SHRI BABA MAST NATH ENGINEERING COLLEGE

Submitted By: DEEPAK Roll No. 1 Me!"#$i!#l SEM

ACKNO%LEDGEMENT
The & mo$t" i$du't(i#l t(#i$i$) program is perhaps the most important and integral part of our curriculum. The reason as to why these six weeks are more than just a sabbatical from college are self evident. The training provides an ample opportunity to obtain genuine and first hand industrial experience and to augment theoretical knowledge through actual implementation and observation. The trainee works in office environs of some of the premiere industrial establishments of our country. Naturally the work culture leaves an indelible mark and a powerful impression also giving an ample opportunity to interact with professional in their respective streams. Training at B"u'"#$ *o+e( #$d 'teel ltd. has not only been beneficial in the technical aspects, but has also contributed immensely and actively towards growth in the personal capacity, organized and aware individual. I would like to pay my sincere thanks and gratitude to principal of our college. I would also like to thanks all lecturers of the mechanical department for their unconditional support and motivation. I am just truly indebted to them. ithout their support my training would not have been a success. I am thankful to ,i!e P(e'ide$t M(. A$u- Ke($ey allowing us to do our training in his reputed organization. I am thankful to A'tt. Ge$e(#l M#$#)e( M(. ,i.#' A(o(# our training in charge for his constant motivation and guidance and for the years of industrial experience that he has so readily shared with us. !ur training would not have been a success without his unconditional and never ending support "inally, I am thankful to the engineers and production managers working in their respective #epartments who contributed major in making the environment a better place to work in.

INTROD/CTION
The great demand for steel sheets in the %utomobiles, %ircrafts and other industries has caused rapid growth of strip&rolling production in many countries of the world. In the industrially developed countries the fraction of flat rolled products in the total volume of rolled products amount to '(&)( percent with the production of thin sheets and strips continuously increasing. India is also not lagging behind in this field. ith the economy poised for take off, the prospects of all core sectors industries&especially steel are bright. #eregulation five years ago has increased the level of activity in this sector and given it much needed volatility. *onsider the bigger picture for the steel industry+ The ninth five year plan projects suggest that the re,uirement of steel by the power sector alone would be about '.- million ton per annum .tpa/, which is more than the combined capacity of all the country0s integrated steel plants. hile construction of an platform consumed $((( tones of steel a process platform re,uire 1(,((( tones of steel. Thus the growth of the upstream and down stream sector of the oil industry augurs well for the steel industry too if these numbers are right they are only indicative of what lies in store+ a gap between domestic steel demand and steel supply of 1$ million tones per annum has been projected by $(($.

COMPAN0 PRO1ILE: 3hushan 4ower 5 6teel 7td., an I6! 8(($ certified company, is a merged entity of 3hushan Industries 7td., 3hushan 9etallics 7td. and #ecor 6teel 7td. having turnover of more than IN: 2((( *rores .;6# <-( 9illion/ is a leading manufacturer of "lat, :ound and value added products in 6teel. 3hushan 4ower 5 6teel 7td. has by continuous up&gradation of technology, redesigning structures, integrating and synergizing operations made a special place in production of various value added products in 6econdary 6teel segment among the steel producers in India. "rom production of special steel for vehicles and exports, 3hushan has made its mark. 3hushan 4ower 5 6teel 7td. is having < orld class and state of art plants at hite =oods segment to high class 6teel for

*handigarh, #erabassi, >olkata and !rissa in India. % completely integrated plant is commissioned under 4hase I in !rissa and 4hase II is all set for take off. In !rissa plant, technology and e,uipments are procured from world&renowned *ompanies like 7uirgi from =ermany, %33 7td., 696 #emag, 6iemens etc. 3hushan is selling its ?alue added range of products in 6econdary 6teel through a large distribution network in India .comprising more than 2- sales offices/ and %broad. % rock&solid foundation combined with continuous upgradation and innovation has ensured that we have constantly surpassed our goals. !ur end&to&end portfolio offers a wide spectrum of products with consistently superior ,uality. In addition to our export thrust, we supply to fast&growing sectors like automotive, white goods, construction, furniture, fasteners, telecommunication, etc. MISSION 2 ,ISION:

