sail inplant report by srmuniv-140629074721-phpapp02

8/11/2019 sail inplant report by srmuniv-140629074721-phpapp02

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SAIL SALEM STEEL PLANT

SRM UNIVERSITY

STEEL AUTHORITY OF INDIA LIMITED

SALEM STEEL PLANT

SALEM

INPLANT TRAINING

Department of ELECTRONICS AND COMMUNICATION ENGINEERING

SRM UNIVERSITY

KAATANKULATHUR-6!"!

CHENNAI#

Done $%

GOKULNATH#& '()("(6*+

,AYARAGHAENDRAN#, '()("(*.6+

AS/INKUMAR#R '()("(*0*+

1


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SRM UNIVERSITY

ABSTRACT

In order to study the process that takes

place inside the steel plant industry we selected to do

inplant training in SALEM STEEL PLANT , And we

people successfully completed our inplant training on

!M , "!M, and process taking place inside those

mills # The process that we understood ha$e %eensu%mitted as the report# ere%y,we thank the !& of

SSP who ga$e this opportunity#

AS/INKUMAR#R'()("(*0*+1

,AYARAGHAENDRAN#,'()("(*.6+1

GOKULNATH#&'()("(6*+#

2


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SRM UNIVERSITY

S#no INDE2

' Introduction

( Industry profile

) SAIL mission * $ision

+ "ompany profile

-unction of company

#'.!M #(."!M

/ Strength 0eakness * 1pportunity

2 "onclusion

3


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SRM UNIVERSITY

SALEM STEEL PLANT 'SSP+

(# INTRODUCTION

Salem Steel Plant is a premium producer of international 3uality stainless steel in

India# "ommissioned in '45', the plant has a capacity to roll '5/666 tonnes of hot rolled

car%on and stainless steel flat products and 26666 tonnes of cold rolled stainless steel

sheets and coils per annum#

Its products ha$e %ecome a household name 7SALEM STAINLESS8 in domestic

market and are e9ported# In hot rolled special grade car%on steels, SSP has %een

recogni:ed as well;known manufacturer of %oiler 3uality steel#

A


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SRM UNIVERSITY

occupies the summit of Salem Steel priorities# The products are well accepted in national

and international markets for its top;notch 3uality#

Or3an45at4on Name SAIL ; Salem Steel Plant DSSP., Salem#

In789tr% 4t $e:on39 to Steel

C;a4rman 'SAIL+ "#S#arma

Ee D4re=tor 'SSP+ PangaF Bowtham

Fore43n e


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SRM UNIVERSITY

H49tor% of t;e In789tr%

The Indian steel industry is almost ''6 years old now# Till '446, the Indian steel

industry operated under a regulated en$ironment with insulated markets and large scale

capacities reser$ed for the pu%lic sector# Production and prices were determined and

regulated %y the go$ernment, while SAIl and TATA steel where main producers, the latter

%eing the only pri$ate player# In '446, the Indian steel industry had a production capacity

of ()MT# '44( saw the onset of li%erali:ation and the Indian economy was opened to the

world# Indian steel sector also witnessed the entry of se$eral domestic pri$ate players and

large pri$ate players and large pri$ate in$estments flowed into the sector to add fresh

capacities#

Steel industry in India is on an upswing %ecause of the strong glo%al and domestic

demand# India>s rapid economic growth and soaring demand %y sectors like

infrastructure, real estate and automo%iles, at home and a%road, has put Indian steel

industry on the glo%al map# According to the latest report %y International Iron and Steel

Institute DIISI., India is the se$enth largest steel producer in the world#

The Indian steel industry is organi:ed in three categories i#e main producers, other

maFor producers and the secondary producers# The main producers and other maFor

producers ha$e integrated steel making facility plant capacities o$er 6#MT and utili:ed

iron ore and coalH gas for production of steel# The main producers are TATA steel, SAIL

and !INL, while the maFor producers ESSA!, ISPAT and @SL#

Contr4$8t4on of Co8ntr4e9 to G:o$a: Stee: In789tr%

The countries like India, china @apan and South Jorea are in the top of the a%o$e

in steel production in Asian countries# "hina accounts for one third of total production

i#e+'4MT, @apan accounts for 4K i#e''5MT, India accounts for )MT and South Jorea isaccounted for +4MT, which all totally %ecomes more than 6K of glo%al production#

