INDEX

Sl. No Contents Page No

1 OVERVIEW OF SALEM STEEL PLANT
1.1 Introduction 4
2 STEEL MELTING SHOP 7
2.1 Introduction 7
2.2 Electric Arc Furnace 7
2.3 Argon Oxygen Decarburization 8
2.4 Laddle Furnace 8
2.5 Slab Caster 8
2.6 Slab Grinder 9
2.7 Scrap Handling and Storage 9
2.8 Slag Handling 9
2.9 EOT Cranes 10
2.10 Process Flow In SMS 10
2.11 SMS Layout 11
3 HOT ROLLING MILL
3.1 Introduction 12
3.2 Process 12
3.3 Reheating Furnace 13
3.4 Reversing Roughing Mill 14
3.5 Steckel Mill 16
3.6 Roll Shop 19
3.7 Roll Grinding Machine 20
3.8 Down Coiler 21
3.9 HRM Cranes 23
4 COLD ROLLING MILL
4.1 Introduction 24
4.2 Coil Build up line 25
4.2.1 Coil Preparation Line 26
4.3 Bell Annealing furnaces 27
4.4 Annealing & Pickling lines (1,2&3) 28
4.5 20-High Sendzimir Mills (1,2&3) 36
4.6 Roll Shop 41
4.7 Strip grinding line 42
4.8 Skin pass Mill 43
4.9 Shearing line 44

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 4.10 Slitting line 45
4.11 Tension Leveling Line 46
4.12 Rotary Polisher 47
4.13 Re-squaring Shear 48
4.14 Coil Packing & Dispatch 49
4.15 Coin Blanking line 49
4.16 CRM Cranes 51
5 UTILITIES
5.1 Introduction 52
5.2 Boilers 52
5.3 Feed water treatment 53
5.4 Air Compressors 53
5.5 Liquefied Petroleum Gas 54
6 SERVICES
6.1 General Administration 55
6.2 Public Relation 55
6.3 Material Management 55
6.4 Marketing 55
6.5 Finance & Accounts 56
6.6 Safety Engineering & Fire Services 56
6.7 Water Supply 57
6.8 Medical and Health Services 57
6.9 Corporate Social Responsibility 57
6.10 Central Engineering Shop 58
6.11 Electrical Repair Shop 58
6.12 Production Planning and Control 58
6.13 Metallurgical Services 58
6.14 Centralized MechanicalMaintenance 59
6.15 Auto Garage 59
6.16 Centralized Electrical Maintenance 59
6.17 Total Quality Management 59
6.18 Technical Bureau 60
6.19 Computer & Information Technology 60

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 1. OVERVIEW OF SALEM STEEL PLANT

INTRODUCTION:
Salem Steel Plant is one of India’s leading producers of quality Stainless
Steel. The Plant was commissioned in 1981. “Salem Stainless” has become a
house hold name in India. SSP products are also widely exported.

The entire Salem Steel Plant is certified with ISO 9001:2008 for Quality
Management System (QMS), ISO 14001:2004 for Environment Management
System (EMS), OHSAS 18001: 2007 for Health Services, SA 8000:2008 for Social
Accountability, ISO 14001:2004 EMS for Township also.

Hi-tech industries like atomic power stations prefer ‘Salem Stainless Steel’.
The products from SSP are widely used in industrial sectors like Dairy and food
processing, Chemical and fertilizer, Heavy engineering, Railways, Automobiles,
Bulk solid handling, Power etc. The building and architecture segment which is
growing at a rapid pace, sees ‘Salem Stainless’ as the most dependable
companion.

In architecture, building and construction, the prestigious structures where

‘Salem Stainless’ was used include the parliament House Library complex, New
Delhi, the world’s tallest Petronas Twin-Towers, Malaysia and the retractable
roofing at Melbourne Tennis Stadium, Australia. The coaches of the Jan–Shatabdi
Express trains are furnished with modular rail marts and sub-pantries made
entirely of ‘Salem Stainless’. Korean blue resin coated corrugated curved roofing of
the Koparkhairane Railway Station in Navi Mumbai is a trend setter for railways in
India.

SSP supplies 409M, a special grade of stainless steel sheets to Indian

Railways for fabrication of wagons, for handling coal, etc.

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 Capacity (Tonnes)

Description Before Expansion After Expansion

SLABS ---- 1,80,000

HR COILS 1,86,000 3,64,000

CRSS 70,000 1,46,000

SALEABLE STEEL 1,75,000 3,40,000

Table 1.1 Capacity of SSP before and after expansion

General Information: (Commissioning)

Phase I (CRM-I) : 13.09.1981
Phase II (CRM-II) : 26.03.1991
Blanking Line : 24.12.1993
Hot Rolling Mill : 03.11.1995
Steel Melting Shop : 01.08.2010
Area acquired : 15.5 Sq.Km (3973 Acres)
Township Dwelling : 832 Units (802 Acres)
Consulting Engineers : M/S MN Dastur & Co Ltd
Civil Construction : M/S Hindustan Steelworks Construction Ltd
The Slab input for various units of SSP is shown in Fig1.1.

Fig 1.1 Slab input of SSP

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 2.STEEL MELTING SHOP

2.1INTRODUCTION:

In order to have better slab chemistry, financial control & market

competitiveness, SSP has started commissioning of Steel Melting Shop with the
following production.

Grades TPA % of Production

200 Series 54,000 30% of which SSLN1-80% &others is 20%.

300Series 1,08,000 60% of which 304 is 80%,316 is 10% & others is 10%.

400 Series 18,000 10% of which 409M is 45%,430 is 45% & others is 10%
Total 1,80,000 100%
Table 2.1 Capacity of Steel Melting Shop for Various Grades

Major Equipments to be installed in Steel melting shop are:-

1. 55T Electric Arc furnace - Supplier - Danieli, India
2. 60T AOD Converter - Supplier - Technofab, Kolkata
3. 60T Laddle Furnace - Supplier - Danieli, India
4. Single Strand Slab Caster - Supplier - SMS Demag, Germany
5. Slab grinder - Supplier - TRICAM , USA
6. Associated Auxiliary facilities

2.2ELECTRIC ARC FURNACE (EAF): Heat Size-55 T

EAF is a batch process producing batches of molten steel called “heats”. Furnace
operating cycle is called tap to tap cycle.
 In Furnace, roof & electrodes are raised to allow scrap charging (MS Scrap /
SS Scrap and Ferro-alloys). After scrap charging roof & electrodes are
lowered.
 Melting process is the heart of EAF. First intermediate voltage tap is
selected until electrodes bore into scrap. After 15% of scrap is melt, voltage
is increased so as to have long arc.

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  Once scrap is melted, both temperature and samples are taken to analyze
path chemistry & to determine oxygen to be blown for refining.
 In refining, oxygen is lanced at the end of meltdown to lower path carbon
content to desired level of tapping.
 Deslagging process is done to remove impurities from the furnace & finally
tapping is done once desired steel composition & temperature is achieved.
Liquid Steel is then poured into Laddle placed on transfer car and taken to
AOD by means of EOT Crane.
In EAF power consumption is 390 kWh/T. Tap to Tap time is 72 minutes and
Electrode consumption is 2.2 Kg/T. EAF also has a fume extraction system.

2.3 ARGON OXYGEN DECARBURIZATION (AOD): Heat Size-60 T

In AOD, Oxygen lancing is being done to obtain the exact percentage

composition of Carbon & other alloys such as Chromium, Nickel in the presence of
inert gas atmosphere of Argon/Nitrogen. Here Oxygen lancing is done through top
blowing & Argon blowing is through tuyers. In AOD Fluxes/Ferro -alloys is to be
used. AOD has also fume extraction system.

2.4 LADDLE FURNACE (LF): Heat Size-60 T

Purpose of Laddle furnace is for heating, alloy addition for final adjustment
& desulphurization. Rate of temperature rise is 4o C/min & the electrodes used
here is graphite. LF has Inert gas stirring system, twin transfer car. LF has also
fume extraction system.

2.5 SLAB CASTER:

It is a single strand continuous slab caster designed for processing heats of

liquid steel in continuous casting mode. After laddle is placed on laddle turret, the
laddle turret rotates the laddle 180o to casting position. It has two laddle positions
to provide sequence casting. Steel flow from laddle to tundish is controlled by slide
gates. Tundish is a steel device which distributes steel to the mould. Tundish
capacity is approx. 26 T.

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 The mould is straight type with copper plates & has a length of 700 mm.
Strand guide system is of 10 segments. At the end, Torch cutting is done to get the
slab of required size.
Average Casting speed is 1.0 - 1.4 m/min. Maximum machine speed is 2.0
m/min. Secondary cooling system is Spray water. Laddle turrets maximum lifting
capacity is 120 T.
Slab caster is equipped to cast slabs of dimensions shown in Table 2.2.

Width 600-1300 mm
Thickness 145 & 175 mm
Length 5.0-10.5 m
Table 2.2 Slab Dimensions

2.6 SLAB GRINDER:

Its main purpose is to grind slabs, if required for removing defects from surface.

2.7 SCRAP HANDLING & STORAGE:

Both plant return scrap & purchased scrap will be used as melting stock.
Both categories of scrap will be stored in scrap aisle & material storage aisle.
Purchased scrap will be brought either by rail or road & stored in open yard & then
transferred by trucks to storage aisle as required. Plant return scrap wil l also be
transported by in-plant trucks to this aisle & stored in segregated manner.

2.8 SLAG HANDLING:

Annual generation of slag from SMS is estimated to be around 40,000T. Slag

from EAF will be poured in slag pit & disposed in dump yard. Slag from AOD will
be poured in slag pot & dumped in deslagging area in furnace aisle. Remnant slag
from slab caster will be dumped in deslagging area of casting aisle.

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2.9 LIST OF EOT CRANES IN STEEL MELTING SHOP:

S. No Aisle Capacity Nos.

1 Scrap Aisle 15 / 10T 2
2 Material storage Aisle 15 / 10T 2
3 Furnace Aisle 130+50 / 20T 2
4 Casting Aisle 60 / 30T 2
5 Slab Storage Aisle 15+15 / 5T 2
6 Open Scrap yard 20 / 5T 3
7 Scale Pit 10T 1
Table 2.3 EOT Cranes in SMS
All the EOT cranes for SMS are supplied by Anupam, Gujarat and Laddle
Cranes are supplied by WMI, Bangalore.
Civil work in SMS-Zone1 is being taken care by Mysore Construction,
Bangalore and SMS-Structural supplier is Chettinad Engg Constructions.

