İsdemİr erdi karaçal mechanical engineering 3rd year orientation programme report

1 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship

GAZIANTEP UNIVERSITY

ENGINEERING FACULTY

MECHANICAL ENGINEERING DEPARTMENT

ME 399 ORIENTATION PROGRAMME

SUBMITTED TO: Asist. Prof. Mehmet Akif KÜTÜK

SUBMITTED BY : ERDİ KARAÇAL

Contact Adresses: [email protected]

Phone Number: 0553 455 3779

SEPTEMBER 2013


CONTENT

CHAPTER 1 PAGES 1) DESCRIPTION OF THE COMPANY…………………………...….4

1.1 NAME OF THE COMPANY………………………………………..…..4 1.2 LOCATION OF THE ORGANIZATION………………………………4 1.3 BRIEF INFORMATION ABOUT FACTORY…………………………5 1.4 COMPANY PROFILE………………………………………………….6

1.4.1 General Information About Personel………………….……….6 1.4.2 Number of Engineers Employed………………………………6 1.4.3 Operation Capacity…………………………………………….7

CHAPTER 2

INTRODUCTION……………………………………………………..8

2.1 PRODUCTS OF FACTORY………………………………….…..9 2.1.1 MAIN PRODUCTS AND WORKING AREAS……………………..9

2.1.2 BY-PRODUCTS AND WORKING AREAS………………………...10

2.2 PRODUCTION STEPS OF PROCESSES………………………..11 2.2.1 Isdemir Harbour………………………………………………………11

2.2.2 Sintering Plant and Ore Preparation…………………………………..12

2.2.3 Coke and By-Product Plant…………………………………………...13

2.2.4 Iron Making Plants (Blast Furnaces)………………………………….14

2.2.5 Steel Making Plant…………………………………………………….15

2.2.6 BOF Shop (Basic Oxygen Furnaces Shop)……………………………16

2.2.7 Continious Casting Plant………………………………………………17

2.2.8 Rolling Mill……………………………………………………………18

CHAPTER 3 3.1 SELECTION CRITERIAS OF THE FACTORY LOCATION...…20

* Aspect of raw material

* Energy

* Transportation

* Effect of Climate

3.2 PLANT LAYOUT…………………………………………….22


PAGES

CHAPTER 4

4.1 CONTROL TECH AND PRODUCTION PLANNING……..23 4.2 ACCOUNTING………………………………………………23

4.3 PURCHASING DEPARTMENT…………………………….24

4.4 POWER PLANTS AND ENERGY FACILITIES…………...25

4.5 QUALITY AND STOCK POLICY…………………………..26 4.5.1 Definitions About Quality………………………………………26

4.5.2 Quality Control…………………………………………………..27

4.5.3 Quality Control in Production Process…………………………..27

4.5.4 Quality Policy……………………………………………………29

4.5.5 ISDEMIR Quality Management System………………………....29

4.5.6 Stock Policy………………………………………………………29

4.6 WORKERS HEALTH AND WORK SAFETY………………30

CONCLUSION……………………………………….….31

APPENDIXES……………………………………………32


CHAPTER 1

DESCRIPTION OF THE COMPANY

1.1 Name Of The Company:

1.2 Location Of The Organization:

İSKENDERUN DEMİR VE ÇELİK A.Ş.

Karayılan Beldesi

31319 İSKENDERUN / TÜRKİYE Tel : +90 (326) 758 4040 (Santral-PBX)

Faks : +90 (326) 755 1184 - 758 5351 - 758 3838 Web:http://www.isdemir.com.tr

Figure 1: General view of the İSDEMİR


1.3 Brief Information About Factory

ISDEMIR is the biggest integrated Iron & Steel Plant of our country in terms of long

product production capacity. ISDEMIR is the only integrated facility of Turkey producing

long and flat product with its 5.5 million tons/year capacity.

Integrated means that ISDEMIR produce its products by using iron ore as a raw

material. And the output product of one department’s are used to another departments.For

example when producing coil, the output of the continuous casting plant as slab is used. For

example in the coke factory when coal is heated without oxygen to making coke, lots of coke

gas are produced and these gases are collected, filtered and are used at another department.

