A REPORT ON

“Flatness Measurement Guage (FMG)”

Ankush kumar yadav(21120020)

Anish dash(21120019)
Piyush bisen
Akash kumar

BACHELOR OF TECHNOLOGY
METALLURGICAL AND MATERIALS ENGINEERING (2020-24)
(10 JUNE ,2024-06TH JULY ,2024)

NATIONAL INSTITUTE OF TECHNOLOGY

RAIPUR, CHHATTISGARH -492010
 CERTIFICATE

This is to certify that Ankush kumar yadav, Anish dash, Piyush bisen, Akash kumar has worked under my
guidance for completion of their project on:

“flatness measurement guage(FMG)”

Apart from suggestions made by me, the credit for all experimental work goes to them. I appreciate their
hard working, involvement and tenacity to complete their project well in time.

Guided by

Shri. Sunil kumar Shukla (Assistant General Manager, RSM)

SAIL, Bhilai Steel Plant (BSP)

 ACKNOWLEDGEMENT

We would like to express our sincere gratitude and appreciation to everyone who helped us to complete this project. First of
all, thank you to our caretaker Thanks to Shri. Sunil kumar Shukla for his guidance, support and valuable insight in this
effort. Their expertise and dedication helped us to direct and improve the quality of our work. His valuable feedback and
constructive criticism contributed greatly to the refinement of this project. He encouraged us during difficult times in our
studies and gave us great confidence.
Furthermore, I would like to thank the team members for this project. Their insights, discussions and motivation are
invaluable in shaping our ideas and keeping the team enthusiastic.
Finally, I would like to thank our family for their continued love, encouragement and understanding. His constant support
and trust in us are the driving force behind our success. I would like to thank all of you for your valuable support, guidance
and encouragement.

Place: Bhilai, Date : 06-07-2024

Bhilai Steel Plant is the flagship of SAIL. The quality of rail tracks produced by bhilai steel plant is being monitored by using the
specially designed machined called flatness measurement guage (FMG).

In this project work we have detailed what is flatness measurement guage (FMG), the structure and its component, detailed working of
it, factors affecting the flatness of rails, performance of FMG, caliberation technique , quality check methods and process along with
other methods, data and graph related to it, variance between manual data and computer data.
We have also stated the quality parameter imposed by the central government on the quality test of rails. We have also discussed about
the threshold criteria for the quality check tests.
The Bhilai Steel Plant (BSP), located in Bhilai, in the Indian state of Chhattisgarh, is India’s First and main producer of steel rails, as
well as a major producer of wide steel plates and other steel products.
Eleven times winner of Prime Minister’s Trophy for Best Integrated Steel Plant in the Country,Bhilai Steel Plant (BSP) has been India’s
sole producer and supplier of world class Rails for Indian Railways including 260 meter long rails, and a major producer of large variety
of wide and heavy steel plates and structural steel. With an annual production capacity of 5 MT of saleable steel, the plant also
specializes in other products such as wire rods and merchant products. The entire range of TMT products (Bars and Rods) produced by
the plant is of earthquake resistant grade and superior quality. The plant also produces heavy structural including channels and beans.
Bhilai Steel Plant functions as a unit of SAIL, with corporate offices in New Delhi. The chief Executive officer controls operations of the
plant, township and iron mines. The CEO is assisted by his D.R.O.s(Direct Reporting Officers), i.e. the functional heads, Executive
Directors, general Manager concept of zonal heads, and HODs who integrate functions with Clear accountability for achieving corporate
vision, company goals and objectives.
Since BSP is accredited with ISO 9001:2000 Quality Management System Standard, all saleable products of Plant come under the ISO
umbrella. The Plant’s HR Dept. is also Certified with ISO 9001:2000 QMS Standard. ISO: 141001 has been awarded for environment
Management System in the Plant, Township and Dalli Mines. The Plant is accredited with SA:8000 certification for social accountability
and the OHSAS-18001 Certification for Occupational Health and Safety.
BSP has receive Integrated Management System (IMS) Certificate by a single certifying agency (M/s DNV), Integrating QMS, EMS,
and OHSAS & SAMS- becoming the first SAIL unit and among few corporate houses in India to achieve this unique distinction. Since
BSP is accredited with ISO 9001:2000 Quality Management System Standard, all saleable products of Plant come under the ISO
umbrella. The Plant’s HR Dept. is also Certified with ISO 9001:2000 QMS Standard. ISO: 141001 has been awarded for environment
Management System in the Plant, Township and Dalli Mines. The Plant is accredited with SA:8000 certification for social
accountability and the OHSAS-18001 Certification for Occupational Health and Safety.
BSP has receive Integrated Management System (IMS) Certificate by a single certifying agency (M/s DNV), Integrating QMS, EMS,
and OHSAS & SAMS- becoming the first SAIL unit and among few corporate houses in India to achieve this unique distinction.