2.10 PROCESS FLOW IN SMS:

Purchased Revert
MS Scrap SS Scrap
Fluxes Ferro-alloys

Coolant
EAF Fluxes Ferro-alloys

Fluxes & trimming

AOD additions
RAW STEEL

LF
LIQUID STEEL
SLAB
CASTER
LIQUID STEEL

CONDITIONING
SLAB

TO EXISTING
CONDITIONED SLAB HRM

Fig 2.1 Process Flow in Steel Melting Shop

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2.11 STEEL MELTING SHOP LAYOUT:

It consists of 5 adjacent & parallel aisles namely

1. Scrap aisle (AB) - 24 m Length & Crane height-15 m
2. Material aisle (BC) - 24 m Length & Crane height-15 m
3. Furnace aisle (DE) - 35 m Length & Crane height-26 m
4. Casting aisle (EF) - 35 m Length & Crane height-26 m
5. Slab storage aisle (FG) - 24 m Length & Crane height-12 m

FES of EAF &

LF

FES of AOD

(A)

Scrap/Ferro Scrap/Ferro
Alloy Storage Alloy Storage
(B)

Ferro Alloy/ Ferro

Alloy/ Flux
Flux Storage Storage

(C)

(D)
50T EAF

60T Refining
Converter
60T Laddle furnace
(E)
Slab Caster

(F)

Slab X’er Car

Turn Out Table

Slab Storage Area
(G)

Fig 2.2 Steel Melting Shop Layout

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 3. HOT ROLLING MILL

3.1 INTRODUCTION:

The Hot Rolling Mill was commissioned in November 1995. Installation of

additional roll grinding machine in hot rolling mill to increase hot rolling capacity to
3,64,000 tpa.
The major equipment in Hot Rolling Mill are
1. Walking beam type Reheating furnace
2. Primary Descaler
3. Reversing Edger and Roughing Mill
4. Reversing Steckel Mill (Finishing Mill)
5. Laminar cooling
6. Down Coiler

Input Slab Size:

Stainless Steel Carbon Steel
Thickness 140 to 190 mm 140 to 220 mm
Width 600 to 1,300 mm 600 to 1,300 mm
Length 5,000 to 10,500 mm 5,000 to 10,500 mm

Total slab requirement : 3,70,000 tpa

• ASP route : 1,90,000 tpa
• Steel Making at SSP : 1,80,000 tpa

3.2 PROCESS:

Slabs of carbon steel or Stainless steel are received through wagons/

trailers and stored in slab yard. As per the schedule the slabs are charged into the
Walking Beam Reheating Furnace and heated to the discharge temperature of
1150˚ C to 1250˚ C depending on the grade. These slabs are discharged from
furnace and the primary scales are removed by means of high pressure water at
primary descaler. Then the slab thickness is reduced by rolling in Roughing Mill to
a thickness of about 25 mm, which is called Transfer bar (T-bar) in 5,7 or 9 passes
depending on input slab thickness.

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 The head end and tail end of the T-bar from Roughing Mill are cut in rotary
Drum Shear before further rolling in Steckel Mill. Having achieved the required final
thickness in 3, 5 or 7 passes as per the pass schedule, the strip is cooled by
laminar cooling system in RORT and wound in Down Coiler mandrel. After
strapping, weighing and marking, the coils are taken out from conveyor and
dispatched to CRM or customers.

Fig 3.1 Process Flow of Hot Rolling Mill

3.3REHEATING FURNACE:

The furnace section consists of Slab Yard and Re-Heating Furnace. The
walking beam type Reheating furnace is hydraulically operated, top and bottom
fired and has a flat roof. The combustion system is of recuperative type designed
for firing LPG or natural gas. The Reheating furnace has been designed and
supplied by M/S Italiampianti, Italy and Erected by M/S Wellman Incandescent,
India.

Furnace capacity:
For Stainless Steel : 55 T/hr (For a reference slab of 170 mm thick)
For Carbon Steel : 70 T/hr (For a reference slab of 170 mm thick)

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 The different types of material that can be processed are:
Stainless Steel : AISI 200 & 300 Series (Austenitic)
AISI 400 Series (Ferritic & Martensitic)
Carbon Steel : IS 1079 D, IS 1079 DD, IS 1079 EDD, IS 6240.
IS 2062B, IS 10748, E38, E34, SAILCOR.

The slabs are uniformly heated in the Re-heating furnace so that they are brought
to the discharge temperature of 1150 ˚C to 1250˚C.

No of burners installed 56
Fuel used : LPG
Calorific value : 22,000 Kcal/N m
No. of combustion blowers installed 2
Recuperator : Metallic type to recover the waste heat
from flue gases.
Automation system supplier : M/S Siemens India, Mumbai
Distributed Control System supplier : M/S Yokogawa Blue Star, Bangalore.

Slab temperature is measured by the radiation pyrometer installed in the

furnace roof of discharging side. Oxygen analyzer is provided in the recuperative
zone of charging side to measure the oxygen percentage in waste gas.

3.4 REVERSING ROUGHING MILL:

Roughing Mill Supplier(4 hi Reversing Mill) : M/S Schloemann Siemag (SMS),

Germany.
Automation supplier : M/s Siemens, Germany.
Rouging Mill is controlled by Level 1 Automation.
The Roughing Mill housing accommodates TWO work rolls and TWO supporting
rolls called Back-up rolls.
Max Dia Min Dia Length
Work roll 1050 mm 950 mm 1475 mm
Back up roll 1350 mm 1250 mm 1425 mm

In Roughing Mill the thickness of Reheated and Descaled (Primary scales) slab is
reduced to 20 – 32 mm by rolling process in 5,7,9 passes depending on the input

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slab size by controlling the width during rolling in Edger. The complete rolling and
edging operation is carried out as per the proper selection of pass schedule.

Discharge temperature of slabs:

1. Carbon Steel : 1200 - 1280˚C
2. 200 Series : 1190 ±20˚C
3. 300 Series : 1220 - 1280˚C
4. 400 Series : 1140 ±20˚C.
The temperature of the Transfer bar (T-bar) after the last pass rolling in Roughing
Mill: 950˚C - 1100˚C.
The fish tails formed at head end and tail end of the T-bar during edging and
roughing process is removed in Drum Shear and the final reduction in thickness is
achieved by rolling in Steckel Mill.

a. Equipment from Reheating Furnace to Roughing Mill:

 Slab reject roller tables
 Furnace delivery roller table
 Descaler connecting and descaler roller table
 Primary descaler
 Roughing mill approach roller table
 Front mill roller table
 Roughing mill feed rollers
 Roughing mill entry side guides
 Vertical edger

b. Roughing Mill Equipment:

 Roughing Mill Screw Down System
 Un-jamming device
 Roughing mill guides
 Lifting rails
 Work roll cooling system
 Back up roll balancing
 Spindle balancing
 Back up roll changing sled
 Work roll change cover plate, tilting flap
 Roll change car

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 c. Systems:
 Hydraulic system
 Booster pump system (Centralized for Steckel Mill and Roughing Mill)
 High pressure water system
 Morgoil system (Centralized for Roughing Mill and Steckel Mill)
 Oil lubrication system (Centralized for Roughing Mill and Steckel Mill areas)
 Pneumatic system
 Grease systems

3.5 STECKEL MILL:

Steckel Mill is a 4 Hi Reversing Mill Supplied by M/S Schloemann Siemag

(SMS),Germany.
Automation supplied by M/S Siemens, Germany.
The Steckel Mill housing accommodates two work rolls and two supporting rolls
called Back-up rolls.
Max. dia Min. dia Length
Work roll 760 mm 680 mm 1825 mm
Back up roll 1350 mm 1250 mm 1425 mm

a. Steckel Mill Specifications:

Type: Single stand, 4 Hi reversible Mill, provided with one coiler furnace on each
side to wind the hot strip just after rolling in each pass and also to maintain the
strip temperature suitable for hot rolling.
Steckel Mill is built with sophisticated facilities & control systems to obtain
high quality flat product such as
 HGC - Hydraulic gap control
 AGC - Automatic Gap Control
 MON - (Thickness monitoring system)
 RAC - Roll alignment control
 CVC and Work Roll Bending system
 PGM - Profile Gauge Meter
 Model Server
The state-of-the-art automatic pass schedule calculation facility (model server) is
installed to have trouble free rolling.

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Automatic work roll change facility is provided for quick and easy changing of work
rolls.
 Main drive capacity : 4500 kW each for top and bottom work
rolls Back up roll is friction driven.
 Maximum roll force : 30,000 kN
 Maximum rolling speed : 10 metre/sec
 Maximum bending force : 3,000 kN

 CVC shifting range : ± 200 mm

 CVC crown values : - 0.7 mm to +0.3 mm

 Pass line deviation allowed : ± 10 mm

COILER FURNACE:

 Temperature maintained : 950˚C - 1000˚C

 Fuel used : LPG
 Air/gas ratio : 28 – 32
 Number of burners : 6 for each furnace
 Coiler Drum diameter : 1350 mm
 Coiler Drum drive capacity : 650 kW
 Combustion air pressure
for coiler furnace : 800 mm wc
 LPG working pressure : 800 mm wc
TECHNICAL DETAILS:
Material Specifications:
Transfer bar thickness : 20 mm - 32 mm (carbon steel)
: 20 mm - 28 mm (Stainless steel)
Transfer Bar Width : 600 mm - 1300 mm
T-Bar temperature : 950 - 1100˚C
Strip thickness:
Carbon Steel : 1.6 mm – 12.7 mm
Stainless steel : 2.0 mm – 10.0 mm

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SYSTEMS:
 Auxiliary hydraulic system
 Servo hydraulic system
 Booster pump system (Centralised for Steckel Mill and Roughing Mill)
 High pressure water system
 Morgoil system (Centralised for Steckel Mill and Roughing Mill)
 Oil lubrication system (Centralised for Steckel Mill and Roughing Mill)
 Laminar cooling system
 Pneumatic system
 Grease systems
 Re-circulating water system

b. AIR COMPRESSORS:
4 Nos. of air compressors are installed to meet compressed air requirement
for the Hot Rolling Mill complex.

c. MODEL SERVER:
The Model Server is the Level 2 automation system consisting of a mill
process computer. The mill process computer based on mathematical models and
strategies, calculates the set up values for the mill like roll gap, roll force, CVC
position, bending values etc., (in association with the slab data and transfer bar
data). Finally the set up values allow for an accurate control of strip thickness,
profile and flatness.