This is the adventure of iron ore to billet, slab, sheet metal.

Long products are producing like pig iron, bloom, billet, construction steels in

international quality standards. Production is made with Coke- Sinter –Blast furnace – Steel

mill – Continuous Casting and Hot Rolling Processes.

All of the shares of ISDEMIR are transferred to ERDEMIR by Privatization

Administration with Share Transfer Agreement dated 31 January 2002 on the condition that

investments shall be made towards flat product production in ISDEMIR.(3 billion dolar

investments) Currently, 92.91% of ISDEMIR shares are owned by ERDEMİR, and 7,09% are

owned by ISDEMIR Employees Support Foundation.

ISDEMIR’s initially 2.2 million tons/year liquid-steel capacity will be increased to 5.5

million ton/year and besides long products, mainly production of flat products will be made

when Modernization and Transformation investments (MTI), planned in 2003 and initiated in

2004, are completed.


1.4 COMPANY PROFILE

1.4.1 GENERAL INFORMATION ABOUT PERSONEL

Total Number of Employees : 5571

Top Level Managers: 7

Middle Level Managers: 49

White Collar Staff : 497

Blue Collar Staff: 4442

Contractual Personal: 36

Employees with Disabilities: 119

1.4.2 NUMBER OF ENGINEERS EMPLOYED:

Figure 2:Graphics of the employees

Man:%90

Women:%10

Blue Collar:%80.2

White Collar:%19.8


1.4.3 OPERATION CAPACITY

Capacity of the main units are shown in below ;

Table -1-

Units Capacity ( ton/year ) Explanation

Harbor 12 million Handling - Unloading

Coke Plant 2 million 6 battery (over 275 oven)

Sinter Plant 2.9 million 4 Machine

Blast Furnace

Produced

Have 7.8 million Capacity

4 million

4 Blast Furnace

Aim 5 million

Pig casting machine 0.7 million __

Steel Making Plant 5.5 million Pure Steel

Continuous casting Plant 5 million 2 slab casting machine

Coil Rolling Plant 3,5 million __

Energy Facilities 220.4 MW __


CHAPTER 2

INTRODUCTION

Aim of this summer practice programme is to improve knowledge which we learned at the

university and give us a chance for practice. Summer practices provide good opportunities to

make students see the application areas of the theoretical knowledge in industry.

Third Year of my education life at mechanical engineering, orientation programme

ME399 covers the following topics;

Plant organisation and management like type of organisation

Factors taken into account for plant location for example due to staff, energy, raw

material, sale and delivery.

Storage and stock layout, quality control applications.

Auxiliary facilities like power plant of the factory

Theoretical knowledge is very important at the enginering part of a product. An

engineer must know the criteria for the proper design of the product. But theoretical

knowledge alone is not sufficient to manufacture a product. Some perfect desing might be

developed with only theoretical knowledge, but such desing might not be manufactured

because of the impossibilities on the production stage. Thus, practical knowledge has a great

importance in the education

Factory work introduces the engineering student to the real world and the actual

problems which engineers usually encounter with on of an engineer.

I have done my third orientation at Isdemir Iron and Steel Factory at the department of

Study Project Directorship.I have been there 4 weeks from the date of 26/August /2013 to

23/September /2013 as 20 workday.


2.1 PRODUCTS OF FACTORY

2.1.1 MAIN PRODUCTS AND WORKING AREAS

Main product range of ISDEMIR consists of pig iron, billet, coil, slab, hot rolled coils

and plates. Besides these products, by-products such as coke, oxygen, nitrogen, argon,

ammonium sulphate, granulated slag, coal tar and benzene are also obtained.

BILLET

Steel billets are produced via continuous casting of liquid steel, which is obtained from basic oxygen furnaces. Billet is a semi-finished product mainly used in manufacturing of wire rod, reinforcing steel bar, steel profiles and seamless pipe.

WIRE ROD

Wire rod is used in the production of commercial products such as mesh, wire, nail as well as it is used in the production of industrial products such as bolt, spring, electrode and welding wire.