S.No. Raw materials Sources

1 Iron Ore Fines Dalli Rajhra

2 Iron ore lumps Dalli Rajhra

3 High Silica Limestone Nandini

4 High Silica Dolomite Hirri Mines

5 Low Silica Limestone Jaiselmer, katni, kuteshwar

6 High Silica Mn Ore Rantake Tirodi

7 Coal (Indegenous) Bhojudh,

Nandan,Rajarappa
8 Coal (Imported) Australia, New Zealand
Sources of Raw materials in BSP –

Presently, the total requirement of iron ore of Bhilai Steel Plant is met from Dalli Rajhara IronOre Complex (IOC). In view of IOC’s
rapidly depleting reserves, BSP is opening an iron ore mine at Rowghat, about 80 kilometres (50 mi) from Dalli Rajhara in Narayanpur
District of Chhattisgarh. Accordingly, Bhilai Steel Plant will develop the mine in Block-A of deposit-F of Rowghat with a production
capacity of 14.0 MT per year during 2011-12.
Departments in Bhilai Steel Plant –
Rail & Structural Mill
Coke Ovens
Blast Furnace
Steel Melting Shops
Mills
Sinter Plant
Research & Control Lab
Foundry
Rail & Structural Mil
 INTRODUCTION

In recent years, high-speed railways have undergone rapid development, resulting not only in economic growth, but also in higher
requirements for high-quality railway construction. Straightness is a geometrical feature to evaluate rail quality , and refers to the
roughness perpendicular to the rail reference plane, which directly affects the running speed, and therefore the safety of train.
Many straightness measurement methods for rails have been proposed. In the recent years, systems tend to use noncontact
techniques, mainly based on automated visual inspection using structured light. For example, machine vision methods that use
different light sources to scan the surface of the rails, are also used to detect straightness. Other methods are based on a laser
triangular ranging principle using distance sensors.
The most widely used method in rail welding plants is to use an electronic straightness ruler, such as the Flatness measurement
guage(FMG), which is placed on the rail ridge lines, and the measurement results are sent to an embedded handled computer, which
records the straightness results.
In this paper, an accurate and convenient approach is proposed to measure rail straightness. This method avoids human
errors during the rail quality evaluation, and significantly promotes the development of fully automatic non-contact rail straightness
detection. The rest of the paper is organized as follows: Section summarizes the related standards, Section describes the proposed
approach, Section shows the experimental results and Section presents conclusions.
 CONCLUSION
In this paper, the non-contact vision system is used to replace the artificial use of the physical straightness ruler and feeler to measure
the top straightness error. It has certain enhancing and reference significance, for realizing automation and intelligence on the rail
straightness measurement.
In this paper, an accurate and convenient approach is proposed to measure rail straightness. This method avoids human
errors during the rail quality evaluation, and significantly promotes the development of fully automatic non-contact rail straightness
detection. The rest of the paper is organized as follows: Section summarizes the related standards, Section describes the proposed
approach, Section shows the experimental results and Section presents conclusions.