'

*ompany0s 9ission is to achieve clear identity and leadership globally in 6teel production and distribution by integration of complete chain of production starting from captive iron ore to end user 6teel products. *ompany0s revolution in 6teel production has helped it to carve a niche uni,ue only to a market leader. @very year passes by with new value additions and more accolades from their customers & 7ocally and =lobally. *ompany0s rising chart in respect of all& important parameters of production and finance is a testimony to its claim. I$ *u('ui$) it' mi''io$3 t"ey B"u'"#$ Po+e( 2 Steel Ltd. #(e )uided by t"e 4ollo+i$) 5#lue' 6 7u#lity & To be the best in ,uality. e aim and achieve excellence.

Te!"$olo)y & 6tate of the art technology and product enrichment by continuous :esearch and #evelopment. Cu'tome( 1(ie$dly & 4roducts are world class and more and more clients are appreciating and using our products. %lso undertake customized products with values addition and enhancement. Co(*o(#te Go5e($#$!e & *omply with all applicable laws and regulations. 3elieve in maintaining clean environment and conservation of natural resources. *ontribute towards betterment of our staff and provide them with best of facilities. E$5i(o$me$t P(ote!tio$ #$d P(#!ti!e & %dopting and implementing pollution control measures as a matter of policy

LOCATION O1 GRO/P COMPANIES:

M#$u4#!tu(i$) /$it'

1/ Industrial %rea *handigarh, 4lot No (2 $/ Industrial %rea *handigarh, 4lot No <1 2/ Industrial %rea *handigarh, 4lot No A2 '/ Industrial %rea *handigarh, 4lot No 1'1 & 1'$ -/ #erabassi, 4unjab )/ 3angihatti #ist. Booghly est 3engal </ Thelkoloi, !rissa

PLANT LA0O/T

B:6

4I*>7IN=

=%6 47%NT ! : > 6 B ! 4

*37

:ewinding 7ine

9I77 1

9I77 $

* T 7 1

*T7 2

*:6 $

*:6 1

% N N @ % 7 I N =

*:6 '

*:6 2

*:6 -

6>IN 4%66

#I64%T*B

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PROCESS 1LO% CHART

RA% MATERIAL

H.R. SLITTER

C.B.L.
.*!I7 3;I7# ;4 /

RE%INDING DEGREASING

ROLLING MILLS MILLSMIL L228 SKIN PASS MILL

PICKLING LINE

ANNEALING

7/ALIT0 CONTROL

PACKAGING

C.T.L.
*;T T! 7@N=TB

C.R. SLITTER

DESPATCH

PROD/CTS: 1/ T!: 6T@@7 $/ 6T@@7 3I77@T6 2/ =I 4I4@6 '/ =4 *!::;=%T@# 6B@@T6 -/ %77!C 6T@@7 :!;N#6 )/ *: *!I76 </ N%::! *: *!I76 A/ *: 6B@@T6 8/ =4 *!I76 D 6B@@T6 1(/ 4:@*I6I!N T;3@6 11/ *%37@ T%4@6 1$/ 37%*> 4I4@ 12/ I:@ :!#6 1'/ 4! @: 1-/ 64!N=@ I:!N

MARKETS: 19 Dome'ti! Cu'tome(' Bero Bonda Bonda 6cooters Camaha 9otorcycles E39 3ajaj %utos 797 7td. 4olar Industries =@ 9otors 347 B9T =N% group Bero *ycles %von *ycles %tlas *ycles #elton *ables "inolex *ables 6terlite 4aramount *ables

1(

 T36 6uzuki !max %uto 9aruti ;dyog 7td

89

E:*o(t Cu'tome(' *hina, 6ingapore, 9alaysia, Bong >ong, Indonesia, 4hilippines, #ubai, !man, 6audi %rabia, 6outh %frica, Thailand, >orea, 9yanmar, 6ri 7anka, Nepal, 3angladesh, ?ietnam, ;6%, Nepal,

