SUMMER TRAINING REPORT

TO STUDY VARIOUS OPERATIONS OF COLD ROLLING MILL

SUBMITTED BY:

GAURAV PANDEY ISHU

MECHANICAL ENGINEERING

3rd YEAR (0816140016)

KRISHNA ENGINEERING COLLEGE GHAZIABAD

Bhushan Steel Ltd.

CONTENTS

1 Introduction

2 Acknowledgement

3 Company Profile

4 HRS

5PICKLING LINE

6 ELECTROLYTIC CLEANING LINE

7ANNEALING

8SKIN PASS MILL

9FINISHING

10 ROLL GRINDING MACHINE

11GP 1

12GP 2

13SAFETY

14RESEARCH & DEVELOPMENT

15QUALITY SYSTEM

16CONCLUSION

INTRODUCTION

This entire report deals with the study of the various operations conducted in

NCRM (New Cold Rolling Mill) in order to manufactured the products like cold

rolled sheets, galvanized coil etc. during the entire period we deals with the

various processes that are involved in the manufacturing of the above mentioned

products.We visited departments like HRS, SPM, RGM, GP-1, GP-2 etc. where the

various operations are conducted involved in the production of CR coils,

Galvanized coil. The machines and equipment’s used are of higher standard and

norms which are imported from the JAPAN, GERMANY and other countries in

order to maintain the accuracy and precision as well as to produce good quality

products.The working environment of the company is excellent, technicians and

workers are highly skilled.They work hardly to develop standards products and

achieving the goals of the company. Workers are trained by the company to update

their knowledge and skills.

Finally it’s really a great learning experience for me while working in the BSL,

SAHIBABAD. This training helps me to learn the basics of the industrial work and

other relevant factors which work as the stepping stone of my professional life. I

am thankful to each and every one who is involved in my work and all the officials,

technicians and workers which help me to learn a fruitful lesson from the working

environment of the BSL, SAHIBABAD.

ACKNOWLEDGEMENT

This summer training is stepping stone towards the beginning of my professional

carrier and its satisfactory has endowed me with broader horizons of knowledge. This

training period is a fruitful culmination of my concerned affords during my summer

training at Bhushan Steels Ltd. Sahibabad.

I would like to express my thanks to Mr. Manish Jain (personal) for given me an

opportunity to a part of this esteemed organisation. I would like to express my deep

sense of gratitude to the entire workers and technicians of NCRM (New Cold Rolling

Machine) department. Especially the HOD’s of various departments of NCRM for their

inspiring guidance, continuous encouragement and valuable suggestion.

At last but not the least, I would like to thank all personnel of Bhushan Steels Ltd, who

are directly or indirectly involved in my work for their cooperation and precious help to

complete my training successfully.

CCOOMMPPAANNYY PPRROOFFIILLEE

Bhushan Steel Ltd. has recently successfully implemented SAP system at its Sahibabad works along its sales outlets with the help of Siemens Information Systems ltd. (SISL) in first phase.

Bhushan Steel Limited is dedicated to conduct global business in a

professional and ethical manner. Bhushan Steel promotes a positive work

relationship where our Board of Directors, Executive Team and employees

are encouraged to take personal responsibility for furthering these values

through adherence to our conventional principles. Explicitly expressed, our

Board, management and employees are expected to do the right thing

every day as we serve our customers and business collaborators.

The perpetual input of our employees is a powerful and invaluable tool used to ensure ceaseless maintenance of our culture of ethical behaviour. If any employee, officer or director of the company gets aware of a violation of the Code, they are not only encouraged, but obligated, to report it. We have worked hard to create an environment where an individual who becomes aware of a Code violation can feel comfortable reporting this incident to their supervisor, or any other manager or Personnel department with whom they feel comfortable.

Principle of Bhushan:-

“Our mission is to grow our company by providing innovative strong and

highperformance products and solutions to meet our global customer needs.” Bhushan Steel Ltd formerly known as Bhushan Steel & Strips Ltd. is a globally

renowned one of the leading prominent player in Steel Industry. Backed by more than two decades, of experience in Steel making, Bhushan Steel is now India’s 3rd largest Secondary Steel Producer Company with an existing steel production capacity of 2 million tons per annum’s (approx.).

It was the vision of the founder; Brij Bhushan Singal, that the first stake was driven into the soil of Sahibabad (Uttar Pradesh) in 1987. His vision helped BSL overcome several periods of adversity and strive to improve against all odds. The company has three manufacturing units in the state of Uttar Pradesh (Sahibabad Unit),Maharashtra (Khopoli unit), and Orissa Plant (Meramandali unit) in India and sales network is across many countries.

The company is a source for vivid variety of products such as , Galume Sheets and Coils, Hardened & Tempered Steel Strips , Billets, Sponge Cold Rolled Closed Annealed, Galvanized Coil and Sheet, High Tensile Steel Strapping, Colour Coated Coils Iron, Precision Tubes and Wire Rod.

As one of the prime movers of the technological revolutions in Indian Cold Rolled Steel Industry, BSL has emerged as the country’s largest and the only Cold Rolled Steel Plant with an independent line for manufacturing Cold Rolled Coil and Sheet up to a width of 1700mm, as well as Galvanized Coil and Sheet up to a width of 1350 mm.