The area of the model server is restricted to the Steckel Mill stand and coiler
furnace. The primary data is transmitted by the production control PC to furnace
PLC. When a slab is discharged from the furnace, furnace PLC transmits the
primary data of this slab and the next slab to Roughing Mill PLC. After
acknowledgement from Roughing Mill operator, Roughing Mill PLC transmits the
primary data to model server. With the completion of the last pass in the Roughing
Mill, Roughing Mill PLC transmits the actual values of the last pass in the Roughing
Mill, (Width, last pass roll force, roll gap, temperature and speed) to model server.

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 The availability of primary data and T-bar data enable the model server to
calculate the pass schedule. After the calculation, the set up values are transmitted
to the Steckel Mill PLC. The Steckel Mill PLC will do the sequence control of the
process in Steckel Mill. During the pass in Steckel Mill, actual values like roll force
and strip temperature are measured by Steckel Mill PLC and sent to Model server.
After 35-50% of that pass length is rolled the model server will process the
measured values sent by Steckel Mill PLC. Based on this feedback, the models will
re-calculate an improved set up for the remaining passes. However, the thickness
distribution, speed, tension values will not be changed. This process will be
repeated pass by pass until the last pass is reached.

The model server has the following automation functions:

1. Strip tracking
2. Pass schedule calculation
3. Acquisition and processing of measured values
4. Dialogue and display
5. Logging function.

3.6 ROLL SHOP:

Roll Shop caters to the
 Work rolls and back up roll requirements of Roughing Mill and Steckel Mill
by supplying rolls with chocks assembled with bearings as and when
required.
 Turning and assembling of Edger rolls.
 Grinding of Pinch rolls of Steckel Mill and Down Coiler.

The used work rolls, Back up rolls of Roughing Mill and Steckel Mill, Edger
rolls and Pinch rolls of Steckel Mill and Down Coiler are reground in the Roll
grinding machine. Roll grinding m/c is supplied by M/S Toshiba machine company,
Japan. State – of –the- art CNC roll grinder is working on Level -3 automation
which ensures fully automatic grinding where special functions like wheel quick
approach, Automatic roll alignment and wheel surface speed control are done by
machine itself.

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 Overhauling and maintenance of all Work roll and Back up roll bearings are
taken up on a regular basis. The chocks earmarked for overhauling are
dismounted from rolls. Then the bearings, seals and chock internals are taken out,
cleaned and checked for any mark or wear and tear. Based on the condition, the
bearings and chock internals are either replaced with new or are put back after
thorough cleaning and removal of marks.

3.7ROLL GRINDING MACHINE (RGC 1400 X 5000 CNC GRINDING MACHINE) hot
Rolling Mill (HRM) of Salem Steel Plant have different rolls like Backup
Rolls, Work rolls, Edger Rolls and Pinch Rolls. All these Rolls in HRM need
grinding after a stipulated tonnage of rolling for better surface finish. So, these rolls
are being ground by CNC grinding machines.

In HRM, in addition to the existing CNC grinding machine supplied by M/S

Toshiba, a new Roll grinding machine of Type: RGC 1400 x 5000 CNC, [supplied
by M/S World Machinery Works (WMW), Romania] was also commissioned in July
2009 to grind HRM rolls for production of 3,70,000 t of Slabs per year.
The main equipments and automation of this new Roll Grinding Machine
a. CNC : SINUMERIK 840D
b. MIDA : Roll Alignment System
c. MARPOSS : Wheel Balancing and auto wheel touching
d. LISMAR : Flaw detection
e. Meas4 Roll : Profile measurement Wheel
measurement and dressing
PLC : SIMATIC S7-300
This machine consists of mainly 9 axes. The details are as follows
C1 : Roll drive rotation
C2 : Wheel Rotation
Z : Longitudinal Movement of the Carriage
X : Traverse Movement of grinding wheel (coarse)
X1 : Traverse Movement of grinding wheel (fine)
B : Wheel assembly swiveling
A : Diameter measurement arm rotational movement
Y : Diameter measurement
U : Roll alignment

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 Special features of RGC 1400 x 5000 CNC grinding machine:
 The roll grinding machine RGC 1400 x 5000 CNC type performs
grinding, measuring and testing E.C cylindrical surfaces, Plane or
Cambered (concave or convex).
 Highly productivity output ranges, optimal machine accuracy and
decreasing preparation period.
 All types of profile can be ground Viz. Straight, Taper, Concave, Convex,
Radius, CVC etc.
 Backup Rolls and Edger Rolls can be ground with chocks
 Roll diameter can be measured during grinding
 Grinding accuracy
- Roundness : 0.002 mm
- Cylindricity : 0.002 mm
- Crown profile : 0.0025 mm
- CVC profile : 0.0025 mm

3.8 DOWN COILER:

The finished strip from Steckel Mill rolling is coiled around the Down Coiler
mandrel.
The finish strip thickness:
For Carbon steel : 1.60 mm to 12.7 mm
For Stainless steel: 2.00 mm to 10.0 mm
The equipments are supplied by M/S Schloemann Siemag (SMS), Germany. The
automation is done by M/S Siemens, Germany.
The Down Coiler is controlled by Level -1 automation. The walking beam
conveyor is used for the transportation of coils to the Coil Yard. The coil is
strapped by a single band circumferential automatic Strapping machine, weighed
in the weighing m/c and marked by an automatic marking machine supplied by M/S
Infosight Corporation, USA.

3.8.1Down Coiler consists of

a. Run out Roller table (RORT): This consists of 184 rollers (Roll dia: 300
mm) separated into six groups. This helps in transporting the finished strip from
Steckel Mill to Down Coiler

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b. SIDE GUIDES: Side guides are provided for guiding the strip straight into
the Coiler.
c. HOLD DOWN ROLL: The main function of the hold down roll (Roll dia: 300
mm) is to avoid fluttering in the strip. This roll will be in the up position when the
strip is coming and will get down when the strip enters the pinch roll.
d. PINCH ROLL: The function of the pinch roll is to guide the strip into the
mandrel
Max Min
Top Roll : 900 mm 880 mm
Bottom Roll : 400 mm 370 mm

e. STRIP Switch: The strip switch guides the strip to the mandrel. During
coiling it opens and it allows the strip to the mandrel and afterwards it closes
the way to the mandrel.
f. CHUTE PLATE: The chute plate feed the strip to wrapper roll 1 which
makes the strip to wind on the coiler
g. WRAPPER ROLLS: Three wrapper rolls are provided for wrapping the
head end of the strip into the mandrel. The wrapper rolls will get retracted after
the mandrel expanded and tension built.
h. MANDREL: The finished strip from Steckel Mill winds on the mandrel
The diameter of the mandrel:
Collapsed : 727 mm Pre-
expanded : 738 mm Fully
expanded : 762 mm
i. OUTBOARD SUPPORT BEARING: Two support bearings are provided ,
one in right and the other in the left side to hold the mandrel during rolling.
j. COIL CAR: The coil car transports the finished coil from the mandrel to the
walking beam conveyor. It has a lifting table which is provided with two rollers
and locking provision for the rollers.

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3.9 HRM – Crane Details

location capacity Supplier

1 Slab yard EOT crane 55 T JESSOP

2 Slab yard SEMI-GANTRY crane 25 T JESSOP
3 Scale pit crane 5T GREAVES LTD
4 Mill Bay crane 40 T MUKAND
5 Mill Bay crane (2 Nos) 5T MM Engineers
6 Roll Shop crane 63 T WMI
7 RM Motor Yard crane 63 T WMI
8 SM Motor Yard crane 63 T WMI
9 DC Yard crane 25 T GREAVES LTD
10 Old Goliath crane 25 T GREAVES LTD
11 New Goliath crane 25 T FEFCO
12 SP Pump House 5T KAPANI AGENCIES
13 LC Pump House 5T KAPANI AGENCIES

Page 22 of 61
 4. COLD ROLLING MILL

4.1 INTRODUCTION:
Capacity:
Phase 1 : Installed capacity 32,000 Tonnes / Annum
Phase 2 : Installed capacity of CRM is 70,000 Tonnes / Annum.

Fig 4.1 Process Flow of Cold Rolling Mill

New CRM equipment details:

S. No Package Supplier
1 Coil Preparation Line Andritz, Austria
2 Annealing & Pickling Line Andritz, Austria
3 Z-Mill-3 Waterbury Farrel, Canada
4 Up gradation of Existing Z-Mill T Sendzimir, USA
5 Skin Pass Mill SMS Demag, Germany
6 Slitting Line Fagor, Spain
7 Tension Leveling Line REDEX, France
8 Roll Grinder WMW, Romania
9 Acid recovery system Andrtiz, Austria
Table 4.1 Machines in NEW-CRM and their Supplier

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 Expansion of cold rolling mill capacity together with value adding facilities to
enhance cold rolled stainless steel (CRSS) production from 70,000 tpa to 1,46,000
tpa.

GRADES PRODUCED :
STAINLESS STEEL - Austenitic, Ferritic & Martensitic Grades
301, 304, 304L, 304M, 316, 321, 409, 409M, 410S,
430 , 201, SSLN1,SSLN4, SSLNQ , 204 Cu
Major Equipments to be installed in Cold Rolling Mill are:-
 Annealing and Pickling Line
 Mixed Acid Recovery System
 Coil Build up line
 Coil Preparation Line
 20 High Sendzimir Mills
 Skin pass Mill
 Tension Leveling Line
 Slitting Line
 Roll Grinders for CRM (2 nos)
 Rotary Polisher
 Associated auxiliary facilities
 Online shape control
 New wiping system (For improvement of quality and productivity)

4.2 COIL BUILD UP LINE:

Coil build up line is installed for
a. Joining together small coil into bigger ones,
b. Welding reusable service ends and
c. Trimming the edges of hot rolled strip.
d. Making saleable sheets and coils in thickness range of 2.5 mm to 8mm.
f. Rewinding of hot rolled coils for Inspection and cutting into sheets .

The line is equipped with a MIG welding m/c and has a speed of 50 m/min.
Equipment was Supplied by M/S Sundwig, Germany in association with HEC, India.

Page 24 of 61
 Coil preparation line is used to attach header & leader end to the coil before it
is sent to Sendzimir mill. It is done so as to have effective utilization of the coil.
Capacity of Coil Preparation Line is 50,000 tpa.
Coil preparation line will be located at the place where currently Bell
Annealing furnace is located i.e. in CD bay. Bell annealing furnace will be
relocated behind APL-3.