Apart from this GSA,

Pre9ent Stat89 of t;e Stee: In789tr%

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SRM UNIVERSITY

Indian economy growing at 5 to 4K is one of the fastest growing

economics in the world#

The tenth plan in$estment in infrastructure has %een en$isaged at around

!s#556, 6 crores#

&uring ele$enth plan D(662;65. to D(6'';'(., the proFected in$estment

toward infrastructure is likely to %e !s#(6(2666 crores, an increase of

'56K o$er '6thplan#

Per capita consumption at )kg low as compared to world a$erage of

'6kg and )66kg for "hina#

Lot of Steel proFect %oth


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SRM UNIVERSITY

Although India has moderni:ed its steel making

considera%ly, howe$er nearly /K of its crude steel is still

produced using the outdated open;hearth process

La%our producti$ity in India is still $ery low#

Steel production in India is also hampered %y power

shortages#

India is deficient in raw materials re3uired %y the steel

industry#

Insufficient freight capacity and transport infrastructure

impediments to hamper the growth of Indian steel industry#

In74an Iron Stee: Str8=t8re

Indian Iron and steel industry

Steel producers

Sponge iron producers

Stee: pro78=er9

a. Main producers

i# SAIL

ii# !INL

iii# TSL

%. MaFor producers

i# @S0 steel limited

ii# ESSA! steel limited

iii# ISPAT industries limited

i$# @indal Steel * Power limited

c. 1ther producers

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SRM UNIVERSITY

i# EA- %ased units )) working units

ii# Introduction -urnace %ased units 426 working units

d. M


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SRM UNIVERSITY

To %e respected world class corporation and the leader in Indian steel

%usiness in 3uality, producti$ity and customer satisfaction#

A world of pro$en talent

&eli$ering %reak through inno$ation

Bi$ing our customer a uni3ue competiti$e edge

Ena%ling societies to master their most $ital challenges#

Cre7o

0e %uild lasting relationships with customers %ased on trust and mutual

%enefit#

0e uphold highest ethical standards in conduct of our %usiness#

0e create and nurture a culture that supports fle9i%ility, learning and is

proacti$e to change#

0e chart a challenging career for employees with opportunities for

ad$ancement and rewards#

0e $alue the opportunity and responsi%ility to make a meaningful difference

in people>s li$es#

M4994on

0e will seek glo%al market leadership#

&e$elopment and growth in oriented firms will %e our focus#

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SRM UNIVERSITY

0e will continue to create a winning culture, operating in the highest

standards of ethics and $alues#

0e will stri$e for e9cellence in customer ser$ice, 3uality and !*&

a:8e9

!esponsi%le "ommitted to ethical * responsi%le action

E9cellent Achie$ing high performance * e9cellent results

Inno$ation


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SRM UNIVERSITY

SAIL traces its origin to the formati$e years of an emerging nation ; India# After

independence the %uilders of modern India worked with a $ision ; to lay the infrastructure

for rapid industriali:ation of the country# The steel sector was to propel the economic

growth# industan Steel Pri$ate Limited was set up on @anuary '4, '4+#

E


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SRM UNIVERSITY

&ecem%er (, '42(# 1n this %asis the concept of creating a holding company to manage

inputs and outputs under one um%rella was mooted# This led to the formation of Steel

Authority of India Ltd# The company, incorporated on @anuary (+, '42) with an

authori:ed capital of !s# (666 crore, was made responsi%le for managing fi$e integrated

steel plants at


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SRM UNIVERSITY

-or any M


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SRM UNIVERSITY

There are two maFor units in Salem Steel Plant DSSP.

a. !M

%. "!M

HRM Hot Ro::4n3 M4::

Inp8t

a. "ar%on Steel sla%s from sister steel plants $i:


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SRM UNIVERSITY

Sla%s of car%on steel Dor. stainless steel are recei$ed through wagons from Alloy

Steels Plant, &urgapur or


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SRM UNIVERSITY

0hen the hot sla% is discharged from the furnace, some elements in the sla% will

react with the o9ygen in the atmosphere and forms a compound called Scales on the

surface of the sla%s# These scales are unwanted elements and to %e remo$ed from the

surface of the sla%# The hot sla%s with these scales are passed through a descaler, which

will %reak the scales# The scales so %roken are wiped off the sla%s with high;pressure

water Fets# Scale free sla%s will come out of the descaler and will %e forwarded to the

roughing mill# !oller ta%le ena%les mo$ement of these sla%s without damaging the

surface

Ro83;4n3 M4::

This is a re$ersi%le mill# The sla% thickness, which enters the mill, will %e of the

order of (66mm# This will %e reduced down to (;)6mm depending on the final

thickness to %e rolled in Steckle Mill# This thickness reduction from (66mm to (;)6mm

takes place in se$eral passes#

Crop S;ear

The plate from roughing mill will ha$e minor fish tail at leading and tailing ends#