SLAB

Steel slabs are produced via continuous casting of liquid steel, which is obtained from basic oxygen furnaces. Slab is a semi-finished product mainly used in manufacturing of hot rolled coil and hot rolled plate.


HOT ROLLED FLAT PRODUCTS

With the modernization and transformation investments (MTI) made, besides the long products, also flat products production started of at August 2008.ISDEMIR’s hot strip mill has a capacity of 3.5 million ton per year.

Usage: Automotive industry and ship building, can and tin production, pipe and profile

2.1.2 BY PRODUCTS AND WORKING AREAS

During steel production process, a variety of by-products are produced.ISDEMIR use some of them in the factory.

For example in the coke factory ,when making the coal as coke so many coke gases rise.Gas holders collects these gases and pumped to another department to use.

Another example is ; when producing steel ,many slags occur.Isdemir sell this slags to the cement factory.

When producing steel from pig iron sulfür content must be reduced.when doing this, sulfur is collecting and ammonium sulphate is producing.Isdemir sell this products to fertilizer (gübre) factory.

Granulated Blast Slag 500.000 tons/year (is selling to the Cement Factory) Coke coal : Melting of the pig iron for casting operations. Crude Benzene(Light Oil) (ham benzol) 30.000 tons/year (chemistry sector) Ammonium Sulphate (Fertilizer) 40.000 tons/year (is selling to fertilizer

factory) Tar (Ham Katran) 75.000 tons/year


2.2 PRODUCTION STEPS OF PROCESS

2.2.1 ISDEMIR HARBOUR

We can say that production starts with the raw materials which are transported to factory by

means of Harbour

Isdemir harbour is very important for loading export products that are produced by the

plants as well as unloading iron ore which is main raw material of factory, pollet ,coal and

fuel oil.Moreover ,Isdemir makes significant income from loading and unloading of third

party cargoes (another factory’s cargoes).Isdemir serve to customers from cities such as

Antakya, Adana, Mersin, Kayseri, Nevşehir, Niğde, Ankara, Gaziantep, Kahramanmaraş,

Malatya and Elazığ. Furthermore, loading/unloading, terminal and warehousing services

could be provided for transit trade customers.

Figure-3: Cranes and Coils Figure-4:Capacity of Harbour

Required improvement on the existing harbour is made to load products (billets ,slab

,coil ,wire road and pig iron), which will be sent to domestic and foreign markets and to

unload raw materials required by increase in productions.

Today,Isdemir harbour has 2 unit 50 tons unloading cranes, 5 unit 15 tons cargo crane

,4 unit 10 tons cargo cranes,2 unit 50 tons cargo cranes will be purchased and builded at Dock

no.4

ISDEMIR use long converyors to transport to raw material from harbour to departments.


2.2.2 SINTERING PLANT AND ORE PREPARATION

The main aims of the plant are unloading and stocking the raw materials like iron ore, pellet,

dolomite, limestone etc., reclaiming, grinding and screening of these materials, preparing

sintering mix and producing sinter, supporting Blast Furnaces and BOF Shop with these

materials.

Figure-5:General view of the sinter furnace

Ore Preparation and Blending (Mixing) Facilities enable raw materials that are

brought to Isdemir to be taken to stocks, to be ground and to be blended and the user units to

be fed by the prepared raw materials.

Ore preparation facilities consist of open stocking areas with capacity of 700,000 tons,

160,000 tons capacitated pellet stocking pool, 2 x 40,000 tons blending yards and other

stocking yards. There are 4 stocker/reclaimed machines on open stocking areas and 4 stockers

in stoking yards.


2.2.3 COKE AND BY-PRODUCT PLANT

The main function of coke factories is to produce metallurgical coke for the blast

furnaces. The plant consists of coal preparation facilities, coke oven batteries and by-products.

Figure-6: Coke plant

Coal preparation facilities (tesis) consist of open stocking areas with capacity of

480.000 tons, 4 stocker/reclaimed machines that work on stock areas, 12 coal silos that have a

total capacity of 29.600 tons, coal crashers and mixers.

