final btech me

8/17/2019 Final Btech Me

1/43

ACKNOWLEDGEMENT

I am grateful for the inspiration and wisdom of all the esteemed persons who

helped me to turn this training into a success.

At the very outset, I would like to express my deep gratitude to Bhushan Power &

Steel td, !handigarh for giving me an opportunity to work upon and do my

training in this reputed organi"ation.

I would also like to thank #r. Arun kam$o% and #r. andhir singh under whose

guidance and rich pool of experience I have completed my training.

I would $e failing in my duty if I don't spell my thanks to the employees of

Bhushan Power & Steel for giving shape to my ideas and thinking. (hey were

more than encouraging and helpful, $y giving me time from their schedule to ask

my )ueries.

1 | P a g e


2/43

HISTORY OF BHUSHAN

*rowing from strength to strength+

1970 Started with very small initial outlay for manufacturing -oor inges& later on, ail (rack /asteners.

1973 - #anufacturing facilities set up for Steel and 0ire od in !handigarh.

1981 - olling #ill Pro%ect commissioned at !handigarh for ound and 1arrow

Strips.

1985 - Backward Integration Pro%ect for Steel #elting facilities.

1986 - 2pgrading of #ini Steel Plant with continuous casting and ladle furnace

facilities.

1997 - !ommissioning of 1arrow 0idth !old olling Pro%ect at !handigarh with a

pro%ect cost of s. 34 crores.

1998 - !ommissioning of Precision Pipe Pro%ect at !handigarh with a pro%ect cost

of s. 45 crores.

2001 - !ommissioning of 6olkata Pro%ect with a pro%ect cost of s. 789 crores.

2002 - Addition of narrow width !old olling facilities.

2003 - :xpansion of wide width !old rolling facilities, :0 0ater Pipes & (u$es

down stream facilities at 6olkata with a capital outlay of s. ;; crores.

200 - /urther expansion of !old olling facilities at 6olkata with a capital outlay

of s. 3< crores.

2005 - !ommissioning of =rissa phaseI pro%ect consisting of > -I 6ilns, Steel

#aking /acilities, !oal 0ashery and 4 mtpa, Sinter Plant


3/43

-olomite 7x99 (P-, Steel #aking /acilities 9.89 mpta, !oil ?!SP Plant@

9.89 mtpa with a capital outlay of s.7899 crores is under implementation.

2007 =xygen Plant and one :lectric Arc /urnace ?:A/@ commissioned under

=rissa PhaseII pro%ect

!ROFILE

3 | P a g e


4/43

Amongst the various reasons $ehind BPSs unprecedented growth and rapid

integration on the steel value chain, perhaps, the most important would $e its

unwavering focus on ac)uiring the latest technology and knowhow.

(he most important reason $ehind this focus has $een BPSs commitment to

provide its customers with the $est )uality products. (he result, to say the least, has

$een aweinspiring growth.

Bhushan Industries imited is an integrated mini steel plant, located at !handigarh

with facilities for manufacturing more than 7 lakh tones per annum of steel $illets

and rolled products C rounds, flats, narrow strips. /rom a modest start in


5/43

Bhushan Power & Steel td., produces a num$er of steel products for domestic

users, Industrial concerns etc. for infrastructure development at its manufacturing

$ases at !handigarh, -era$assi ?Pun%a$@, 6olkata and =rissa .ALL OUR

!RODUCTS CONFORM TO INDIAN AND INTERNATIONAL S!ECIFICATION"

TOR STEEL STEEL BILLETS GI !I!ES G! CORRUGATED SHEETS

ALLOY STEEL ROUNDS CR COILS NARROW CR COILS CR SHEETS

G! COILS # SHEETS !RECISION TUBES

$ERW %&' CEW(

CABLE TA!ES BLACK !I!E

WIRE RODS !OWER S!ONGE IRON

INTRODUCTION TO BHUSHAN !OWER )

STEEL L*'+ CHANDIGARH"