11

@ngland, 3elgium, Turkey

INTROD/CTION TO DI,ISION: COLD ROLLING DI,ISION This plant of the 3hushan power and steel ltd. produces a number of steel products for domestic users.
4:!#;*T !" TB@ #I?I6I!N

19 NARRO% CR COILS Narrow *: *oils are used in the manufacture of %utomobiles, 4recision Tubes, *able Tapes, hite =oods, @lectrical 4anels, "urniture, Transformers, !il barrels and drums and general engineering products.

1$

89 CR SHEETS *old :olled 6heets are used in the manufacture of %utomobiles, engineering products. hite =oods,

@lectrical 4anels, "urniture, Transformers, !il barrels and drums and general

;9 CR COILS *old :olled *oils are used in the manufacture of %utomobiles, products. hite =oods, @lectrical

4anels, "urniture, Transformers, !il barrels and drums and general @ngineering

12

PLANT LA0O/T <P(o!e'' L#yout9 19 H.R.SLITTER 89 CBL<Coil Buildu* Li$e9 ;9 PICKLING &9 & HI MILL<Cold Roll Mill9 =9 RE%INDING LINE >9 ANNEALING <1u($#!e9 9 8 HI MILL <S.i$ P#'' Mill9 ?9 COLD ROLL SLITTER @9 C/T TO LENGTH 1A9 PACKAGING AND DESPATCHING

1'

RA% MATERIAL 9.6. .9ild 6teel/ 9@#I;9 *%:3!N 6T@@7 a/ 9.* 11.carbonF (.1$&(.$-/ b/ 9.* 1$.carbonF (.$-&(.2-/ 9.6. =:%#@6 .according to carbon F/ T0PE @.#.# .extra deep drawing/ #.# .deep drawing/ # =rade !ver =rade CARBON B (.('6(.()F (.()6(.(AF (.(A6(.1(F (.1(6(.1$F

SO/RCES O1 RA% MATERIAL 1/ 3!>%:! 6T@@7 47%NT $/ :!;:>@7% 6T@@7 47%NT

1-

2/ T%T% I:!N 5 6T@@7 47%NT '/ @66%: B!T :!77IN= =;E%:%T

19 H.R.SLITTER

1)

Hot (oll 'litte( #''embly !o$'i't' o4 4ollo+i$): *oil stand ay of coil car 4ay off assembly 6nubber assembly 4illar table 4inch roll assembly 6hearing machine =uide roll assembly *utter assembly 6crap rewinder 7oop pit Tension unit :ecoiler assembly Bydraulic pusher =ear box :otary union 4ower pack

1<

1/NCTION: The main function of the B.:.67ITT@: is to cut the sheet into different size of the widths according to the demand.

%ORKING: "irstly the coil is loaded on the coil stand then it is moved up to the pay off cones and is loaded on these cones. Then it is feeded to the levelers with the help of the pillar table then it is passed through the pinch rolls to remove the bends in the coils. %fter that the sheet is passed through the shearing machine where the unwanted front of the sheet is cut of. "rom here the sheet is then guided by the guide rolls to the cutter assembly. here the cutters according to the width demand are set on the cutter shaft and the sheet is slittered into different widths. The scrap is rewinded on the scrap rewinders on the both sides of the machine. hen the sheet is slittered as the sheet has a little

bit of taper in it so the thick side of the sheet gets easily recoiled at the end but the thin part gets loosened so, loop pit is provided so that the surface of the sheet don0t get scratched. Then the sheet passes from the tension unit where the tension is provided to the sheet. %fter that the sheet is recoiled on to the recoiler with separately according to the widths.