This portion has to %e remo$ed in order to ha$e a s3uare ends# "rop shear chops off the

fish tail ends#

Ste=?:e M4::

This is also a re$ersi%le mill with le$el ( automation# This is the main unit of

!M "omple9# The plates that enter this mill from roughing mill will further %e rolled

down to the scheduledH planned thickness Das per PP">s re3uirement.# To compensate for

the heat loss during rolling, the mandrel is housed inside reheating furnace# LPB is used

for heating the strip# This helps in relie$ing the stress induced, to some e9tent, in the

strip due to rolling# 0hen the final re3uired thickness is reached, the strip tra$els o$er a

roller run ta%le# The %ring down the temperature of the strip laminar cooling towers are

installed a%o$e the run ta%le, which showers water at rated pressure on the strip#

Don Co4:er

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SRM UNIVERSITY

The strip from the steckel mill is wound on the mandrel and if forwarded to the

Num%eringH strapping machine#

N8m$er4n3 an7 /e43;4n3 Ma=;4ne

To a$oid unwinding of the coils, they need to %e strapped# Since the coil will %e

hot condition, manual strapping is not possi%le# ence an automatic strapping machine

which will %ind the straps together o$er the coil# The num%ering machine prints the

following parameters on the strip Dspray painting method.

"oil num%er

Brade

Thickness

0idth

The coil is also weighed in the weighing machine and the weight also is marked

on the strip#

Tran9fer =ar

The coils from the weighing machine are mo$ed to the storage yard using transfer

cars#

PROCESS

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SRM UNIVERSITY

PROCESS FLO/ HOT ROLLING MILL

'# !eheating furnace

(# &escaler

)# Edger

+# !oughing mill

# "rop shear

/# "oiler furnace

2# Steckel mill

5# Laminar cooling

4# Pinch roll

'6# &own coiler

CRM COLD ROLL MILL

Inp8t

a. ot rolled stainless steel coils from hrm to ssp#

%. Imported source hot rolled coils D+)6 grade coils.#

O8tp8t

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SRM UNIVERSITY

Stainless steel coils and sheets of $arious si:es as mentioned in the marketing and

metallurgical ser$ices manual# The $ery purpose of any industry is to produce an end

product that has a wide range market# As stated a%o$e ssp produces a wide range of

products, which is the input of raw material for se$eral industries of

-ood processing

Gtensil

ea$y engineering

!ailways

Ele$ators

"oinage

0ashing machine

0ater coolers and refrigerators

0all panelling

Interior decoration of officeHhouse


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SRM UNIVERSITY

New delhi;( offices

"oim%atore

Pune

Salem

The a%o$e said


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SRM UNIVERSITY

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Inp8t

The input sla%s are stored in sla% storage yard# As per the schedule the sla%s are

charged into the walking %eam !eheating -urnace and annealed to a suita%le temperature#

Later these sla%s are discharged from furnace and sent to !oughing Mill# In !oughingMill the sla% are rolled to transfer %ar to a thickness of (mm and sent to Steckel Mill for

further reduction# a$ing achie$ed to the re3uired thickness, the material is cooled with

the system of Laminar "ooling in case of car%on steel and coiled in &own "oiler# In case

of stainless steel the material is directly coiled in &own "oiler after natural cooling# -rom

&own "oiler ! "oils are taken to "!M or customer through truck#

O8tp8t

ot !olled "ar%on Steel and

ot !olled Stainless Steel "oils and Plates#

Re;eat4n3 F8rna=e

The furnace section consists of

a.Sla% Oard

%.!e;heating -urnace

The walking %eam type !eheating furnace is hydraulically operated, top and

%ottom fired and has a flat roof# The com%ustion system is of recuperati$e type

designed for firing LPB or natural gas# The !eheating furnace has %een designed and

supplied %y MHS Italiampianti, Italy and Erected %y MHS 0ellman Incandescent, India#

F8rna=e =apa=4t%

-or Stainless Steel THhr D-or a reference sla% of '26 mm thick.

-or "ar%on Steel 26 THhr D-or a reference sla% of '26 mm thick.

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SRM UNIVERSITY

T;e 74fferent t%pe9 of mater4a: t;at =an $e pro=e99e7 are

Sta4n:e99 Stee:AISI (66 * )66 Series DAustenitic.

AISI +66 Series D-erritic * Martensi tic.

