SECTOR-26, CHANDIGARH

DIPLOMA ENGINEERING
SESSION= 2011-2014
VOCATIONAL TRAINING PROJECT REPORT
SUBMITTED BY: SUBMITTED TO:
NAME – SHUBHAM SHARMA SMT. SEEMA SINGH

BRANCH – MECHANICAL (TRAINING OFFICER)

ROLL NO. – 5349/10 MR. CHAMAN LAL

REGN NO. – 110095329772 (H.O.D MECHANICAL)

SEMESTER – 5th

IN PLANT – BHUSHAN POWER & STEEL LTD., FACTORY NO.-22, IND. AREA, PHASE -1

CHANDIGARH.
 REPORT
On
One Month Industrial Training
At
Bhushan Power & Steel Pvt. Ltd.
(From 15 June 2012 – 14 July 2012)
 CONTENTS
S.NO TEXT PAGE NO.
1. Acknowledgement 1-4
2. Company Profile 5-10
2.1 Products 11-12

3. Training Report 13-32

3.1 Wire Rods 14-15
3.2 Raw Material Section 16
3.3 Step For Production Of Wire Rod 17
3.3.1 Reheating Furnace 17
3.3.2 Rolling Mill 18-20
3.3.3 Cooling Bed 21
3.3.4 Pre Delivery Inspection (PDI Section) 22
3.4 Wire Pointing M/C 23
3.5 Wire Straightening & Cutting M/C 24
3.6 Wire Drawing M/C 25-27
3.6.1 Medium Pulley Type Continuous Drawing M/C 25
3.6.2 Straight Line Wire Drawing M/C 26-27
3.7 M.S Wires 28
3.8 Wire Drawing Process 29-31
3.9 TOR Steel 32

4. Time Study 33
5. Observation & Calculation 34-37
6. Machinery & Tool Details 38-50
7. Bibliography 51


I would sincerely like to thanks BHUSHAN POWER & STEEL LTD. for allowing
me to persue 1 month Industrial Training in their esteemed organization.

I would also like to thanks Mr.ROSHAN LAL (General manager) and

Mr. SUNIL (Production Engineer) who guided us and told us about the
various processes in the plant.

I would also like to thanks other staff members of the company who shared
their great and helpful experience with me to get the useful knowledge

I would like to thanks our training & placement officer for giving me a golden
opportunity of Industrial training, which would help me to enhance my
technical aspects.
BHUSHAN-The Beginning
Brij Bhushan Singal, the prime mover, a visionary entrepreneur founded the
Bhushan group than 20 years ago in Chandigarh.

Making a moderate start with manufacture of hinges rail track fasteners in

early 70’s with a capital less than a lakh of rupees, the group has
continuously grown by modernizing, expanding and integrating its fascilities/
operations.

Joined by his young and dynamic sons Sanjay & Neeraj in the 80’s and taking
advantage of the liberalized environment in the steel sector, Brij Bhushan
Singal has propelled the group to the success earning it a permanent place
among the large players of the steel industry, with a turnover of Rs. 2200
crore, cash profit of over Rs. 180 crore and net worth of Rs. 500 crore

BHUSHAN POWER & STEEL LIMITED

Bhushan power & steel limited, is an ISO 9002 certified company of
erstwhile Bhushan Group, is a merged entity of Bhushan Power & steel
Limited, Bhushan Mettalic Limited & Décor Steel Limited having turnover of
more than INR 2000 Crores (USD 460 Million) is a leading manufacturer of
Flat, Round and value added products in steel.

Bhushan Power & Steel Limited has by continuation up-gradation

of technology, redesigning structures, Integrating & synergizing operatios
made a special place in production of various value added products in
secondary Steel segment among the steel producers in India.
From production of special steel for vehicles and white goods segment to
high class steel for Exports, Bhushan has made its mark. Bhushan Power &
Steel Limited is having 7 World Class & state of art plant at Chandigarh,
Derabassi, Kolkata & Orissa in India.

A completely integrated plant is commissioned under Phase-I in

Orissa and Phase-II is all set for take off. At all of these plants, technology and
equipments are procured from world-renowned Companies like Luirgi from
Germany, ABB limited, SMS Demag, Siemens etc. Bhushan is selling its value
added range of products in Secondary Steel through a large distribution
network in India ( comprising more than 25 Sales offices ) and Abroad.

