Presentation

Presented by- Mr. Neeraj sharma Mr. Pawan Kumar Roy

Plant Locations

Sahibabad

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HISTORY

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Q&SHE Management Certificates

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PROCESS ROUTE – SAHIBABAD PLANT

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MILLS SPECIFICATION

MILLS (Sahibabad l t) MAKE Max.width

( )Max.I/P-

thi k ( )Min. O/P-

thi k ( )Max.speed

( )Annual line

it (MTS)plant) MAKE (mm) thick (mm) thick. (mm) (mpm) capacity (MTS)

6HI-CRM(WIDER) HITACHI JAPAN 1700 6 0.17 1200 300000(Excluding

24000 skinpass)JAPAN 24000 skinpass)

6HI-CRM(WIDER) CMI(FPE) 1335 4 0.17 1200 222000

6HI-CRM(WIDER) CMI(FPE) 1090 4 0.088 1200 168000

4HI-CRM(NARROW) CMI(FPE) 550 5.5 0.2 450 60000

4HI-CRM(NARROW) CMI(FPE) 550 5.5 0.2 650 66000

8,16,000, ,

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Name of Steel Plant TATA STEEL BSL LIMITED SAHIBABAD

Techno-Economic Parameters of 6HI-HITACHI Rolling Mill

Name of Rolling Mill 6 HI HITACHI(1700 mm)

Design capacity of Mill, MT 300000(EXCLUDING 24000 SKINPASS)Brief description of facilities at the Mill ASC, AGC, AISD,ASD, SHAPEMETER, SPOT COOLINGProduct mix CRCA APPLICATIONS & CRFH FOR CGLSize range of input material mm 1 8mm TO 6 0 mmSize range of input material, mm 1.8mm TO 6.0 mmSize range of finished products, mm 0.170 mm TO 4.00 mm

Parameters for all mills 2017-18 2018-19 (Apr-Dec’18)Production, MT 267871.586 210520.925Availability % of calendar hour 100 00 100 00Availability, % of calendar hour 100.00 100.00Utilisation, % of available hour 72.86 74.73Rolling rate / production rate, t/hr 41.97 42.69Yield, % 96.95 96.95Specific fuel/heat consumption, GCal/t - -Specific power consumption kWh/t 69 77 64 73Specific power consumption, kWh/t 69.77 64.73Specific water consumption, m3/t 0.048 0.048Specific roll consumption, kg/t 0.032 0.030Specific lubricant consumption, l/t 0.018 0.025Specific rolling oil consumption, l/t 0.638 0.597Quality diversion % NIL NILQuality diversion, % NIL NIL

Parameters for specific mills/linesProportion of high strength steel (YS>550 MPa), %

NOT APLICABLEProportion of normalised plates in plate mill, %Proportion of hot charging in reheating furnace %

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Proportion of hot charging in reheating furnace, %Cobble in hot strip mill, %Specific acid consumption in pickling line, kg/tSpecific zinc consumption in HDGL, kg/t

Name of Steel Plant TATA STEEL BSL LIMITED SAHIBABAD

Techno-Economic Parameters of 6HI-FLAT Rolling MillName of Steel Plant TATA STEEL BSL LIMITED SAHIBABADName of Rolling Mill 6 HI FLAT (1050 mm)Design capacity of Mill, MT 168000 MTBrief description of facilities at the Mill Auto gauge control(AGC), Auto slow down(ASD)Product mix GALVANIZING(TRADE, OEM),GALUME(BARE GALUME, CCL),CRFH(BP

SHEET) CRCA(STAMPING GRADE)SHEET),CRCA(STAMPING GRADE)Size range of input material, mm 1.8 mm TO 4.0 mmSize range of finished products, mm 0.088 mm TO 1.975 mm