Car$on Stee: IS '624 &, IS '624 &&, and IS '624 E&&

IS (6/(er94n3 Ro83;4n3 M4::

The !oughing Mill is a + hi !e$ersing Mill#

Supplied %y MHS Schloemann Siemag DSMS., Bermany#

Automation supplied %y MHs Siemens, Bermany#

!ouging Mill is controlled %y Le$el ' Automation#

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SRM UNIVERSITY

The !oughing Mill housing accommodates two work rolls and two supporting rolls

called


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SRM UNIVERSITY

Sla% reFect roller ta%les

-urnace deli$ery roller ta%le

&escaler connecting and descaler roller ta%le

Primary descaler

!oughing mill approach roller ta%le

-ront mill roller ta%le

!oughing mill feed rollers

!oughing mill entry side guides

ertical edger

$# Ro83;4n3 M4:: EB84pment

!oughing Mill Screw &own System

Gn;Famming de$ice

!oughing mill guides

Lifting rails

0ork roll cooling system


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SRM UNIVERSITY

Pneumatic system

Brease systems

Ste=?e: M4::

Steckel Mill is a + hi !e$ersing Mill

Supplied %y MHS Schloemann Siemag DSMS.,Bermany#

Automation supplied %y MHS Siemens, Bermany#

The Steckel Mill housing accommodates two work rolls and two supporting rolls

called


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SRM UNIVERSITY

PGM Profile Bauge Meter

Mo7e: Ser>er

The state;of;the;art automatic pass schedule calculation facility Dmodel ser$er. is

installed to ha$e trou%le free rolling# Automatic work roll change facility is pro$ided

for 3uick and easy changing of work rolls#

Ma4n 7r4>e =apa=4t% +66 J0 each for

top and %ottom work


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SRM UNIVERSITY

Te=;n4=a: Deta4:9

Material Specifications

Transfer %ar thickness (6mm ; )( mm Dcar%on steel.

(6mm ; (5 mm DStainless steel.

Transfer


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SRM UNIVERSITY

C# Mo7e: Ser>er

The Model Ser$er is the Le$el ( automation system consisting of a mill process

computer# The mill process computer %ased on mathematical models and strategies,

calculates the set up $alues for the mill like roll gap, roll force, "" position, %ending$alues etc#, Din association with the sla% data and transfer %ar data.# -inally the set up

$alues allow for an accurate control of strip thickness, profile and flatness#

The area of the model ser$er is restricted to the Steckel Mill stand and coiler

furnace# The primary data is transmitted %y the production control P" to furnace PL"#

0hen a sla% is discharged from the furnace, furnace PL" transmits the primary data of

this sla% and the ne9t sla% to !oughing Mill PL"# After acknowledgement from

!oughing Mill operator, !oughing Mill PL" transmits the primary data to modelser$er#

0ith the completion of the last pass in the !oughing Mill, !oughing Mill PL"

transmits the actual $alues of the last pass in the !oughing Mill, D0idth, last pass roll

force, roll gap, temperature and speed. to model ser$er#

The a$aila%ility of primary data and T;%ar data ena%le the model ser$er to

calculate the pass schedule# After the calculation, the set up $alues are transmitted to

the Steckel Mill PL"# The Steckel Mill PL" will do the se3uence control of the

process in Steckel Mill# &uring the pass in Steckel Mill, actual $alues like roll force

and strip temperature are measured %y Steckel Mill PL" and sent to Model ser$er#

After );6K of that pass length is rolled the model ser$er will process the measured

$alues sent %y Steckel Mill PL"#


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SRM UNIVERSITY

'# Strip tracking

(# Pass schedule calculation

)# Ac3uisition and processing of measured $alues

+# &ialogue and display

# Logging function#

Ro:: 9;op

!oll Shop caters to the

0ork rolls and %ack up roll re3uirements of !oughing Mill and Steckel Mill

%y supplying rolls with chocks assem%led with %earings as and when

re3uired#

Turning and assem%ling of Edger rolls#

Brinding of Pinch rolls of Steckel Mill and &own "oiler#

The used work rolls, %ack up rolls of !oughing Mill and Steckel Mill, Edger rolls

and Pinch rolls of Steckel Mill and &own "oiler are reground in the !oll grinding

machine#

!oll grinding mHc is supplied %y MHS Toshi%a machine company, @apan#

State of the; art "N" roll grinder is working on Le$el ;) automation which

ensures fully automatic grinding where special functions like wheel 3uick approach,

Automatic roll alignment and wheel surface speed control are done %y machine itself#