The total capacity of coke batteries is 2.000.000 tons/year in dry base. Coke factories

consist of 6 batteries each has 69 furnaces. There are one coke wet (with water)quenching

station and one coke dry(with nitrogen) quenching (söndürmek) plant in order to quench the

hot coke. Crashed coke then screened and classified according to the dimensions as

metallurgical coke, coke nut(ceviz) and coke breeze (kül).

The coke gas that is produced during coking process of the coal is treated in the by-

products plant, and products such as pure benzene, pure xylene, pure toluene, solvent naphtha,

ammonium sulphate, coal tar and electrode pitch are produced. The coke gas that is cleansed

at the end of these processes is used as fuel in coke batteries and in the other units. Coke

ovens and by-products plants are intended (designed) for the production of metallurgical coke

to be used in Blast Furnaces.


2.2.4 IRON MAKING PLANTS ( BLAST FURNACES )

Figure-7: Molten metal

The main task of this unit is to produce hot metal. There are 4 blast furnaces in Isdemir

namely Cemile, Ayfer, Gönül and Dilek.As it seen that furnace’s names are woman’s

name.The aim of these is; women can bring a child to the world and this event liken to making

iron from raw material.Production capacities of Cemile and Ayfer is 2.000 tons/day for each

and the production capacity of Gönül is 3.000 tons/day, so the total production capacity is

7.000 tons/day and 2.450.000 tons/year. In order to get hot metal, sinter, pellet, lump ore and

metallurgical coke are charged into the blast furnace. Also, supplementary materials that help

slag (cüruf) formation such as limestone, quartzite, and dolomite are charged into the furnace.

Figure-8: Molten metal is poured into ladle


2.2.5 STEEL MAKING PLANT

Steel Making Plant accomodates (barındırmak) two mixers where molten metal

from blast furnaces is poured. Also employed are 200 tonnes LD converters where

conversion into steel is accomplished . Converters are first charged with steel scrap then

with molten metal from mixers in ladles (pota) . On completion of charging ,oxygen is

blown into the converter and lime as well as other flux material are added . After

accomplisment of required steel chemistry and temperature ,molten metal is trapped

into steel ladles .Meanwhile ,alloying and deoxidation elements are added.

There are two ladle metallurgy stations ,a chemical station and a electrical station

which are both used for further refining and adjustment of steel composition and

temperature.

Figure-9:Loading of Melted Pig Iron


2.2.6 BOF SHOP (BASIC OXYGEN FURNACES SHOP)

The hot metal transferred from blast furnaces to BOF shop in ladles is fed into 2 mixers,

each having a capacity of 1.300 tons, using 200 ton cranes. The mixers provide buffer (tampon)

storage of hot metal from blast furnaces and a homogeneous composition suitable for the

operation conditions of the converters. The hot metal in the mixers is heated by coke oven gas

to maintain its temperature. Each mixer is provided with a weighbridge (kantar) and a slag

removal apparatus.

Steel is produced in 3 top-blown basic oxygen furnaces (BOF), each having a charging

capacity of 130 tons. Having an annual capacity of 2.2 million tons.

The converter is first charged with steel scrap and then liquid metal transferred from the

mixers in ladles. Such elements as carbon, sulfur, silicon, manganese and phosphorus contained

in liquid metal are reduced to required levels by blowing oxygen for 17-20 minutes and adding

other supplementary materials (calcinated lime, dolomite, coke breeze, fluorite, etc.).

Lime (kireç) calcinations plant produce the calcined lime used in BOF shop. There are

6 vertical (fixed) kilns each with a capacity of 100 tons/day, all designed to obtain

metallurgical lime by calcinations of limestone. Dolomite and meerschaum are also treated in

these kilns. The Scrap Manipulation Unit has been established to prepare and store the

internally produced and purchased scrap for use in the converter.


2.2.7 CONTINIOUS CASTING PLANT

There are one electrical and one chemical ladle metallurgy stations to adjust the

quality and temperature of liquid steel tapped from the converter at required levels. The liquid

steel from the converters is poured into ladles, and directly treated in ladle metallurgy stations

(chemical and electrical), and then sent to radial continuous billet casting machines.