Technical Data:
Material :Hot and cold rolled Stainless steel strips of AISI 200,300 & 400 Series.
Strip dimensions :
Hot rolled : 630 mm to 1300 mm wide and
2.5 mm to 8 mm thick.

Cold Rolled : 600 mm to 1300 mm wide and

1.5 mm to 3 mm thick

Coil Dimensions :
Coil Inside diameter : 610/762 mm at the uncoiler
610 mm at the Coiler

Coil Outside diameter : Maximum: 1830 mm

Minimum : 900 mm
Strip speed : 5 – 50 m/min
Threading speed : 20 m/min
Maximum weight of the built up coil : 15 T
Dimensions of leader ends: Thickness : 3 to 5 mm
Length : 6 to 12 m.

4.2.1 COIL PREPARATION LINE

Coil preparation line is mainly used for Leader end attachment and saleable
steel production of sheets and coils.

Supplied by M/S Andritz, ausria.

Page 25 of 61
Technical Data:

Thickness : 2.0 to 7.0 mm

Maximum width : 1300 mm
Leader end length : Min 8000 mm To Max 14000mm
Maximum weight : 15 tons
Inner diameter : 610/760mm
Maximum outer diameter : 1900 mm
Min outer diameter : 900 mm
Threading speed : 20 m/min
Processing speed (up to 4.0 mm) : 0-50 m/min
Processing speed (up to 4.0-7.0 mm): 0-30 m/min

Main equipment:

1. Uncoiler, flattener, Crop shear, welding machine, Tension bridle, coiler.

Welding machine supplied by M/S Guild international.The RCM 500-54(Rotary

cutting machine) .

4.3 BELL ANNEALING FURNACES:

All 400 series hot rolled black coils are to be bell annealed to get the uniform
structure.
No of furnaces installed: 3 (In phase I - 1; In phase II – 2)
Type of heating : Electrically heated
No of bases installed :8

LINE CHARACTERISTICS:
Phase I Phase II
Supplier : Wesman Wellman
Heating furnace : 1 No 2 No
Furnace bases : 3 5
Inner cover : 3 5
Coil Size (mm) : 610 610/760
Outside dia : 1830 mm 1900 mm
Strip width (mm) : 600/1300 600/1300
Maximum furnace temperature : 900 ˚C 1000˚C

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Maximum operating temperature : 870 ˚C 870˚C
Coil Weight : 15 T max 15 T max
Hot rolled strip thickness : 3.0 to 6.0 mm 2.5 – 7.0 mm
Cold rolled strip thickness : 0.3 to 4.0 mm 0.3 to 4.0 mm
Cooling hood :1 2
Expected base output : 0.9-1.0 T/hr 1.0-1.1 T/hr

4.4 ANNEALING AND PICKLING LINES:

Two annealing and pickling lines are provided for processing hot rolled strip
and cold rolled strip at intermediate and final stages.
One continuous Annealing & Pickling Line is envisaged for processing hot
rolled strip of thickness 2 to 7 mm. Capacity of A&P line is 5,00,000 tpa.
Annealing is done to relieve the stresses & formation of new grain. Pickling is
done to remove the scales which are generated during annealing. Annealing &
Pickling Line consists of different important sections which are:

 Entry Section- Unwinding of coils, cutting of head/tail ends, welding two coils
to maintain continuous feeding of strip. Tension bridles are used maintain strip
tension. Strip centering is done through correcting rolls.

 Entry Looper- Temporary storage of coil for continuous feeding of strip to

furnace. Entry looper is horizontal.

 Annealing Furnace- Relieving of stresses & for new grain formation. After
heating strip will be cooled by air jet & water spray followed by drier unit. In
Annealing furnace dual fuel fired burners (LPG / Natural gas) have been
envisaged.

 Shot Blasting unit- Scales removed by steel shot at high velocity.

 Pickling Tank- Pre-rinsing of scales by spraying of water. First part of tank will
have electrolytic pickling where 80% of scales will be Removed & remaining
20% will be removed by mixed acid having a mix of HNO3 & various % of HF
depending upon grade.

 Exit Looper- Temporary storage of coil to compensate for stoppages while

removing finished coils. Exit looper is horizontal.

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 Exit Section- Its purpose is to shear the coil at welded joints & winding on
coiler.

DIFFERENCE BETWEEN EXISTING APL & NEW APL

S.No Parameters APL-1 APL-2 APL-3
1 Capacity Total=2,00,000 tpa 5,00,000 tpa
2 Line Speed 60mpm 45mpm 50mpm
3 Coil Handling Both HR &
Only CR Both HR &CR
CR
4 Exit Looper Vertical Horizontal Horizontal
5 Annealing One integrated
3 furnaces 3 furnaces
Furnace with furnace with 6
with 7 zones.
with zones 7 zones. zones.
6 Starting
thickness 0.3 to 4.0mm 3.0 to 6.0mm 2.0 to 7.0mm
of strip
7 Shot Blasting
No Unit One Unit Two Units
unit
8 Sources of heat
LPG LPG LNG/LPG
In furnace
9 Automation Level 1 Level1 Level 2
Table 4.2 Difference between APL – 1 and APL - 2

Suppliers:
Entry & Exit Sections – M/S Dujardin Montbard Somenor (DMS)
Furnace - M/S Drever International, Belgium
Pickling - M/S Ruthner, Austria.
The entire electrics of these lines were supplied by M/S BHEL of India.
The lines are equipped with latest ‘Neutral Electrolytic Process’ (Ruthner Process)
for pickling. The process has many advantages like reduced cost of operation,
more consistent quality, less environmental pollution and better safety.

Page 28 of 61
 Fig 4.2 Process Flow in Annealing and Pickling Line

To meet metallurgical and mechanical properties of material, coil should be

passed through annealing and pickling process. For this we have two AP Lines.
APL-1 is used for process of Cold rolled finished material and APL-2 is used for
processing of Intermediate cold rolled and hot rolled material. Hot roll coils from
HRM goes to CBL for leader end attachment. After this it comes to APL-2 for
annealing and pickling. For Annealing process we have three number of LPG fuel
operated furnace in each line. According to the grade of strip temperature of the
furnaces varies from 850 to 1250˚ C.
“Annealing is a process used for removing hardness from the material “.
Before pickling temperature of the strip should be approximately 80 ˚C. For this we
have quench tank. We have three type of cooling
 Air cooling
 Water and air cooling
 Water cooling
Then dryer is used for removing water from the strip.
In APL-2 only HR coils are processed. for the removing of hard scale,
we have short blasting facility here. In this 80% of scale removed by high pressure
hitting of 0.3 to 0.7 mm diameter metal balls (Shots) on the strip with the help of
four turbines. The speed of shots is 80 m/s. For chemically removing of scale and
brightening of surface, we are using pickling process. In APL-2, tank 1 & 2 has
Neolyte (Na2SO4) and tank no. 3 & 4 have mixed acid (HNO3 (10-12%) + HF (2-
3%)) because of HR coils, but in APL-1, tank no.3 has HNO3 and tank 4 has mixed
acid. After Pickling strip will pass through drier and brush. In both lines we are
providing entry and exit loopers for storage of material to maintain the continuity
during welding.

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PROCESS CONTROL AND INSTRUMENTATION:
In APL 1 & 2 proper process parameter should be maintained like process
temperature, gas flow rate, % oxygen in side furnace, proper speed, direction and
tension of strip etc. For this control and Instrumentation is very important. Inside
furnace temperature measurement and control we are using PTRH (Platinum +
Rhodium) R-type thermocouples, which operating at a temperature range of 0-
1400˚ C and Output is 4-20 mA. With the help of temperature controller and relay
assembly we can maintain temperature in a required range. Similarly for pickling
tank we are using RTD. K-Type thermocouples operating range is 0 to 100˚ C
using material (Cr-Al).

ANNEALING PICKLING LINE-3:

Annealing and pickling line is provided for Annealing and pickling of Hot
rolled coils and Cold rolled coils Austentic grades of 300 series and 200 series.
Annealing pickling line supplied by M/s Andritz, Austria.
Tehnical Data:
Capacity of APL-3; 5, 00,000 TPA
Strip Thickness: 2.0 - 7.0 mm for HR Coil
: 1.0 - 4.0mm for CR
coil Strip Width : 600-1300mm
Maximum Line speed: 50 m/min
Coil Inside Diameter : Entry-760 mm for HR coil
: 610 mm for Cr coil
Tensile strength : 300N/mm2 (HR-Material)
:1400 N/mm2 (CR-Material)
Coil Weight : Max 15000 kg
Entry Looper capacity : 320 m
Exit Looper capacity : 250 m

Annealing is done to relieve the stresses & formation of new grain. Pickling is done
to remove the scales which are formed during annealing. Annealing &Pickling Line
consists of different important sections which are:

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 1. Entry Section
2. Process section.
3. Exit Section.
Entry Section-
Unwinding of coils, cutting of head/tail ends, welding two coils to maintain
continuous feeding of strip. Tension bridles are used maintain strip Tension. Strip
centering is done through Steering roll Mechanism. Entry section consists of POR,
Leveller, Crop shear, Welding Machine and Entry looper.

Welding Machine:
Supplier : Supplied by M/S Guild, USA.
Welding Process : MIG
Welding Machine : RCM 500-54 (Rotary cutting Machine)

Entry Looper- Temporary storage of coil for continuous feeding of strip to

Furnace. Entry looper is horizontal.

Process Section
Annealing Furnace:
Annealing is done to Relieving of stresses formed during hot rolling or cold
rolling & for new grain formation. After heating strip will be cooled by air jet, air
&water jets followed by water cooling. Furnace chambers are divided in to 1,2,3
and 4.Chamber 1 is preheating chamber where no nurners.Furnace chamber 2,3
and 4 will be heated by special Nox type hot air burners suitable for 500º
preheated air operation.Burners are suitable for operation with both LPG AND
Natural gas.
Material Strip Speed(m/min) Temp(ºc) Product(T/h) TV value
size(mm)
HR-304 3.0x1250 50.0 1,100 88.9 150

The equipment is designed to heat a maximum of 89 t/h of type AISI-304 strip to

1,100ºC at TV=150, with 50% excess air firing followed by cooling to , 70ºc. Entire
furnace

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Principal Dimensions of Furnace Equipment (m)
Length of Heating section 80.2
Inside width of heating chamber 2.4
Inside Height of heating chamber 2.8
Design operating temperature-700-1150 ºC
Maximum allowable operating temperature 1230ºc
The furnace is provided with the following measurement and control functions:
1. Furnace zone control and alarm/safety temperature measured by double
thermocouple (type S) and monitored by separate alarm contacts.
2. Combustion air flow to each zone incl air temperature and air pressure
compensation by differential pressure flow sensor.
3. Gas flow to each zone incl temperature and pressure compensation by
turbine meter.
4. Air gas ration adjustable with range 1.0-1.5.
5. Measurement of the strip temperature at the end of the last two heating
chambers 3 and 4.
After annealing strip will be cooled to immediately by air, air &water and then
water. After annealing and quenching strip will enter scale breaker.