Vision of company:-

“The vision of evolving into a totally Integrated Steel Producer by committing to

achieve the highest standards of Quality through Cutting-Edge Technology.”

The key to Vision is to use rigorous conceptual framework and to understand how that

framework connects to the underlying DNA of enduring great companies.

A well-conceived vision consists of two major components—“CORE IDEOLOGY” and

an “ENVISIONED FUTURE”. A good vision builds on the interplay between these two

complementary Yin-and-Yang forces; it defines “What we stand for and Why we exist”

that does not change the Core Ideology and sets forth “What we aspire to become, to

achieve, to create” that will require significant change and progress to attain

the Envisioned Future.

Our Vision

About Culture: -“To make it a place where all the people can thrive living,

learning and working in a clean, safe and healthy environment.”

About Values:-To corporate values as “the rules or guidelines by which a

corporation exhorts its members to behave consistently with its order, security

and growth.”

About People: - “See the good in people and try to develop those qualities” i.e.

preparation and grooming of the next generation of the young thinkers.

About Customers: - “Sell good merchandise at reasonable price; treat our

customer like we would treat our friends and the business will take care of itself.

Bhushan Steel’s endeavour is to attain the highest level of Customer

Satisfaction.”

About Products: - “We should always be the pioneers with our products – out

front leading the market.”

Policies:-

INTEGRATED QUALITY, ENVIRONMENT, OCCUPATIONAL HEALTH & SAFETY

MANAGEMENT SYSTEM POLICY

Bhushan Steel Ltd. commits to produce cold rolled and galvanized steel sheets of world

class quality in a safe, healthy and clean environment by involving employees with

continual improvements in system implementation, technological advancement,

operational integration, prevention of pollution & hazards maintaining

Legal compliance and satisfying needs & expectations of Customers:-

For Environmental Management System we have ISO 14001:2004 Certification

For Quality System we have ISO/TS 16949:2002 Certification

For Safety Management System we have OHSAS 18001:2007 Certification

Current Capacities:-

Milestone:-

Most brilliant milestone in BSL’s journey of excellence is setting up of Steel and Power

Plant in Orissa.On completion, the Plant will be one of the largest integrated Hot

Rolled Steel and Power complexes of the nation.

BSL has emerged as the country’s largest and the only CR Steel Plant with an

independent line for manufacturing Cold Rolled Coils and Sheets up to a width of

1700mm, as well as Galvanized Steel Coils and Sheets up to width of 1350mm.

Bhushan Steel has transformed to 3rd largest producer of Cold Rolled Steel with an

installed capacity of one million tons and sales of more than USD 1 Billion.

Finished Product List of Sahibabad Plant:-

1. Cold Rolled Coil

2. Cold Rolled Sheet

3. Galvanised Plane Coil

4. Galvanised Plane Sheet

5. Galvanised Corrugated Sheet

PROCESS ROUTE OF CRCA MATERIAL:-

Pickling line:-

Mainly pickling of coil is used to remove corrosion or rust, which is produced on coil surface due to interaction of coil surface with air and moisture. This may form an oxide layer on coil Surface, which may cause of reduction of metal and improper surface finish. Pickling in a solution of hydrochloric or sulphuric acid. The acid dissolute the oxide scale from the strip surface according to the reaction: Fe2O3 + 6HCl = 2FeCl3 + 3H2O .

Rinsing and passivation of the strip. At this stage the acid residuals are washed by water from

the strip. Passivation film is formed on the strip surface providing corrosion protection.

Drying.

Edge Trimming.

Oiling.

Recoiling.

Specification:

Type of Line Push - Pull. Material Hot Rolled M.S.

Strip Thickness 6.0 mm. Strip Width 1700 mm.

Coil O.D. 2000 mm.

Coil Wt. 30 MT.

Pickling Cascade with 2 / 3/ 4 Tanks. Rinse Multi Stage Cascade Hot Rinse.

Pickling Medium HCL.

Additional Features:- Online Side Trimming.

Oiling. Roll Bending.

Quick Work Roll Change.

These pickling lines can process strips varying from 1.0mm to 12.0mm thick and 200mm to 2000mm

wide. Picking lines process one coil at a time, therefore eliminating the need for joining strips. This

process allows immense flexibility of operation & also ensures easy operation and maintenance. As

accumulators are not required in these lines, thus making them cost effective in nature. These

pickling lines are capable of producing between 200,000 to 1,000,000 Tons per annum.

Hot Rolled Slitter :- This process is performed for removing unwanted material, giving fatness, side cutting to get desired shape or width , remove side bending, defects like notches etc.

Various process involved are- • Loading of coil

• Feeding of coil • Setting of cutter

• Trimming • Recoiling

• Removal of coil • Stepping & labeling of output material

• Storage of output material

Slitting Lines Slitting Lines, Slitting Lines have been successfully put into operation in well-known production plants & service centres. These lines have the capability to meet client's demand for minimum burr, no damage to the

surface, high production capacity etc., to the fullest. The high automation level of the lines reduces the need for operator attendance and ensures economy of operation.