Figure-10: Billets

There are 2 radial continuous billet casting machines, as replacement of vertical

bloom casting machines installation in October 2003. These casting machines has square

cross sections and the billet length is torch-cut.The total capacity of the machines is 2.5

million tons/year.

In continuous billet casting machines, the steel is fed into the tundish, where it is

poured through water-cooled copper crystallizer moulds. The steel is cooled down and

solidified in the mould and the second cooling zone of the machine and shaped into billets.

There is a schematic view about continuous casting at the Appendix.


2.2.8. ROLLING MILL

In Rolling Mills, the billets from continuous casting are passed through rolling stands

to obtain semi-finished and finished products in desired cross sections and dimensions. There

is one rolling mill in Isdemir, namely Wire Rod Mill.

Figure-11: Wire Rods

The billets coming to the Wire Rod Mill are rolled into finished products

(round bars). The billets are first heated in the reheating furnaces (annealing) with a capacity

of 130 tons/hr, and then passed through the rolling stands. The capacity of the Wire Rod Mill

is 500.000 tons/year wire rods of 5.5-16 mm in coils.

The length of billets is limited with 12 meters due to the reheating furnace dimensions;

the mill can roll maximum 130x130 mm billets; consequently maximum coil weights are 1.5

tons.


Also in sheet metal producing plant the figure shows us the manufacturing steps of

production

Figure-11: Flow Chart of Hot Rolling


CHAPTER 3

3.1 SELECTION CRITERIAS OF THE FACTORY LOCATION

Figure-12: Factory Location

İSDEMİR is located in Yakacık, 17 kms to İskenderun, the center of the Southern

Anatolia Industrial Zone, near to highways, railways and marine transportation facilities in

one single point. Its surface is 16.75 million m together with social facilities (plant surface is

6.8 million m2).

İSDEMİR is located on İskenderun Industry Region and there are many factories and

corporation with it. These provide good interaction opportunities between companies and

many chances at production levels.


In addition to, İskenderun near to market of Middle East is advantage.

Aspect of raw material: İsdemir uses pellet,lump iron,concentrated iron and

iron ore as raw material.This type of materials are produced in

Divriği/Sivas,Hekimhan/Malatya and Russia. It can easily transport by big

harbor railway and highway.

Energy: İsdemir does not have any problem about energy such as electricity

from Çukurova Company and self plant production, sea water from

Mediterranean sea, coke and natural gas. ln Industrial Region, these are enough

infrastructure to get these type of energy and the public has taken necessary

precautions .In this way, İsdemir has suitable place for continuous production.

Transportation: İsdemir Region has highway, railway and big one harbor.

İsdemir usually sent its products by big these ways.In the factory 80 km

railway are built and this railways are used to transport materials departments

to departments.And also these railways connecting to TCDD line.

Effect of climate: Climate of İskenderun have advantage and disadvantage.

Hot weather is advantage to storage of raw materials. As well as, this weather

is disadvantage for workers in working facilities.

Products of Isdemir are sold in domestic markets and exported to Middle East,

Europe, Asia, Africa countries and to the USA.


3.2 PLANT LAYOUT

The plant layout facilitates the arrangement of machines, equipment and other physical

facilities in a planned manner.Plant layout differs from plant to plant, from location to

location and from industry to industry. But the basic principles governing plant layout are

more or less same.

Isdemir is designed according to Process Type of Layout because in this factory they

are producing a lot of type products.

In this type of layout ,machines of a similar type are arranged together at one place.

ISDEMIR have lots of departments. Totally we can accept the factory has process type

of layout. But when we analyse the departments individually, They are arranged to another

type of layouts.For example when we analyse the sheet metal production unit we can say that

this department is producing one type of product as called sheet metal in totally one long line.

The grouping of machines according to the process has to be done keeping in mind the

following principle:

The distance between departments should be as short as possible for avoiding long

distance movement of materials.In Isdemir railways help the movement of materials.