SCALE BREAKER:
To break the scale layer on the strip surface. This will be done by bending
the production material around the working rolls of the scale breaker. The outer
fibres of the strip will be lengthened so that the scale will break. This leads to the
advantage that the access of the pickling fluid to the scale will be improved.
Furthermore the strip can be lengthened by the combination of bending (work rolls)
and tension (bridle rolls).This leads to a better strip shape. The scale breaker
consists of one bending and two flattening rolls set in a welded mono block frame.

Technical Data:
Pass line rolls : 1x entry and 1x exit side.
Diameter : 300 mm
Face length : 1,600 mm
Lining : PU
Bending cartridges : 4 pieces each 2 top/2 bottom
Page 32 of 61
Bending roll diameter : 70 mm
Face length : 1600 mm
Flattening cartridges : 2 pieces, 1 top/ 1 bottom
Flattening roll diameter : 200 mm
Face length : 1600 mm
Top cartridge adjustment By means of two hydraulic cylinders with integrated
linear sensors, controlled by machine mounted servo
valves.
Cartridge clamping : 2x per catridge,hydraulic cylinder.

Elongation rate control:

The elongation of the strip will be realized by means of a combination of
bending and tension. The tension will be generated by the entry and exit bridle
rolls.
The elongation rate is defined as the percentage of speeds between the
entry and exit bridle of the scale breaker.

SHOT BLASTING MACHINES:

After scale breaker strip enters the shot blasting machine where maximum
amount of scale will be removed by blasting with steel shots of S170.After bla sting
with shots removed scale/dust will be collected by separate dust collector.

Technical Data:
Supplier : M/S DISA, Switzerland.
Number of blast wheels 8
Number of throwing blades per wheel 8
Throwing speed : 52-78 m/s.
Abrasive flow per blast wheel : 1200 kg/min
Drive power (frequency controlled) : 8x110 KW
Current of blast wheel motor : by 78 m/s and 1200 kg/min - 141A
Dust collector : 67,000 m3/hr
Low pressure : 1200 pa
Rotary piston blower : 2 Nos (2x2325 m3/hr)

Page 33 of 61
Differential pressure : 0.8 bar.

PICKLING:
Neutral Electrolytic pickling:
Pickling is used for removing the left scale on the surface. Pickling is divided
into 2. One is Neutral electrolytic pickling and acid pickling.
The type of the pickling tank is an electro-chemical one. That means that
there are anodes and cathodes installed in the tank. As electrolyte sodium -sulfate
(neolyte) can be used.
In the neutral-electrolytic pickling section - NEOLYTE - the strip is de-scaled
with the help of electric current (current density is controll ed by the mathematical
model) at an operating temperature of approx. 80 °C (controlled by the
mathematical model).
The heat requirement for the pickling bath is covered by the Joule effect
(=electricity) and by steam via heat exchanger.The electrolyte is an aqueous
solution of sodium sulphate (Na2SO4). The concentration has to be as high as
possible.
Concentraion: 140 g/lit

Mixed acid Pickling: The mixed acid pickling sections serves to make the strip
free of scale and to brighten the strip surface.
The mixed acid pickling section No. 1 consists of one pickling treatment
tank. 2 circulation pumps (1 as stand by) pump the mixed acid via 2 switch-over
circulation tanks in circuit.
The mixed acid pickling section No. 2 consists of one pickling treatment
tank. 3 circulation pumps (1 as stand by) pump the mixed acid via 2 switch-over
circulation tanks in circuit.
Cooling and heating of the mixed acid is done by means of external heat
exchangers.

3.Exit Section: Exit section is used for separation of the coil and equipped with
Tension reel and exit looper.

Page 34 of 61
ACID RECOVERY SYSTEM
Acid Recovery system designed to recover free and total acids(hydrofluoric
acid and nitric acid) and metals(iron,chrome,nickel,etc) in form of oxides from
waste acids of 5,00,000 TPA annealing and pickling line 3.

Supplier : M/S ANDRITZ

Designed capacity : 4500 lit/hr
Effective operating time of regeneration plant : 7000 h/year.
Recovery rate of Hydrofluoric aicd : 97%
Recovery rate of Nitric acid : 70%

Equipment specification:
1. Reactor: for thermal decomposition of the concentrated waste acid. Reactor is
divided into upper and lower parts. Upper part contains main burners.
3 burners (for heating)
3 Pilot burners
3 Flame detectors.
Capacity of burners: 8,500 MJ/hr/burner
2. Spray system: to spray the waste acid in to the reactor..2 spray booms with
exchangeable nozzles.
3. Rabbling device: 2 rabble rakes to transport the oxide from the upper part of
the reactor to the lower part and to withdraw the oxide form the reactor.
4. Combustion air fan: To cater the burners with the required air for proper
combustion.
Capacity 8,500 m3/hr.
Pressure 12 kpa.
5. Preconcentrator,absorbtion column, jet scrubber ,spray cooler, oxidation column
are installed to help the further process.

4.5 20-HIGH SENDZIMIR COLD ROLLING MILLS

The Sendzimir Mills are reversing type cold strip mills capable of reducing
the thickness of stainless steel strips in cold condition under tension. Sendzimir
cold rolling mills differ fundamentally from conventional 2 -high or 4-hi
mills. The main difference is the way in which the roll separating force is

Page 35 of 61
transmitted from work rolls to the housing through the intermediate rolls and back-
up assemblies. As the design permits the support of work rolls throughout their
barrel length, work roll deflection can be minimized and extremely close gauge
tolerance can be held across the full width of the material being rolled.

Fig 4.3 Process Flow of Z- Mill

Page 36 of 61
Sendzimir Mill Type : 20-Hi ZR-22B-52
Manufactured by : M/S Hitachi, Japan
Supplied by : M/S Nissho Iwai Co Ltd, Japan.
A ZR-22B-52 type Z-Mill with a capacity of 32,000 tpa in 1st stage & 38,000
tpa in 2nd stage i.e. 1,10,000 tpa in total has been envisaged. Z-Mill will be
capable of processing coil of thickness from 2.0 mm to 7.0 mm & finished strip
thickness will be in the range of 0.3 mm to 4.0 mm. Maximum rolling speed will be
800 mpm. In this mill thickness of the strip is reduced by tension & is done below
recrystallization temperature.
Z-Mill-3 will have Automatic Gauge Control with the help of servo valves. In
order to have better flatness & controlling the shape, support saddles on back-up
rolls are provided. Mineral oil serves as lubricant as well as roll coolant. A
filtration system will ensure supply of clean oil. For obtaining final thickness
between 0.3 to 0.5 mm the rolling cannot be done in one stage & hence has to be
annealed & pickled before 2nd stage of rolling. This is done to overcome
work hardening.

UPGRADATION OF EXISTING SENDZIMIR MILL:

In the existing sendzimir mill roll wipers are being changed to avoid the
carryover of oil. Stress meter is added on entry & exit side of mill. With the help of
this we will have automatic control over roll for lateral adjustment of 1 st

intermediate rolls of Z-Mill.

S.No Parameter Z-Mill-1 Z-Mill-2 Z-Mill-3
1 Capacity 32000 TPA 38000 TPA 1,10,000 TPA
2 Max. Line Speed 600 mpm 600 mpm 800 mpm
3 Thickness Gamma Gamma ray Gamma ray
Measurement ray gauge gauge gauge
4 Drive D.C Drives D.C Drives A.C Drives
5 LTR,RTR & Mill 3.1 MW 3.1 MW 4.2 MW
Motor Combined
Rating
6 Automation Level 1 Level 1 Level 2
Table 4.3 Details of Various Z - Mills

Page 37 of 61
Main Specification of Sendzimir Mill – I:
Type : ZR-22B-52
Material to be rolled : AISI 200, 300, 400 series of Stainless steel which
Will be annealed and pickled.
Tensile strength : 120 Kg/mm (max)
Coil Size : ID - 610 mm
OD - Max 1830 mm (including sleeve and Interleaving paper).

Coil weight : Max 15 T

Strip width : 600 mm to 1300 mm

Starting thickness of the strip: 3.0 to 6.0 mm hot rolled
0.6 to 3.0 mm intermediate cold rolled.
Rolling Speed : 0-300-600 mpm.
Pay off speed : 0-250 mpm
Threading speed : Approx 30 mpm.
Tension reels : Max tension : 50,000 Kg upto 300 mpm
25,000 Kg upto 600 mpm
Min tension : 2,500 Kg

Pay off reel : Max tension : 10,000 Kg upto 150 mpm

6,000 Kg upto 180 mpm
: Min tension : 1,000 Kg
Roll separating force : Max 700 T

Zmill-3 Technical Specifications

The third Sendzimir Mill of SSP is Supplied by M/S Waterbury Farell with a
capacity to produce 1,10,000 tons/annum of Stainless Steel of which 22,000 tons
is through second stage rolling. It is designed to roll AISI 200, AISI 300 and AISI
400 series of stainless steel coils. This mill is equipped with level 2 automation.
Supamic type filters are used for rolling oil filtration unlike the other mills which
uses diatomaceous earth as filter aid. As-U-Roll power crown adjustments is

Page 38 of 61
included on the B&C and F&G backup assemblies in this mill. Oil wiping is by
means of one set of two roll wipers and one set of 3 roll wipers. 3 roll wipers is
equipped with air edge blow off as well as an Air Knife. Electric and controls are by
M/s ABB.

Main Specification of Sendzimir Mill – 3:

Type : ZR-22WFT-52
Material to be rolled : AISI 200, 300, 400 series of Stainless steel
which will be annealed and pickled.
Tensile strength : 120 Kg/mm (max)
Coil Size : ID - 610 mm

OD - Max 1830 mm (including sleeve and Interleaving paper).

