INTERNSHIP REPORT –Ι

SUBMITTED BY :

PRASHANT RANJAN 11EEO15

INTERNSHIP – Ι

AT

BHUSHAN STEEL LTD.

LINGAYA’S UNIVERSITY,FARIDABAD

SESSION 2011-2015

ACKNOWLEDGEMENT

Every Work big or small is successful largely due to the effort of a number of wonderful people who have always given their valuable advice or lent a helping hand. I sincerely appreciate the inspiration; support and guidance of all those people who have been instrumental in making this internship a success.

I,  PRASHANT RANJAN, the student of LINGAYA’S UNIVERSITY(EEE), am extremely grateful to “BHUSHAN STEEL” for the confidence bestowed in me and entrusting my six month internship.

 At this juncture I feel deeply honored in expressing my sincere thanks to MR. ANCHIT TIWARI at the company for making good information about the process under going in the company  and providing valuable insights leading to the successful completion of my six month internship.

 I express my gratitude to College Director  for arranging the summer training in good schedule. I also extend my gratitude to my mentor Guide MR. RAKESH CHOUDHARY , who assisted me in compiling the internhip.

I would also like to thank all the faculty members of LINGAYA’S UNIVERSITY for their critical advice and guidance without which this internship would not have been possible. Last but not the least I place a deep sense of gratitude to my family members and my friends who have been constant source of inspiration during the internship.                                                                                        

ABSTRACT

In today’s world, Bhushan group has a commendable presence in India among the leading industrial houses. Since 1987, Bhushan steel ltd. has epitomized itself as a pioneer in product innovation and technological upgradation.

The company now commands an enviable positions of having India’s one of the best steel manufacturing plants, production of steel sheet up to a width of 1700mm, as well as Galvanized Coil and Sheet up to a width of 1350 mm.

Bhushan group is constantly on the lookout for advanced technology assimilation for product development and innovation. Product process optimization and benchmark itself with world class quality products and customer service have made the group highly competitive, reliable and efficient.

CONTENT

Acknowledgement

Abstract

Content

1. CHAPTER 1 : INTRODUCTION

1.1 ABOUT BHUSHAN STEEL LTD.

2.CHAPTER 2 : THEORETICAL PROCESS

2.1 SAFETY

2.2 PICKLING/HRS

2.3 HITACHI MILL

2.4 ECL (ELECTROLYTIC CLEANING LINE)

CHAPTER 1

INTRODUCTION

CHAPTER 1.1

BHUSHAN STEEL.

Bhushan Steel Ltd formerly known as Bhushan Steel & Strips Ltd. is a globally renowned one of the leading prominent player in Steel Industry. Backed by more than two decades, of experience in Steel making, Bhushan Steel is now India’s 3rd largest Secondary Steel Producer company with an existing steel production capacity of 2 million tones per annum’s (approx.).

It was the vision of the founder; Brij Bhushan Singal , that the first stake was driven into the soil of Sahibabad (Uttar Pradesh) in 1987. His vision helped BSL overcome several periods of adversity and strive to improve against all odds.

The company has three manufacturing units in the state of Uttar Pradesh (Sahibabad Unit), Maharashtra (Khopoli unit), and Orissa Plant (Meramandali unit) in India and sales network is across many countries.

The company is a source for vivid variety of products such as Cold Rolled Closed Annealed , Galvanized Coil and Sheet, High Tensile Steel Strapping , Colour Coated Coils , Galume Sheets and Coils, Hardened & Tempered Steel Strips , Billets, Sponge Iron, Precision Tubes and HFW/ERW Pipe.

As one of the prime movers of the technological revolutions in Indian Cold Rolled Steel Industry, BSL has emerged as the country’s largest and the only Cold Rolled Steel Plant with an independent line for manufacturing Cold Rolled Coil and Sheet up to a width of 1700mm, as well as Galvanized Coil and Sheet up to a width of 1350 mm.

In due course of time, BSL has grown incredibly its turnover and production capacity by successive expansions as well as improved realizations with these manufacturing units.

The dynamic reason of awesome and unparallel growth of BSL, is rapid integration on the Steel value chain; conceivably, it would be its unwavering focus on acquiring the latest technology and know how, also the BSL’s commitment to provide its customers with the best quality products.

Given a vibrant Steel industry dynamics in India, we are on a course to become a fully Integrated Steel & Power Company with market leading offerings in value added Steel in Automotive and White Good Segment with the quality been approved by ISO 9001:2008 & ISO 14001:2004.

CHAPTER 2.1

SAFETYNO JOB OR TASK IS MORE IMPORTANT THAN WORKER SAFETY.

SAFETY COMMITTEE

The primary purpose of the Safety Committee is to promote safety awareness and reduce the potential for injury/loss throughout the Company.