5 | P a g e

http://www.bhushanltd.com/torsteel.htmhttp://www.bhushanltd.com/steelbillets.htmhttp://www.bhushanltd.com/gipipes.htmhttp://www.bhushanltd.com/steelcoils.htmhttp://www.bhushanltd.com/steelrounds.htmhttp://www.bhushanltd.com/crcoils.htmhttp://www.bhushanltd.com/crcoils_narrow.htmhttp://www.bhushanltd.com/crcoils_sheets.htmhttp://www.bhushanltd.com/gpcoils.htmhttp://www.bhushanltd.com/precisiontubes.htmhttp://www.bhushanltd.com/precisiontubes.htmhttp://www.bhushanltd.com/cabletapes.htmhttp://www.bhushanltd.com/steelstrips.htmhttp://www.bhushanltd.com/wirerods.htmhttp://www.bhushanltd.com/power.htmhttp://www.bhushanltd.com/spongeiron.htmhttp://www.bhushanltd.com/blackpipe.htmhttp://www.bhushanltd.com/torsteel.htmhttp://www.bhushanltd.com/torsteel.htmhttp://www.bhushanltd.com/steelbillets.htmhttp://www.bhushanltd.com/steelbillets.htmhttp://www.bhushanltd.com/gipipes.htmhttp://www.bhushanltd.com/gipipes.htmhttp://www.bhushanltd.com/steelcoils.htmhttp://www.bhushanltd.com/steelcoils.htmhttp://www.bhushanltd.com/steelrounds.htmhttp://www.bhushanltd.com/steelrounds.htmhttp://www.bhushanltd.com/crcoils.htmhttp://www.bhushanltd.com/crcoils.htmhttp://www.bhushanltd.com/crcoils_narrow.htmhttp://www.bhushanltd.com/crcoils_narrow.htmhttp://www.bhushanltd.com/crcoils_sheets.htmhttp://www.bhushanltd.com/crcoils_sheets.htmhttp://www.bhushanltd.com/gpcoils.htmhttp://www.bhushanltd.com/gpcoils.htmhttp://www.bhushanltd.com/precisiontubes.htmhttp://www.bhushanltd.com/precisiontubes.htmhttp://www.bhushanltd.com/precisiontubes.htmhttp://www.bhushanltd.com/cabletapes.htmhttp://www.bhushanltd.com/cabletapes.htmhttp://www.bhushanltd.com/steelstrips.htmhttp://www.bhushanltd.com/steelstrips.htmhttp://www.bhushanltd.com/wirerods.htmhttp://www.bhushanltd.com/wirerods.htmhttp://www.bhushanltd.com/power.htmhttp://www.bhushanltd.com/power.htmhttp://www.bhushanltd.com/spongeiron.htmhttp://www.bhushanltd.com/spongeiron.htm


6/43

Bhushan Power & Steel imited is an IS= 8997, DS 8999 certified !ompany. (he plant at

!handigarh is e)uipped with latest technology. It is one of the $est

plants of B2SA1. In this plant the layout of machinery is In ine

and the Plant works for 7>E5.ere the control is semi automated.

As one of the prime movers of the (echnological evolution in the Indian !old olled Steel Industry,

BS has emerged as the countries largest and the only ! steel plant with an independent line for

manufacturing !old olled coils and sheets up to a width of


7/43

chain right from coal mining, $illets, coil, pig iron, ! coils, *PG*!,

precision tu$es, $lack pipeG*I pipe, ca$le tapes, tor steel, wire rod and

special alloy steel.

P=-2!(S #A12/A!(2:- A( BPS

PA1( 1= +

BPS plant no. operates on semi automated hot rolling mill producing

a$out 779 to 774 tones of tor a$out 4 tones of ms wires per day. A $riefly

description of the products is descri$ed $elow+

(or Steel

(or steel $ars are manufactured at our !handigarh plant no. (or steel is

formed from E> inch in cross section $y the process of hot

rolling. 0eight of the $illet is 7


8/43

made from one $illet is 499m ?appor@ depend upon the diameter of the tor

steel rod. :ither it is ; mm or 3 mm or


9/43

Application+ wire rod is used as raw material $y wire drawing unit, electrodes, wire

mesh, fasteners, hardware and automo$ile components manufactures. 0e meet

stringent )uality parameters.