1A

89 CBL <Coil Buildu* li$e9 T"e !oil buildu* li$e !o$'i't' o4 t"e 4ollo+i$): *oil stand 4ay off assembly 6nubber assembly 4illar table 4inch roll assembly 6hearing machine elding platform Tension unit. - rolls, 2 ideal, $ working/ :ecoiler assembly Bydraulic pusher =ear box :otary union 4ower pack

1/NCTION T"e m#i$ 4u$!tio$' o4 t"e CBL #(e Inspection of the coil

18

To reduce the diameter of the coil .from )'(mm to -'(mm/ To join the )&< m long extra material is joined at the both ends, called leader end.

%ORKING "irstly the leader end is feeded to the leveler with the help of the pillar table. Then the coil is loaded on the pay off assembly and then it is feeded to the leveler with the help of the pillar table. %fter that the coil is sheared at the shearing machine and then the leader end is welded to it with help of the electric arc welding. Then the sheet is passed on to the tension unit with the help of the guide rolls here the tension is given to the sheet and then it is recoiled on the recoiler. %nd then it is taken off from the recoiler with the help of the hydraulic pusher after that it is carried over to the pickling line with the help of the crane.

;9 PICKLING T"e *i!.li$) li$e !o$'i't' o4 t"e 4ollo+i$): *oil stand 4ay off assembly 6nubber assembly 4illar table

$(

4inch roll assembly Tension unit. - rolls, 2 ideal, $ working/ :ecoiler assembly Bydraulic pusher =ear box :otary union 4ower pack 4unching machine Bydraulic clamping plate %cid tanks .2/ %cid tank I& 1.' to <F B*l %cid tank II& < to 1(F B*l %cid tank III& 1- to 1AF B*l

ater tanks .2/ Tank I && *old rinse water Tank II G *old rinse water Tank III G Bot rinse water

#ryers .$/ %ir blowers

$1

1/NCTION To remove oxide layer and maintaining surface To give brightness to the sheet 6urface maintaining depends upon following %cid temperature Bot rinse water temperature $$

4roper water flow spray

%ORKING "irstly the coil is loaded on the uncoiler and then is feeded to the leveler with the help of the pillar table. Then it is passed through the pinch roll assembly and then it is moved to the punching machine where the new entered sheet and the end of the ongoing sheet is punched together and then are bolted so that the new sheet easily get through the whole line. The sheet then passes through the first acid tank which contains B*7 acid 1.'&< F "e 1-&1)F and the temperature is )(H* and gets reacted with the acid solution Then the sheet passes through the second acid tank which contains B*7 <&1(F "e 12& 1'F and temperature is )$H* %fter that it passes through the third acid tank which contains B*7 1-&1AF "e <&AF and temperature )'H*. %fter it has been sprayed by plain water the coil passes through the three water tanks to remove the acid from the surface of the coil water inside the tank is slightly warm, temperature being '(&'-H*. The coil is passed through hot blower where temperature is <(&A(H*. "inally after sprinkled by rust preventive oil, it is recoiled at the recoiler end.

&9 & Hi Mill T"e & "i mill !o$'i't' o4 t"e 4ollo+i$):

$2

P#yo44 (eel Pi$!" (oll !um 4l#tte$e( E$t(y te$'io$ (eel <ETR9 T"e(mo )#u)e61 S"e#( &6Hi (olle(' T"e(mo )#u)e68 Deli5e(y te$'io$ (eel <DTR9

$'

1/NCTION The main function of the mill is to reduce the thickness of the sheet by providing tension.

T"i!.$e'' <mm9 ;pto (.1) (.'1 (.<' 1.$1 (.1&& (.'( && (.<2 && 1.$( && 2.((

Tole(#$!e <mm9 I (.(1I (.($( I (.(2( I (.('( I (.(-( I (.($( I (.(2( I (.('( I (.(-( I (.()(