Among our major and valued customers in India are Hero Honda, Honda
Scooters, Yamaha Motorcycles, JBM, BPL, HMT, GNA Group,
Hero Cycles, Avon Cycles, Atlas Cycles, Delton Cables etc.

Bhushan’s products are being exported to China, Singapore, Malaysia,

Hong Kong, Indonesia, Philliphines, Dubai, Oman, Saudi
Arabia, South Africa, Thailand, Korea, Mayanmar, Srilanka,
Nepal, Bangladesh, Vietnam etc. and a host of African
countries.
GROWING FROM STRENGTH TO STRENGTH
1970 - Started with very small initial outlay for manufacturing Door Hinges &
later on, Rail Track Fasteners.

1973 - Manufacturing facilities set up for Tor Steel and Wire Rod in
Chandigarh.

1981 - Rolling Mill Project commissioned at Chandigarh for Round and

Narrow Strips.

1985 - Backward Integration Project for Steel Melting facilities.

1986 - Upgrading of Mini Steel Plant with continuous casting and ladle
furnace facilities. 1997 - Commissioning of Narrow Width Cold Rolling Project
at Chandigarh.

1998 - Commissioning of Precision Pipe Project at Chandigarh.

2001 - Commissioning of Cold Rolling & Galvanizing Complex at Kolkata.

2002 - Addition of narrow width Cold Rolling facilities at Kolkata.

2003 - Expansion of wide width Cold Rolling facilities, ERW Water Pipes &
Tubes down stream facilities at Kolkata.

2004 - Further expansion of Cold Rolling facilities at Kolkata.

2005 - Commissioning of Orissa Project consisting of 4 DRI Kilns, Steel Making

Facilities, Coal Washery and 100 MW Power Plant.

2007 - Commissioning of further expansion of Orissa Project consisting of HR

Coil Mill, Steel making, Blast Furnance, Sinter plant, Coke oven plant, Oxygen
plant and Lime & Calcining Plant.
2009 - Commissioning of 3.5 million tpa Coal Washery, 146 MW Power Plant
and 0.3 million tpa Sponge Iron under Phase III of Orissa Project.

2010 - Commissioning of 130 MW Power Plant and Electric Arc Furnace

under Phase III of Orissa Project and further expansion of Orissa Project
under Phase IV consisting of 6 DRI Kilns, 130 MW Power Plant, Steel Making
Facilities, 6th strand, 2nd CSP Caster & Tunnel Furnace, Oxygen Plant, Lime
Calcining with downstream facilities - Cold Rolling, Galvanizing, Galvalume,
Colour Coating, Precision Tube & Black Pipe/GI Pipe.

MISSION & VALUE

Our Mission is to achieve clear identiy and leadership globally in Steel
production and distribution by integration of complete chain of production
starting from captive iron ore to end user Steel Products.

Our revolution in Steel production has helped us to carve a niche unique only
to market leader.

Every year passes by with new value additions and more accolades from our
customers- Locally and Globally.

Our rising chart in respect of all important parameters of production and

finance is a testimony to our claim.

In persuing our mission, we at BHUSHAN POWER & STEEL LIMITED are

guided by following values—

QUALITY—To be the best in quality. We aim and achieve excellence.

TECHNOLOGY—State of art technology and product enrichment by

continuous Research and Development
CUSTOMER FRIENDLY— Our products are world class and more and more
clients are appreciating and using our products. We also undertake
customized products with values addition and enhancement.ss

CORPORATE GOVERNANCE— We comply with all applicable laws and

regulation. We believe in maintain clean environment and conservation of
natural resources.

We contribute towards betterment of our staff and provide them with best
of fascilities.

ENVIROMENT PROTECTION AND PRACTICE— We are adopting and

implementing pollution control measures as a matter of policy.