Characteristic Features:

• High automation level to achieve high economic efficiency • Minimum burr on strip edges due to high running accuracy of knife arbors

• No manual interferences required as the edge scrap baller is pit mounted

Additional Features : o Quick Slitter Head Change with Standby Slitter Head. o Dual speed lines to cover wider range of thickness.

H.R.Slitter Specification :

a) Type of Line Loop / Pull Thru'. b) Material Hot Rolled M.S. c) Strip Thickness 10.0 mm. d) Strip Width 2000 mm. e) Coil O.D. 2000 mm. f) Coil Weight . 3MT. g) Line Speed 200 mpm.

Additional Features :

Quick Slitter Head Change with Standby Slitter Head.

C.R.Slitter Specification:

I. Type of Line Single / Double Loop.

II. Material CR FH / CRCA / GALVANIZED / COLOUR COATED.

III. Strip Thickness 3.0 mm.

IV. Strip Width 1650 mm.

V. Coil O.D. 2000 mm.

VI. Coil Wt. 3MT.

VII. Line Speed 250 mpm.

Additional Features:

Quick Slitter Head Change with Standby Slitter Head.

Galvanizing Lines:-

Galvanizing Lines: -We offer hot-dip galvanizing lines. The lines manufactured by us are furnace

type, heat to coat type or wet flux type. Efficient air-knives control the thickness of coating with great

precision, either through manual settings or through automatic coat control systems. The materials

can be pickled hot rolled steel, cold-rolled steel of CQ, DQ quality & full hard in nature.

Specification:

Type of Line Wet flux.

non-ox furnace.

Material C.R. full hard.

Strip Thickness 0.6 mm. (wet flux)

1.5 mm (furnace)

Strip Width 1250 mm.

Coil O.D. 1850 mm.

Coil Wt. 22 MT.

Line Speed 90 mpm. (wet flux)

150 mpm (furnace).

Coating 90 - 250 gms/m2.

Additional Features:

• On Line Skin Passing.

• On Line Tension Leveling.

• Double Recoiler on Exit Side

TECHNICAL DATA SHEET FOR PREPAINTED GALVANIZED PRODUCTS

Parameters Technical details/specifications/Stds

Product name BHUSHAN RAINBOW

Reference standard ASTM 755

0ther containing standards JIS G3312, IS 14236, ECCA

Strip thickness mm 0.20 to 1.2 0

Strip widths mm 900 to 1250

Substrate material Zinc coating as per ASTM A 653/A 653M with steel base as per

ASTM std

Substrate Coating mass gm/m2 Substrate coating mass class

80 to 275

Z120; Z150; Z180 and Z275 as per ASTM std

Or As mutually agreed

Grade designation

Gr 50/ Gr 80/CS type A, B as per ASTM std

Yield strength Mpa min Tensile strength Mpa min

340 for Gr 50 & 550 fo r Gr 80

410 for Gr 50 & 570 for Gr 80

Paint type Regular Polyester/Silicon Polyester/PVDF

Paint coating thickness (DFT) Top coat 18 to 22 microns (+5 microns primer)

Back coat 5 to 8 (including primer)

Digital DFT meter accuracy Accuracy +/- 2% of reading) as per ASTM A 153

Pencil hardness H or Harder

Gloss 15-80% at 60 degrees ASTM D 523

Resistance to chalking QUV ASTM D 53

1000 HRS –rat ing ≤4 for PVDF,

750 HRS –rating ≤4 for others

Resistance to corrosion (ASTM B 117)

500 HRS with blister density ≤2, creepage ≤2 mm.

Resistance to Humidity 1000 HRS blister density ≤ 2 (ASTM D 2247)

Resistance to color change QUV- ASTM

G 53 2000 HRS (delta E ≤ 5 unit) for PVDF

1000 HRS (delta E ≤ 5 unit) for others

Flexibility 4 T- (ECCA) - no cracking

Resistance to abrasion ≤20 mg as per 100 cycles

Resistance to Acid/solvents No discoloration/no blistering- ASTM D 1308

Product certification All products are accompanied with MTC and packing list.

Quality System ISO 9001 – 2000

Galvanized Plain CoilTechnical details/specifications

PLAIN SKIN

PASSED CORRUGATED

HILGP

PETROL/FUEL

TANK

FGP

FAN

BLADE

GPC

BUSES/COACHES

Thickness

(mm)

0.10 to

2.50

0.30 to

2.50 0.12 to 1.60 0.30 to 2.50

0.40 to

1.20 0.60 to 1.60

Width

(mm) upto 1350 upto 1350

602,762,800,

900,1050 200 to 1350

100 to

1350 100 to 1350

Surface

Finish Regular &

mim.spangle

Matte with

zero/min.

spangle

Regular

Spangle

Matte, Bright

Finish, No

spangle

Matte

finish,

No

spangle

Matte, Bright finish,

No spangle

Coating

Mass

(gms/m2)