Parameters for all mills 2017-18 2018-19 (Apr-Dec’18)Production MT 134214 180 121955 870Production, MT 134214.180 121955.870Availability, % of calendar hour 100 100Utilisation, % of available hour 66.09 77.19Rolling rate / production rate, t/hr 23.22 23.96Yield, % 96.68 96.99Specific fuel/heat consumption GCal/t - -Specific fuel/heat consumption, GCal/t - -Specific power consumption, kWh/t 90.26 86.34Specific water consumption, m3/t 0.031 0.038Specific roll consumption, kg/t 0.082 0.063Specific lubricant consumption, l/t 0.043 0.051Specific rolling oil consumption l/t 0 360 0 350Specific rolling oil consumption, l/t 0.360 0.350Quality diversion, % NIL NIL

Parameters for specific mills/linesProportion of high strength steel (YS>550 MPa), %

NOT APLICABLEProportion of normalised plates in plate mill, %

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NOT APLICABLEProportion of normalised plates in plate mill, %Proportion of hot charging in reheating furnace, %Cobble in hot strip mill, %Specific acid consumption in pickling line, kg/tSpecific zinc consumption in HDGL, kg/t

Name of Steel Plant TATA STEEL BSL LIMITED SAHIBABAD

Techno-Economic Parameters of 6HI-FLAT Rolling MillName of Steel Plant TATA STEEL BSL LIMITED SAHIBABADName of Rolling Mill 6 HI FLAT (1335 mm)Design capacity of Mill, MT 222000 MTBrief description of facilities at the Mill Auto gauge control(AGC), Auto slow down(ASD)Product mix CRFH FOR CGL & CRCA APPLICATIONS

Size range of input material, mm 1.8 mm TO 4.0 mmSize range of finished products, mm 0.17 mm TO 2.010 mm

Parameters for all mills 2017-18 2018-19 (Apr-Dec’18)Production, MT 223804.982 186720.223oduct o , 223804.982 186720.223Availability, % of calendar hour 100.00 100.00Utilisation, % of available hour 78.23 82.59Rolling rate / production rate, t/hr 32.79 34.25Yield, % 96.75 96.61Specific fuel/heat consumption GCal/tSpecific fuel/heat consumption, GCal/t - -Specific power consumption, kWh/t 79.86 75.86Specific water consumption, m3/t 0.0432 0.0387Specific roll consumption, kg/t 0.079 0.065Specific lubricant consumption, l/t 0.028 0.026Specific rolling oil consumption, l/t 0.384 0.317Quality diversion, % NIL NIL

Parameters for specific mills/linesProportion of high strength steel (YS>550 MPa), %

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g g ( )NOT APLICABLEProportion of normalised plates in plate mill, %

Proportion of hot charging in reheating furnace, %Cobble in hot strip mill, %Specific acid consumption in pickling line, kg/tSpecific zinc consumption in HDGL, kg/t

PRODUCT RANGE

COLD ROLLED STEEL COILS / SHEETS

•THICKNESS ( MM ) 0.10 TO 4.0 MM

•WIDTH 10 TO 1700 MM

•CUT-TO-LENGTH UPTO 4500 WITH TOLERANCE OF +2/-0 MM.

•COIL WEIGHT(MT) UPTO 30 MT (7 TO 18 KG/MM)

•SURFACE FINISH SUPER BRIGHT, BRIGHT, DULL & MATT. (RA VALUE WITH CONTROLLED RMAX ON REQUEST )(RA VALUE WITH CONTROLLED RMAX ON REQUEST.)

•GRADES EDD/DD/D, IF STEEL FOR OUTER SKIN PANELS(JSC-270 CC & EN), HIGH TENSILE , STEEL LIKE JSC440,SPC340/390 FOR AUTOMOBILES.MEDIUM & HIGH

CARBON CORROSION RESISTANT MC 11 MC 12 CORTAN STEEL STAMPING GRADESCARBON, CORROSION RESISTANT,MC-11,MC-12 ,CORTAN STEEL,STAMPING GRADES.

•ALL OTHER GRADES AS PER CUSTOMER’S SPECIFICATION / REQUIREMENTS CAN BE MANUFACTURED.

