sail ssp ipt report by srm univ

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-603203

CHENNAI.

Done by

GOKULNATH.B (1041210605)

JAYARAGHAVENDRAN.J (1041210586)

ASWINKUMAR.R (1041210595)

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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

HRM , CRM, and process taking place inside those

mills . The process that we understood have been

submitted as the report. Hereby,we thank the HRD of

SSP who gave this opportunity.

ASWINKUMAR.R(1041210595),

JAYARAGHAVENDRAN.J(1041210586),

GOKULNATH.B(1041210605).

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S.no INDEX

1 Introduction

2 Industry profile

3 SAIL mission & vision

4 Company profile

5 Function of company

5.1)HRM 5.2)CRM

6 Strength Weakness & Opportunity

7 Conclusion

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SALEM STEEL PLANT (SSP)

1. INTRODUCTION

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

India. Commissioned in 1981, the plant has a capacity to roll 186000 tonnes of hot rolled

carbon and stainless steel flat products and 70000 tonnes of cold rolled stainless steel

sheets and coils per annum.

Its products have become a household name “SALEM STAINLESS” in domestic

market and are exported. In hot rolled special grade carbon steels, SSP has been

recognized as well-known manufacturer of boiler quality steel.

A Blanking Line, the first of its kind in India, was established in 1993, with an annual

capacity to produce 3000 tonnes of Ferritic grade coin blanks or 3600 tonnes of utility

blanks.

SSP has revalorized application of stainless steel in India both conventional and

unconventional area. High tech industries like atomic power station prefer ‘Salem

Stainless’ .it also chosen industrial sectors like dairy and food processing, chemical and

fertilizer, heavy engineering, railways, automobiles, bulk solid handling, power, value

added products, etc. The building and architecture segment which is growing at rapid

pace sees ’Salem Stainless’ as the most dependable companies.

In architecture, building and construction, the prestigious structure where ‘Salem

Stainless’ was chosen includes`The parliament house library complex-New Delhi.The

worlds tallest twin building-THE PETRONAS TWIN-TOWER, in Malaysia.The

retractable roofing at the Melbourne Tennis Stadium, Australia.The coaches of high

speed JAN SHATABDI EXPRESS trains are furnished with modular rail marts and sub

pantries made entirely of ‘Salem Stainless’SSP has developed new application of its

products, viz. LPG tanks for automobile, stainless steel ceiling fans, exhaust fans,

corrugated sheets, water tanks, etc.Salem Steel Plant customer spans over 37 countries

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worldwide. Quality occupies the summit of Salem Steel priorities. The products are well

accepted in national and international markets for its top-notch quality.

Organization Name : SAIL - Salem Steel Plant (SSP), Salem.

Industry it belongs to : Steel

Chairman (SAIL) : C.S.Varma

Executive Director (SSP) : Pangaj Gowtham

Foreign exposure : The major exposure countries are China, United

States, Australia, Singapore, Honkong,

Malaysia, Indonesia, Pakistan, Srilanka.

Entry and Exit Barrier : In 1981, the Salem Steel Plant is the only steel

manufacturer in India. The price was fixed by

them, but after globalization in 1995 many

players entered into the market and the price was

fixed by customers. The customer goes either by

quality or by price.

Carrier planning : As for the organization, establishing the new

SMS (Steel Melting Shop) plant for

manufacturing slabs, which is the raw material

for HRM. In past the slabs are brought from their

sister concern plant Bhilai, Durgapur and

Bokaro. The recruitment is based on the need.

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2. INDUSTRY PROFILE

History of the Industry

The Indian steel industry is almost 110 years old now. Till 1990, the Indian steel

industry operated under a regulated environment with insulated markets and large scale

capacities reserved for the public sector. Production and prices were determined and

regulated by the government, while SAIl and TATA steel where main producers, the

latter being the only private player. In 1990, the Indian steel industry had a production

capacity of 23MT. 1992 saw the onset of liberalization and the Indian economy was

opened to the world. Indian steel sector also witnessed the entry of several domestic

private players and large private players and large private investments flowed into the

sector to add fresh capacities.

Steel industry in India is on an upswing because of the strong global and domestic

demand. India’s rapid economic growth and soaring demand by sectors like

infrastructure, real estate and automobiles, at home and abroad, has put Indian steel

industry on the global map. According to the latest report by International Iron and Steel

Institute (IISI), India is the seventh largest steel producer in the world.