$-

%ORKING The coil is passed through the work rolls and then the load is transferred from back up rolls. The current re,uired for '(2 mill is 1$(( ampere and for '(A mill is 1'((& 1-(( ampere. #uring initial pass maximum load is given to the coil and then it gradually decreases with increase in no. of passes. The reduction, which takes place, is maximum up to $-F during the initial pass. There is an automatic gauge control .%=*/, which controls the gauge at every pass. It tells the thickness from both sides i.e. @T: 5 #T:. Beat is generated during rolling of the coil. 6o to prevent the coil and work rolls being damaged by excessive heat, coolant is continuously sprayed. This ensures running of the coil. oolen felts are used as scrubbers for coolant running, steel

wool is used when coil is slightly rusty even after pickling, may get removed. There is exhaust fume blower present. "or the exit of the fumes formed during rolling of coil. The presence of these fumes may hamper the surface finish if not removed. The coolant sprayed during rolling should not pass on the coil surface during the final pass as it can make black patches of coil. 6o for this felt is necessary.

$)

=9 RE%INDING T"e (e+i$di$) li$e !o$'i't' o4 t"e 4ollo+i$): /$!oile( Le5ele( S"e#( S#ddle t#ble B(idle (olle(' Re!oile( d(um

1/NCTION The main function of the rewinding is to reduce the tension of the coil and avoid stickiness between the coil. 6econd is that of cutting the scrap metal sheets from the leading and trailing ends of the coil, which has joined during *37 operation.

%ORKING The coil is loaded onto the uncoiler by a coil car. The uncoiler is hydraulically operated and it feeds the coil to the feed table. 6hear is used for head end cropping of coil and also the leader and tail ends. %fter that the saddle table is actuated with the hydraulic cylinder 5 helps to feed the strip into leveler. Then bridle rolls are

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used to release the tension in the strip. There are two bridle rolls.

hen the speed of

the bridle rolls is more than the recoiler then it will loosely wrap the recoiler drum. Then the coil is recoiled at the recoiler drum. Then the tilter table is used to bring the coil into horizontal position as in the next step annealing this position is re,uired.

>9 ANNEALING

T"e #$$e#li$) li$e !o$'i't' o4 t"e 4ollo+i$) B#'e Lo#di$) Co5e( ti)"te$i$) P(e''u(e te'ti$) Pu()i$) He#ti$) So#.i$) Cooli$) /$lo#di$)

$A

1/NCTION T"e m#i$ 4u$!tio$' o4 #$$e#li$) #(e To relive the internal stresses set up during cold rolling To soften the metal and thus improve its machinability

$8

To produce brighter coil %ORKING "irst the lo#di$) is done by putting the coil strip on the b#'e one over the other by head operator. % pot is kept over the rubber sealing to make it air tight so that there is no contact of the coil with the atmosphere. ater is poured on the rubber sealing

to keep it cool. "an blows the hot air all around the pot. %fter clamping the base and the cover, air pressure is created inside. To know the pressure inside and also to check leakage or not, *(e''u(e te't is conducted. To remove air, *u()i$) is done. If not removed it may lead to irregular heating. !xygen present in air may form oxide scales on the surface of the coil. 6o it is necessary to eliminate it. 4urging is done by circulating nitrogen throughout the cover after purging only nitrogen is present in the cover. It is done for '(&)& minutes. "urnace is placed on the cover, temperature is set, fuel control valve containing diesel is opened, and combustion air is blown through the blower to the burner, which is fired by high speed diesel. The mode of heat transfer here is conduction. The empty space between the cover and the furnace is heated up which in turn heats the nitrogen gas inside the cover. This heated nitrogen gas is uniformly distributed inside the cover by the base fan. It is generally done for 11 to 1- minutes. #uring "e#ti$) we give the holding time so that any oil or coolant present on the coil surface should evaporate. The temperature is raised from (H to )'(Hc .for approx. ) coils/ and temperature varies as it depends on the thickness of the coil. The whole heating process is done for 1$ hours.