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PRODUCT RANGE

GALVANISED COILS / SHEETSPLAIN SKIN PASSED CORRUGATED HLGP FOR FUEL

TANK

THICKNESS (mm) 0.10 ~ 2.00 0.30 ~ 2.0 0.12 ~ 1.20 1.2 ~1.60

WIDTH (mm) UP TO 1350 UP TO 1350 660 762 800 900 UPTO 1250WIDTH (mm) UP TO 1350 UP TO 1350 660, 762, 800, 900, 1050

UPTO 1250

CUT-TO-LENGTH (mm)

UP TO 4500 UP TO 4500 UP TO 4100 UP TO 2500

SURFACE FINISH REGURLAR & MINIMUM SPANGLE

MATTE WITH ZERO / MINIMUM SPANGLE

REGULAR SPANGLE

ZERO SPANGLE MATTE

COATING MASS 40 ~ 300 40 ~ 300 40 ~ 300 DIFFERENTIALCOATING MASS (Gms/m²)

40 300 40 300 40 300 DIFFERENTIAL COATING 30/30 GSM

GRADES SOFT / LOCK FORMING

EDD, DD, & D (SPCEN, SPCD, &

ROOFING IF

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( , ,SPCC)

OUR ROLLING STRENGTH

Depending on the product mix, our single stand cold rolling mills can deliver rolling capacities up to

816000 MTS/Annum and width up to 1700mm.

Rolling schedules can be carried out with an even or odd number of passes to maximize millRolling schedules can be carried out with an even or odd number of passes to maximize mill

availability and performance.

The Universal Crown Control Hitachi mill (UCM mill) with work roll bending, intermediate roll

bending, intermediate roll shifting and all straight roll application ensure enhanced flatness control.

Also strip flatness measuring equipment ( shape meter rolls) mounted at both ends of the mill

( ) fcombined with multi-zone work-roll cooling(spot coolant system) to meet the highest demands for

flatness and this works with Auto shape control (ASC).

Minimum off-gauge length (Advanced Auto gauge control (AGC) system).Minimum off gauge length (Advanced Auto gauge control (AGC) system).

Flexible ,low-cost rolling of wide range of products, especially for small order lots.

High surface quality.

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MILESTONES ACHIEVED IN SKINPANEL JOURNEY BY TSBSL

• Supplies started for Tata Motors Indica car for Outer Skin Panels.

• Commercial Supplies started

• Angul HR plant approved for supplying auto grade HR

• Lab Approval obtained for all

d f • Commercial Supplies started for MUL & Honda

• Supplies started to all major auto manufacturers like Hyundai,M&M,A.Leyland

grade HR Supplies to Sahibabad Plant

auto grades from SMC ( Japan)

19981999 2000 20152008 2016-17 2018

• First Supplies to Tata LCV unit in

• Supply started to Daewoo Matiz in SPRC35 & IF grade.

• Supplies started for Honda Brio & Amaze Car for Outer Skin Panel

• Regular Supplies started from Angul HR

EDD , IF Grade • For Outer Skin Panel Plant approved by MUL

Outer Skin Panel From Sahibabad Unit

gSubstrate to MSIL

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PRODUCT MIX

3 % 7 % 1.5%

CRCA51 5%

3 % 7 %

CRCAGPGALUMECCLH&T

51.5%36 %

H&T

Base on Data of Sahibabad works

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OPERATING CHALLENGES

ROLL MARK/SOFT SPOTRoot cause-a> Iron particles pickup on work rolls.

Control a> Minimized by using filtration system (magnetic separator /paper filter)Control- a> Minimized by using filtration system (magnetic separator /paper filter)

COOLANT PATCH Root cause- a>Inadequate wiping or blowing to remove excess emulsion.

b>Scum in coolant .

Roll mark/soft spot

b Scu coo a t

C t l > M i t i i ffi i t f i i i /bl iControl- a> Maintaining sufficient pressure for air wiping/blowing.

b>Using cationic oil for emulsion for low scum formation.

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Coolant patch/emulsion mark

ROLLED IN SCALERoot cause-a>Inadequate preliminary de-scaling or pickling of HR coil.