80 to 300 80 to 300 80 to 300 20 to 80 60 to

90 60 to 80

Grades Soft/Lock

forming EDD,

DD,D,

SPCEN,

SPCD,SPCC

Roofing

EDD, DD,D,

SPCEN,

SPCD,SPCC

SPCD,

SPCC

SPCEN, SPCD,

SPCC

Galvanized Plain sheet Technical details/specifications

PLAIN SKIN PASSED CORRUGATED

HILGP

PETROL/FUEL

TANK

FGP FAN

BLADE GPC BUSES/COACHES

Thickness

(mm) 0.10 to 2.50 0.30 to 2.50 0.12 to 1.60 0.30 to 2.50

0.40 to

1.20 0.60 to 1.60

Width (mm) upto 1350 upto 1350 602,762,800,

900,1050 200 to 1350

100 to

1350 100 to 1350

Cut to

Length (mm) upto 4500 upto 4500 upto 4500 upto 4500

upto

4500 upto 4500

Surface

Finish Regular &

min.spangle

Matte with

zero/min.

spangle

Regular Spangle

Matte, Bright

Finish, No

spangle

Matte

finish, No

spangle

Matte, Bright finish, No

spangle

Coating

Mass

(gms/m2)

80 to 300 80 to 300 80 to 300 20 to 80 60 to 90 60 to 80

Grades Soft/Lock EDD, DD,D, Roofing EDD, DD,D, SPCD, SPCEN, SPCD, SPCC

GP 2

PROCESS MACHINE/EQUIPMENT

Loading of coil coil car &uncoiler

Welding Welding unit

Degreasing-1 spray tank

Brushing brushing unit with motor

Degreasing -2 spray tank

Hot rinsing spray tank

Dryer two blowers

Pickling spray tank

Rinsing spray tank

MATERIAL SPECIFICATION Low carbon cold rolled full hard steel strips

Thickness 0.08mm to 0.5 mm

Width 1005 mm (max.)

Weight 6 MT (max.)

LINE SPECIFICATION

Speed

Entry speed 20 M/min(min.) 95 M/min(max.)

Tension of the strip

Entry end 60 kg(min.) 166 kg(max.)

Entry accumulator 90kg/cm2 (max.)

WELDING LINE SPECIFICATION Welding unit type DH 100/3 ML-125

Input voltage 415V +5%

Frequency 50 Hz

KVA 50 % DC Min.100 amp Max. 200 amp

Throat depth 125 cm(Max.)

Stroke 5cm

Air pressure 6kg/cm2

Transformer cooling water cooling

Flow rate of water 15 litre (Minimum)

WORK INSTRUCTION FOR GP -2 CENTRE SECTION PROCESS MACHINES/EQUIPENTS

Preheating Electric Heater

Fluxing Steel Box

forming SPCEN,

SPCD,SPCC

SPCEN,

SPCD,SPCC

SPCC

Galvanizing Zn tank (having 25 MT Zn , 95 MT Pb) temp. 723 -738 K

Air cooling Air Blower

Water quenching Quenching tank

LINE SPECIFICATION

Speed

Process section 20 M/min (Min.) 78 M/min (Max.)

Threading speed 15M/min

FLUXING Ph is kept in the range of 2-3. The properly cleaned strip passes through flux bath in zinc pot having temperature 723 – 738 K Composition of flux bath should be

Zinc chloride 35-60 %

Ammonium Chloride 1-6%

Sodium chloride 4.5- 8 %

Any other content less than 1 ppm.

Fe content should not be more than 0.01 gram/litre

GALVANIZING SECTION Composition of Zn bath

Zinc 96 – 99%

Aluminium 0.10 – 0.30%

Lead 0.5 1.5%

Tin As per requirement

Antimony As per requirement

Air Cooling Galvanized strip passed through the jet of air.

WATER QUENCHING Strip is quenched by treated water in quenching tank at temperature of maximum 343K & water is discarded if hardness exceeds 80 ppm.

Whole surface of strip should be dipped in quenching tank filled with 50 – 75 % of treated

water for even quenching.

GP 2 EXIT SECTION

PROCESS MACHINE/EQUIPMENT

Passivation Dipping Tank

Dryer L-84

Printing Printing Machine Recoiling Recoiler & coil car.

PASSIVATION The quenched galvanized strip passes through a passing tank containing passivation salt (Conc. 1 – 2.5 %) at

temperature of 40 -80%.

PRINTING

Dried galvanized strip then passes through printing assembly & the required “WORD/FIGURE” is

printed on the galvanized strip.

RECOILER Printed galvanized strip is wound on recoiling mandrel.

DEFECTS

Dent

Roll Mark & Scratches.

Passivation Spot.

Flux Carryover /Black Spot/Flux Spot.

Over coating

White Rust.

If Ph value > 3 then let it should be drain out. DRYER Passivized strip is then dried with hot air blast. Hot air removes all moisture from its surface. Temperature of hot air is kept in the range of 393 – 453K.

PRESSURE/TENSION ON STRIP

Recoiler Tension 100 Kg (Min.) 1010 Kg (Max.)

Exit accumulator pressure 90 Kg/cm2 (Max.)