The Indian steel industry is organized in three categories i.e main producers, other

major producers and the secondary producers. The main producers and other major

producers have integrated steel making facility plant capacities over 0.5MT and utilized

iron ore and coal/ gas for production of steel. The main producers are TATA steel, SAIL

and RINL, while the major producers ESSAR, ISPAT and JVSL.

Contribution of Countries to Global Steel Industry

The countries like India, china; Japan and South Korea are in the top of the above

in steel production in Asian countries. China accounts for one third of total production

i.e419MT, Japan accounts for 9% i.e118MT, India accounts for 53MT and South Korea

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is accounted for 49MT, which all totally becomes more than 50% of global production.

Apart from this USA, BRAZIL, UK accounts for the major chunk of the whole growth.

Present Status of the Steel Industry

Indian economy growing at 8 to 9% is one of the fastest growing

economics in the world.

The tenth plan investment in infrastructure has been envisaged at around

Rs.880, 550 crores.

During eleventh plan (2007-08) to (2011-12), the projected investment

toward infrastructure is likely to be Rs.2027000 crores, an increase of

180% over 10th plan.

Per capita consumption at 35kg low as compared to world average of

150kg and 300kg for China.

Lot of Steel project both Brown field and Green field likely to the come

up and are in various stage of execution.

Due to infrastructure focus, production of long products is gradually

increasing and ratio of flat to long products is narrowing.

With due focus on infrastructure on development and strong economic

indicators, the demand for steel in India shall continue to remain robust.

Strengths of Indian Steel Industry

Low labour wage rates

Abundance of quality manpower

Mature production base

Positive stimuli from construction industry

Booming automobile industry

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Weakness of Indian Steel Industry

Although India has modernized its steel making

considerably, however nearly 6% of its crude steel is still

produced using the outdated open-hearth process

Labour productivity in India is still very low.

Steel production in India is also hampered by power

shortages.

India is deficient in raw materials required by the steel

industry.

Insufficient freight capacity and transport infrastructure

impediments to hamper the growth of Indian steel industry.

Indian Iron Steel Structure

Indian Iron and steel industry

Steel producers

Sponge iron producers

Steel producers

a) Main producers

i. SAIL

ii. RINL

iii. TSL

b) Major producers

i. JSW steel limited

ii. ESSAR steel limited

iii. ISPAT industries limited

iv. Jindal Steel & Power limited

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c) Other producers

i. EAF based units: 33 working units

ii. Introduction Furnace based units: 970 working units

d) MBF-ETF based units-2units

Sponge Iron producers

a) Gas based sponge iron units

i. ESSAR steel limited

ii. ISPAT industries limited

iii. Vikram Ispat limited

b) Coal based Sponge Iron unit.

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3. SAIL VISION, CREDO, MISSION & VALUES

Vision

To be respected world class corporation and the leader in Indian steel

business in quality, productivity and customer satisfaction.

A world of proven talent

Delivering break through innovation

Giving our customer a unique competitive edge

Enabling societies to master their most vital challenges.

Credo

We build lasting relationships with customers based on trust and mutual

benefit.

We uphold highest ethical standards in conduct of our business.

We create and nurture a culture that supports flexibility, learning and is

proactive to change.

We chart a challenging career for employees with opportunities for

advancement and rewards.

We value the opportunity and responsibility to make a meaningful difference

in people’s lives.

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Mission

We will seek global market leadership.

Development and growth in oriented firms will be our focus.

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

standards of ethics and values.

We will strive for excellence in customer service, quality and R&D

Values

Responsible – Committed to ethical & responsible action

Excellent –Achieving high performance & excellent results

Innovation – Being innovative to create sustainable value

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4. COMPANY PROFILE

The Precursor

SAIL traces its origin to the formative years of an emerging nation - India. After

independence the builders of modern India worked with a vision - to lay the infrastructure

for rapid industrialization of the country. The steel sector was to propel the economic

growth. Hindustan Steel Private Limited was set up on January 19, 1954.