OUR COMMITMENTS—

 To improve the quality of our products and complete integration of

various stages of production.
 To be conscious towards quality and pricing of our products. We strive
by continuous research and development to make our products world
class, having distinct identity and uniqueness. Our customers get best
value for their money.
 To run the company profitably year after year.
 To workforce motivated, skilled and well looked after.
PRODUCTS :-
1. Flat Products-
 Cable Tapes
 GP Coils
 Steel Coils
 GP Coils & Sheets
 Cold Rolled Sheets
 Narrow CR Coils
2. Long Products-
 Steel Billets
 Alloy Steel Rounds
 TOR Steel
 Wire Rod
 Precision Tubes
 Black & Galvanized Pipes
3. Sponge iron
4. Pig Iron
5. Power Plant
PRODUCTS

`
PRODUCTS PRODUCED BY BHUSHAN POWER & STEEL LTD.
(3.1) WIRE RODS—
BHUSHAN POWER & STEEL LIMITED are manufacturers of IS-2062 and
Electrode Quality in our Plant located at 3, Industrial Area Phase-I,
Chandigarh.

WIRE RODS
(3.1.1) Applications—
Wire Rod is used as raw material by Wire Drawing Units, Electrodes, Wire
Mesh, Fasteners, Hardware and Automobile components manufacturers. We
meet stringent quality parameters.

We manufacturer Wire Rod from superior quality Billets produced

by our own Integrated Steel Plant situated at Jharsuguda (Orissa) to ensure
high strength and long life. The sizes of Wire Rod being manufactured by us
are from 7.5mm to 13mm.
3.1.2) PROCEDURE TO MANUFACTURE WIRE RODS
In Bhushan Power & Steel Ltd. Wire rods is manufactured by
hot rolling process.
The various steps of this process are described as follow-

RAW MATERIAL (BILLETS)

REHEATING FURNACE

ROLLING MILL

COILER

COOLING BED

FINISHING

FINAL PRODUCT (WIRE RODS)

FLOW CHART TO MANUFACTURE WIRE RODS

(3.2) RAW MATERIAL SECTION
This is the Section of the company where the raw materials
are placed which are used in the manufacturing process of
the products.

Fig 2-BILLETS
Billet is used as a raw material semi finished length of Steel
which can be worked in a rolling mill or for forging
operations. Billet is made up of mild steel. These are also
known as bloom, slab, sheet bar. Billets are available as round
bar, flat bar, wire rod etc. These Billets are produced at our
Chandigarh and Orissa Plants.
These billets are cut according to the diameter and length of
the products. For less diameter products billets are cut into
three pieces and for large diameter billets are cut in two
pieces. After cutting these billets are put into the furnace.
(3.3) STEPS FOR THE PRODUCTION OF WIRE RODS
(3.3.1) REHEATING FURNACE
Furnace is the heart of the factory. Rolling is impossible
without heating the billets. Billets are heated so as to make
them soft and suitable for rolling. Moreover heating also
prevents residual stresses. Furnace has three parts: walls,
roof and hearth (floor). Furnace is lined with several layers of
refractory bricks. It is insulated by glasswool. Heating zone of
the furnace has temperature of 1100 degree Celsius. Low
Alumina bricks are used for this zone. Soaking zone has

Fig 3- REHEATING FURNACE

temperature in excess of 1250 degree Celsius. High Alumina
bricks are used for this zone.
(3.3.2) ROLLING MILL
Once heated to the appropriate temperature the billet then enters the continuous bar rolling line. In basic
terms the rolling line has three phases - the “roughing” stands or preliminary rolls, which do the initial
rough shaping, then the “intermediate” stands which further refine the steel to a more oval shape and
finally the “finishing” stands which finally shape the steel to the appropriate size, deformation pattern and
shape.

Fig 4-PROCESS OF PRODUCTION OF WIRE RODS

The steel can pass through various sets of rolls to reach
its final shape. As the steel billet passes through each
roll it speeds up as the area of the bar gets smaller,
The length gets longer and therefore it accelerates,
quite like rolling out pastry.
This can be quite a sight when you see the glowing steel
passing through the line.
Each of the rolls are technically designed to not only
produce the correct size product,
But do it in a way that ensures the product quality, and
considers the limitations of the way steel behaves, and
the equipment that controls and drives the rolls.
This process of manufacturing the wire rods is
processed at such a very fast rate that a bundle of wire
rods weighing 200 Kg is prepared in just approx. 42
seconds after coming out the hot billet from reaheating
furnace.

