Report on

Faculty Development Programme

On
“Industrial Processes & Practices”
( Sponsored by TEQIP-III)
Organised by IIT Bhilai & CSVTU
At Bhilai Steel Plant, Bhilai
14-16 Nov 2019
A faculty development programme was organized from 14th to 16th Nov, 2019 at Bhilai Steel Plant on
“Industrial Processes & Practices” under TEQIP-III jointly by IIT-Bhilai & CSVTU Bhilai. This was a three
day Faculty development programme that had a combination of theoretical exercise as well as practical
exposure of the same on the same day.
The FDP aims to provide opportunities to faculty members to enrich their knowledge and skill related to
various industrial practices and processes. This programme also intends to help faculty members to
guide and mentor students for vocational training.

INAUGURAL SESSION:
The esteemed personalities present on the inauguration of the programme:
 Shri Saurabh Sinha GM( HRD ), Bhilai Steel Plant
 Shri S K Dubey ED (P&A), Bhilai Steel Plant
 Dr. S Gangopadhyaya Chief Coordinator, FDP , IIT-Bhilai

Shri Subhash Bhai Patel, Mgr ( HRD) welcomed all the respected dignitaries and participants. Shri S K
Dubey , ED (P&A), Bhilai Steel Plant appreciated the program organized by IIT-Bhilai in his speech and
spoke about the importance of industrial oriented education in the country. Shri Saurabh Sinha, GM(
HRD ), Bhilai Steel Plant also encouraged for such activities. Dr. S Gangopadhyaya Chief Coordinator, FDP
, IIT-Bhilai stressed upon the paradigm changes from black board based teaching to modern practical
approach based teaching he also emphasized the benefits of such kind of resourceful activity and
described the objectives of this FDP.

TECHNICAL SESSIONS:

1ST DAY (14th Nov 2019)

Session-I
In the first technical session of the first day of the programme, Shri Vivek Verma, GM (Blast Furnace)
Bhilai Steel Plant delivered an interactive lecture covering the below topics:
 Overview of Bhilai Steel Plant
 Working of Integrated Steel Plant & Blast furnaces
 Raw materials and their sources
 Iron making process
 Steel making process
 Finishing mills
Session-II
In the next sessions of the day, Shri K Ramakrishna, GM (SMS-III) Bhilai steel plant delivered talks
related to Steel Melting Shop covering the below topics:
 Constituents of Iron and Steel
 History of Steel making process
 Casting process used in Bhilai steel plant
 Ingot casting
 Continuous casting
 Process flow of SMS-II
 Sequence of Operation in SMS-II & SMS-III
 Brief discussion of various sections in SMS-II & SMS-III

Session-III
An informative briefing on safety was given by Shri V K Shrivastav, GM (Safety Engineering
Department) Bhilai Steel Plant in which the below points were covered:
 Why Safety? Moral, Legal and Economical aspects
 Domino theory of accident causation
 Unsafe acts, Unsafe Conditions, Accidents and near miss
 Hazard Pyramid and safety triangle
 Hazard control strategy
 Behavior based safety challenges
 Accident prevention

Visit-1 :
Blast Furnace-8

Special thanks to Mr. Vikash Nashine,(BF #8) who addressed, guided and shared his knowledge with all
the faculty members.
Visit-2 :
Steel Melting Shop (SMS-III)

2nd DAY (15th Nov 2019)

Session-I
In the first technical session of the second day of the programme, Shri Pankaj Puri, GM (R&SM) Bhilai
Steel Plant delivered an enlightening lecture on “Theory of Rolling Process and manufacturing of rails
and Structural” covering the below topics:
 Rolling and its types
 Recrystallization temperature and it importance
 Long and flat products in rolling
 Draft, Spread, Angle of contact and Angle of Bite
 Effects of Hydrogen in rails
 Various structural profiles
 Rail making process
 Inspection: Acceptance and qualifying criteria
 Pre cambering & Rail straightening
 Thick web rails (TWR)
 Universal Rail Mill (URM)

Session-II
In the next sessions of the day, Shri Yogesh Shastri, GM (BE) Bhilai steel plant delivered talks related to
“Total Productive Maintenance” covering the below topics:
 Maintenance and its importance
 Overall equipment effectiveness
 Evolution of maintenance system
  5S System
 Eight pillars of Total Productive Maintenance

Session-III
In the third session Dr. Kaushik Bandyopadhyay, IIT Bhilai explained in detail about the mathematical
analysis in rolling operation.

Visit-3
Universal Rolling Mill

Visit-4
Merchant Mill & Wire Rod Mill
3rd DAY (16th Nov 2019)
Session-I
In the first technical session of the last day of the programme, Shri AM Danny, GM (Instrmn) Bhilai Steel
Plant delivered an enlightening lecture on “Industrial Automation” covering the below topics:
 Industrial Automation, it’s advantages and disadvantages
 History of process control and operations
 Automation in production system
 Levels of industrial automation
 PLC & DCS system, their advantages, disadvantages, historical background and major
components
 Important automation system in BSP
 Industrial Internet of things
Session-II
In the next sessions of the day, Dr. Rahul Jain, IIT Bhilai delivered talks related to “Maintenance and its
economic justification” covering the below topics:
 Reliability and failure rate
 Bathtub curve in reliability
 Service rate and its importance in maintenance
 Availability
 Case Study: Maintenance of equipments in industries

Session-III
In the third session of last day Shri Alok Goyal, DGM (RCL) Bhilai Steel Plant delivered an interactive
lecture on “Inspection & Quality Control in BSP” covering the below topics:
 Plant Layout
 Process Parameters and testing of Coke Oven, Sinter making, iron making, steel making and
rolling.
 Standards and specification code for steel making

FEEDBACK SESSION:
Participants shared their experience and feedbacks in which they talked about their enriching
experience at the FDP.

VALEDICTORY SESSION:
The honorable personalities present in this occasion were Shri V Dhawan, CGM ( Quality) BSP and Shri
Saurabh Sinha, GM( HRD ), BSP ,they gave their concluding remarks and distributed the certificates to
all the participants. In the end Shri Subhash Patel gave the vote of thanks and concluded the three day
faculty development programme.
OUTCOME:
All the sessions were very much informative. The discussed areas are of great benefit for the
participants as the topics match with the academic curriculum. Participants were enlightened with the
most widely used advance strategies in steel making. This in turn will help in motivating participants as
well as students & student’s placement opportunity.

ACTION PLAN:
 Mechanical Engineering department to introduce a job orientated subject as Maintenance
Engineering. Course should be taught such that 70% of this course is cover by our faculty & 30%
will be covered by ON-Skills experts. Experts will be asked to come and cover during the
semester.
 Pre-Training Lectures to be given to students who are going for vocational training, so that they
can understand the importance of training and have some prior knowledge before vocational
training.

Name of Participant: Prabhjot Singh Virdi

Branch: Mechanical Engineering
College: BIT, Raipur