Expanding Horizon (1959-1973)

Hindustan Steel (HSL) was initially designed to manage only one plant that was

coming up at Rourkela. For Bhilai and Durgapur Steel Plants, the preliminary work was

done by the Iron and Steel Ministry. From April 1957, the supervision and control of

these two steel plants were also transferred to Hindustan Steel. The registered office was

originally in New Delhi. It moved to Calcutta in July 1956,and ultimately to Ranchi in

December 1959.The 1 MT phases of Bhilai and Rourkela Steel Plants were completed by

the end of December 1961. The 1 MT phase of Durgapur Steel Plant was completed in

January 1962 after commissioning of the Wheel and Axle plant. The crude steel

production of HSL went up from .158 MT (1959-60) to 1.6 MT. A new steel company,

Bokaro Steel Limited, was incorporated in January 1964 to construct and operate the steel

plant at Bokaro. The second phase of Bhilai Steel Plant was completed in September

1967 after commissioning of the Wire Rod Mill. The last unit of the 1.8 MT phase of

Rourkela - the Tandem Mill - was commissioned in February 1968, and the 1.6 MT stage

of Durgapur Steel Plant was completed in August 1969 after commissioning of the

Furnace in SMS. Thus, with the completion of the 2.5 MT stage at Bhilai, 1.8 MT at

Rourkela and 1.6 MT at Durgapur, the total crude steel production capacity of HSL was

raised to 3.7 MT in 1968-69 and subsequently to 4MT IN 1972-73.

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Holding Company

The Ministry of Steel and Mines drafted a policy statement to evolve a new model

for managing industry. The policy statement was presented to the Parliament on

December 2, 1972. On this basis the concept of creating a holding company to manage

inputs and outputs under one umbrella was mooted. This led to the formation of Steel

Authority of India Ltd. The company, incorporated on January 24, 1973 with an

authorized capital of Rs. 2000 crore, was made responsible for managing five integrated

steel plants at Bhilai, Bokaro, Durgapur, Rourkela and Burnpur, the Alloy Steel Plant and

the Salem Steel Plant.

In 1978 SAIL was restructured as in operating company. Since its inception,

SAIL has been instrumental in laying a sound infrastructure for the industrial

development of the country. Besides, it has immensely contributed to the development of

technical and managerial expertise. It has triggered the secondary and tertiary waves of

economic growth by continuously providing the inputs for the consuming industry.

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OBJECTIVES OF IN-PLANT TRAINING

For any MBA student, a learning combination of theory and practice is an

invaluable asset, as it helps in understanding the core principles of business by way of

first hand experience. This in-plant training is a stepping stone which will groom me

future in the corporate world.

Following are the objectives on in-plant training :-

To get an industrial exposure

To be aware of the happening in a particular industry

To achieve knowledge about different sectors in market for making choice as to which

go for.

To learn functioning and operations of different in an organization

To get knowledge about the working culture of the organization

To have knowledge about the huge management practices and get the practical

knowledge of what we have studied.

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5. FUNCTIONS OF THE COMPANY

5.1 PRODUCTION DEPARTMENT

There are two major units in Salem Steel Plant (SSP)

a) HRM

b) CRM

HRM: Hot Rolling Mill

Input

a) Carbon Steel slabs from sister steel plants viz Bhilai Steel Plant and Bokaro Steel

Limited.

b) Stainless Steel Slabs from Alloy Steel Plant, Durapur and from imported sources.

Output

a) Hot Rolled Carbon Steel and Stainless Steel Coils and Plates.

Product-Mix, Process, Equipment and Infrastructure of Hot Rolling Mill

Hot Rolling Steckel Mill

The Hot Rolling Mill Complex consists of a Slab Yard, a Walking Beam

Reheating Furnace, a Roughing Mill, a Single Stand 4 High Reversible Steckel Mill, a

Down Coiler and a Coil Yard for marking, cooling & dispatch.

Product Mix

With the commissioning of Hot Rolling Steckel Mill, Salem Steel Plant has also

entered the market of carbon steels. The Hot Rolling Steckel Mill is capable of

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producing both stainless as well as non-stainless steels. In case of carbon steels, the

minimum thickness which can be achieved is 1.6 mm and in the case of stainless steel the

minimum thickness achieved would be 2.0 mm. The mill has the capacity to roll up to

1300 mm width.

Process

Slabs of carbon steel (or) stainless steel are received through wagons from Alloy

Steels Plant, Durgapur or Bhilai Steel Plant or from abroad and stored in slab storage

yard. As per the schedule the slabs are charged into the Walikng Beam Reheating

Furnace and annealed to a suitable temperature. Later these slabs are discharged from

furnace and sent to Roughing Mill. In Roughing Mill the slabs are rolled to transfer bar

to a thickness of 25 mm and sent to the Steckel Mill for further reduction. Having

achieved required thickness, the material is cooled with the system of Laminar Cooling in

case of carbon steel and coiled in Down Coiler. In case of stainless steel the material is

directly coiled in Down Coiler after natural cooling. From Down Coiler HR Coils are

taken to CRM or customers through trucks.