0e manufactures from superior )uality $illets produced $y own integrated steel

plant situated at %harsuguda ?=rissa@ to ensure high strength and long life the si"es

of wire rod $eing manufactured $y us are from 7 mm to 4.4 mm .

9 | P a g e


10/43

WIRE ROD

Harious departments in BPS

(here are four departments in BPS which are as

follows+


11/43

In this section the wire rod so produced in hot rolling mills is used as sa raw

material which is allowed to pass through wire drawing panel. (he diameter

of rod after passing this panel reduces to great extent and #Swires of si"e

7mm and >mm can $e manufactured.

.#achine shopin this section unfinished rollers are $eing finished after undergoing various

maching process on different machine provide in this shop. -amaged

machine e)uipeents and parts are also $eing repaired.

11 | P a g e


12/43

>.Duality sectionIn this section various parameter of the finished products are $eing inspected

for $etter )uality of finished products.

ot rolling

olling is a fa$ricating process in which the metal,plastic ,paper,glass etc. is

passed through a pair ?or pairs@ of rolls.there are two types of rolling process,flat

and profile rolling. In flat rolling the final shape of product is either classed as

12 | P a g e


13/43

sheet ?typically thickness less than mm,also called stripJ@ or plate?typically

thickness less than mm@. in profile rolling the final product may $e a round rod or

other shaped $ar such as a structure section ?$eam,channel,%oist [email protected] is

also classified according to the temprature of the metal rolled.If the temprature of

the metal is a$ove its recrystalli"ation temprature, then the process is termed as hot

rolling. If the temprature of the metal is $elow its recrystalli"ation temprature the

process is termed as cold rolling.Another process also termed as Khot $ending ' is

induction $ending,where$y the section is heated in small scetion and dragged into

a re)uired radius. eavy paltes tend to $e formed using a press process, which is

termed forming, rather then rolling.

ot Billet passing through moving rollers

ot rolling is a hot working metal working process where large pieces of metal,

such as sla$s or $illets , are heated a$ove their recrystalli"ation temprature and

then deformed $etween rollers to form thinner cross sections.ot rolling produces

thinner cross sections than cold rolling process with the same no of stages.hot

rolling, due to recrystalli"ation ,will reduce the average grain si"e of metal while

maintaining an e)uiaxed microstructure where as cold rolling will produce a

hardened microstructure.

13 | P a g e


14/43

HOT BILLET !ASSING THROUGR THE ROOLERS

ot olling Process

A sla$ or $illet is passed or deformed a set of work rolls and the temprature of the

metal is generally is a$ove its recrystalli"ation temprature ,as opposed to cold

rolling ,which takes place $elow this temprature .ot olling permits large

deformation of the metal to $e achieved with a low no of rolling cycles. As the

rolling process $reaks up the grains , they recrystalli"e maintaining an e)uiaxed

structure and preventing the metal from hardening .ot rolled material typically

does not re)uire anneling and the high temprature will prevent residual stress from

accumulating in the material resulting $etter dimensional sta$ility thyen coldworked materials.

14 | P a g e


15/43

ot rolling is primarrily concerned with manipulating material shape and geometry

rather than mechanical properties. (his is achieved $y heating acomponent or

material to its upper critical temprature and then applying controlled load which

forms the material to a design specification or si"e.

T/ /* ,&4 ,',

olling is a forming procedure ,either for the production of flat products like

strips,foils or sheet metal, or for long products like profiled

sections,rails,tu$es,wire or rods. !ontrary to cold rolling , in the hot rolling

process the $ase material is heated to


16/43

diameter of the steel. ot rolling is a procedure consisting of various forming

process,the so called roll passes . :very roll passincreases the length and

simultaniously reduce the thickness of rolling stock and leads to the Kdestruction'

of the original structure. (he fact that the rolling stock is heated causes its

crystallographic condition to change .0hen processsing steel the structure is

changed from the hard ferritic to the soft austenitic form.In this condition the

plastic deformation takes place,deformation grades of upto 749 +< are possi$le.

(his is why a sla$ may have a thickness of 7>9 mm $efore hot rolling and

afterwards of only 9.; mm .In cold rolling the maximum deformation grade is


17/43

ot rolling is used mainly to produce sheet metal or simple cross sections such as

rail road $ars from $illets,tor steel, wire rods etc.