Advantages: Process layout provides the following benefits;

The overhead costs are relatively low

Breakdown of one machine does not result in complete work stoppage


CHAPTER 4

4.1 CONTROL TECHNIQUES AND PRODUCTION PLANNING

Plans and procedure of the all applications which are done in this organization, are created

by planning department. The production plan of the order, which is coming from selling

department, is done by the planning department. The production plan includes what kind of

raw material needed, calculation of the amount of needed raw material, package material; to

produce the order. Calculation of production time or how many machines and which ones in

the production line must be used according to the delivery period; are included in the plan.

The hardware and software settings accordindg to the order are contained in the plan.

Planning department not only plans the production activities but also plans the

maintenance activities,quality control activities and general medikal check up activities.

Every kind of controls are done according to an annual plan which was done

beforehand.Controls are classified like these daily, weekly, monthly from the point of view

of the time.

Some controls that are done in this organization are;

Software settings of the machines on the production line,

Hardware settings of the machines like, gear’s number, roller’ number,

Machine’s output data sheets,

Imperfection of the raw material,

Wasted material at the production time,

4.2 ACCOUNTING

The accounting department maintains this company’s financial records. Also, it provides

information and services on the followings;

1. Cost accounting

2. Financial reports

Financial reports generally include financial position of the organization and the process of

the getting money from a bank or somewhere for a new project.


4.3 PURCHASING DEPARTMENT This department aims to procure materials at required time and place, with minimum stock level, reasonable cost, sustainable competitive approach and long-term cooperations. Accordingly, Purchasing Department operates procurements covering all of the following processes excluding raw material and service:

Procurement of steel scrap, refractory materials, ferroalloys, fuel-oil products, mineral oil, dyes-chemical materials, machine components and other general consumables from domestic and foreign resources.

Domestic and international transportation of materials, customs clearance and warehousing operations, delivery to our plant.

Raw Materials Purchasing

Raw Material Purchasing Department is working with a head of Vice President Purchasing for purchasing raw material as iron ore, coal, manganese etc.

Raw materials as iron ore, coking coal, metallurgical coke, manganese, manganese with iron, quartzite, dolomite, limestone, silica send, dunite, magnesite, metallurgical lime are purchasing from domestic or imported resources with sea way, rail way or high way transportations. Raw Material Purchasing Department also making deals with contracting firms for exploiting licenced mines of ISDEMIR.

Raw Material Purchasing Department work in a coordination with concerned departments in order to take necessary precautions while purchasing, using and stocking of raw materials and auxiliary raw materials. Stock levels and analyses values of raw materials and auxiliary raw materials are followed up constantly. All prepared reports are submitted to concerned departments.

Raw material and auxiliary raw material requirements of ISDEMIR;

Iron ore are purchased from foreign countries and domestic suppliers. Our domestic supplier are; ERDEMIR Maden and other companies which have licence belong to third people.

Coking coal, metallurgical coke, pulvarised injection coal and anthracite are purchased from foreign countries (Australia, China, U.S.A., Russia, Canada, Poland)

Limestone, dolomite, quartz, dunite and silica sand from ISDEMIR’s licenced mine areas.

Manganese, ferromanganese and magnesite from domestic suppliers Metallurgical lime from domestic rolling mills and factories near surroundings of

ISDEMIR.


4.4 POWER PLANTS AND ENERGY FACILITIES

In these plants, distilled water, steam and electricity, blast air, oxygen, nitrogen,

compressed air requirements of production facilities are produced, blast furnace gas is

cleaned, blast furnace and coke oven gas are distributed. LPG, argon, nitrogen and oxygen are

procured and stored in liquid phase, and distributed in gas phase.

The annual installed capacity of power station generating electricity is 1.1 billion

kWh. Furthermore, the power station is also designed so as to be supplied by national

interconnected network. The power station is equipped with 2 x 25 MW, 3 x 55 MW and 1 x

5.4 MW turbo-generators. The steam required for the generators is supplied by 5 steam

boilers each with a capacity of 220 tons/h.The blast air for blast furnaces is supplied by 3

turbo blowers each with a capacity of 2,900 m3/min. and 2 turbo blowers each with a capacity

of 3,600 m3/min.