ROLLERS USED IN ROLLING MILL

The rollers in the rolling mill are mounted in a stand, ready to
be installed in the rolling mill has a series of differently
shaped grooves and the material pass them in a pre-
determined sequence in order to get a thoroughly worked
material.
 Fig 5-ROLLING STAND WITH REVERSIBLE ROLLERS

The intermediate and final pairs of rollers are mounted in

line, one after the other.
After the very final pairs of rolls the wire rod is laid by a
laying head in coil form on a conveyor and transported to
cooling and heat treatment, if any.
(3.3.4) COOLING BED
After the steel leaves the rolling line it goes on cooling bed, as the
name suggests, is where finished bars are placed for cooling. Cooling
bed is simply a raised platform with chains ‘wrapped’ round it.
Chains roll on sprockets.
 Fig 6-COOLING BED
These sprockets are mounted on a shaft, which rotates very slowly.
Slow speed is maintained to allow time for bars to cool down. These
chains carry the bars from one end to the other, from where it is
dropped on to a conveyor. Once on the cooling bed the bar cools to
a manageable state and is then further processed at a cold shear
where it is cut to the customer required length.

(3.4) PRE DELIEVERY INSPECTION (PDI SECTION)

In this section, the product(WIRE RODS) is checked / tested
after manufacturing against its various characterstics like
shearing, hardening, bending, breaking etcbefore dispatch.
All the finishing processes are completed by this department.
When the products are inspected that they are ok for use
then these products are transported to their packaging
section.

(3.5) FINISHED PRODUCT

Fig 7- WIRE RODS

(3.6) WIRE POINTING MACHINE—

This machine is suitable for pointing different types of materials like
Mild Steel, High Carbon Steel, Aluminium, Copper, etc. The pointing
rolls are made of EN-31 material and are ground finished. They are
driven by power as well as by hand. The machine is mounted on 4
wheels, thereby making it mobile and useful to serve several
drawing machines. The machine is of a swiveling type with12mm-
0.8mm thickness of wires.

Wire Pointing Machine

(3.7) WIRE STRAIGHTENING MACHINES & CUTTING MACHINES—

Wire Straightening and Cutting Machines are used to straighten &
cut wires to make cut length rods out of coils. This machine is used
wherever wire is further processed in form of Rods and where
accurate straightening of coiled wire with clean cut, tolerances and
high outputs are of importance. The wire is drawn from the Coil Pay-
off Stand through the Driven pinch rollers having grooves of
different diameters & passed through the high speed rotating
spinner, which is equipped with five numbers of quickly and easily
adjustable dies of different material like carbide, Cast Iron, Cast
Nylon etc depending on the material to be straightened.
Finally passing through the cutter, actuated by the push rod fitted
on the conveyor, the length required can be adjusted as desired on
the conveyor gauge. The straightened and cut - to - length wires are
collected on the wire collector at the bottom to be removed
manually.

Wire Straightening Machines & Cutting Machines

(3.8) WIRE DRAWING MACHINES—

(3.8.1) Medium Pulley Type Continuous Wire Drawing Machine
 Medium Pulley Type Continuous Wire Drawing Machine

Our pulley type continuous wire drawing machine has the

characteristics of simple structure, low cost, and easy operation, and
it is suitable for drawing a variety of medium and thin fiber material,
especially for mild steel wire, galvanized iron wire, steel head wire,
stainless steel wire, rubber hose steel wire, spring steel wire, rod
welding wire and copper wire aluminum rod, etc. Scope of
application: gas-protection welding wire, welding electrode,
stainless steel wire, galvanized iron wire, bullet and hard wire,
copper wire, and metal product wire, etc

(3.8.2) Straight Line Wire Drawing Machine

Straight Line Wire Drawing Machines were developed for
straight or deflection free drawing of wire to provide better
drawability lower frictional contact and lower operator
interference.