#echanical properties of the material in its final Kasrolled' form are a function of+

#aterial chemistry

eheat tempraure,

ate of temprature decreasing during deformation,

ate of deformation,

eat of deformation

(otal reduction,

ecovery time,

ecrystalli"ation time ,and

Su$se)uent rate of coolin after deformation.

(ypes of ot olling #ills

Prior to continues casting technology ,ingots were rolled to approximately 799

mm ?5.8 in@ thick in a sla$ or $loom mill .Blooms have a nominal s)uare cross

section ,whereas sla$s are rectangular in cross section.

Sla$s are the feed material for hot strip mills or plate mi;lls and $looms are rolled

to $illets in a $illet mill or large sections in a structural mill.

(he output from a strip mill is coiled and ,su$se)uently ,used as the feed for a cold

rolling mill or used directly $y fa$ricators. Billets , for rerolling,are su$se)uently

rolled in either a merchant , $ar or rod mill

17 | P a g e


18/43

#erchents or $ar mills produce a variety of shaped products such as angels,

channels, $eams ,rounds?long or coiled@ and hexagons, ounds less then


19/43

technologies L!A-, !A#,!AxM@,to control industrial machinery and processes

,reducing the need for human intervention . In the scope of industriali"ation,

automation is a step $eyond mechani"ation. 0hereas mechani"ation provided

human operators with machinery assist them with physical re)uirements of

work,aurtomation greatly reduces the need for human sensory and mental

re)uirements as well. Processes and systems can also $e automated.

Automation plays an increasingly important role in the glo$al economy and in

daily experience. :ngineers strive to com$ine automated devices with

mathematical and organi"ational tools to create complex systems for a rapidly

expending range of applications and human activities.

#any roles of humans in industrial processes presently lie $eyond the scope of

automation . uman level pattern recognition, language recognition ,and language

production a$ility are well $eyond the capa$ilities of modern mechanical and

computer systems. (asks re)uiring su$%ective assement or synthesis of complex

sensory data , such as sents and sounds , as well as high level tasks such as

strategic planing, curently re)uire human expertise . In many cases , the use of

human is more cost effective then mechanical approaches even where automation

of industrial tasks is possi$le.

Specialised hardened computers , referreds to as programma$le logic controllers

?P!s@, are fre)uently used to synchroni"e the flow of inputs from ?physical@

sensors and events with the flow of output to actuators and events. (his leads to

precisely controlled actions that permit a tight control of almost any industrial

process.

19 | P a g e


20/43

umanmachine interfaces?#I@ or computer uman Interfaces ?!I@,for merely

known as m,anmachine interfaces are usually employed to communicate with

P!s and other computers , such as entering and monitering tempratures or

pressures for further automated control or emergency response.service personnal

who moniter and control these interfaces are often referred to as stationery

engineers .

I#PA!(

Autmation has had a nota$le impact in awide range of hoghly visi$le industrious

$eyond manufacturing. =nce Cu$i)uitous telephone operators have $een replaced

largely $y automated telephone switch $oards and answering machines. #edical

processes such as primary screening in electrocardiography or radoiography and

20 | P a g e


21/43

la$oratory analysis of human genes ,sera ,cells ,and tissues are carried out at much

greater spped and accuracy $y automated systems. Automated teller machines have

reduced the need for $ank visits to o$tain cash and carry out transactions . In

general ,automation has $een responsi$le for the shift in the world economy from

agrarian to industrial in the


22/43

side effect of this shift is that unskilled la$ourJ is in higher demand inmany first

world nations ,$ecause fewer people are availa$le to fill such %o$s. At first glance ,

automation might appear to devalue la$or through its replacement with less

expensive machinesNhowever, the overall effect of this on the work force as a

whole remains unclear .(oday automation of the automation is )uiet advanced,and

continues to advance increasingly more rapidly throughout the world and is

encroaching on evremore skilled %o$s , yet during the same period general

well$eing and )uality of life of most people in the world?where political factors

have not muddied the picture @ have improved dramatically . 0hat roll automation

has played in thes e changes has not $een well studied.

A2(=#A(I=1 PI1!IP:S A1- S(A(I*I:S

2SA Principle

It is the most common and effective principle which is used very widely for

automating any manufacturing company.2SA stands for+


23/43

7.SI#PI/F the process.

.A2(=#A(: the process.

1" UNDERSTAND */ *&4 , "

(he o$vious purpose of the first step in the 2SA approach is to comprehend the

!urrent process in all of its details.

0hat are the inputsO

0hat are the outputsO

0hat exactly happens to the work unit $etween inputs and outputsO

0hat are the function of the processO

ow does it add value to the productO

0hat are upstream and downstream operation in the production se)uence and can

(hey $e com$ined with the process under considerationO

2"SIM!LIFY */ ,"

=nce the existing process is understood,then search can $egain for ways to

simplify .this often involves a check list of )uestions a$out the existing process.

0hat is the purpose of this step or this transportO

23 | P a g e


24/43

Is this step necessaryO

!an this step $e eliminatedO

!an this step $e simplifiedO

Are the unnecessary steps that might $e eliminated without detracting from

/unctionO

!an steps $ecom$inedO

!an steps $e performed simultaneouslyO

!an steps $e intergrated into a manual production lineO

3"AUTOMATE */ ,

=nce the process has $een reduced to its simplest form then automation can $e

considered.

HAI=2S P=!:SS:S I1 P=-2!(I=1 =/

(= A1- 0I: =-(: P=-2!(I=1 =/ (= A1- 0I: =- IS A!I:H:- I1

/==0I1* S(:PS+

24 | P a g e


25/43

.Billet heating in heating furnance

4.Billet pushing out of furnance

3.Billet feeding to rolling unit

5.:nd cutting

;./inal rolling unit

8.!oiling unit


26/43

(he 2SA principle of automation $eing followed in each and every step procedure

in production of tor anf wire rod.

Billets are $eing unloaded from trunks carrying.(hese heavy rectangular cross

sectional $ars are difficult to $e lifted manually.=verhanging cranes are used for

lifting purposes.(hese !ranes pick $illets from trucks $y the action of magnatic

effect and drop them to $illet cutting section.!ranes are opened $y the operator

sitting in it. 2nloading of $illets with help of crane Billets lifted with help of crane

Its an automated work as latest technology cranes are $eing used.As shown in the

picture heavt $illets are $eing lifted.(hese $illets are lifted from trucks carrying

them. =nly crane operator is re)uired for this purpose.0ith help of this automation

in $illet unloading la$oour reduction reduces up to


27/43

2"B* C**&4

After unloading of $illets they are taken to cutting section .In this section these

$illets are cut manually.!utting is re)uired for easy feed of $illets in the heating

furnance.!ranes are used for carrying $illets from unloading point to cutting

pointand from cutting point to heating furnance.

M%&% =* **&4

As shown in the picture unloaded $illets are cut manually.(hese $illets are first

marked as per re)uired si"e and are then cut with the help of gas welding.(here are

> to 4 workers involved in this cutting.Its an old techni)ue and needs automation.

M%&% =* **&4

27 | P a g e


28/43

A*


29/43

BILLET SLAB SAWING MACHINE

Advantages of $illet sla$ sawing machine+


30/43


31/43

HEATING FURNACE

(he melting point of /= is ;9 degree centigrade.

/or maintain efficient flow in $urners the temperature of this residual fuel oil is

maintained $etween


32/43

B* ;'&4 * ,&4 &*

ot $illet coming out of furnace are manually feeded to rolling units. (he heated

$illet in the furnace is in%ected out of it with the help of in%ector. (hese hot $illets

are than feeded to rolling stands manually , worker is holding the hot $illet with

holding stand and feed it to rolling stands manually. (his is most dangerous part of

hot rolling. (his part is largely prone to accidents any mishappening can result in

serious trou$le for the workers. It is an ha"ardous environment where temperature

is very high. It is difficult for worker to work here. So this part re)uires

automation.

G,%:*> M*/'

(he gravity method can $e used for automating this part of unit. /or this

purpose the heating furnace and rolling stands should $e in a single line. (he

window from furnace and rolling stands should $e in straight line. (he

window from which $illets are in%ected out of the furnace should $e raised to

a greater height. /urther this window must $e attached to rolling conveyers or

a slanting path having moving pulley attached with it, so that when the hot

$illet comes out of the window it must $e guided and directed to rolling

stands automatically without the help of any human.

A':%&*%4 ; %*


33/43

>. a"ardous environment for working of la$our is simplified and eliminated $y

automating this section

4. a$our reduction uoto > to 4 workers.

3. a"ardous environment for working of la$our is simplified and eliminated $y



;. a"ardous environment for working of la$our is simplified and eliminated $y



to 4 workers.


34/43

Simple phase motor can $e connected in either star or delta. In star the maximum

power is reduced $ut the starting current is lower then for delta In delta the motor

gives maximum power $ut the starting current is often too high and overload trip

out. (o overcome this stardelta is fittedAll 3 wires from the motor winding are

connected to the starter and the starter functions are as follows+ 0hen start $utton

is pressed the motor is automatically connected in star and the star current is

accepta$le. At the same time a tier is initiated ant after a predetermined time the

starter automatically changes from star connection to delta. (he motor now runs in

delta until switched off. (his is fully automatic starter.

F>?/

FLY WHEEL

F&*& ; ;>?/

34 | P a g e


35/43

A flywheel is heavy metal wheel attached to drive shaft, having most of its weight

concentrated at the circumference. By slowly increased the speed of a flywheel a

small motor can store up energy which ena$le the motor to perform a function for

which it is ordinarily too small. /lywheel resists change in speed and helps steady

the rotation of shaft.

0eight of flywheel is inch $illet its diameter reduces $y 9mm s). in sixth pass its cross section

area reduce to 74mm s). and it ac)uires an oval shape.

/or overheating of rollers water is $eing constantly sprayed over rolling stands. the

purpose of water is to prevent the rolling stand from damage and wearing out (he

oval shaped $illets are then allowed to pass through cutters. (he purpose of this

cutter is to provide an appropriate si"e of $illet to the next rolling stand.

:nd pieces of this $illet are cut in this process and appropriate si"e as per the

re)uirements is maintained.

35 | P a g e


36/43

0eight loss during end piece cutting+


37/43

(he final material coming out of rolling stands is made to a)uire a shape of a coil

with the help of this coiling. ed hot coiled tor and wire rod are thus $eing

manufactured at this particular point.

C&4 ; ;&/' ,'*

!oiled tor and wire rod thus $eing manufactured are allowed to cool $y keeping

them on ground. (hese are $eing cooled $y the action of atmospheric air cooling.

T?*&4 &*

!oiled tor produced $y hot rolling of $illets are then carried to twisting unit. In

twisting unit there is straightening the coiled tor and its length is maintained as

re)uired and cut as per re)uired length of tor steel depending on diameter of tor.

(he standard length pieces are then twisted $y keeping $oth the end of tor in

twisting unit. (or is twisted $y rotating the tor in opposite direction from the $oth

side. After completing the twisting the tor steel is ready for construction purposes.

37 | P a g e


38/43

(0IS(I1* S=P

38 | P a g e


39/43

TWISTING SHO!

W, ',%?&4 *&

(he wire rod so produced in hot rolling of steel $illets is now fed to wire draw

section. (he wire draw section reduces the diameter of wire rod as per re)uired. It

is so achieved $y passing wire rod through the set of rolling drums, $rushing unit

and dies.

39 | P a g e


40/43

WIRE DRAWING SECTION

40 | P a g e


41/43

WIRE DRAWING SHO!

A*


42/43

All these machine are operated manually $y the operators. It is old form of work

and lots of time can $e saved $y automating this section.

/or automating this section present day !1! machine can play a vital role.

C


43/43

/or fully automating, semi automating type hot rolling mill BPS plant no. few

ideas have $een suggested.

. Billet heating in furnace ?no need of automation@

4. Billet in%ecting out of furnace ?already automated@

3. Billet coming out of furnace ?was done manually $efore C suggested ideas

can $e helpful for automating it.@

5. #achine shop ?!1! machines can $e used for automating it.@

O:,% %=, ,'*&

4 to 49 workers

final btech me

Documents