The oxygen plants consist of 5 oxygen blocks each with a design capacity of 4.850

m3/h. Oxygen production up to a purity of 99.5% is mainly transported to the converters in

BOF shop department and other units of the facilities through pipelines, but may also be

contained in oxygen cylinders to meet the requirements of the works and market. Besides,

nitrogen is also obtained in the plants up to a purity of 99.

Water Facilities

Fresh water from Mersin çayı 5500 m3/hour

Fresh water from Aslantaş barajı 3500 m3/hour (since 2009)

Drinkable water 400 m3/hour

Sea Water 57500 m3/hour


4.5 QUALITY AND STOCK POLICY

4.5.1 DEFINITIONS ABOUT QUALITY

Isdemir uses some terms when defining the problem.

K1 Quality: Products should be equivalent to products in Isdemir cataloque which is

designated the criterias of national and international quality standars. Also products should

meet the expectations (beklenti) of buyers. Tolerance values, limits and specifications can be

changed from one buyer to another one.

Divert: Deviation (sapma) of specification values while producing steel.

Dispose: Deviation of specification values while block or wire rod is being checked.

Quality Stoppage: Loss of feature on product’s surface compared with specification

values, standarts and tolerances.

K2 Quality: Deviations of specification values, standarts, and tolerance of products on

surface, body or modal.

K3 Quality: If any dimension of the product is not proper to tolerance values or any

problem of K2 included to this.

Manufacturing Practice Code ( MPR ): Special number given to products while quality

control process.


4.5.2 QUALITY CONTROL

Quality control management makes the quality control in Isdemir. They are

responsible for: analysis and control of raw material, semi products, and final products

according to standarts. Also they do phsical and chemical tests.Preparation of specification

cards of final products coordinated with related department.Preparation of manufacturing

process cards of alloys, pigs, and steel.

4.5.3 QUALITY CONTROL IN PRODUCTION PROCESS

Sulphur removal-- Pig Casting--Steel Production--Continuous Casting--Control Area--Wire Rod Mill( Bobbin )-- Storage/Delivery

Production process is carefully controlled for best quality from start to delivery of

product. If any problem occur in process , this is reported to quality control engineers and

then precautions are taken. After final product produced its either checked without destruction

or a sample is taken for physical and chemical tests. If there is not any problem on products

quality it is delivered to buyers else it is used as second quality or recycle material.

I have also been at the quality control labrotary.They use very long steel pipe which

are built from department to department.This pipe is used to send the specimen to labrotary

with Pneumatics pipeline.This is very useful for shorten the controlling time of specimen.


ISDEMIR laboratories operates internationally to service specializing in the analysis of a variety of sample types (soil, sediment, rock cuttings, raw materials, lime stone, iron ore, slags, sinter, ferro alloys, refractories, coal, initial product, in-process product and finished product steel). ISDEMIR plants provides to companies and customers with a broad range of laboratory services from raw material to finished product analysis. ISDEMIR laboratories have TSE Laboratory Certificate of TS EN ISO/IEC 17025 that is; the general requirements for the competence of testing and calibration laboratories.

ISDEMIR laboratories provide following list of services:

Raw Materials Analysis

Lime stone Iron ore Coal, slags Ferroalloys Refractories Fe-Ti & Ca-Si cored steel

These analysis are made by using XRF spectrometer, ICP & AAS machines.

Initial - In process - Final Products Analysis

Pig iron Billets Wire rods Slab Coil Hot rolling roll and plate

These analysis are made by using Optical Emission Spectrometers and also N-H-O elements can be determined by LECO.

Physical & Mechanical Tests

Physical Tests

Breaking Grinding Elimination Resistance Density

Mechanical Tests

Pull Tilt Hardness Press Shock

Physical & mechanical tests are made according to the type of the material.

Technological & Metallurgical Tests

Technological Tests

RUL test LTD test RDI test FSI test

Metallurgical Tests

Microhardness Grain size Inclusions Impact Ultrasonic

Technological tests are made by RUL test, LTD test, RDI test and FSI test machines. ISDEMIR provide a comprehensive range of metallurgical and mechanical testing services with a dedicated machine shop to provide specimen preparation.


4.5.4 QUALITY POLICY

Improve company to produce best goods by using Total Quality Management System.

Manage the company by targets and use sources effectively.