Coil weight : Max 15 T
Strip width : 600 mm to 1300 mm
Starting thickness of the strip : Entry 2.0 to 7.0 mm
Minimum Thickness : 0.3 mm
Tension reels : Max tension : 50 kN upto 450 mpm
28kN upto 800 mpm
Pay off reel : Max tension : 12,.5 kN
: Min tension : 5 kN
Roll separating force : Max 8090 kN
First intermediate adjustment travel : 254 mm
Mill Opening : 6.35 mm with nominal dia rolls
Nominal dia of rolls:
Work roll : 66 mm
First Intermediate rolls : 98 mm
Drive and Idler rolls : 175 mm
Back Up Bearings : 300 mm

Main Equipment Charactaristics:

Unit Pay –Off – Front Tension Mill Stand Back
Reel Reel Tension
Reel
Diameters mm 610 / 1830 610 / 1830 ZR-22WFT- 610 / 1830
(min/max) 52

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Motor kW 1 * 600 1 * 4200 1 * 4200 1 * 4200
Capacity
Tensions kN 5 - 125 25 - 500 25 - 500
Equipment m/min 0 - 270 0 – 450 - 800 0 - 800 0 – 450 -
Speed 800

High Pressure system:

System Pressure : 125 bar
Capacity : 80 lpm
Auxillary Hydraulic system:
System Pressure : 80 bar
Capacity : 280 lpm
Ciruclating oil system:
Capacity : 760 lpm
Roll coolant system;
Capacity : 13500 lpm
Fume Exhaust system
Capacity : 100000 m3/hr

4.6 ROLL SHOP

Grinding and rectification of all the used and damaged steel rolls as well as
different types of rubber covered or polyurethane covered rolls catering to
Z Mills, AP Lines , Coil build up line and finishing lines

Roll shop consists of

a)Grinding Section
b) Bearing Section.

Grinding Section:
There are 9 machines comprising 5 no.of Z Mill roll grinding machines , 1 Skin
pass mill roll grinding machine and 1 rubber roll grinding machine, and 1 surface
grinding machine and 1 HMT Lathe.

Page 40 of 61
Bearing Section:

Bearing section caters to the assembly of bearing used in Z Mill back-up

assemblies. Also, it assembles and maintains the chock bearing assemblies for
Skin pass mill work rolls, This section is also equipped with a furnace for periodic
stress relieving of used rolls.

4.7 STRIP GRINDING LINE

Strip grinding line is provided for removing the surface defects of the strip.
The Strip grinding line consists of six grinding heads where the surface of the strip
is ground by moving abrasive belts. The line has a speed of 30 m/min(max) and an
output of 8 to 14 T/hr depending on the stock removal needed.
The line was supplied by M/S Sundwig of Germany and M/S HEC of India.

LINE CHARACTERISTICS:

Material : Stainless steel of AISI 200,300 and 400 series.

Strip dimensions
Width : 600 mm to 1300 mm
Thickness : 0.4 mm to 6.0 mm
Coil dimensions
Inside diameter : 610 mm
Outside diameter : 900 mm – 1830 mm
Coil weight : 15 T
Line speed : 3 to 30 m/min
Threading speed : 15 m/min
Strip tensions
Uncoiler : 25,000 Kg max
Recoiler : 32,000 Kg max
Grinding head : 30,000 Kg max.
Degreasing unit : By means of spraying degreasing agent on both side
of the strip, oil is removed from surface.
Degreasing agent : Kerosene / Servocut.
Stock removal : 10 micron/head (max)

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The control system originally supplied with analog control is converted into PLC
(Programmable Logic Control) system.

4.8 SKIN PASS MILL

Stainless steel strips reduced to the required thickness in the Sendzimir mill
re-processed in Annealing and Pickling line before coming to Skin pass mill. The
purpose of skin passing is to obtain a flat strip profile with the desired mechanical
and surface properties. In addition for ferritic and martensitic steels, skin passing
serves to suppress the sharp yield point, thus eliminating the formation of stretcher
strains in subsequent deep drawing operations. For this purpose a 2 -hi design mill
has been envisaged with capacity of 1,00,000 TPA for processing Cold rolled
annealed stainless steel coils from APLinel. elongation in SPM is up to 0.8 %. Skin
pass mill has three important sections:

 Entry Section- It has Coil car, pay-off reel, snubber roll, peeler blade & pre-
straightener. It has strip edge control device to provide central feeding of
coil.

 Mill- It is reversing 2-high mill. Hydraulic roll positioning system is envisaged

for rolling under constant pressure.

 Exit Section- It consists of tension reel, coil car & swinging table. Paper
winder/ unwinder is provided at two reels for removing/ feeding of
interleaving paper.

The 2-hi Skin pass mill was supplied by M/S MECON (India) Ltd of Ranchi
in collaboration with M/S Wean United, USA. The design of the Skin pass mill has
been made to incorporate many special features such as constant elongation
control, automatic slow down at the end of the strip, constant hydraulic roll force
system with provisions for possible future computerization of the process.

MILL CHARACTERISTICS:

Material : Stainless steel grades included under

AISI 200,300 and 400 series.
Coil dimensions
Inside diameter : 610 mm

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Outside diameter : 1830 mm
Coil width : 600 mm to 1300 mm
Coil weight : 15 T
Strip thickness : 0.3 mm to 4,0 mm
Tensile strength of the material to be rolled: 70 Kg/mm (normal rolling)
120 Kg/mm (Occasional rolling)
Elongation : up to 0.80 %
Strip speed : 180 m/min at full torque
360 m/min at reduced torque
30 m/min at threading

Tension range of Pay off cum tension reel: 14,000 Kg (max) at 360 m/min
: 700 Kg (min)
Max roll force : 1200 T
Max roll opening : 80 mm
Mill pass line : 1000 mm above floor level
Roll material : Alloy forged steel

The control system originally supplied with analog control is converted into PLC
(Programmable Logic Control ) system.

4.9 SHEARING LINE

Shearing line is provided to cut the coiled strip into sheets of different sizes as
required by the customers. The Shearing line consists of a Pay off Reel, Entry
Crop Shear and Side Trimmer unit for trimming the edges, precision level to the
strip in the different thickness ranges, a traveling shear to cut the sheet to accurate
length and Vacuum piler to pile the sheets. The line can handle strips from 0.3 mm
to 4 mm thickness and has a maximum speed of 70 m/min. The line was
manufactured by M/S Heinrich Georg and supplied by M/S Hoesch Tecna of
Germany.

LINE CHARACTERISTICS:
Materials to be sheared: Cold rolled stainless steel grades
of AISI 200,300 and 400 series

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Width of the initial Coil : 600 mm to 1300 mm.
Sheet Width : 500 mm to 1300 mm

Thickness : 0.4 mm to 4.0 mm

Tensile strength :120 Kg/mm (max)
Sheet lengths : 500 mm to 4,000 mm
Line speed
Threading speed : 15 m/min
Shearing speed : 0 to 70 m/min
The control system originally supplied with analog control is convert ed into
PLC (Programmable Logic Control ) system.

4.10 SLITTING LINE

The Slitting line caters to the requirement of the customers, who need coil in
narrow widths and smaller widths. It is equipped with a Slitting head which can
make up to 15 slits at a time. The line speed is 140 mpm (max). The minimum
width of the slit coils is 50mm, the large coils can also be divided into smaller coils.
The line was supplied by M/S Hoesch Tecna of Germany. After modification, the
line can slit coils up to 35 mm width and also taping of plastic sheet is done on strip
in the line itself as per demand of the customers.
Slitting line has been envisaged to obtain cold rolled coil of various grades
in variable width as per requirement. The slit coils are called baby coils.
Depending upon the requirement the width of coil is determined. Annual capacity
of slitting line will be 70,000 tpa. Slitting line consists of various sections:

1. Entry Section- It includes pay-off reel with head, peeler cum threading table &
a level. Automatic width & height centering device on pay-off reel. An automatic
strip centering device which facilitates feeling of the strip centrally to the line.

2. Slitting Machine- It is provided to slit the strip to required width. Slitting

machine consists of circular slitting knives which are designed for taking maximum
of 15 slit strands from max. 4.00mm thick strip including trimming either side of the
strip. Two complete sets of slitting heads with arbors are provided to facilitate
quick change. A 4-arm turnstile shall hold the new set of tools & shall be used to
pull existing tools in one head, turn & push new set of tools from other head. A

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scrap baler is proved for winding the trimmed edges & compacting in the form of a
ball.

3. Exit Section- Slit coils are fed onto the recoiler mandrel. Provision will be made
in the tension reel to wind coils with inner diameter 406,508 mm as well as 610
mm.

LINE CHARACTERISTICS:

Material : Hot and cold rolled, annealed and pickled and skin
passed/un skin passed coils of AISI 200, 300 and 400 series.
Width of the initial coil : 600 mm to 1300 mm
Width of the slit material : 35 mm to 1300 mm
Material thickness : 0.3 mm to 4 mm- cold rolled
3.0 mm to 4 mm- hot rolled
Coil inside diameter
Entry and recoiling side : 406 mm, 508 mm and 610 mm.
Coil outside diameter : 750 mm (min)
: 1830 mm (max)
Line speed
Threading speed : 15 m/min
Strip speed at Transmission range I : 70 m/min
Strip speed at Transmission range II : 140 m/min

PACKING
The slit coils/baby coils of different width and weight are taken out of Tension Reel
mandrel and packed in packing section as per the customer requirement.

4.11 TENSION LEVELLING LINE

Tension leveling line is to be envisaged with annual capacity of 70,000T. It

consists of sections:

1. Entry Section- It consists of saddle type coil storage, floor mounted coil car,
spool/pup coil ejection, pay off with head, outboard bearing support, paper winder,
peeler cum threading table & a entry decurve roll, deoiler rolls & dirt removal pad.

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Automatic width & height centering device with non-contact sensors are provided
in pay-off to facilitate quick loading. An automatic strip centering device.

2. Tension leveler- It is of 6-Hi construction fully supported. The leveler

includes two elongation sections and two decurving sections. Top elongation roll
cassettes are held in fixed position. Bottom decurve roll cassettes are adjusted
vertically with motorized screw jacks & auto set. Bottom banks of roll cassettes will
have hydraulic quick open device. Roll cassette removal rig. Top roll cassettes
can be rotated off-line for access.