ROLL GRINDING MACHINE It is a three rolled grinding machine. It is basically used to treat the rolls which are used continuously in certain machines like Hitachi Mill, Pickling line etc. In this machine we use two categories of rolls namely Intermediate Rolls Back up roll

PROCESS FLOW DIAGRAM FOR RGM Pre inspection of roll: - In this step the rolls are inspected in order to identify their defects.

Loading of roll: -In this step the rolls which are found defected ones are load with the help of coil car. Selection of Machine Control Program (MCP): In this step particular computer operated programs are selected to operate on the loaded roll. Rough Cutting of Roll: -In this step rough cutting of rolls are done with the help of shear.

A shear cutting oil is used in order to control friction and to reduce the temperature develop on the surface. Inspection of roll: - This step is performed to find the any defects or extra material attached to the surface of

the rolls. If any defect is found then the roll is sent for the cutting operation to remove those defects .Finishing of rolls: - After the inspection process finishing operation is done on the roll. Now the rolls are ready

to use for their operation in the machines like Hitachi Mills, SPM etc. Texturing (only for W/R): In this process Electric discharge is used in order to provide the desired Roughness to

the rolls so that they perform their function satisfactorily.

If this operation is not conducted then roll will not perform its work properly and hence the product formed will not be of good accuracy and precision.

Unloading, storage & Transport: Finally the defect free roll is obtained .Now it is ready for reuse. Now it is unloaded with the help of coil car and sent back to the different mills for use.

DEFECTS OF ROLLS Roll Bite Pinchers

Chattering Marks Floppers (Pinching Marks)

GP1

A. WORK INSTRUCTION FOR ENTRY SECTION

APPROVED PROCESS APPROVED MACHINERY Coil loading Coil car & uncoiler Welding Welding unit

B. LINE SPECIFICATION MONITORING OF PROCESS PARAMETERS

SPEED Entry speed 15 – 20mpm

TENSION Entry (POR) 56 –560mpm

Entry accumulator 105 TO 1050 Kg

POSITION Entry accumulator1 – 90% Filled POR initial data 500mm – 600mm

C. OLD ROLED MATERIAL SPECIFICATION

Hardness of material 45 – 100 HRB

Thickness of strip0.17 – 2.2mm

Width500 – 1280 mm

Weight0.5MT (min.), 22MT (max.)

Initial diameter of coil 500 mm – 600mm D. COLD ROLLED MATERIAL INSPECTION

Preferably coil should be free from edge cut & saw edges.

Shape & surface finish of the cold rolled coil is inspected by entry operator & also enters the

same in log book.

E. INTRODUCTION FOR ENTRY SETUP Made entry section ready by pressing switch.

Make accumulator tension on by pressing switch.

Make POR tension on by pressing switch.

Make entry start by pressing switches.

F. COIL LOADING

Coil is loaded with the help of coil car.

Electrolytic Cleaning Line

Utilizing a performance enhanced, low-temperature, high

volume, updraft re-circulating hot air design, the Electrolytic

cleaning line is ideal for refreshing steel products and other

metallic mater. The Electrolytic cleaning lines are the ideal

wet cleaning complement for advanced Electrolytic

components.

Specification :

Type of Line Electrolytic Cleaning with Alkali

Material Cold Rolled M.S.

Strip Thickness 2.5 MM.

Strip Width 1650 MM.

Coil O.D. 2000 MM

Coil Wt. 30 T.

Line Speed 200 MPM.

Additional Features : On line Trimming

Electrolytic Cleaning is required in case material rolled with high percentage of oil while

reduction in mills goes for annealing in furnace. Oil free base material is essential for the

production of bright and corrosion resistant steel. Sodium Orthosilicate is used as cleaning

agent in ECL. Tension is given according to thickness, width based on customer

requirement.

The installed production capacity of the line is 86102 MT/Annum.

ROLL GRINDING MACHINE:- It is a three rolled grinding machine. It is basically used to treat the roll which are used continuously in certain machines like Hitachi Mill , Pickling line etc. In this machine we use two categories of rolls namely

Intermediate Rolls

Back Up Roll

PROCESS FLOW DIAGRAM FOR RGM

1 Pre inspection of roll:

In this step the rolls are inspected in order to identify their defects.

2 Loading of roll: In this step the rolls which are found defected ones are load with the help of coil car.

3 Selection of Machine Control Program (MCP):

In this step particular computer operated programs are selected to operate on the loaded

roll.

4 Rough Cutting of Roll: In this step rough cutting of rolls are done with the help of shear.

A shear cutting oil is used in order to control friction and to reduce the temperature develop on the surface.

5 Inspection of roll:

This step is performed to find the any defects or extra material attached to the surface of the rolls.

If any defect is found then the roll is sent for the cutting operation to remove those defects.

6 Finishing of rolls:

After the inspection process finishing operation is done on the roll.

Now the rolls are ready to use for their operation in the machines like Hitachi Mills, SPM etc.

7 Texturing (only for W/R) :

In this process Electric discharge is used in order to provide the desired Roughness to

the rolls so that they perform their function satisfactorily .If this operation is not conducted then roll will not perform its work properly and

hence the product formed will not be of good accuracy and precision.