2(

%fter heating is done, here the temperature of )((&)-(H* is maintained constantly for 1(&1- hours. #uring 'o#.i$) process exhaust valve is closed so as to increase the pressure inside the cover. The stress in the coils is relieved during this stage and coil tends to soften. =rain refinement takes place during soaking. %fter soaking, !ooli$) takes place. "irst the coils are slowly cooled in the presence of air for ,uite a long time to bring down the temperature of coil to $((& $-(H*. Then it is water cooled till the temperature of the coil comes to 1((H*. #uring cooling process the exhaust valve is closed so as to increase the pressure inside the cover. *ooling takes place by placing cooling hood on the top of the base there is water inlet and outlet valve. 4resence of water is necessary between base top and cover bottom as it maintains coolness between them. If it is not maintained then due to excessive heating, the seal between may get damaged which will lead to gas leakage to the outside atmosphere. It can also lead to melting of base top and cover bottom. There are total eight burners on the furnace through which combustion takes place. 3ut during soaking not all burners are working and the flow of diesel is also limited. There is an oxygen analyzer in the furnace indicating the percentage of the oxygen present. "irstly the cooling hoard is removed and then the cover is removed. %fter this the coil is allowed to cool up to the room temperature. The overall annealing process takes 'A hours.

9 SKIN PASS MILL

21

T"e '.i$ *#'' mill !o$'i't' o4 t"e 4ollo+i$) /$!oile( 1eed t#ble 8 Hi (olle(' Re!oile(

1/NCTION The main function is to produce accurate thickness and very smooth surface.

%ORKING In skin pass mill the coils are either given bright surface or matt surface as per re,uirement. The coil is loaded onto the uncoiler by a coil car. The uncoiler is hydraulically operated and it feeds the coil to feed table. The feed table is actuated with the hydraulic cylinder 5 helps to feed the strip into leveler. Then there are two backup rollers which are to impart impression upon the coil. Then the rust preventive oil is sprayed on the coils and they are recoiled at the recoiler.

2$

?9 C.R.SLITTER T"e C.R.Slitte( !o$'i't' o4 t"e 4ollo+i$) /$!oile( Coil *eele( t#ble Ko(4le: (oll De4le!to( (oll #$d 'ide )uide' Slitte( S!(#* (e+i$de( Loo* *it Te$'io$ t(olley O5e( #(m 'e*#(#to( Re!oile(

1/NCTION In this the wider coil is cut into three or four coils as per re,uired widths.

%ORKING The coil is loaded onto the uncoiler by a coil car. The uncoiler is hydraulically operated and it feeds the coil to feed table. The feed table is actuated with the hydraulic cylinder 5 helps to feed the coil to back up rolls. #eflector rolls are fitted in side guides that ensure proper coil path. Then cutters are used to cut the coil into different widths. Two power unloading scrap rewinders are located under a table to

22

keep the scrap away< from the line operators. 7oop pit is provided to prevent the coil from rubbing by the floor when the coli move through the loop and also to avoid scratch lines on the coil. >orflex rolls are used to remove burr from the soil edges. *oils are guided into tight straight walled coils by an over arm separator that is supported from the exit unit. Then the coil is recoiled at the recoiler.

@9 C.T.L < Cut To Le$)t"9

1/NCTION To cut coil into re,uired lengths.

%ORKING It is a hydraulically operated machine and fitted with a shear cutter. The coil is pre adjusted. Thus the coil is cut down into the strips of precisely e,ual lengths. These strips are then sent for packing and then they are dispatched.

2'

1A9 PACKAGING AND DESPATCHING

This is the last department of the manufacturing plant. %fter the coil has been 4rocessed, that is, it has been rolled annealed and slitted in *:6 section as per the 4arty0s re,uirement, it is then packed in packing section. The packing is done by to party0s re,uirement. The packing is done either by Bessian .(F moisture/ J polythene .generally for *DT product/ or by Bessian only. %fter the coil is wounded with Bessian or polythene, it then secured tightly by packing party. Then the coil according to its size is then weighed in weighing machine. The slitted coils are then shifted to godown and the coil status is given to the excise department. %fter that marketing department issues dispatch order to packing and then the coil is loaded into trucks to be delivered to the concerned party.

2-

2)