3. Exit section- Tension level coils are wound on recoiled head supported by
auto edge guide.

4.12 ROTARY POLISHER:

The “Rotary Polisher” which produces “Mirror Finish” or (No 8 Finish), is a

finishing line which combines high productivity with a homogenous and non
directional surface finish. It is characterized by high reflectivity and low roughness.
The polishing unit consisting of felt discs which are mounted on vertical spindles
which is part of a multi mandrel system. The work processing is carried out using a
suitable activated solution distributed on the surface of sheet to be polished by
means of special felt discs. The polishing line is also equipped with distribution and
filtration systems which recover the polishing compound. It filters it from the metal
parts removed during polishing thus reducing loss to the minimum of polishing
compound. The washing and drying unit allows preparing the surface of the sheet
for further coating with protective film.

Basic Machine features:

1. Material Width : 600 to 1300 mm
2. Material Thickness : 0.5 to 4 mm
3. Material Length : 1000 to 3000 mm
4. Material grades : AISI 200/300/400 series
5. Adjustable Feed speed : 0 to 2 m/ min
6. Diameter of Felt Discs : 210 mm
7. Thickness of Felt Discs : 40 mm

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 8. Spindles : 14 Nos per Head
9. Spindle rev (adjustable) : 0 -600 rpm
10. Oscillation Amplitude& Frequency : 0 -235 mm & 0.05 to 8 M/ Min
Production rate & Surface Finish :
The “Rotary Polisher” is designed to produce 1000 tons per year.
Production Rate:
a) 1300 mm wide x 3000 mm long x 2.0 mm thick – 61 Kgs / hour
b) 900 mm wide x 2500 mm long x 1.0 mm thick – 18 Kgs / hour

Surface Finish:
a) Sheet Surface finish: No 8 Finish (Mirror Finish) is guaranteed on the sheets
b) The finished product is free from marks, scratches, lines, patches
(difference in surface colouring), encrustations, gauging and indentations due to
the “Rotary Polishing Line” equipment

4.13 RESQUARING SHEAR

Resquaring shear is a salvaging unit supplied by M/S Sumitomo of Japan.

The Resquaring shear is mainly utilized to cut out
 defective portion of finished sheets
 the ends of sheets with jaw marks from stretcher leveler.
 out of square sheets from the Shearing line.

LINE CHARACTERISTICS:

Materials : Hot rolled /cold rolled, stainless steel sheets

of grades AISI 200,300 and 400 series.
Sheet width : 570 mm (min); 1300 mm (max)
Sheet length : 1500 mm (min); 4000 mm (max)
Sheet thickness
Hot rolled : 3 mm to 4 mm
Cold rolled : 0.3 mm to 4 mm
Tensile strength : 120 Kg/mm (max)
Shearing speed : 32 cuts per min (max)

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4.14 COIL PACKING & DISPATCH

For Prevention from the dust and defects during storage and transportation,
proper packing should be done. For export and house material different type of
packing is required. Packing also depends on the thickness of the material. For
packing of different grade and thickness material we are using following materials.
PVC Coating, Interleaving paper (ILP) , Bubble sheets, wood and metallic pillers
and Oil sheets. Less than 0.63mm coil should be covered with GI sheets. 1.2 mm
or less coil, inner ring provided and upper coating should be GI Sheet.
For special finishes like No.4 hard boards are used both sides top and
bottom side. Packing strap is used for coils having 0.7mm thickness and widths
are 19mm and 32mm. Other parts of this line are conveyer, weight section and
strip packing section.

4.15 BLANKING LINE

The purpose of Blanking line is to produce polished coin blanks and utility
blanks. Blanking facilities supplied by M/S Schuler, Germany has an installed
capacity of producing 3,000 Tonnes of coin blanks or 3,600 Tonnes of utility blanks
per annum. It was commissioned on December 24, 1993. The high speed blanking
press can punch out about 600 Kg of coin blanks per hour at a speed of 600
strokes per minute. These blanks after being de-burred and degreased are rimmed
in a rimming machine.

Fig 4.4 Coin Blanking Unit

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 The double drum rotary furnace anneals the blanks in a protective nitrogen
atmosphere. The centrifugal pickling and polishing equipment has a rotary drum
where the coin blanks and stainless steel balls are rotated at high speed. The coin
blanks are then counted and packed.

Blanking line specifications:

Blanking Press:
Rated capacity : 3600 Tonnes
Stroke length : 30 mm
Coil width : 470 mm
Thickness of strip : 0.3 – 2.5 mm
Rimming Machine:
Production capacity : 600 Kg/hr
Rimming disc speed : 225 rpm (max)
Capacity : 6,50,000 blanks per hour for 14 mm dia
1,80,000 blanks per hour for 50 mm dia
Coin diameter : 14 – 50 mm
Annealing furnace:
Output capacity : 600 Kg/hr
Specific energy consumption: 0.16 – 0.17 kWh/Kg
Blank thickness : 1 – 3 mm
Blank diameter : 14 – 50 mm
Furnace temperature
Zone 1 : 750 ˚C
Zone 2 : 900 ˚C
Zone 3 : 900˚ C
Annealing time : 24 – 34 min
Protecting gas temperature: 800˚C
Charge weight : 10 Kg
Pickling and polishing:
Production capacity : 600 Kg/hr
Composition of pickling : Ferric chloride 40% and Hydrochloric acid 0.5 %
Counting machine:
Capacity

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 25 Paise : 3,000 coins per minute
50 Paise : 2,500 coins per minute
1 Rupee : 2,200 coins per minute
Diameter : 14 – 50 mm
Thickness : 1 – 3 mm
Speed : Depending on the diameter.

4.16 CRM – CRANE DETAILS

CAPACITY
S NO LOCATION MAIN AUX SUPPLIER
(TON) (TON)
1 CRANE 11 25 5 M/s BRAITHWAITE, CALCUTTA
2 CRANE 12 25 5 M/s BRAITHWAITE, CALCUTTA
3 CRANE 13 25 5 M/s BRAITHWAITE, CALCUTTA
4 CRANE 21 25 5 M/s BRAITHWAITE, CALCUTTA
5 CRANE 22 25 - M/s BRAITHWAITE, CALCUTTA
6 CRANE 23 25 - M/s BRAITHWAITE, CALCUTTA
7 CRANE 24 25 5 M/s BRAITHWAITE, CALCUTTA
8 CRANE 25 25 5 M/s BRAITHWAITE, CALCUTTA
9 CRANE 31 30 5 M/s BRAITHWAITE, CALCUTTA
10 CRANE 32 25 5 M/s BRAITHWAITE, CALCUTTA
11 CRANE 33 15 - M/s BRAITHWAITE, CALCUTTA
12 CRANE 34 25 5 M/s MUKUND LTD BOMBAY
13 CRANE 41 25 - M/s FAFECO
14 CRANE 42 25 5 M/s FAFECO
15 CRANE 43 25 5 M/s FAFECO
16 CRANE 44 25 5 M/s FAFECO
17 CRANE 51 25 5 M/s FAFECO
18 CRANE 52 30 5 M/s FAFECO

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 5. UTILITIES
5.1INTRODUCTION

Utility Services include

1. Boilers
2. Fuel oil Pump House
3. Main Air Compressors
4. LPG
5. Pipelines

5.2 BOILERS:

Process steam at a main pressure of 12.5 Kg/cm is required for the following
uses in this plant
- Heating of pickling baths and drying of coil surfaces
- in Annealing andPickling lines.
Heating of LP Gas in LPG vapourizers
Cooking food and sterilizing of dishes in Plant Canteen
Steam ejector to pump out seepage water
Purging of other pipe lines.

In most of the above cases, the pressure of steam will be reduced to around 2.5
Kg/cm or less by means of pressure reducing valves. Average steam
consumption of the plant is about 4 T/hr.

SPECIFICATIONS: FLUIDISED BED COMBUSTION BOILER

Type : Two drum, integral furnace water tube boiler

with fluidized bed combustion system
Supplier : M/S ISGEC JOHN THOMPSON Ltd, Kolkatta.
M/S Cethar Vessels P Ltd, Trichy
Fuels : Rice Husk / DOB (De-Oiled Bran) / Coal

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5.3FEED WATER TREATMENT:

An ion exchange type water softening plant with two numbers of basic softeners of
capacity 18 m /hr each has been installed.

Supplied by M/S Arudra & Co, Chennai.

This plant serves for both Coal fired boiler and Oil fired boiler.

OIL FIRED BOILER

Type : Two drum integral furnace water tube boiler.

Working parameters : 12.5 Kg/cm , 12.5 T/hr saturated steam output.
Soot blowers : Fixed jet type.
Fans : One number of forced draft fan
Feed pumps : KSB Horizontal turbine pumps.
Supplied by : M/S Steel Plant Pvt Ltd, Mumbai.

5.4 AIR COMPRESSORS

Compressed air at 7 Kg/cm is required for the following purposes.

- Pneumatic cylinders in the mills
- Pneumatic tools
- General air jet cleaning and stirring of solution tank
- Operation of indicating/recording instruments
- Purging of other pipelines.

SPECIFICATIONS :Air Compressors (4 No)

Type : Horizontal, balance opposed water cooled,

2 stage, 4 cylinder type.
Working parameters : 7 Kg/cm , 1824 Nm /hr
Drive : Electric Motor 225 HP through V-belts
Load control : Suction valve opening type (0% or 100 % load)
Lubrication : Force feed by gear pump for crank case parts and
Mechanical force feed lubricator for cylinders

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5.5 LIQUIFIED PETROLEUM GAS: (LPG)

This high calorific value fuel is used to fire the continuous annealing
furnaces of the Annealing and Pickling lines. The Liquefied petroleum gas arriving
in special tank wagons is unloaded into the storage spheres using gas
compressors by the indirect displacement method. Thus the compressors will draw
gas from the top of the storage spheres (which is filled to 70 % capacity only) and
pump it under pressure into the top of the tank wagons, creating a lower pressure
in the spheres and a higher pressure in the wagons. Under the differential pressure
the liquid from the wagons will flow into the spheres.
For supplying gas to the furnace, the liquid is piped into the vapourisers
where it is heated by a steam coil . The gas thus produced flows from the top of
vapourisers into the supply mains. The vapourisers are fully automatically
regulated with regard to the level of liquid in the vapouriser and the pressure of
output gas. The LPG storage spheres are guarded against excess temperature by
a special water sprinkler system.(For HRM furnace, AP Lines, Slab Caster torch
cutting, Slab scarfing, Miscellaneous cutting).