8 Unloading, storage & Transport:

Finally the defect free roll is obtained .Now it is ready for reuse. Now it is unloaded with the help of coil car and sent back to the different mills for use.

DEFECTS OF ROLLS Roll Bite

Pinchers Chattering Marks

Floppers (Pinching Marks)

Annealing Line

Annealing Line: - The demand for better annealed stainless steel has increased. Annealing is a heat-

treating process conducted under controlled-atmosphere furnace to minimize oxidation, so that the

product surface remains clean. It is very common for continuous annealing of strip products and stainless

steels.

Type of Line Horizontal Tight Line.

Material Stainless Steel.

Strip Thickness 1.5 MM.

Strip Width 660 MM.

Coil O.D. 1650 MM.

Coil Wt. 10 T.

Line Speed 30 MPM.

AdditionalFeatures: Tension control in closed loop.

Annealing For Stainless Steel:-

The heat treatment has to be specific in annealing and

pickling line to find the best compromise between strength and ductility without neglecting the surface finish.

Annealing and pickling lines (APL's) are used for the treatment of hot rolled (HR) and cold rolled (CR) stainless steel strips.

HR Austenitic & CR strip is annealed and pickled

continuously in an APL and HR ferric strip is only pickled. Lines for HR & CR, as well as dedicated APL's process the majority of the stainless steel production.

Annealing at a temperature 1100-1300ºF (600-700ºC) in a controlled reducing atmosphere (commonly a mixture of Hydrogen and Nitrogen) preventing oxidation of the steel surface. Annealing results in recrystallization of the steel Grain structure and in stress relief. There are two alternatives of annealing process continuous annealing line and batch annealing furnace. In the continuous annealing line (see the picture below) steel strip passes annealing furnace at a controlled speed. In the batch process steel strip coils are stacked on top of each other in the bell type furnace. Batch annealing allows

to achieve lower hardness and higher ductility of the steel than in alternative continuous annealing.

BATCH ANNEALING FURNACE

The process of annealing of cold rolled coil is carried out to obtain the desired properties in the

finished coils. For this, the material is heated to predetermined temperature in a protective atmosphere and soaked for a specified time before it is put to room temperature. Optimum condition with annealing atmosphere, annealing cycle, sealing and purging have to be maintained to obtain a finished product with bright surface, desired micro structure and uniform properties throughout the coil.

HSD is used for heating the surface. Nitrogen is purged inside the inner cover. Nitrogen is obtained from PSA Unit. The installed production capacity of the line is 75881 MT/annum.

Finishing/Slitting Lines

Slitting Lines: -Slitting Lines have been successfully put into operation in well-known production plants &

service centres. These lines have the capability to meet client's demand for minimum burr, no damage to the surface, high production capacity etc., to the fullest. The high automation level of the lines reduces the need for operator attendance and ensures economy of operation.

Characteristic Features:

High automation level to achieve high economic efficiency Minimum burr on strip edges due to high running accuracy of knife arbors No manual interferences required as the edge scrap baller is pit mounted

Additional Features :

Quick Slitter Head Change with Standby Slitter Head. Dual speed lines to cover wider range of thickness.

H.R.Slitter

Specification :

Type of Line Loop / Pull Thru'.

Material Hot Rolled M.S.

Strip Thickness 10.0mm.

Strip Width 2000 mm.

Coil O.D. 2000 mm.

Coil Wt. 30 MT.

Line Speed 200 mpm.

Additional Features :

Qquick Slitter Head Change with Standby Slitter Head.

C.R.Slitter:-

Specification:

Type of Line Single / Double Loop.

Material CR FH / CRCA / GALVANIZED / COLOUR COATED.

Strip Thickness 3.0 mm.

Strip Width 1650 mm.

Coil O.D. 2000 mm.

Coil Wt. 30 MT.

Line Speed 250 mpm.

Additional Features :

Quick Slitter Head Change with Standby Slitter Head.

Rewind cum Trimming Line Built from the basic elements of the compact trimming line, the modular line mechanically trims the edges through chip removal process. Any desired dimension is possible depending on strip width and thickness. The number of tools operating simultaneously is variable. It is frequently used in the welded tube production.

Specification: Type of Line Tight Line With Driven Trimmer.

Material CRFH / CRCA.

Strip Thickness 2.0 mm.

Strip Width 1250 mm.

Coil O.D. 2000 mm.

Coil Wt. 25 MT.

Line Speed 500 mpm.

Additional Features: Two - speed arrangement.

Coil build-up Lines

The coil build-up lines are used for side-trimming of the strips and also provide the coils with leader strips that can be reused for optimization of the yield. With suitable inclusion of welder, these lines can

be used for building up bigger coils from small coils, with roll-able weld.

1. LOADING OF COIL

Cold Rolled (CR),GP Coil or skin passed coil is loaded on the coil car/turnstile by

crane.

2. FEEDING OF COIL

The coil is fed from uncoiler using Peeler Table.

The coils outer 2/3 damaged wraps are cut by shear.

3. SETTING OF SLITTER & SLITTING OF COIL

Proper set of cutters and rubbers to be used for setting of slitter.

During slitting the operator must check the back tension & regulate it properly.

The pneumatic pressure on pressure pad should in between 2-2.5 bar.

4. CLEANING OF MACHINE

All rotating parts & rolls should be cleaned regularly.

Line should be cleaned regularly after processing of approx. 80 – 100MT of

material.

5. RECOILING &UNLOADING.

6. PACKING OF COIL

COLD ROLLED SLITTER

MINIMUM MAXIMUM

I. Speed- 400 mpm

II. Coil width400 mm1700 mm

III. Strip thickness0.10mm3mm

IV. Coil weight - 3 MT

COLD ROLLING MILL:- There are two types of Cold Rolling Mills operates, which are 6 Hi Cold Rolling Mill and 4 Hi Cold Rolling Mill. Pickled Hot Rolled Coils of higher guages are reduced to required thinner guages by passing through the Mills. In 6 Hi Mill the reduction achieved is upto 0.13mm ultra-thingauge whereas 4 Hi can reduce the thickness upto 0.25mm. The computer controlled rolling process ensures closure thickness tolerances and perfectly flat strips. The installed production capacity of 6 Hi Mill is 23,856 MT/annum and 4 Hi Mill is 43,502 MT per annum.

Cold Rolling Mills Our cold rolling mills are specifically designed for breakdown rolling of ferrous/

non-ferrous sheet & strip. The rolls are manufactured from alloy steel, having high hardness of about

60-62 HRC. The produced steel is considered to be "full hard". Cold-rolled steel products begin as hot

rolled pickled and oiled coils. These coils are "cold-reduced" by passing them through a cold

reduction process on a reversing mill under high tension and pressure.

Mill Specification:

Type 2HI / 4HI / 6HI.

Material HR. / MS / SS / AL.

Input Thickness 6.0 MM.

Output Thickness 0.15 MM. (Output).

Width 1250 MM.

Coil O.D. 2000 MM.

Coil Wt. 25 T.

Mill Speed 500 MPM.

Additional Features:

Hydraulic Automatic Gauge Control. Thickness Gauges. Roll Bending. Quick Work Roll Change.

Skin Pass Mill:-

Skin Pass Mill These skin pass mills are specifically designed for manufacturing sheet / strip of

medium hardness or to provide finish pass. The Rolls are made of alloy steel & have high hardness,

which is generally up to 65 HRC or more. For increasing demands with respect to strip flatness,

elongation and roughness, especially for hard material grades, skin-pass mill is an ideal solution due

to higher rolling forces and torques that can be achieved in this case.

Temper rolling (skin pass rolling) - final cold rolling operation with low thickness reduction

conducted in order to impart to the steel required levels of hardness, evenness and surface finish.

Four-high rolling mill is used for tempering.

Most of annealed low carbon steel strips are tempered since they are too soft (HV<110) in annealed

condition. Bending and deep drawing operations of soft annealed steel may cause formation of kinks

(cross breaks) and stretcher strains, which are the result of localized stretching of the strip at low cold

deformation beyond the yield point. Light tempering of annealed strip (non-kinking temper, pinch

pass) produces strip surface conditions, which do not cause formation of cross breaks and stretcher

strains. Hardness of pinch passed steel is about 115 HV. Other temper conditions of steel strip are:

eighth hard (105<HV<125), quarter hard (115<HV<130), half hard (130<HV<160), three quarter hard

(150<HV<185).

SAFETY

The service provider and his men should comply with personal protection equipment(PPE)requirement decided by the organization safety department like Cut Resistance , Hand Gloves, Safety Helmets and safety Helmets and Safety Shoes.

All the PPE’Smust be worn while working on job. The service provider should be competent enough to supervise his men.

GENERAL SAFETY GUIDELINES

Service Provider must not operate any equipment in manual mode without permission

from authorized engineer.

Service Provider must not go to any equipment while moving.

No person is allowed to stand on coil car / slitting line.

No By-passing of interlocks and no pre assumptions for any equipment operation.

Use Proper PPE’S& Safety platform while packing.

Ensure that, fingers should be away from strapping procedure and while working with tensioner.

Service Provider trained operator should handle consumables for packing of Coils.

Operators should be away from under crane, while crane carrying the Coil/ Plates to packing saddle/ packing area.

Service Provider must remove the waste consumables immediately, disposal to Specified scrap bin and keep the area neat &clean.

Service Provider must keep only good quality wooden logs for packing. Service Provider must always wear sufficient PPE’s inside the plants.

Service Provider must keep safe distance to the coils & packs while packing.

Service Provider must not modify any tools or equipment’s. Service Provider must not touch any movable parts.

Service Provider must riggers must be alert while pack stacking procedure in yard.

Extra care to taken while packing with fork lifter. The signal to be given to fork lifter

driver by standing at least one meter away from pack.

Service Provider must keep the packs stack height maximum 6 feet and must not

stackthe packs more than 6 feet height.

Rigger must ensure as coil properly gripped in sling-gofer/c-hook than after give the

signal to the crane operator.

Service Provider must not put wooden blocks for packing while the crane is moving with load.

Quality control: We have fully fledged laboratory with test equipment’s such as Emission

spectroscope for the chemical analysis, computerized Universal testing machine with stress-strain graph for tension tests, surface finish tester, Hardness testers using both Vickers and Rockwell scales, LFQ testing machine, Cupping tester, on line Radiometric and off line chemical lab for coating mass, salt spray tester for

corrosion resistance, and Humidity chamber.

For Environmental Management System we have ISO 14001:2004 Certification

For Quality System we have ISO/TS 16949:2002 Certification

For Safety Management System we have OHSAS 18001:2007 Certification

The main concern of the company is to maintaintheinternational norms ofsteel industry to develop the accurate and precise products by preserving the environmental balance and constituting an ecofriendly environment by

utilizing modern and advanced techniques available in the market.

R & D department :

For continuous bench marking of our product quality, we keep carrying out testing from outside laboratories. This has resulted in continuous upgrading of the process parameters confirming to any international standards. Further, we have online backup SGS inspection for all test parameters up to the point of dispatch. We are IS0 900l certified. Our products are accompanied with mill test certificates and packing lists.

Following tests are conducted in order to maintain the accuracy and

precision and standardisation of the products manufactured in the plants according to international norms of the steel market.

HARDNESS TEST: -

Hardness is a surface property.

It is defined as “the resistance of a material against permanentdeformation of the surface in the form of scratch, cutting, indentation, or mechanical wear”.

BRINELL HARDNESS TEST:-

This test is conducted for the specimen with range 0 to 10.

In this test hardened steel ball is used as an Indentor. Indentor is used to

introduce indentation on the surface.

This machine is called “push-pull button type machine” because the indenting load is applied by pushing a button.

Before conducting the test, the surface of specimen is made free from oil, grease, dust and dirt.

FORMULA:- BHN =Indenting load in (kgf)/spherical surface area of indentation in (mm2) VICKERS HARDNESS TEST

This test is similar to Brinell’s test but uses a different type of Indentor.

A Square based Pyramid Indentor of cone angle (=136 degree Celsius) between opposite faces of pyramid is used.

The applied loads may be 5, 10, 30, 50, 50, 100 or 120 kgf.

FORMULA:- VICKERS HARDNESS = 1.8544P/d2 (for cone angle = 136)

This test is performed for smaller cross sections, very hard materials, polished and nitride surfaces, and very thin test pieces.

TENSILE TEST This test is performed on machines such as given below. 1 Hounsfield Tensometer,

1 Universal Testing Machine(UTM) 2 Instron or other Material Testing Machine (MTS).

Universal Testing Machine (UTM)

The UTM have large load capacity, generally ranging from 0-4 Tonne. Materials with large sections and high tensile strength such as steel bars are tested on them.

Tensometer is generally mechanically operated while UTM’s are hydraulically operated. They can be controlled by computers or can be operated manually.

Conclusion:- Process Flow Diagram of CRM Complex

HRBlack

Cold

Continuous Pickling & Parting

Cold Rolling Process

Rewinding Annealing of Cold

Skin Pass of Cold

Cold Rolling Mill Complex (CRM)

The various processing units involved in the CRM complex and their functions are given below :

The waste liquor from pickling line, recoiling line are treated in effluent treatment plant ensuring pollution free environment. The acid regeneration plant ensures regeneration of hydrochloric acid

from waste pickled liquor for reuse in pickling line.

Continuous Pickling Line (Cpl) :

The HR Coil, which is the basic raw material, is passed through CPL to remove the oxides or scales from

strip surface to enable further reduction of thickness to desired level in Cold Rolling Mills. This processing is required since rust is formed on the surface of the coils at room temperature whereas

scales are formed at high temperature during rolling in Hot Strip Mill.

Cold Rolling Mill

Pickled Hot Rolled Coils of higher guages are reduced to required thinner guages by passing through the Mills. In 6 Hi Mill the reduction achieved is upto 0.13mm ultra-thin guages whereas 4 Hi can reduce the thickness upto 0.25mm. The computer controlled rolling process ensures closure thickness tolerances and perfectly flat strips.

Electrolytic Cleaning Line

Electrolytic Cleaning is required in case material rolled with high percentage of oil while reduction in mills goes for annealing in furnace. Oil free base material is essential for the production of bright and

corrosion resistant steel. Sodium Orthosilicate is used as cleaning agent in ECL. Tension is given according to thickness, width based on customer requirement.

Annealing Furnace

The process of annealing of cold rolled coil is carried out to obtain the desired properties in the finished coils. For this, the material is heated to predetermined temperature in a protective atmosphere and soaked for a specified time before it is put to room temperature. Optimum condition with annealing atmosphere, annealing cycle, sealing and purging have to be maintained to obtain a finished product

with bright surface, desired micro structure and uniform properties throughout the coil. HSD (High Speed Diesel) is used for heating the surface. Nitrogen is purged inside the inner cover.

Skin Pass Mill

In this process the cold rolled annealed strips are given a desired surface finish. It improves the flatness and suppresses the yield point elongation. Anti-rust oil is used on strip surface as protection from

rust.