Control—a>Line speed of pickling has been reduced to 30 to 60 mpm ,depending on grades and

sources for removal of proper oxide layer and foreign particles(visual inspection) .

PINCH / SHADE MARK Rolled in scale

Root cause—a> Over rolling

b> HR gauge variation/ lack of strip flatness.

Control—a>Auto gauge contro (AGC) ,Auto shape control(ASC).

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Pinch/shade mark

SCRATCH MARKRoot cause-a>pickup of metal chips on pressure pad

b>Any projected part in the lineb>Any projected part in the line.

Control- a>Inspected pressure pads and mill during every roll change.

RUSTY

Root cause- a>coolant carryover on strip

Scratch mark

Root cause a>coolant carryover on strip

b> High chloride & low PH of coolant.

c> High air humidity and long storage times.

C t l M i t i i i i iControl- a>Maintaining proper air wiping pressure.

b>maintaining coolant parameters, by testing at the interval of 8 hrs.

c>Coil processed at ECL line with in 8 hrs and after annealing all coils stored

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in Kathabar (maintaining humidity ). Rusty mark

CHATTERING MARKS

Root cause—a>Vibration due to sudden speed change.

b>developed during grinding process(on work roll)

control- a> Auto slow down(ASD).( )

b> proper inspection at Roll grinding machine.

SAW EDGESAW EDGE

Root cause—a>Improper trimming at edges prior to rolling.

Control- a> proper trimming at HRS line( by proper gap setting).

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Saw edges

SAMPLING PROCEDURES

Cut three sample from each coil, of 1.5 meter in length & full width of coil after 2.0 meters from roll bite for oil stoning(Below 0 9 mm thickness and visual inspection for thicker gauges)

FOR SURFACE DEFECTS

for oil stoning(Below 0.9 mm thickness and visual inspection for thicker gauges)

FOR PHYSICAL/ MECHANICAL PROPERTIES

Cut another one sample from each coil, of length 300 mm for physical & mechanical testing. All the samples should have the following information

a) Top & Bottom position b) Front & rear Positionc) rolling directiond) Coil IDe) Size & Grade of coilf) Customer Name .g) For skin panels this sample should be cut after cutting above three samples of 1.5 meters

All Inspection records are considered at Finishing Lines.

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TESTING FACILITIES

• SPECTROMETER FROM HYLGER, U.K. (FOUR ALLOY BASE).

• FULLY COMPUTERISED UNIVERSAL TESTING MACHINE FROM ZWICK,GERMANY

FOR MEASUREMENT OF Y.S., U.T.S, %E, R VALUE, n VALUE, YPE, U.E., , , , , ,

• METALLURGICAL MICROSCOPE AXIOVERT GERMANY UPTO 500X MAGNIFICATION .

• FULLY COMPUTERISED MICRO HARDNESS TESTER FROM ZWICK GERMANY.

• AUTOMATIC SURFACE ROUGHNESS TESTER FROM HOMMEL GERMANY

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• AUTOMATIC SURFACE ROUGHNESS TESTER FROM HOMMEL,GERMANY.

• RAPID DRAWABILITY TESTER, R MODULE FROM TINUS OLSEN U.S.A.

SURFACE QUALITY IMPROVEMENT

STEPS TAKEN TO IMPROVE SURFACE QUALITY OF ROLLED PRODUCT

Mill Cleaninga) Mill housing as well as mill pan cleaning manually after every 2 months.) g p g y y

b) Using of emulsifier along with emulsion just before emulsion dumping to avoid sludge sticking

the emulsion pipelines and in emulsion tank through recirculation of emulsion through mill

c) Using of cleaner along with emulsion just before emulsion dumping to avoid sludge sticking thec) Using of cleaner along with emulsion just before emulsion dumping to avoid sludge sticking the

emulsion pipelines and in emulsion tank through recirculation of emulsion through mill

d) Using of cleaner for cleaning mill housing and other auxiliary equipment’s to clean sludge stuck to

avoid emulsion droplets

Emulsion flowa) Regular cleaning of emulsion nozzles to avoid nozzles chocking and to ensure full emulsion flow.