SPECIFICATIONS:
Storage: 3 spherical tanks of 500 tonnes capacity each ( i.e. 1070 m each).
- Unloading platform for 60 LPG wagons at a time.
- Unloading compressors (6 No) of the following type:
- Single stage, double acting non lubricated reciprocating compressor of
250m /hr swept volume.
- Vapourisers : Shell and tube type
- Quantity : 3 No
- Heating medium : Steam
- Capacity : 4000 Kg / hr (or) 54,233 Nm3 / day

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 6. SERVICES

6.1 GENERAL ADMINISTRATION:

General Administration department takes care of the furniture and office

stationery requirements of the entire plant. It does the job of distribution of Dak,
Service dresses to employees, couriering of mails/parcels. The dept also looks
after the sanitary requirements.

6.2 PUBLIC RELATIONS:

The Public Relations Department publishes the plant information and co-
ordinate with media. In house and external communication through Stainless
News, Monet is taken care by the department. They takes care of Photo coverage /
Video coverage and keeping records of the events.

6.3 MATERIAL MANAGEMENT DEPARTMENT(MMD):

MM Department does the function of floating tenders and issuing of purchase

orders as per the technical specification given in the purchase requisition for all the
required materials like Raw materials, tools, spares and consumables. It also does
the function of collecting/receiving / inspecting and taking into custody of the
ordered materials. The Central Stores section of MM Department issue the
materials to the indenting departments based on SIV. They keep the records of
Receipts / Stocks / Issues.

6.4 MARKETING:

The Salem Steel Plant Marketing office is merged with Central Marketing
Office(CMO), Head Office located at New Delhi. The product from Salem Steel
Plant are marketed worldwide by its CMO marketing net work with the branches
located in India and world.
Indian Stainless Steel Scenario in the year of 2010

Salem Steel Plant : 90 000 T ( IN T)

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CATEGORY 2008-09 2009-10 2010-11 .

DOMESTIC SALES 38433 51997 53273

MINTS 9195 4054 13688

RAILWAY BOARD 25045 11413 21031

EXPORT 158 1931 584

COMML. QUALITY 3526 2827 2465 .

TOTAL SS 76358 72222 91041

CARBON STEEL 84030 166302 151628 .

GRAND TOTAL 160388 238524 242669

Table 6.1 Stainless steel Scenarios of Various years

6.5. FINANCE & ACCOUNTS DEPARTMENT (FAD):

FAD continuously up-dates and monitors the financial position of the
company. They make the Balance Sheet /Reports of Profit/Loss and various
payments. They look into the various aspects of taxes, duties, levies, MODVAT
claims etc. They monitor and provide information on variable costs of production
affecting the profitability for better control.

6.6 SAFETY ENGINEERING & FIRE SERVICES:

Safety Engineering dept governs the industrial safety to be followed, and
they control and maintain the records of industrial accidents (Reportable/Non-
Reportable) as per Factories Act. They inspect and give safety clearance to the
contact labour’s prior to starting any contract work. All statutory requirements/
records are maintained by the dept. They look after the procurement and issue of
all PPEs (Personal Protective Equipments like Safety Shoes, Goggles, Ear Muff,
Face shield, Aprons, Helmet and Hand gloves etc.
The Fire Services does the fire fighting function which is under CISF under the
Central Home Ministry. Fire Services regularly checks, refills, inspects, ensure
healthiness and working condition of the various fire extinguishers

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6.7 WATER SUPPLY:
The requirement of water for the industrial use and for the Mohan Nagar
Township is drawn from the Cauvery river at Poolampatti and is pumped from the
Head Works at Poolampatti and carried through 28 KM pipe line of 600 mm
diameter and stored in the Balancing Reservoir in the plant. The balancing
Reservoir can store the quantity of water requirement for the Plant and Township
for 10 days.
The following pump houses / plants are installed to meet the water requirement for
various purposes and processes.
1) Make up water Pump house
2) Recirculating water pump house.
3) Water treatment plant
4) IFFS – Independent Fire Fighting System pump house.

6.8 MEDICAL AND HEALTH SERVICES:

Salem Steel Plant Hospital was commissioned on 19.02.1983 and renders

Health Care services to its employees, CISF personnel and their dependents. The
population in the peripheral areas are also utilizing the services on payment basis.
The Salem Steel Plant Hospital is equipped with modern facilities. The following
services are available in the Hospital for the out-patients like In house pharmacy,
physiotherapy, lab services, X-ray and ECG, Utra sound colour Doppler. The
following services are available under In-patient services – Nursing, Male and
female wards, Intensive Care Unit, Neonatal care unit and Operation Theatres and
labour Rooms. Blood bank Services, Dietary Services and Ambulance Services
are the Allied Services. SSP hospital is equipped with 40 beds. The Hospita l is
under the scope of ISO 14001 EMS for Township, our company is preparing for
certification.

6.9 CORPORATE SOCIAL RESPONSIBILITY:

Since inception, SSP has been working in different areas of Corporate

Social Responsibility such as Education, Medical facilities, Women upliftment ,
providing drinking water supply, laying Roads etc., in the peripheral and adjoining
areas of the plant. In order to help the weaker segments of the society under
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sustainable development activities, SSP has identified 31 villages out of which the
plant has already implemented several community development works in 16
villages. SSP has adopted ‘Thirumalaigiri village`, socially and economically
weaker with low standard of living and infrastructure as Model Steel Village under
SAIL’s Corporate Social Responsibility..

6.10 CENTRAL ENGINEERING SHOP (CES):

Central Engineering Shop contains the conventional machine tools like

Lathe, Drilling m/c, Shaping m/c, etc Slotting m/c, Milling m/c etc. CES caters to
the spares requirement of the CRM, HRM and utilities. CES also can take up
fabrication and assembling jobs.

6.11 ELECTRICAL REPAIR SHOP(ERS):

ERS carries out the motor rewinding jobs and testing of motors. Adjoining to
ERS, a loco shed is functioning for the maintenance of our loco which transports
the raw materials like slabs, cements, rails etc. from the railway siding yard to the
plant.

6.12 PRODUCTION PLANNING AND CONTROL (PPC):

The function of PPC department starts from raw material procurement,
receipt of Input material, scheduling the production and finally servicing the
customer / Stock yard as per the requirement. The PPC department plans for the
production of orders received from Marketing department. The department
procures the necessary raw material in coordination with material management
department and carries out the fulfillment of customer orders by ensuring the
availability of the production units and Management Information system.

6.13 METALLURGICAL SERVICES:

Metallurgical services department does the function of testing and
inspection of the incoming raw material and the in process material at various
stages of production. It carries out Chemical analysis, Hardness testing, Tensile
testing and composition. The disposition of the next operation for the process

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material is given by the Met. Services dept. It also governs the Techno economic
parameters such as Prime, Seconds, Commercial quality etc. They are the
certifying agency of the finished product to the requirement of the customers based
on standards..

6.14 CENTRAL MECHANICAL MAINTENANCE(CMM):

The main function of CMM is to operate and maintain the utility services /
CES & to procure and supply the Mechanical spares and Consumables through
Methods Section for CRM, HRM, Utilities and Auto garage. The Technical Bureau
which centrally takes care of the condition monitoring of rotating machinery such
as Blowers, fume exhaust fans etc is also under CMM dept.

6.15 AUTO GARAGE:

The Auto garage takes care of transport requirement and a fleet of company
vehicles like Trucks, dumpers, Trailers, Mobile Cranes, Jeeps, Vans, Cars,
Ambulances etc., Auto garage upkeeps and maintains all the company vehicles in
good running condition.

6.16 CENTRAL ELECTRICAL MAINTENANCE(CEM):

The main function of CEM is to operate and maintain the electrical utility
services like MRSS (Main Receiving Sub Station), WRSS(Works Receiving Sub
Station), ERS, Telecommunication, 6 MW DG Set, Township Electrical etc. and to
procure and make available the Electrical spares and consumables through
Methods Section for CRM, HRM, Utilities etc.,

6.17 TOTAL QUALITY MANAGEMENT (TQM):

TQM department coordinates with all the other departments in
implementation of various Management Systems like QMS,EMS and OHSMS. It
coordinates in Quality Circle activities, and Employees Suggestion Schemes. The
Head of TQM is the MR (Management Representative) for all the ISO and OHSAS
Systems. TQM governs all the Internal and external audits w.r.t to the various ISO
systems.

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6.18 TECHNICAL BUREAU:

Role/function of Technical bureau:

 Apart from regular preventive maintenance and breakdown maintenance for
proper working of life of the equipment predictive maintenance is necessary
to avoid sudden breakdowns. This department carried out regular vibrations
measurement on different machinery.
 This department act as a consultant for different plant outside Salem.
 This department has highly sophisticated equipment with current software
which help to analysis problem deeply.

6.19 C&IT DEPARTMENT

C&IT (Computer and Information Technology) department of Salem Steel

Plant is catering to the functional requirements of Material Management, Finance &
Accounts, pay roll and planning & production requirements of various production
lines of Steel Melting Shop, Hot Rolling and Cold Rolling Mills on real time basis.
The department is provided with central servers having OS as Windows 2008 R2
(server) with Oracle 8 database with dotnet as front end. A separate Novell
NetWare based server is used for the production requirements of various lines.
Fibre optic backbone with core and area switches located in various areas of the
plant catering to about 400 clients. Hardware & software details of existing setup
are given below:

Material Management
Application is running on servers mentioned below:

Application Server: Application is running on two servers. Two servers are sharing the
load of the network & it also takes care of fail over situation.

Make: : HP PROLIANT DL 360P GEN8 (XENON based-2 No’

Operating System: Windows 2008 R2 Server
RAM : 24 GB
Hard Disk : 300 GB SAS hot pluggable– 2 No’s
Front End : ASP.NET C#

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Database Server : Oracle is running on primary server, in case of failure of the
primary server secondary server will be automatically
activated.
Make : HP INTEGRITY RX280014 (RISC/EPIC-2 No’s)
Operating System : HP UX 11I V3, HP Service Guard for fail over
Back end : Oracle 11g
RAM : 32 GB
Processor : Itanium
Hard Disk : 300 GB SAS hot pluggable – 2 No’s
SAN Storage : HP PA 6000 (8 TB, After RAID5 3 TB, Active- Active
controller)
Installed disks : 18 numbers of 450 GB SAS Hot pluggable expandable up to
36 disks. Connectivity to servers via FC (Fiber channel)
Backup Server : HP PROLIANT DL 360P GEN8 (XENON based)
Backup Software : HP Data Protector 7 (Magnetic tape drive used for Backup)

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