2011

Bhushan Power & Steel Ltd.

Navdeep Lakhera

[TRAINING REPORT-BHUSHAN POWER & STEEL LTD.]

Six weeks industrial training from 25 june 2011, at Bhushan Power & Steel Ltd.

COMPANY PROFILE
Bhushan Power & Steel Limited, a fully integrated 1.5 Million TPA Steel making Company with turnover of INR3873 Crores (USD 950 Million) and 7 World Class ISO 9000 Certified State of the Art Plants at Chandigarh, Derabassi, Kolkata and Orissa in India. A leading manufacturer of flat, rounds and long products including value added products with total steel value chain right from Coal Mining, Billets, HR Coils, Pig Iron, CR Coils, GP/GC, Precision Tubes, Black Pipe/GI Pipe, Cable Tapes, Tor Steel, Wire Rod and Special Alloy Steel. Successfully commissioned 1.5 Million TPA Greenfield Steel and Power Plant in Orissa with HR Coil making facility First in Private Sector in the State of Orissa. For the Orissa plant, technology and equipments are procured from world-renowned companies like Lurgi from Germany, ABB Ltd., SMS Demag, Siemens etc. Bhushan is selling its Value added range of products in Secondary Steel through a large distribution network in India (comprising more than 35 sales offices) and Abroad. A rock-solid foundation combined with continuous up gradation and innovation has ensured that we have constantly surpassed our goals. Our end-to-end portfolio offers a wide spectrum of products with consistently superior quality. In addition to our export thrust, we supply to fast-growing sectors like automotive, white goods, construction, furniture, fasteners, telecommunication, etc.

COMPANY OVERVIEW
Commenced operations in 1989 with a capacity of 60,000 tons & a turnover of USD 11.24 million. Transformed to 3rd largest producer of Cold Rolled Steel after Steel Authority of India (SAIL) & Tata Steel with an installed capacity of one million tons and sales of more than USD 1 Billion. Focused on niche high value added segment of automobile and white goods & is today a leader in these segments. Recently started the countrys largest Colour Coated line and first to manufacture the Galume (zinc and aluminum coated sheets / coils). Principal production facilities at Sahibabad, Uttar Pradesh, Khapoli, Maharashtra and Dhenkana in Orissa (scheduled to be completed in July 2009. Invested in latest technology/ equipment without compromising over cost. First to set up a high tech plant in 1996 to cater to automobile and white good sector, in technical tie-up with Sumitomo Metals, Japan. BSL has a good debt-servicing track record. Profit making and dividend paying company since inception.

RAW MATERIAL SOURCES

The company processed mild steel (MS). It receives raw material from various sources: B.S.P (Bokaro steel plant) R.S.P (Rourkela steel plant) Tata steel plant Essar

The sizes of raw material ranges from 5.5 to 6mm thickness, 920 to 1600mm width.

TYPES OF RAW MATERIAL

Mild Steel D (Drawing-0, 08 to 0.1 % carbons) DD (Deep Drawing -0, 06 to 0.08% carbon) EDD (Extra Deep Drawing -0.04 to 0.06 % carbon) O (Others 0.12 to 0.13 % carbon) CS 11 (Above 0.18 %)

VARIOUS PROCESSES
The various processes deployed at the Industry in cold rolling of steel are: H.R. SLITTER (Hot Rolled Slitter) C.B.L. (Coil Build up Line) Pickling Cold Rolling Mill Rewinding Annealing C.R Slitter (Cold Rolled Slitter) CTL (Cut to length) Packing & Dispatch

H.R SLITTER (HOT ROLLED SLITTER)

This machine is used for slitting or cutting the hot rolled coils which have been received as raw materials from various sources such as Tata or Sail Bokaro. Initially, the hot rolled coils have width up to 1550 mm. The rolling mills which are set up in the plant cant roll such wide coils. The width of the hot rolled sheet (Raw materials) is decreased or the sheet is slit into two or three rolls, as the requirement of the customer may be. The maximum width of the coil that can be cut is 540 mm and minimum is 200 mm. Raw materials received have width up to 1550mm (approx.). Diameter of ring cutter is 395mm. Material of the cutter is high speed steel.

Parts of H.R Slitter

1. Coil stand 2. Coil car 3. Pay off stand 4. Uncoiler 5. Sunnbber 6. Feed table 7. Leveler 8. Pinch roller 9. Shear 10.Guide 11.Cutter slit 12.Loop pit 13.Tension rolling 14.Re coiler

HOT ROLLED SLITTER

COIL BUILD UP LINE (CBL)

In CBL extra sheet is welded at the beginning and at the end of the coil called the Leader and Tail end respectively. This strip called Leader End is about 3 meters in length. This is done to increase the yield of coil during rolling because initially some sheet is taken in some initial rounds in rolling and thus the starting and ending part of the coil cannot be rolled properly. Leader End is added to the coil to save yield and prevent wastage. Coil bend and damages in HR slitter are inspected here.

Parts of CBL
1. Uncoiler 2. Feed table 3. Leveler 1 4. Shear 5. Clamping Plate 6. Welding 7. Guide 8. Pressure Pad 9. Leveler 2 10.Tension rolling 11.Recoiler drum

PICKLING PROCESS
The H.R coils as raw materials are somewhat rusted. They contain oxide scales on their surface containing chemical compounds like iron oxide FeO, Fe2O3 and Fe3O4. So as to improve the surface finish and to remove these oxides pickling process is undertaken. Acid used is HCL. Coil is passed through 3 acid tanks, after that through 3 water tanks. The acid proportion in first tank is 3 to 5% and in the second tank is 7-10 % and in the third tank is 12 to 15 %. HCl used is dilute. Dilution varies from tank to tank. Coil is dried with hot air dryers and cold air blower. The temperature of the HCL ranges from 58 to 68 `C. Finally after sprinkled by rust preventive oil, it is finally recoiled at the recoiler end. Parts of line are Acid tank, Uncoiler, feed table, Shear, Heat exchanger, Water tank, Dryers, Tension trolling and Recoiler drum.

COLD ROLLING MILL

Cold rolling is a metallurgical process in which metal is passed through a pair of rollers at a temperature below its recrystallization temperature. This process hardens the metal, by compressing and stretching the metal. There are two rolling mills namely Mill 1 and Mill 2. ln mill 1 coil of 545mm maximum width and mill 2 coil of 465mm maximum width can be cold rolled. In both the mills there are 2 work rolls and 2 backup rolls. Diameter of work roll is 210mm and Diameter of backup roll is 550mm. Cold rolling is done to reduce the thickness of the coil. The range of the thickness reduced in the plant is from 3mm to 0.28mm. The thickness obtained finally is according to the requirement of the customer. The mill is operated by programmable logic controllers. There is an operator assigned to each of the two mills. The operator feeds various parameters into the system and then the process proceeds automatically. The coil is first loaded into the pay off roll. From here it passes to the entry tension roll and then it passes to the delivery tension roll via the working rolls where it recoils. The tension to the backup rolls is given by the hydraulic cylinders which then transmit the load to the working roll which further transmits the load to the sheet. There is 20 to 30 % reduction in thickness of the coil in one pass. Non contact gauges are used in these mills which measure the thickness of the sheet. The recoiling and uncoiling process takes place at both entry and delivery tension roll. A coolant named as aqua roll is also used.

1. Saddle table it is actuated with the hydraulic cylinders help to feed the strip into the leveler. 2. Bridle roller these are used to release the tension in the strip and are made of iron over which rubber is wrapped . there are two bridle rolls when the speed of bridle rolls is more than recoiler then it will loosely wrap over the recoiler drum. 3. Recoiler drum this is the drum on which the slitted coil are recoiled

4. Tachogenerators it sis used to control the speed of motor. 5. Hydraulic Power pack it provides the oil to hydraulic system. There is pump and directional valves. PC valves are used to control the supply of oil. Defects occurring during rolling process - Roll mark Soft mark Skidding mark Folding mark Roll crack mark Scratch mark

HISTORY
Growing from strength to strength 1970 - Started with very small initial outlay for manufacturing Door Hinges & later on, Rail Track Fasteners. 1973 - Manufacturing facilities set up for Tor Steel and Wire Rod in Chandigarh. 1981 - Rolling Mill Project commissioned at Chandigarh for Round and Narrow Strips. 1985 - Backward Integration Project for Steel Melting facilities. 1986 - Upgrading of Mini Steel Plant with continuous casting and ladle furnace facilities. 1997 - Commissioning of Narrow Width Cold Rolling Project at Chandigarh. 1998 - Commissioning of Precision Pipe Project at Chandigarh. 2001 - Commissioning of Cold Rolling & Galvanizing Complex at Kolkata. 2002 - Addition of narrow width Cold Rolling facilities at Kolkata. 2003 - Expansion of wide width Cold Rolling facilities, ERW Water Pipes & Tubes down stream facilities at Kolkata. 2004 - Further expansion of Cold Rolling facilities at Kolkata. 2005 - Commissioning of Orissa Project consisting of 4 DRI Kilns, Steel Making Facilities, Coal Washery and 100 MW Power Plant. 2007 - Commissioning of further expansion of Orissa Project consisting of HR Coil Mill, Steel making, Blast Furnance, Sinter plant, Coke oven plant, Oxygen plant and Lime & Calcining Plant. 2008 - Implementation of further expansion in Orissa Project in progress. Consisting of DRI Kilns, Coal Washery, Coal Mining, Power Plant & Steel Making facilities.

Annealing
During cold rolling of the coil, the density of imperfections and dislocations increases. These imperfections have strain energy associated with them. On annealing , metal tenda to loose excess energy acquired during cold rolling and revert back to initial stage. The general purpose of annealing is to reduce hardness, facilitate machining and to relieve internal stresses. This heat treatment process is given to the metal so as to achieve one or more of the following objective: To relieve the grains and provide homogeneous structure To relieve internal stresses set to cold rolling To soften the metal and thus improve its machinability To effect changes in some mechanical, electrical and magnetic properties. To prepare further treatment or processing

Here only full annealing takes place, and we have 9 furnaces, 9 cooling hoods, 18 covers and 16 bases. Base - on which coil with cover , cooling hood and furnace is placed. Cover which covers the coil after the coils are loaded on the basis. Technical specifications of annealing furnace Equipment HSD fired type bright annealing furnace Charge material Cold rolled mild steel strips Coil inner diameter - 508 600 mm Coil outer diameter 1850 mm (max) Coil width 200 500 mm Strip thickness - 0.3 2.0 mm Coil weight 9MT (max)

MATERIAL HANDLING EQUIPMENT

To produce only 1 tones of finished rolled metal, it is necessary to haul about 40 tones of various materials. In the course of production materials are moved and transferred by means of hoisting and conveying machines and mechanisms are an integral part of the production.

The major material handling equipment used in this plant are: HOOKS:

Hook is a multipurpose gripping appliance which is widely used as a working member of hoisting mechanism ( load cranes) and as an end elements of slings and other lifting devices.

OVERHEAD BRIDGE CRANES: Overhead bridge cranes are the most widely spread type of cranes in ferrous metallurgy. They are different in their purpose, load capacity and design. A traveling electric crane comprises a crane bridge having a traveling mechanism, a trolley with a hoisting mechanism and control cab. The cranes travel along the workshop or work site over cranes tracks. Depending on the crane purpose the hoisting mechanism is provided with various lifting attachments; hook, load beams, tongs mechanical grips electromagnet or clamshell. As distinct from a

hook crane, the clamshell crane trolley carries alongside with a traveling mechanism two similar mechanisms; one for lifting the clamshell and other for its locking.

COIL CAR:

This is a special hydraulic operated material handling equipment used to transport coil from one part of the plant to another. It is also used to carry the coil under the rails of overhead traveling crane, where the approach of the crane is not possible. The coil car is similar to a massive trolley having wheels at the lower end. These wheels move on the rail which are installed a few feet below the shop floor. These coil cars can be move up or down using hydraulic pressure. The forward movement of the coil car is assisted by a gear pinion arrangement.