INTERNSHIP REPORT WRITING | STEEL PLANT

DEPARTMENT OF MECHANICAL ENGINEERING GITAM UNIVERSITY VISAKHAPATNAM

INDUSTRIAL TRAINING REPORT ON “ENGINEERING SHOPS AND FOUNDRY” Report submitted in partial fulfilment of the requirement for the award of Degree of bachelor technology in mechanical

engineering

FROM 02-05-2016 TO 27-05-2016 SUBMITTED BY #######NAME#######

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CERTIFICATE

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DECLARATION

I hereby declare that internship report is authentic record of my work, performed at VISHAKAPATNAM STEEL PLANT, VISHAKAPATNAM during the period of 2nd may 2016 to 28th may 2016.Submitted in partial fulfilment of the requirements of the award of degree of Bachelor of Technology in Mechanical Engineering, GITAM INSTITUTE OF TECHNOLOGY, GITAM UNIVERSITY, and the interpretations therein based on material collected by myself.

(Signature of the student) #####NAME#####

DATE:

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ACKNOWLEDGEMENT Firstly, I would like to thank Mr V.SRINIVASULU for guiding me in the right way to improve technical knowledge in my subject and helping me in getting permission for doing my internship in STEEL PLANT. I would like to thank my HOD, Mr. M R S Satyanarayana who accepted my request of internship in STEEL PLANT. I would like to thank my guide Mr. J. PRABHAKARA RAO who encouraged me in all the aspects during my internship. His immense knowledge in subject and his experience not only made me inspired but also gave me confidence to achieve a valuable position in my life. Now I would like to thank all the service departments of STEEL PLANT who helped in doing my internship comfortably Now I would like to thank all my friends who made me feel comfortable and befriended all the time. ######NAME##### (ID NO)

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TABLE OF CONTENTS INTRODUCTION _________________________ 6 EQUIPMENT REPAIR SHOP _______________ 7 CENTRAL MACHINE SHOP(CMS) ____________ 14 STRUCTURAL STEEL SHOP (S.S.S) __________ 16 LIGHT & MEDIUM MERCHANT MILL (L.M.M.M) ___ 18

WIRE ROD MILL _________________________ 19 STEEL MELT SHOP _______________________ 20 CONCLUSION ___________________________ 21

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INTRODUCTION Visakhapatnam Steel Plant, popularly known as Vizag Steel is an integrated steel producer in Visakhapatnam, India built using German and Soviet technology. Its products have been rate the best in the world market. The company has grown from a lossmaking industry to 3-billion-dollar Turnover Company registering a growth of 203.6% in just four years. Vizag Steel Plant was conferred Navratna status on 17 November 2010. Founded in 1971, the company focuses on producing value-added steel, with 214,000 tons produced in August 2010, out of 252,000 tones total of salable steel produced. It is the largest single site plant in India and Asia Minor (or south and East Asia combined).

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EQUIPMENT REPAIR SHOP Repair shop is like a diagnosis centre where the equipment’s come for repairs or modifications. This shop mainly consists of 4 sections:-

Fitting & Assembly

Machine

Fabrication

Reclination

1) Fitting & assembly - The 1st section takes us through the dismantling kind of work where the components like gearbox, hydraulic parts, conveyor drums etc. come for repairs & they are separated down. After work is done they are set back to original positions. 2) Machine - Machine section contains heavy lathe, milling, grinding etc. They come in to play when there is any precision modifications. 3) Fabrication - Penultimate section comprises of welding wherein the desired product is made as per the design 4) Reclination - At last there lies the repairing section which takes care of the decayed products.

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PLANAR MACHINE A planar is a type of metalworking machine tool that uses linear relative motion between the work piece and a single point cutting tool to cut the work piece. A planer is similar to a shaper, but larger, and with work piece moving, whereas in a shaper the cutting tool moves.