Straight Line Wire Drawing Machine

These heavy Straight Line Wire Drawing Machines provide
remarkable drawing performance for Low, Medium and High
Carbon Steel Wire, Stainless Steel Wire and special Alloy Steel
Wire and Non-Ferrous Alloy Steel Wire.
This machine has a sensor roller between the drum and the next die
such that the wire passes in contact with this roller.
These rollers have sensors to detect the position of the arm and
maintain tension on the wire by regulating speed of the drums. The
drums of this machine are inclined to the vertical axis to effect fill on
the drums. Principally this machine is best suited for thick wires.
Features of Straight Line Wire Drawing Machine:--
 Machines are built on modular structure, in combination of
Blocks and do not require any special foundation.
 Better productivity due to higher drawing speeds due to twist-
free operation.
 Easy operation and faster threading.
 High pressure Narrow gap, internal water cooling for high
efficiency cooling of wire.
 High degree of reliability - low downtime due to lower no of
wear parts.
 Much better finish wire quality due to a gentler handling of the
wire during the drawing process
(Less wire deviations, low torsion etc.)
As well as an optimized wire cooling.

(3.11) MS WIRES
MS wires are the strong mild steel wires which is available in different sizes
of dia (ranges from 2.00mm to 6.00mm) which are used in various
engineering applications. MS wires is produced by BHUSHAN POWER & STEEL
by wire drawing process in Plant located at 3, Industrial Area Phase-I,
Chandigarh.

MS WIRES

(3.10) VARIETY OF M.S WIRES MANUFACTURED—

M.S Wires are produced from hot rolled product Wire Rods. These Wires are
manufactured in different sizes and quality as per requiring conditions. The
Sizes Available in following Diameters:--

 3.0mm
 3.6mm
 4.2mm
 5.0mm
 6.2mm
 7.0mm
Etc. (as per requirement)

(3.9) WIRE DRAWING PROCESS—

Raw Material: Hot rolled steel bar or wire rods coils are used as raw
material. Because the hot rolled products are produced at elevated
temperatures (1700 - 2200 Deg. F. i.e. hot rolling), they generally
have a rough and scaled surface and may also exhibit variations in
section and size.

 Cleaning: Abrasive scale (iron oxide) on the surface of the hot

rolled rough stock is removed.
 Coating: The surface of the bar or coil is coated with a drawing
lubricant to aid cold drawing.

RAW MATERIAL

CLEANING

COATING

POINTING

DRAWING

FINISHED PRODUCT

FLOW CHART TO DRAW MS WIRE

 Pointing: Several inches of the lead ends of the bar or coil are
reduced in size by swaging or extruding so that it can pass
freely through the drawing die. Note: This is done because the
die opening is always smaller than the original bar or coil
section size.
 Drawing: In this process, the material being drawn is at room
temperature (i.e. Cold-Drawn). The pointed/reduced end of the
bar or coil, which is smaller than the die opening, is passed
through the die where it enters a gripping device of the
drawing machine. The drawing machine pulls or draws the
remaining unreduced section of the bar or coil through the die.
The die reduces the cross section of the original bar or coil,
shapes the profile of the product and increases the length of
the original product.
 Finished Product: The drawn product, which is referred to as
Cold Drawn or Cold Finished, exhibits a bright and/or polished
finish, increased mechanical properties, improved machining
characteristics and precise and uniform dimensional tolerances.
 Drawing: In this process, the material being drawn is at room
temperature (i.e. Cold-Drawn). The pointed/reduced end of the bar or
coil, which is smaller than the die opening, is passed through the die
where it enters a gripping device of the drawing machine. The drawing
machine pulls or draws the remaining unreduced section of the bar or
coil through the die. The die reduces the cross section of the original
bar or coil, shapes the profile of the product and increases the length of
the original product.
 Multi-Pass Drawing: The cold drawing of complex
shapes/profiles may require that each bar/coil be drawn
several times in order to produce the desired shape and
tolerances.
This process is called multi-pass drawing and involves drawing
through smaller and smaller die openings. Material is generally
annealed between each drawing pass to remove cold work and
to increase ductility
 Annealing: This is a thermal treatment generally used to
soften the material being drawn, to modify the microstructure,
the mechanical properties and the machining characteristics of
the steel and/or to remove internal stresses in the product.
Depending on the desired characteristics of the finished
product, annealing may be used before, during (between
passes) or after the cold drawing operation, depending on
material requirements.
(3.12) TOR STEEL

Tor Steel is the strong steel bar which is used in various engineering
applications like Construction activities Buildings, Roads, Bridges etc
to provide more strength where it is used for Concrete
Reinforcements The product finds its uses in manufacturing various
types of CTD wires MS wires, wire rods & many others products.