SAFETY GOALS

The following goals have been established for Bhushan steel Company:

(1) Provide workers with a safe work environment.

(2) Conduct routine/regular workplace inspections.

(3) Provide Personal Protective Equipment.

(4) Develop and implement safe work procedures and rules.

(5) Provide on-going safety training.

(6) Enforce safety rules and appropriate discipline.

(7) Provide on-going property conservation practices.

SAFETY RULES

All safety rules must be obeyed. Failure to do so will result in strict disciplinary action.

All injuries must be reported as soon as possible.

No horseplay, alcohol, or drugs allowed on premises.

No alcohol usage allowed during lunch break.

PPE must be worn as prescribed by management.

All tools/equipment must be maintained in good condition

Only appropriate tools shall be used for specific jobs.

All guards must be kept in place.

No spliced electrical cords/wiring allowed.

Only authorized personnel can operate forklift vehicles.

Smoking allowed only in lunchroom.

Industrial safety items

CHAPTER 2.2

PICKLING/HRS

Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic contaminants, rust or scale from steel metal.

A solution called pickle liquor, which contains strong acids, is used to remove the surface impurities.

SPECIFICATION OF PICKLING

MATERIAL SPECIFICATION : HOT ROLLED STEEL COIL.

DIMENSION SPECIFICATION :

WIDTH : 1700 MAX.

THICKNESS : 60 MM MAX.

WEIGHT OF COIL : 30 MT MAX.

LINE SPECIFICATON :

MAX. SPEED : 120 MPM

STEPS INVOLVE IN PICKLING

1. Loading of coil.

2. Acid treatment of the input material.

3. Hot water rinsing.

4. Drying.

5. Oiling.

6. Recoiling of the coil.

7. Strapping & labeling.

8. Transfer of output material.

LAYOUT OF PICKLING PROCESS

CHAPTER 2.3

HITACHI MILL

The purpose of 6 hi HITACHI ROLLING MILL is to reduce the thickness as per customer requirement.

This mill provides the high quality, improved productivity, energy savings, and other characteristics that are demanded in cold rolling, as well as superior shape control and stable operation.

By reducing the diameter of the work rolls, this mill achieves both high reduction rolling and lower rolling energy consumption.

The rolling mill adds roll coolant control to the 3 existing types of control (intermediate roll bender, intermediate roll shift, work roll bender) to deliver superior shape control capability.

Hitachi mill consists of 6 rolls thats why it is known as 6 HI HITACHI MILL.

These 6 rolls are

1. Backup roll (Number of backup roll 2) .

2. Intermediate roll (Number of intermediate roll 2).

3. Work roll (Number of work roll 2).

The pictorial internal diagram of 6 hi Hitachi

Machine.

GRADE

Grading is the standards of steel material according to their hardness.

Grading provides the information about the Require steps to reduce the thickness as a desire value.

Grading of steel according to increasing hardness

1. IF

2. EDD

3. DD

4. D

5. 340H

6. 390H

7. 400H

8. MC-11

9. MC-12

CHAPTER 2.4

ECL (Electrolytic cleaning line)Cold rolled coils processed in cold rolling mills have a thin film of residual rolling oil on the surface after rolling.

The alkaline cleaning of cold rolled coils by the use of high current density (HCD) ensures totally clean surface of the strip before annealing.

This electro-chemical cleaning process is called Electrolytic Cleaning and the processing line the Electrolytic Cleaning Line. 

An ECL line cleans the strip surface of oil and dirt by chemical action, using an alkaline solution.

The strip passes between electrodes which are immersed in tanks containing the electrolyte.

This technique is more effective in cleaning cold rolled steel than conventional cleaning processes used on high speed electro tinning and alkaline-cleaning lines.

 

ECL SPECIFICATON

MAX. SPEED - 300 MPM

MAX. STRIP WIDTH - 1700 MM

MAX. COIL WEIGHT - 30MT

STEPS INVOLVE IN ECL

1. Loading of coil.

2. Feeding of coil.

3. Welding of coil ends.

4. Primary cleaning.

5. Electrolytic cleaning.

6. Hot water rinsing.

7. Drying.

8. Inspection

9. Recoiling

10. Strapping.

11. Storage and transfer to next process.

LAYOUT OF ECL PROCESS

FUTURE LAYOUT

Internships can be a career deciding factor in a student’s professional life.  Internships are extremely important as they provide students with confidence and experience in working in the real world.In upcoming next 4 months we are going to work under the department such as:1. Annealing2. Skin pass3. Finishing4. Quality 5. Color coating lines6. Mechanical maintenance7. Electrical maintenance8. R & D9. UtilityTHANK U.