Functions of each unit HRM

Slab Yard

Slab yard is to store the slabs in a specific order. The slabs that are received

either by rail or by road are unloaded in this yard.

Goliath Crane

It is used to transfer the slabs from one placed to other within the range of crane

movement area.

Re-heating Furnace

This is a special structure constructed with firebricks to reduce heat loss. Heating

is done using LPG. The temperature maintained inside the furnace depends on the type of

steel in furnace. This furnace contains a walking beam to move slabs from one position to

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other. The main advantage of walking beam furnace is that the hot slabs are moved by

one phase length without any damage (i.e., the beam will lift the entire mass of ten slabs

– placed apart by a definite distance side by side – and moves one step forward and

lowers them on the furnace floor and retracts back to its position.This furnace can contain

ten slabs at a time.

Descaler

When the hot slab is discharged from the furnace, some elements in the slab will

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

surface of the slabs. These scales are unwanted elements and to be removed from the

surface of the slab. The hot slabs with these scales are passed through a descaler, which

will break the scales. The scales so broken are wiped off the slabs with high-pressure

water jets. Scale free slabs will come out of the descaler and will be forwarded to the

roughing mill. Roller table enables movement of these slabs without damaging the

surface

Roughing Mill

This is a reversible mill. The slab thickness, which enters the mill, will be of the

order of 200mm. This will be reduced down to 25-30mm depending on the final

thickness to be rolled in Steckle Mill. This thickness reduction from 200mm to 25-30mm

takes place in several passes.

Crop Shear

The plate from roughing mill will have minor fish tail at leading and tailing ends.

This portion has to be removed in order to have a square ends. Crop shear chops off the

fish tail ends.

Steckle Mill

This is also a reversible mill with level 2 automation. This is the main unit of

HRM Complex. The plates that enter this mill from roughing mill will further be rolled

down to the scheduled/ planned thickness (as per PPC’s requirement). To compensate for

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the heat loss during rolling, the mandrel is housed inside reheating furnace. LPG is used

for heating the strip. This helps in relieving the stress induced, to some extent, in the

strip due to rolling. When the final required thickness is reached, the strip travels over a

roller run table. The bring down the temperature of the strip; laminar cooling towers are

installed above the run table, which showers water at rated pressure on the strip.

Down Coiler

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

Numbering/ strapping machine.

Numbering and Weighing Machine

To avoid unwinding of the coils, they need to be strapped. Since the coil will be

hot condition, manual strapping is not possible. Hence an automatic strapping machine

which will bind the straps together over the coil. The numbering machine prints the

following parameters on the strip (spray painting method):

Coil number

Grade

Thickness

Width

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

on the strip.

Transfer car

The coils from the weighing machine are moved to the storage yard using transfer

cars.

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PROCESS

PROCESS FLOW: HOT ROLLING MILL

1. Reheating furnace

2. Descaler

3. Edger

4. Roughing mill

5. Crop shear

6. Coiler furnace

7. Steckel mill

8. Laminar cooling

9. Pinch roll

10. Down coiler

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CRM: COLD ROLL MILL

Input

a) Hot rolled stainless steel coils from hrm to ssp.

b) Imported source hot rolled coils (430 grade coils).

Output

Stainless steel coils and sheets of various sizes as mentioned in the marketing and

metallurgical services manual. The very purpose of any industry is to produce an end

product that has a wide range market. As stated above ssp produces a wide range of

products, which is the input of raw material for several industries of

Food processing

Utensil

Heavy engineering

Railways

Elevators

Coinage

Washing machine

Water coolers and refrigerators

Wall panelling

Interior decoration of office/house

Bus body building and so on....

To cater to the needs of industries that manufacture equipments of the

kind mentioned above, Branch sales offices are established all over

India at key locations. The following are the BSOs that are currently

operative:

Ahmadabad

Mumbai20


Kolkata

Coinage

Export-Salem

Hyderabad

Conversion- Salem

Bangalore

Chennai

New delhi-2 offices

Coimbatore

Pune

Salem

The above said BSOs will interact with customers/traders in and around the place

and take orders from them for our products. If the order, so taken is a standard product

(as given in the product catalogue), branch will directly issue Release orders to ppc.

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Input

The input slabs are stored in slab storage yard. As per the schedule the slabs are

charged into the walking beam Reheating Furnace and annealed to a suitable temperature.

Later these slabs are discharged from furnace and sent to Roughing Mill. In Roughing

Mill the slab are rolled to transfer bar to a thickness of 25mm and sent to Steckel Mill for

further reduction. Having achieved to the required thickness, the material is cooled with

the system of Laminar Cooling in case of carbon steel and coiled in Down Coiler. In case

of stainless steel the material is directly coiled in Down Coiler after natural cooling. From

Down Coiler HR Coils are taken to CRM or customer through truck.

Output

Hot Rolled Carbon Steel and

Hot Rolled Stainless Steel Coils and Plates.

Reheating Furnace

The furnace section consists of

a)Slab Yard

b)Re-heating Furnace

The walking beam type Reheating furnace is hydraulically operated, top and

bottom fired and has a flat roof. The combustion system is of recuperative type

designed for firing LPG or natural gas. The Reheating furnace has been designed and

supplied by M/S Italiampianti, Italy and Erected by M/S Wellman Incandescent, India.

Furnace capacity

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

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

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The different types of material that can be processed are:

Stainless Steel: AISI 200 & 300 Series (Austenitic)

AISI 400 Series (Ferritic & Martensi tic)

Carbon Steel: IS 1079 D, IS 1079 DD, and IS 1079 EDD

IS 2062B, IS 10748, E38, E34, SAILCOR, IS 6240.

The slabs are uniformly heated in the Re-heating furnace so that they are brought

to the discharge temperature of 1150 ˚C to 1250˚C.

No of burners installed: 56

Fuel used: LPG; Calorific value – 22,000 Kcal/NM.

No of combustion blowers installed: 2

Recuperator: Metallic type to recover the waste heat from flue gases.

Slab temperature is measured by the radiation pyrometer installed in the furnace

roof of discharging side. Oxygen analyser is provided in the recuperative zone of

charging side to measure the oxygen percentage in waste gas.

Reversing Roughing Mill

The Roughing Mill is a 4 hi Reversing Mill.

Supplied by M/S Schloemann Siemag (SMS), Germany.

Automation supplied by M/s Siemens, Germany.

Rouging Mill is controlled by Level 1 Automation.

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

called Back-up rolls.

Max Dia Min Dia Length

Work roll 1050 mm 950 mm 1475 mm

Back up roll 1350 mm 250 mm 1425 mm

In Roughing Mill the thickness of Reheated and Descaled (Primary scales) slab is

reduced to 20 - 32 mm by rolling process in 3,5,7 or 9 passes depending on the input

slab size by controlling the width during rolling in Edger. The complete rolling and

edging operation is carried out as per the proper selection of pass schedule.

Discharge temperature of slabs

1. Carbon Steel: 1200 - 1280˚C

2. 200 Series : 1190 ±20˚C

3. 300 Series : 1220- 1280˚C

4. 400 Series : 1140 ±20˚C.

The temperature of the Transfer bar (T-bar) after the last pass rolling in Roughing

Mill: 950˚C - 1100˚C. The fish tails formed at head end and tail end of the T-bar

during edging and roughing process is removed in Drum Shear and the final reduction

in thickness is achieved by rolling in Steckel Mill.

a. Equipment from Reheating Furnace Upto Roughing Mill

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Slab reject roller tables

Furnace delivery roller table

Descaler connecting and descaler roller table

Primary descaler

Roughing mill approach roller table

Front mill roller table

Roughing mill feed rollers

Roughing mill entry side guides

Vertical edger

b. Roughing Mill Equipment

Roughing Mill Screw Down System

Un-jamming device

Roughing mill guides

Lifting rails

Work roll cooling system

Back up roll balancing

Spindle balancing

Back up roll changing sled

Work roll change cover plate, tilting flap

Roll change car

c. Systems

Hydraulic system

Booster pump system (Centralised for Steckel Mill and Roughing Mill)

High pressure water system

Morgoil system (Centralised for Roughing Mill and Steckel Mill)

Oil lubrication system (Centralised for Roughing Mill and Steckel Mill

areas)

Pneumatic system

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Grease systems

Steckel Mill

Steckel Mill is a 4 hi Reversing Mill

Supplied by M/S Schloemann Siemag (SMS),Germany.

Automation supplied by M/S Siemens, Germany.

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

called Back-up rolls.

Max dia Min dia Length

Work roll 760 mm 680 mm 1825 mm

Back up roll 1350 mm 1250 mm 1425 mm

A. Steckel Mill Specifications

Type: Single stand, 4 Hi reversible Mill, provided with one coiler furnace on each side

to wind the hot strip just after rolling in each pass and also to maintain the strip

temperature suitable for hot rolling.

Steckel Mill is built with sophisticated facilities & control systems to obtain high

quality flat product such as

HGC – Hydraulic gap control

AGC – Automatic Gap Control

MON - (Thickness monitoring system)

RAC – Roll alignment control

CVC and Work roll bending system

PGM – Profile Gauge Meter

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Model Server

The state-of-the-art automatic pass schedule calculation facility (model server) is

installed to have trouble free rolling. Automatic work roll change facility is provided

for quick and easy changing of work rolls.

Main drive capacity: 4500 KW each for

top and bottom work

Back up roll is friction driven.

Maximum roll force: 30,000 KN

Maximum rolling speed: 10 M/sec

Maximum bending force: 3,000 KN

CVC shifting range: -200 mm to +200 mm

CVC crown values: -0.7 mm to +0.3 mm

Pass line deviation allowed: -10 mm to +10 mm

COILER FURNACE

Temperature maintained : 950˚C - 1000˚C

Fuel used: LPG

Air/gas ratio: 28 – 32

Number of burners: 6 for each furnace

Coiler Drum diameter: 1350 mm

Coiler Drum drive capacity: 650 KW

Combustion air pressure for coiler furnace: 800 mm wc

LPG working pressure: 800 mm wc

Technical Details

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Material Specifications:

Transfer bar thickness: 20mm - 32 mm (carbon steel)

: 20mm - 28 mm (Stainless steel)

Transfer Bar Width : 600mm – 1300 mm

T –Bar temperature : 1020 - 1100˚C

Strip thickness for Carbon Steel: 1.6 mm – 12.7 mm

for Stainless steel: 2.0 mm – 10.0 mm

Systems

Auxiliary hydraulic system

Servo hydraulic system

Booster pump system (Centralised for Steckel Mill and Roughing Mill)

High pressure water system

Morgoil system (Centralised for Steckel Mill and Roughing Mill)

Oil lubrication system (Centralised for Steckel Mill and Roughing Mill)

Laminar cooling system

Pneumatic system

Grease systems

Re-circulating water system

B. Air Compressors

4 Nos. of Air compressors are installed to meet compressed air requirement for the Hot Rolling Mill complex.

C. Model Server

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The Model Server is the Level 2 automation system consisting of a mill process

computer. The mill process computer based on mathematical models and strategies,

calculates the set up values for the mill like roll gap, roll force, CVC position, bending

values etc., (in association with the slab data and transfer bar data). Finally the set up

values allow for an accurate control of strip thickness, profile and flatness.

The area of the model server is restricted to the Steckel Mill stand and coiler

furnace. The primary data is transmitted by the production control PC to furnace PLC.

When a slab is discharged from the furnace, furnace PLC transmits the primary data of

this slab and the next slab to Roughing Mill PLC. After acknowledgement from

Roughing Mill operator, Roughing Mill PLC transmits the primary data to model

server.

With the completion of the last pass in the Roughing Mill, Roughing Mill PLC

transmits the actual values of the last pass in the Roughing Mill, (Width, last pass roll

force, roll gap, temperature and speed) to model server.

The availability of primary data and T-bar data enable the model server to

calculate the pass schedule. After the calculation, the set up values are transmitted to

the Steckel Mill PLC. The Steckel Mill PLC will do the sequence control of the

process in Steckel Mill. During the pass in Steckel Mill, actual values like roll force

and strip temperature are measured by Steckel Mill PLC and sent to Model server.

After 35-50% of that pass length is rolled the model server will process the measured

values sent by Steckel Mill PLC. Based on this feed back, the models will re-calculate

an improved set up for the remaining passes. However, the thickness distribution,

speed, tension values will not be changed. This process will be repeated pass by pass

until the last pass is reached.

The model server has the following automation functions:

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1. Strip tracking

2. Pass schedule calculation

3. Acquisition and processing of measured values

4. Dialogue and display

5. Logging function.

Roll shop

Roll Shop caters to the

Work rolls and back up roll requirements of Roughing Mill and Steckel Mill

by supplying rolls with chocks assembled with bearings as and when

required.

Turning and assembling of Edger rolls.

Grinding of Pinch rolls of Steckel Mill and Down Coiler.

The used work rolls, back up rolls of Roughing Mill and Steckel Mill, Edger rolls

and Pinch rolls of Steckel Mill and Down Coiler are reground in the Roll grinding

machine.

Roll grinding m/c is supplied by M/S Toshiba machine company, Japan.

State – of –the- art CNC roll grinder is working on Level -3 automation which

ensures fully automatic grinding where special functions like wheel quick approach,

Automatic roll alignment and wheel surface speed control are done by machine itself.

Overhauling and maintenance of all Work roll and Back up roll bearings are taken

up on a regular basis. The chocks earmarked for overhauling are dismounted from

rolls. Then the bearings, seals and chock internals are taken out, cleaned and checked

for any mark or wear and tear. Based on the condition, the bearings and chock

internals are either replaced with new or are put back after thorough cleaning and

removal of marks. 31


Roll Grinding Machine (RGC 1400 x 5000 CNC grinding machine)

Hot Rolling Mill (HRM) of Salem Steel Plant have different rolls like

Breakup Rolls, Work rolls, Edger Rolls and Pinch Rolls. All these Rolls in HRM

need grinding after a stipulated tonnage of rolling for better surface finish. So,

these rolls are being ground by CNC grinding machines.

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

M/S Toshiba, a new Roll grinding machine of Type: RGC 1400 x 5000 CNC,

[supplied by M/S World Machinery Works (WMW), Romania] was also

commissioned in July 2009 to grind HRM rolls for production of 3,70,000 t of

Slabs per year.

The main equipments and automation of this new Roll Grinding Machine

a. CNC : SINUMERIK 840D

b. MIDA : Roll Alignment System

c. MARPOSS : Wheel Balancing and auto wheel touching

d. LISMAR : Flaw detection

e. Meas4 Roll : Profile measurement

f. Wheel measurement and dressing

g. PLC : SIMATIC S7-300

This machine consists of mainly 9 axes. The details are as follows

C1 : Roll drive rotation

C2 : Wheel Rotation

Z : Longitudinal Movement of the Carriage

X : Traverse Movement of grinding wheel (coarse)

X1 : Traverse Movement of grinding wheel (fine)

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B : Wheel assembly swiveling

A : Diameter measurement arm rotational movement

Y : Diameter measurement

U : Roll alignment

Special features of RGC 1400 x 5000 CNC grinding machine

The roll grinding machine RGC 1400 x 5000 CNC type performs grinding,

measuring and testing E.C cylindrical surfaces, Plane or Cambered (concave

or convex).

Highly productivity output ranges, optimal machine accuracy and decreasing

preparation period.

All types of profile can be ground Viz. Straight, Taper, Concave, Convex,

Radius, CVC etc.

Backup Rolls and Edger Rolls can be ground with chocks

Roll diameter can be measured during grinding

Grinding accuracy

- Roundness : 0.002 mm

- Cylindricity : 0.002 mm

- Crown profile : 0.0025 mm

- CVC profile : 0.0025 mm

Down coiler

The finished strip from Steckel Mill rolling is coiled around the Down Coiler mandrel.

The finish strip thickness:

For Carbon steel : 1.60 mm to 12.7 mm

For Stainless steel: 2.00 mm to 10.0 mm

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The equipments are supplied by M/S Schloemann Siemag (SMS), Germany. The

automation is done by M/S Siemens, Germany. The Down Coiler is controlled by

Level -1 automation. The walking beam conveyor is used for the transportation of

coils to the Coil Yard. The coil is strapped by a single band circumferencial automatic

Strapping machine, weighed in the weighing m/c and marked by an automatic marking

machine supplied by M/S Infosight Corporation, USA.

Down Coiler consists of

a. Run out Roller table (RORT): This consists of 184 rollers (Roll dia: 300

mm) separated into six groups. This helps in transporting the finished strip

from Steckel Mill to Down Coiler

b. Side Guides: Side guides are provided for guiding the strip straight into the

Coiler.

c. Hold Down Roll: The main function of the hold down roll (Roll dia: 300

mm) is to avoid fluttering in the strip. This roll will be in the up position

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

roll.

d. Pinch Roll: The function of the pinch roll is to guide the strip into the

mandrel

Max Min

Top Roll : 900 mm 880 mm

Bottom Roll: 400 mm 370 mm

e. Strip Switch: The strip switch guides the strip to the mandrel. During coiling

it opens and it allows the strip to the mandrel and afterwards it closes the way

to the mandrel.

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f. Chute Plate: The chute plate feed the strip to wrapper roll 1 which makes the

strip to wind on the coiler

g. Wrapper Rolls: Three wrapper rolls are provided for wrapping the head end

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

mandrel expanded and tension built.

h. Mandrel: The finished strip from Steckel Mill winds on the mandrel

The diameter of the mandrel:

Collapsed : 727 mm

Pre-expanded : 738 mm

Fully expanded: 762 mm

i. Outboard Support Bearing: Two support bearings are provided, one in

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

j. Coil Car: The coil car transports the finished coil from the mandrel to the

walking beam conveyor. It has a lifting table which is provided with two

rollers and locking provision for the rollers.

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5.2CRM-COLD ROLLING MILL

Input

Hot Rolled Stainless Steel Coils from HRM of SSP.

Imported source Hot Rolled Coils (430 grade Coils).

Process

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

modern equipment supplier by the leading machinery manufacturer all over the world.

The raw material for CRM is HR Stainless Steel Coils, called hot beams. These coils are

processed in Coil Built-up Line (CBL). Coils from CBL are softened and descaled in

Annealing and Pickling Line (APL. From here they are sent for cold rolling in Sendzimir

Mill (Z-Mill) to the descried final thickness.

The cold Rolled Coils are again softened and descaled to obtain the optimum

finish and mechanical properties. These are passed through the Skin Pass Mill (SPM) to

give a bright finish and necessary flatness. The coils are ultimately either slit or sheared

into finished products in the form of slit/divided coils or cut-lengths. The special surface

finishes are obtained in the Sheet Grinding and in the form in the Strip Grinding Line

(SGL).With the special feature of the computerized gauge control in Sendzimir Mill, it is

possible to obtain very close gauge tolerances. The Ruthner neutral electrolytic pickling

process in the APL ensures excellent surface finish and minimum environmental

pollution.

Units in CRM

Cold build up line

Bell annealing furnace

Annealing and pickling line no:2

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Annealing and pickling line no:1

Strip grinding line

Sendzimir mill no:1

Sendzimir mill no:1

Roll grinding shop

Skin pass mill

Slitting line

Shearing lineStrip grinding and polishing line

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PROCESS FLOW :COLD ROLL MILL

1. Hot rolled coil

2. Coil buildup line

3. Annealing & pickling line

4. Bell annealing furnace

5. Sendzimir mills

6. Strip grinding line

7. Skin pass mill

8. Sharing line

9. Slitting line

10. Coil inspection & dividing line A- Annealing

11. Sheet grinding & polishing line B- Pickling

12. PVC coating unit C- Shot Blating

13. Sheet packing line

14. Strecher leveler

15. Requiring shear

16. coil packing line

17. blanking line

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Output

Stainless Steel coils and sheets of various sizes as mentioned in the marketing and

metallurgical service. The purpose of any industry is to produce an end product that has a

wide range market. SSP provide wide range of products, which is the input raw material

for several industries of:

Food Processing-Utensil

Heavy Engineering-Railways

Elevators-Coinage

Washing Machine-Water Coolers and refrigerators

Wall Paneling-Interior Decoration for Office/House

Bus Body Building and so on…

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6.STRENGTH,WEAKNESS &OPPORTUNITY OF SAIL

STRENGTH

High Quality products

Experienced and skilled personnel

Customer Satisfaction

Leader of Indian Steel Business Effective innovative skills

Employee participation in Decision Making

World Class Respected Company

WEAKNESS

Due to high quality prices are high which can be based on

demand.

The advantage of competition

OPPORTUNITY

To increase steel , coils & steels & other products

Globalization of market is the best way to access the whole world

Salem Steel Plant can better exploit the cheep resources as well as the skilled

employees.

To huge width in India & a number of plant are to formed

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7.CONCLUSION

For an Engineering student a learning combination of theory and practice is an

valuable asset which helps in understanding the core principles of business by the way of

first hand experience This in plant-training in Salem Steel Plant has given me such a

great experience about all the managerial functions, which is going on in the company. It

also helped me to understand the exact mechanism of working of the various

departments.

After completing this in plant-training I could be able to understand much more

about the Salem Steel Plant the MNC which is the most reputed name in the corporate

world. Salem Steel Plant known for its quality products.

This knowledge will help me well to establish myself in the corporate World after

completing my academic session.

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sail ssp ipt report by srm univ

Education

steel plant industry

introduction salem steel

sail salem steel plant

steel manufacturer

tata steel

indian steel industry

stainless steel sheets

application of stainless