deepak bhushan

7/22/2019 Deepak Bhushan

1/46

SUMMER TRAINING REPORT

(BHUSHAN STEEL)

SUBMITTED BY,

DEEPAK SHARMAELECTRICAL AND ELECTRONICS ENGINEERING

(3rd

YEAR 1119421009)

HRCT GROUP OF INSTITUION

Contact : 8826327608


2/46

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 equipments 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 its 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.


3/46

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. Mukesh (personal) for

given me an opportunity to a part of this esteemed organization.

I would like to express my deep sense of gratitude to the entire

workers and technicians of various departments. Especially the

HODs 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.


4/46

COMPANY PROFILE

Bhushan Steel is the largest manufacturer of auto-

grade steel in India and is spending Rs.260 billion to expand its capacity

to 12 million tones annually, from the present installed capacity of

around one million tones.

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 Cold

Rolled Closed Annealed, Galvanized Coil and Sheet, High Tensile Steel

Strapping, Colour Coated Coils, Galume Sheets and Coils, Hardened &

Tempered Steel Strips, Billets, Sponge 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 countrys largestand 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.
http://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Tonnehttp://en.wikipedia.org/wiki/Tonnehttp://en.wikipedia.org/wiki/Steel


5/46

The dynamic reason of awesome and unparalleled growth of BSL is

rapid integration on the Steel value chain; conceivably, it would be its

unwavering focus on acquiring the latest technology and know-how,

also the BSLs commitment to provide its customers with the best

quality products.

Given a vibrant Steel industry dynamics in India, we are on a course to

become a fully Integrated Steel & Power Company with market leading

offerings in value added Steel in Automotive and White Good Segment

with the quality been approved by ISO 9001:2008 & ISO 14001:2004.


6/46

Companys Manufacturing Sites

Sahibabad Plant ( Estb. 1987 )BHUSHAN STEEL LIMITED

23, Site IV, Sahibabad Industrial Area,

Distt. Ghaziabad 201010 (U.P.)

INDIA

Products :

Cold Rolled Coil

Cold Rolled Sheet

Galvanized Plane Coil

Galvanised Plane Sheet

Meramandali PlantNarendra Pur

P.O. Shibapur, Meramandali

District - Dhenkanal - 759 121

Products :

Billets

Sponge Iron

Pig Iron

Char

Khopoli Plant ( Estb. 2004 )Village Nifan, Sarvoli, Kharpada Road

Taluka-Khalapur, Near Khopoli

Distt. : Raigad - 410203 (Maharashtra)

INDIA

Products :

Colour Coated Sheets Galume Sheets

Galvanized Sheets

High Tensile Steel Strapping

Hardened & Tempered Steel Strips

CRCA

Precision Tubes


7/46

PRINCIPLE

Our mission is to grow our company by providing innovative

strong and high-performance 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 Indias 3rd largest Secondary Steel Producer

Company with an existing steel production capacity of 2 million tons per

annums (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 ofUttar 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 suchas, Galume Sheets and Coils , Hardened & Tempered Steel Strips ,

Billets, Sponge, 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 countrys

largest and the only Cold Rolled Steel Plant with an independent line for


8/46

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 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 twomajor 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 forthWhat we

aspire to become, to achieve, to create that willrequire significant

change and progress to attainthe Envisioned Future.


9/46

Our Vision

About Culture: -To make it a place where all the people can thriveliving, 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 Steels endeavor is to attain the

highest level of CustomerSatisfaction.

About Products: - We should always be the pioneers with our

productsout front leading the market.


10/46

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


11/46

Current capacity of Sahibabad Plant

Facility Capacity (TPA)

H.R. Slitting Line(2) 2,40,000

Pickling Line (2) 9,00,000

6 HiHitachi Reversible Mill 3,50,000

6 HiFlat+ Narrow Reversible Mill 1,25,000

Electrolytic Cleaning Line 3,50,000

Annealing Line Batch Type (Hydrogen) 2,76,000

Laddle Refining Furnaces 3,60,000

(Storage

Capacity)

30 Bases

Kathabar 180 T

Roll Grinding Machine 2 Machines

Roll Texturing Machine (EDT Machine) -

4 Skin Pass Cum Tension Leveling Line 3,30,000

C.R. Slitters

Cut-to- Length

3,00,000

Galvanizing Line 2,25,000


12/46

Finished Products at Sahibabad Plant

Cold Rolled Coil

Cold Rolled SheetGalvanised Plane Coil

Galvanised Plane Sheet

Galvanised Corrugated Sheet

Process Layout


13/46

Various Departments and their HODs

Department HOD

Safety Mr. Sudhir Kumar

HRS/Pickling Mr. AK Dixit

Hitachi-Mill Mr. Neeraj Sharma

ECL Mr. SK Sood

Annealing Mr. Neeraj Gupta

Skin Pass Mill Mr. Satyaveer

Finishing Mr. AK Kansal

Colour Coating Mr. Suresh Sharma

Quality NCRM Mr. AK Mukherjee

GP-1 Mr. RC Singh

Utility Mr. AK Gupta

Electrical Maintenance Mr. KK Mathur

Quality System Mr. Deepak Aggarwal


14/46

SAFETY

The service provider and his men should comply with personal

protection equipment (PPE) requirement decided by the organizationsafety department like Cut Resistance, HandGloves, Safety Helmets

and safety Helmets and SafetyShoes.

All the PPESmust 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 PPES& 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.


15/46

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

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 PPEs inside the plants.

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

packing.

Service Provider must not modify any tools or equipments.

Service Provider must not touch any movable parts.

Service Provider must riggers must be alert while pack stackingprocedure 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 stack the 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.


16/46

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 scales 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.


17/46

Specification:

Type of Line PushPull

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


18/46

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 notrequired 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.


19/46

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


20/46

Slitting Lines

Slitting Lines, Slitting Lines have been successfully put into

operation in well-known production plants & service centers. 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 pitmounted

Additional Features :

Quick Slitter Head Change with Standby Slitter Head.

Dual speed lines to cover wider range of thickness.


21/46

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:

1. Type of Line Single / Double Loop.

2. Material CR FH / CRCA / GALVANIZED / COLOUR

COATED.

3. Strip Thickness 3.0 mm.

4. Strip Width 1650 mm.

5. Coil O.D. 2000 mm.

6. Coil Wt. 3MT.

7. Line Speed 250 mpm.


22/46

Galvanizing Line

We offer hot-dip galvanizing lines. The lines manufactured by us are

furnace type, heat to coat type or wet flux type. Efficient air-knivescontrol 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:


On Line Skin Passing.

On Line Tension Leveling.

Double Recoiler on Exit Side


23/46


24/46


25/46


26/46

GP1

A. WORK INSTRUCTION FOR ENTRY SECTIONAPPROVED PROCESS APPROVED MACHINERY

Coil loading Coil car & uncoiler

Welding unit

B.LINE SPECIFICATION

MONITORING OF PROCESS PARAMETERS

SPEED

Entry speed 1520mpm

TENSION

Entry (POR) 56560mpm

Entry accumulator 105 TO 1050 Kg

POSITION

Entry accumulator190% Filled

POR initial data 500mm600mm

C.OLD ROLED MATERIAL SPECIFICATION

Hardness of material 45100 HRB

Thickness of strip0.172.2mm Width5001280 mm

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

Initial diameter of coil 500 mm600mm


27/46

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 entryoperator & 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.


28/46

Electrolytic Cleaning Line

Utilizing a performance enhanced, low temperature, high volume,

updraft re-circulating hot air design, the Electrolytic cleaning line isideal for refreshing steel products and other metallic mater. The

Electrolytic cleaning lines are the ideal wet cleaning complement for

advanced Electrolytic components.

Specification:

Additional Features: On line trimming


29/46

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.


30/46

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.

3Selection of Machine Control Program (MCP):

In this step particular computer operated programs are selected to

operate on the loaded roll.

4Rough 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.


31/46

5Inspection 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 operationto 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.

7Texturing (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)


32/46

Annealing Line

Annealing Line: The demand for better annealed stainless steel has

increased. Annealing is a heat-treating process conducted undercontrolled-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

Additional Features: 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.


33/46

Annealing at a temperature 1100-1300F (600-700C) 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 andbatch 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.


34/46

Rewind cum Trimming Line

Built from the basic elements of the compact trimming line, the modularline mechanically trims the edges through chip removal process. Any

desired dimension ispossible depending on strip width and thickness.

The number of tools operatingsimultaneously is variable. It is frequently

used in the welded tube production.

Additional Features: Two - speed arrangement.


35/46

Coil build-up Lines

The coil build-up lines are used for side-trimming of the strips and alsoprovide 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

o The coil is fed from uncoiler using Peeler Table.

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

3. SETTING OF SLITTER & SLITTING OF COIL

o

Proper set of cutters and rubbers to be used for setting of slitter.o During slitting the operator must check the back tension &

regulate it properly.

o 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. 80100MT of material.


36/46

5. RECOILING &UNLOADING.

6. PACKING OF COIL

COLD ROLLED SLITTER

MINIMUM MAXIMUM

Speed 400 mpm

Coil width II400 mm1700 mm

Strip thickness 0.10mm3mmCoil weight 3 MT


37/46

COLD ROLLING MILL:-

There are two types of Cold Rolling Mills operates, which are 6 Hi ColdRolling Mill and 4 Hi Cold Rolling Mill.

Pickled Hot Rolled Coils of higher gauges are reduced to required

thinner gauges by passing through the Mills. In 6 Hi Mill the reduction

achieved is up to 0.13mm ultrathin gauge whereas 4 Hi can reduce the

thickness up to 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 and4 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 areversing mill under high tension and pressure.

Mill Specification:


38/46


Hydraulic Automatic Gauge Control.

Thickness Gauges.

Roll Bending.

Quick Work Roll Change.


39/46

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.


40/46

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


41/46

Quality control:

BSL have fully fledged laboratory with test equipments such as

Emission spectroscope for the chemical analysis, computerized

Universal testing machine with stress-straingraph 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 spraytester for corrosionresistance, and Humidity chamber.

o ForEnvironmental Management System we have ISO

14001:2004 Certification

o ForQuality System we have ISO/TS 16949:2002

Certification

o

ForSafety Management System we have OHSAS18001:2007 Certification

The main concern of the company is to

Maintain the international norms of steel industry to develop the

accurate and precise products by preserving the environmental

balance and constituting an ecofriendly environment by utilizingmodern and advanced techniques available in the market.


42/46

HARDNESS TEST: -

Hardness is a surface property.

It is defined as the resistance of a material against permanent

deformation 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 Indenter. Indenter 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 indentationin (mm2)


43/46

VICKERS HARDNESS TEST

This test is similar to Brinells test but uses a different type of

Indenter.

A Square based Pyramid Indenter 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,

2. Universal Testing Machine(UTM)

3. Instron or other Material Testing Machine (MTS).

4. Universal Testing Machine (UTM)


44/46

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 UTMs are

hydraulically operated. They can be controlled by computers orcan be operated manually.

R & D department :

For continuous bench marking of our product quality, we keep

carrying out testing from outside laboratories. This has resulted incontinuous 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 standardization of the products manufactured in

the plants according to international norms of the steel market.


45/46

Conclusion

Cold Rolling Mill Complex (CRM)

The various processing units involved in the CRM complex and theirfunctions 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 toremove 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 gauges are reduced to required

thinner gauges by passing through the Mills. In 6 Hi Mill the reductionachieved is up to 0.13mm ultra-thin gauges whereas 4 Hi can reduce the

thickness up to 0.25mm. The computer controlled rolling process

ensures closure thickness tolerances and perfectly flat strips.

Electrolytic Cleaning LineElectrolytic 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 andcorrosion resistant steel. Sodium Orthosilicate is used as cleaning agent

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

customer requirement.


46/46

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 conditionwith 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 surfacefinish. It improves the flatness and suppresses the yield point elongation.

Anti-rust oil is used on strip surface as protection from rust.

Bibliography

1.

Wikipediawww.en.wikipedia.orgwikiBhushanSteel

2.Bhushan Steel Official Website

www.bhushansteel.com/
http://www.bhushansteel.com/http://www.bhushansteel.com/

deepak bhushan

Documents