Focus on work based on consumer.

Consider about education and innovation.

Try to be different.

4.5.5 ISDEMIR QUALITY MANAGEMENT SYSTEM

Isdemir use 5S for better working conditions, higher work safety, lower technical

problems, lower expenditure, and to include every personnel to specific steps of every work.

5s name coming from Japanese;

Seiri – clearing up Seiton—organization Shitsuke – discipline

Seiso – cleaning Seiketsu – standardizing

They use this in every work area of the company. A comission from general

management control every deparment. They look at cleaning, check stored paper if they are in

order or not, in work areas if kits are in order or work safety is done or not, etc. Then every

worker are taken into an exam. After this successful departments are taken gold and silver

flags.

4.5.6 STOCK POLICY

Isdemir uses two kind of storage policy. Reserved and unreserved raw materials.First

demand is created by the organization for unreserved materials. Storage control management

to this job. Then demand for buying is created. After Material management leader confirm

this, department of purchasing take the control. They search the market and at least 10 offers

are taken. The best offer hitch is economic and has enough quality standards. After this

purchasing finish and materials transfer to the related unit.

In reserved materials first material is taken from the storage and stock control is done.

According to number of materials stored they decide to buy or not to buy another one instead

of used one. Then demand for purchasing is created by stock control management.

Department of purchasing take the control after confirm of material management leader.

Again market search is done and material is purchased. At least material is stored again.


4.6 WORKERS HEALTH AND WORK SAFETY

As ISDEMIR Their Occupational Health and Safety Policy is;

To recognize our employees as the most valuable resource of our company by adopting the “Human First” and “Zero Accident” concepts, to provide a healthier and safer work environment.

To obey the current laws, rules and regulations in the scope of “Occupational Health and Safety”.

To implement TS 18001 Occupational Health and Safety Systems that set in ISDEMIR and to assure the sustainability of this system.

To consider the “Occupational Health and Safety” concept as a first priority in all activities.

To enhance the consciousness level of our employees by realizing training and other improving activities and to progress behaviour change in a positive way in the scope of Occupational Health and Safety matters.

To cooperate with the companies in our region, to be involved in an organization which enables common interference to the disasters and emergency situations.

To minimize the occupational health and safety risks and to prevent occupational injuries and illnesses in our company and improve the system in a continuous way by utilizing new technologies and using resources efficiently.


CONCLUSION

I completed my orientation programme at ISDEMIR which is one of the biggest and integrated factory in Turkey..ISDEMIR has huge production area.I have never been such a big factory before.Over 5000 people are worked there.Their coordination is very hard.Lots of department and lots of people focus on production.I am very happy to been there.Twenty day was not enough to travel all of the departments.Isdemir is huge factory.

I have done my orientation programme at the department of Project Directorship and as a unit of Mechanical Spare Part.

In my department 7 mechanical engineers work.I also realize that in Isdemir about 40 percent of engineers are graduated from Gaziantep University.Wherever I went in the factory there was an engineer who is graduated from Gaziantep University.I am very lucky because there is 4 engineer who are graduated from my university in my department.So many times I talked with them.This is very strange because they are graduated from my university before 10 years or 15 years and they recognize our teacher.One of engineers said me IS MR. BAYSEC is stil there I said him yes he is stil there. They give me good advice about my future life after graduation from my university.

I have been lots of departments due to chance of been Project Directorship.Engineers who work in this department is improved themself about design and development.I also improve myself about computer programming which they use there, like Solidworks and Autocad Mechanical.I have drawn lots of mechanical parts which are comes from departments.They are drawn in my department to make mechanical spare part.Engineers in my department make analyses and they work on how to improve the design.

I think this orientation programme will be very useful for my future life.I also realize that each lessons which we learn in university connect with practical area.


APPENDIX

Production of Molten Steel Schematically


Principle of Continuous Casting


Figure:- Dust collector Fan of Coke Factory

İsdemİr erdi karaçal mechanical engineering 3rd year orientation programme report

Education

factory isdemir

shares of isdemir

isdemir shares

production of flat products

isdemir harbour11

products of factory

long products

operation capacity capacity