1$erhauling and maintenance of all 0ork roll and


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SRM UNIVERSITY

Ro:: Gr4n74n3 Ma=;4ne 'RGC () < * CNC 3r4n74n3 ma=;4ne+

ot !olling Mill D!M. of Salem Steel Plant ha$e different rolls like


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SRM UNIVERSITY

A &iameter measurement arm rotational mo$ement

O &iameter measurement

G !oll alignment

Spe=4a: feat8re9 of RGC () < * CNC 3r4n74n3 ma=;4ne

The roll grinding machine !B" '+66 9 666 "N" type performs grinding,

measuring and testing E#" cylindrical surfaces, Plane or "am%ered Dconca$e

or con$e9.#

ighly producti$ity output ranges, optimal machine accuracy and decreasing

preparation period#

All types of profile can %e ground i:# Straight, Taper, "onca$e, "on$e9,

!adius, "" etc#


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SRM UNIVERSITY

Le$el ;' automation# The walking %eam con$eyor is used for the transportation of

coils to the "oil Oard# The coil is strapped %y a single %and circumferencial automatic

Strapping machine, weighed in the weighing mHc and marked %y an automatic marking

machine supplied%y MHS Infosight "orporation, GSA#

Don Co4:er =on949t9 of

a# R8n o8t Ro::er ta$:e 'RORT+ This consists of '5+ rollers D!oll dia )66

mm. separated into si9 groups# This helps in transporting the finished strip

from Steckel Mill to &own "oiler

$# S47e G847e9 Side guides are pro$ided for guiding the strip straight into the

"oiler#

=# Ho:7 Don Ro:: The main function of the hold down roll D!oll dia )66

mm. is to a$oid fluttering in the strip# This roll will %e in the up position

when the strip is coming and will get down when the strip enters the pinch

roll#

7# P4n=; Ro:: The function of the pinch roll is to guide the strip into the

mandrel

Ma< M4n

Top !oll 466 mm 556 mm


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SRM UNIVERSITY

3# /rapper Ro::9 Three wrapper rolls are pro$ided for wrapping the head end

of the strip into the mandrel# The wrapper rolls will get retracted after the

mandrel e9panded and tension %uilt#

;# Man7re: The finished strip from Steckel Mill winds on the mandrel

The diameter of the mandrel

"ollapsed 2(2 mm

Pre;e9panded 2)5 mm

-ully e9panded 2/( mm

4# O8t$oar7 S8pport &ear4n3 Two support %earings are pro$ided, one in

right and the other in the left side to hold the mandrel during rolling#

# Co4: Car The coil car transports the finished coil from the mandrel to the

walking %eam con$eyor# It has a lifting ta%le which is pro$ided with two

rollers and locking pro$ision for the rollers#

*#"CRM-COLD ROLLING MILL

Inp8t

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SRM UNIVERSITY

ot !olled Stainless Steel "oils from !M of SSP#

Imported source ot !olled "oils D+)6 grade "oils.#

Pro=e99

SSP employs the latest technology in cold rolling and incorporates the most

modern e3uipment supplier %y the leading machinery manufacturer all o$er the world#

The raw material for "!M is ! Stainless Steel "oils, called hot %eams# These coils are

processed in "oil


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SRM UNIVERSITY

PROCESS FLO/ COLD ROLL MILL

'# ot rolled coil(# "oil %uildup line

)# Annealing * pickling line

+#


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SRM UNIVERSITY

'2# %lanking line

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SRM UNIVERSITY

O8tp8t

Stainless Steel coils and sheets of $arious si:es as mentioned in the marketing and

metallurgical ser$ice# The purpose of any industry is to produce an end product that has a

wide range market# SSP pro$ide wide range of products, which is the input raw materialfor se$eral industries of

-ood Processing;Gtensil

ea$y Engineering;!ailways

Ele$ators;"oinage

0ashing Machine;0ater "oolers and refrigerators

0all Paneling;Interior &ecoration for 1fficeHouse


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SRM UNIVERSITY

6#STRENGTH1/EAKNESS @OPPORTUNITY OF SAIL

STRENGTH

igh Cuality products

E9perienced and skilled personnel

"ustomer Satisfaction

Leader of Indian Steel


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SRM UNIVERSITY

#CONCLUSION

-or an Engineering student a learning com%ination of theory and practice is an

$alua%le asset which helps in understanding the core principles of %usiness %y the way of

first hand e9perience This in plant;training in Salem Steel Plant has gi$en me such a

great e9perience a%out all the managerial functions, which is going on in the company# It

also helped me to understand the e9act mechanism of working of the $arious

departments#

After completing this in plant;training I could %e a%le to understand much more

a%out the Salem Steel Plant the MN" which is the most reputed name in the corporate

world# Salem Steel Plant known for its 3uality products#

This knowledge will help me well to esta%lish myself in the corporate 0orld after

completing my academic session#

Documents

sail inplant report by srmuniv-140629074721-phpapp02