Fig 1-TOR STEEL

3.3 TWISTING SECTION

After manufacturing of TOR STEEL bars they have to be twisted. The

twisting machines carry out twisting. Finally the ends of twisted bars
(and the untwisted ones) are sheared off by a shearing machine.
Ends are sheared because they are often cracked.

The finished product is then loaded on to trucks and weighed on

weighbridge. The product is then bundled and labeled to provide its
unique identity and send for the inspection before delivery.
(4.2) TIME STUDY
Time Study is defined as work measurement technique recording
the times and rates of the working for the elements of specified job
carried out under specified condition and analyzing the data so as to
obtain the time necessary for carrying out the job at defined level of
the performance
The instruments required for time study are-
1. Stop Watch
2. Time study forms
The Basic Steps in the Time Study are-
1. Obtain & Record all the information about the job, operator
and surrounding conditions.
2. Record the description of the method and break operations
into elements.
3. Examining the breakdown to ensure the most effective method
is used.
4. Note down the time consumed in each step with the help of
stop-watch.
5. At the same time, assess the effective speed of working
operator corresponding to the steady rating.
6. Find the basic time from the observed time.
7. Give the required allowances.
8. Determine the standard time for the complex operation.
(4.3) OBSERVATION & CALCULATIONS:-

Weight of 1 full billet (11m)

420kg

(Before cutting)

Weight of 1 half billet (5.5m)

210kg

(After cutting)

Total Men Power Required

32

I prepared the time study on the production of tor steel by

taking the average weight is 200 kg.
OBSERVATION TABLE:-

Time consumed in marking, cutting & putting the billet into 00:26:00
furnace (20 Billets)
Average Time Consumed in marking, cutting & putting the 00:01:09
billets into the furnace (1 Billet)……….(A)
Time used For Starting/heating he Furnace ( once in shift 01:10:00
)……….(X)

Time consumed in Rolling Mill -----(B)

Time Consumed in First set of 3 Multi-pass Rollers(1 00:00:09

Billet)……….(a)
Time Consumed in other 14 Types of Rollers ( 1 Billet ) 00:00:22
……….(b)
Time Consumed for cutting the tor steel upto desired 00:00:16
length….(c)
Total Time Consumed on Rolling Mill …..(B=a+b+c) 00:00:47

Time Consumed for Cooling ( once in Shift ) ……….(Y) 02:12:00

Time Consumed for Twisting (for 200kg)……(C) 00:06:19
Total time consumed to get tor steel (for 200kg) 00:08:15
( excluding heating & cooling ) i.e A+B+C
Heating (X) & Cooling (Y) are Carrying out for just once in shift (8 hrs)

So, Total time consumed in Heating + Cooling (X+Y) = 3:22:00

Now we have to calculate the production for the remaining time

Period of the shift i.e for = ( 8:00:00-3:22:00 ) = 04:38:00

Amount of tor steel /shift = (04:38:00/00:08:52) ×200=32 ×200=6400kg

(approx.)

Allowances (Relaxation, contingency, breakdown etc. ) = 8.%

Resultant production of tor steel /shift = 5960kg

Total working shifts in a day = 3 (8 hrs. each)

Production of tor steel per day = 5960×3=17880kg=17.8 tonnes

Production of tor steel per month = 17.8×30 = 534 tonnes

(4.4) Suggestions on the basis of time study to
improve the production rate:-

Steel yard should be near to the rolling area to get the

material as soon as possible; which would save the time

Use of conveyor system to lift and transportation of the

rolled material to the racks would greatly reduce in time.

Automation of the machine can save the time.

If we concentrated on these points, then we can save the

time & our average production will rises.
 BIBLIOGRAPHY
ONLINE SOURCES:

 www.bhushansteel.com

For Information on Company Profile

 www.assomacmachine.com

For Information on Machines

 www.answer.com

For definatio & diagrams/sketches

THANK YOU !!