There are two types of planing machine. They are

LINEAR PLANING

HELICAL PLANING

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APPLICATION OF PLANING :  The most common applications of planers and shapers are linear-tool path ones, such as:  Generating accurate flat surfaces. (While not as precise as grinding, a planer can remove a tremendous amount of material in one pass with high accuracy.)  Cutting slots (such as keyways).  It is even possible to do work that might now be done by wire EDM in some cases. Starting from a drilled or cored hole, a planer with a boring-bar type tool can cut internal features that don't lend themselves to milling or boring (such as irregularly shaped holes with tight corners).

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BALANCING MACHINE When a part of machine is rotating it is important to balance the mass evenly so that no vibrations occur.

 In balancing machine there will be two centers on which the rotating part is mounted.  It is joined on one end to the rotating shaft as shown in the fig and the other end is mounted on the two rollers.  There will be two electrical sensors placed on the two ends which shows the mass imbalance on the digital meter as shown in the fig.  Imbalance in mass and the position where it is present is also shown so that the mass is removed or added to make it balanced.  The most important thing is that the person who is operating the balancing machine must be very skilled. 10

MILLING MACHINE Milling is a versatile machine tool that uses a rotating milling cutter, while the work piece reciprocates in contact with the cutting tool. After lathe machine milling machine is most widely used in manufacturing operation .The most important difference between milling machine and lathe is lathe uses a single point cutting tool whereas milling machine uses a multipoint cutter.

WORKING: Milling machine has multi point cutters in which of the cutting edges removes material for only part of the rotation of the cutter. Because of this each of the cutting edge has time to cool before it removes material again , so cooling will be effective in case of milling machine. TYPES OF MILLING MACHINE’S:  Knee and Column type  Production (bed) type  Plano millers 11

GRINDING MACHINE Grinding is a process in which the grinding wheels made of abrasive particles are used to remove the material from the work piece. In this the machining materials which are too hard for other machining processes such as tool and die steels and hardened steel materials. The machine which is used to perform the grinding operation is known as GRINDING machine.

WORKING: The most important part in the grinding machine is the grinding wheel (tool) which will be mounted on a rotating shaft and the material to be machined is traversed across the wheel. The hardness of the material used as abrasive particle for grinding wheel must be more than that of the material to be machined. TYPES OF GRINDING MACHINES: Grinding machines are classified based on the shape of the workpiece to be machined. The grinding wheels used may be one or more.  Cylindrical grinding machine

 Surface grinding machine  Centerless grinding machine

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SHAPER MACHINE Shaper is one of the reciprocating machine tool. Shaper is a relatively slow machine tool with very low metal removal capability. So it is being replaced by more versatile milling machines in many industries. It uses a single point cutting tool which is mounted on the clapper box, which in turn is mounted on the ram.

WORKING: The ram while undergoing the cutting stroke pushes the cutting tool through the work piece to remove the material. When ram returns no cutting stroke take place. In between return and cutting strokes the table moves in a direction perpendicular to the cutting direction termed feed direction. The reciprocating motion in the shaper is because bull gear and pin which run by a motor. To reduce the idle time a process known as quick return motion mechanism is implemented in shaper. TYPES OF SHAPER’S:  Universal shaper  Draw cut shaper  Vertical shaper  Hydraulic shaper 13

CENTRAL MACHINE SHOP The heart of VSP lies in this shop. As we can guess by the name itself it’s the main place where machining is done. The production can consist of cutting, shaping, drilling, finishing, and other processes. The machine tools typically include lathes, milling machines, machining centers, multitasking machines, drill presses, grinding machines, many controlled with CNC. There are 39 lathes in total in CMS of which 28 are manufactured by Hindustan Machine Tools (H.M.T) & 11 are from Heavy Engineering Corporation ltd (H.E.C). The horizontal press of 160 tonnes capacity are used for disengaging the connection between shaft & hole. Other simple techniques like using torque wrench to reduce manpower, heating of hole to let it expand & shaft sits on easily are frequently followed. Now if we talk about the operations in the shop then there is :1) Boring being carried out for making crane wheels. 2) