusion.
The saturated gas is then passed through a Cyclonic separator Which
removes the mist present In the gas by centrifugal action and the clean gas'
is passed to a single stage induced draught fan.
Rest of the clean gas is passed through a water seal before being
exhausted through flare stack. The flare stack (tip burning type) would
ensure the complete combustion of gas before it is exhausted.
4. AUXILIARYEQUIPMENT
 5 tonne single girder crane is provided at the top floor of furnace
building to hoist electrode casing and electrode paste to the building
top.
 A mud-gun and arcing device are provided to plug and open the tap
hole respectively.

19. PRODUCT HANDLINGYARD
As the name suggests, the PH yard is responsible for the handling and
despatch of CFP products.
 The marketing department gives Sale order or Acceptance Tender to
PH yard.
 The PH yard issues authorization slip to transporters.
 Tare weight of truck is donebefore loading the product. The material
is loaded as per demand either directly or in 30 kg(max.) bags.
 In case of transport by rail, loading and unloading contracts are
issued.
 The finished product is discharged to mostly SAIL ISPs (90-95%).
At PH yard we have:
 ONE 100 tonne weigh bridge for Locos
 ONE 60 tonne weigh bridge for Trucks
 ONE 40 tonne weigh bridge for Trucks
Product to be dispatched is arrived through crusher and stocked in PH
yard in heaps and they were properly categorised as per type and
nomenclature.

20. POWER PLANT
The COgas produced duringsmeltingprocessin SAF has high calorific
value. This gas is made useof at CFP in the 4.2 MW power plant. The
broader highlights of this power plantare:
 Captive
 WorkingMedium Water
 For consumption of COgas produced in SAFs
 Power utilization mainly for SAF auxiliaries
Block Diagram Of Captive Power Plant

21. Power Produced in Financial Year 2014-2015
(MW-Hr)
Safety aspects
0
200
400
600
800
1000
1200
1400
1600
1800
2000
0
5000
10000
15000
20000
25000
30000
2008-09 2009-10 2010-11 2011-12 2012-13 2013-14 2014-15
Year-Wise Power Generation (MW-Hr)

22. In areas apart from controlroom earplugs, helmet & safety shoes are
compulsory. Gasmasks should also be worn dueto proximity to COgas.
ELECTRICALDEPARTMENT
As the whole plantis very energy intensive one; this departmenthas
immenseimportance. The electrical departmentlooks after
 33 MVA transformer of SAF
 Power feedingsystem of furnace
 The connection between the secondary terminalsof the
transformer and electrodesthrough aluminium busbar, copper
flexible conductorsand water cooled copper bustubes.
 CAPACITOR BANK to improvepower factor
Safety aspects
Wearingtested rubber hand gloves & safety shoes while doingany
electrical repair work is imperative.
INSTRUMENTATIONDEPARTMENT
The scope of this departmentincludes
 CALIBRATION of instruments
 PREVENTIVE MAINTENANCE of instruments
These dutiesare performed in accordancewith ISO 9001; whichgives us
 Procedureto carry out Calibration of Critical Instrument
 Frequency of Calibration
 Checking Tolerance level
Linear Variable DifferentialTransducer, RTD, PressureGauges, Gas
Analyser, COmonitors, Flow monitors, Weigh Bridges, Ultrasonic Position
Transmitters, power factor meter, watt meter are some of the instruments
we have at CFP.

23. MECHANICALMAINTENANCE ANDUTILITY
Mechanical Departmentcarry out furnacepreventiveperiodic
maintenanceactivity and furnaceshutdown activity. It also looks for
hoisting systems, furnaceelectrode slippingsystem, furnacecharging
system, weighing systems, weldingactivity.
Typically maintenanceactivities are grouped in to Major and Minor
activites. Further maintenance are scheduled accordingly Annual
MaintenancePlan and subsequently Monthly MaintenancePlan.
Utility is an allied departmentwhich providesservices. It take cares
of pumpsinstalled at variouspump houses, water pipelines and their
valves, monitorsoverhand tank, CO gas pipeline network, effluent
treatment plant, and other miscellaneousthings.
The pump houseno 3 is a major station where Auxillary Pumps,
PressureRingPumps, GCP Supply Pumps, Emergency Pumparein housed.
PRODUCTION PLANNING& CONTROL
This department works as the eye of the company. It receives
feedback from all departments on a daily basis which gives it a bird’s eyeof
the entire production cycle. It provides coordination and consultation
between how much has to be produced, how much we have produced and
how to achieve our targets.
The functions of PPC are as follows:

24.  To make annual business plan for the plant which includes
production plan, maintenance plan, market plan, project plan, HR
plan etc.
 To monitor the ABP through daily, weekly, monthly performance
report.
 To providecommunication & feedback between various departments
BUSINESS EXCELLENCE
The primary functions of this department are:
 To make unit scorecard of CFP.
 To look after the scorecard of top management i.e. GMs, DGMs.
 To maintain Quality Management System, Environment Management
System, OHSAS, Six Sigma.
MATERIALS MANAGEMENT DEPARTMENT
MATERIALS MANAGEMENT Department works in accordance with
PURCHASE AND CONTRACT PROCEDURE DOCUMENT laid out by SAIL
from time to time.
For every indent raised a Purchase control order number is
generated; and same is then referred to dealing officers to take decision; if
found viable the tender enquiry is floated. In tenders we specifically
mention about terms and conditions of liquidity damages, performance
guarantee bond, etc.
Tender enquiry can be
 SINGLE TENDER ENQUIRY

25. This type of tender enquiry floated when more than one player is
available in market that can take up job/ can deliver the service/ can
provide product of said specifications.
 PROPRIETARY TENDER ENQUIRY
This type of tender enquiry floated when the said work or product
can be provided by some specific player or specifically by a UNIQUE
one
 OPEN TENDER ENQUIRY
This typeof tender enquiry floated when venders are not known and
specifications are not clear from our side. According to PCP every
tender worth more than 30 lacs should be routed through open
tendering.
Once tendering done; the tenders were then opened publically and
materials procured through L1 bidder.
VIGILANCE DEPARTMENT
Vigilance at SAIL is preventive not punitive. This department maintains
service records for all employees for reference. It undertakes internal
audits so that the departments are prepared in case there is an external
audit. It also keeps watch on whether the CDA rules are being followed or
not.
LAW DEPARTMENT
This departmenttakes care of all legal issues of CFP. Its scope includeslegal
settlements in case of accidents, addressinggrievances of stock holders,
labour union conflicts etc.

26. TRANSPORT DEPARTMENT
The primeduty of TransportDepartmentis to transfersRaw material
from RM yard to ground hoppersand productfrom crusher to PH yard.
Also it looks after operation and maintenance of transportequipmentso as
to give 100% vehicle availability.
At TransportDepartmentwehave;
 Pay loaders 05 Nosof bucket size of 1.75m3 and 3.75 m3
 Dumpers10 Nosof capacities 50, 20 and 10 tonne
 Tractor 01 Nos with 7 trollies
 Dozzer 01 Nos
 Locomotive Engine
 Cars
 Ambulance02 Nos
WORKSHOP
Electrode casings are fabricated in house at Workshop. For this 2.3 mm
thick Mild Steel Hot Rolled plates ordered from Bokaro. On an average 1
casing per electrode per week is required which makes it total 6 casings
per week. Some extra casings are fabricated for emergency purposes. The
workshop also has a lathe machine for odd repair jobs. Maintenance of
charging system is also done by workshop.

27. CENTRAL LABORATORY
Laboratory at CFP has to do physical and chemical specification
checks to conform the quality desired. Laboratory has one X-RAY
FLUORESCENCE machine which on the basis of X-ray fluorescence
spectrometry determines the concentration of elements present in solid,
powered samples within seconds.
Laboratory has to do;
1. Raw Material Specification Check
2. Product and Slag Analysis
3. Stack Analysis (flue gases)
STORES DEPARTMENT
Stores Departmentresponsiblefor maintenanceof inventory stock,
to keep track of inventoriesso as to optimize inventory procurement,
carryingand storage cost.
In accordanceto that items are classified as Category
 A Category: Maximum useitems
 B Category: High on valueitems
 C Category: Generalpurposeitems
For every item a unique6 digit no is given. First two digits read as
item code. For example1-10 for TransportDepartment; 11-for Mechanical
maintenanceDepartment.
Only Any Time Purchaseitems are purchased and looked after by
stores, rest all by user departmentand to procureany productuser
departmenthas to quote an indentfor that.

28. PROJECTS
At CFP the construction of a 45 MVA Sub-merged Arc Furnace to
producearound 90,000 tonnes of High Carbon Ferro Manganese or 70,000
tonnes of Silico Manganese, with an investment of around Rs.185 crores is
going on. Setting up of a 4.00 MW (furnace gas based) Power Plant with an
investment of around Rs.38 crores is also envisaged.
For this Environment clearance has already been obtained and the
furnace is expected to get commissioned by December 2015
The Project is divided in various packages
FURNACE MAIN PACKAGE
The technology provider is Technova Pyromet (South Africa) and
package includes Design, supply and supervision for 45MVA Submerged
Arc Furnace. The main furnace package will have 3 single phase
transformers in place of single 3-phase transformer.
GROUNDHOPPER & TURNKEYPACKAGE FOR RAWMATERIALYARD
The contract was awarded to RELIABLE INFRA LTD and the skeleton
has been completed.
UTILITYPACKAGE
This package has been created for water cooling of furnace sections
and for water storage in case of emergency. The scope of this package
includespipenetwork, pumps and allied services, effluent pond, over head
tank. The contract was awarded to NICCO CO.

29. CIVILAND STRUCTURAL
The contract was awarded to RELIABLE INFRA LTD.
CRANE PACKAGE
This package includes a 5 tonne crane at the top of the furnace for
maintenance of electrode casings, a 60 tonne crane in the tapping area and
a 7.5 tonne crane for slag handling.
SUBSTATION PACKAGE
220kV substation package is given to ABB and 33kV to C&S electric,
New-Delhi. Cable trench construction is in progress.
POWER PLANT
The contract for erection and commissioning of power plant was
given to MSGB, CHENNAI
PASSENGER & MATERIAL LIFT PACKAGE
This package has been planned

30. PERSONNELANDADMINISTRATION
The Personnel & Administration department is responsible for the
healthy relationship of the plant with its employees as well as the outside
world. The important task of Human resource management is carried out
by P&A Department. In a broader perspective P&A carries out the following
tasks:
 Recruitmentof personnelaccordingto no. Of retirements and
requirementfor upcomingprojects.
 Promotion through the performancemanagementsystem
 Maintainingdiscipline, time keeping and attendancerecords
 Providingemployeeservicessuch as EPF, LTC, HRA, Car & Scooter
loans, medical facilities etc.
 Office managementi.e. providing& maintaining office furniture&
other amenities.
 Incentives& pay administration
 Public Relations
 ArrangingCSR activities/drives
 Township Administration
 Industrialrelations Management
FINANCE DEPARTMENT
Finance Department looks after all financial matter. The important
functions performed by this department are
 Preparation of Balance Sheet of company
 Issuing employee salary and wedges
 Allocation of funds received from corporate head office
 Monitoring of expenses occurred on various activities, projects.

31. CIVILDEPARTMENT
The main functionsof the civil departmentare as follows:
 Maintenanceof sheds
 Supportingprojectsdepartmentin expansion
 Raising indentsfor major civil works
Safety aspects
Wearinghelmet & safety shoes is compulsory whiledoingany civil related
job. Workersworkingat a height of 2 metres or above mustwear full body
harness.
ENVIRONMENT MANAGEMENT
Environment management system is extremely necessary for any
production unit due to the stringent environment laws. Every firm is
expected to comply with the air, water & land pollution act. The pollution
control board gives consent for 1 year for running the plant. This is
applicable to both Existing plant and new project.
Functions of environment management department:
 Recycling of oil/batteries through registered recyclers
 Ambient air monitoring which invlolves monitoring of SO2, NOx,
PM10, PM2.5
 Noise level monitoring of Furnace, SP-I & II, Crusher house
 Water monitoring by checking pH, suspended solids.
Steps taken in CFP to reduce pollutants impact on Environment
 Installation of pulse jet type bag filter at EAF
 Scientific treatment and disposal of Transformer oil

32.  Use of lumpy slag in road construction and land filling
 Slag as an ingredient in Welding Electrode Flux
OBSERVATIONS
 The power generation of power plant has reduced because the gas
availability is less and also due to a decrease in turbine efficiency.
 The production of sinter has decreased over the years because
requirement has decreased due to switchover from FeMn to SiMn
and also because tonnage obtained is less due to inferior quality of
raw material
 The careful study of monthwise furnace availability data for the past
years shows that November has been the worst month for SAF-I in
terms of furnace availability. In case of SAF-II the worst month is
July.
 Required safety precautions were seen to be followed in all
departments. But the use of gas masks and ear plugs was minimal.