b) Regular observation on leakage of emulsion from hose pipes and immediate changing with new one

c) Changing of operating of spray pumps to avoid load in single pump

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Optimization of operation of Magnetic separater & Paper filter

a) Iron and cleanliness level of emulsion plays great role on surface quality of rolled high end CRCA

products from the millproducts from the mill.

b) Optimized operating frequency of operation of magnetic separator and paper filter through lot of

exercise and fixed the operating time( 15 mins ON and 45 mins OFF)

c) We have ensured running of paper filter in auto mode to avoid manual intervention and changing of

filter paper.

d) Regular monitoring and frequent cleaning of outlet of magnetic separator to ensure discharge of

scrapped sludge outside of the tank

e) Fixed cleaning frequency of cleaning of self cleaning filter to avoid ingress of higher emulsion particles

in to the emulsionin to the emulsion

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Using of Cationic rolling oil

a) To avoid frequent cleaning sludge deposited due to very high matt rolling on deflector and shape

meter rolls rolling oil has been changed from Non ionic to cationic oil for better detergencymeter rolls, rolling oil has been changed from Non-ionic to cationic oil for better detergency.

b) Keeping emulsion always in loose range with help of top up of specified parameters of DM water

and proper emulsion tank level.

c) Operating of magnetic separator on desired frequency to avoid excess iron in emulsion which

changes the characteristics of emulsion behavior

d) Top up of rolling oil in regular intervals to avoid variation in oil concentration for consistency in ) p p g g y

rolling parameters

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BENEFITS TO CUSTOMERSEXCELLENT MECHANICAL PROPERTIESEXCELLENT MECHANICAL PROPERTIES • Practically, No variation in mechanical properties due to 100 % hydrogen annealing furnace .

•The raw material selection is done by computerized program for different applications, close tolerances

thi k idth d l thon thickness, width and length

•Radioactive isotopic thickness gauge to measure thickness to a fraction of a micron.

•Radiometric thickness checking across the width.

•Automatic computerized thickness control.

•Shim less tooling on slitting lines with computerized setting ensures correct width in close tolerances .

•Precision cut- to – length lines to ensure length tolerances better than 0.75 mm.g g

•Automatic electromagnetic stacker on shearing lines to produce scratch free steel OTHER ADVANTAGES•Better width combination facility to customers, Higher yield in standard width material .y g y•Thickness , length and width tolerances as per customer requirements .The equipment is capable

enough to maintain all these tolerances to the lower side of International standards like JIS , BS , ASTM

and DIN .

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•The largest service centre in the country available to accept the orders in different sizes and service

the same in shortest possible time .

CLIENTS

"Our mission is to grow our company by providing innovative strong and high performance products and solutions to meet our global customer needs."

Our Products continue to be a favourite with all quality conscious users of Automobiles & White Goods/Domestic

Appliances & General Engineering Industries. We take great pride in maintaining the highest standards of quality which

our customers expect and it is no wonder that eminent corporate like Honda Siel Cars, Telco, Hindustan Motors , General

Motor, Hyundai Motors, Ford Motors, Mahindra & Mahindra, MSIL, Eicher Tractors, Ashok Leyland, LG

Electronics, Whirlpool, Videocon, Daikin Shriram, National Matsushita, Samsung

Electronics, Godrej, Voltas, IFB, Fedders Lloyd, Carrier Refrigeration, Electrolux Group, Hitachi Air conditioners, SKF

Bearing, Crompton Greaves, Philips India, BHEL, Alstom Limited, L&T, BPL, GE Motors, Johnson Lift, Kone

Elevator Lucas TVS NRB Bearing Harsha Engineers Limited Bundy India Limited Tecumseh Bajaj Auto HondaElevator, Lucas TVS,NRB Bearing, Harsha Engineers Limited, Bundy India Limited, Tecumseh, Bajaj Auto, Honda

Motorcycle, Yamaha, Bajaj Tempo and so many such big organizations continue their unbounded trust on us and

regularly sourcing our products.

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THANKS

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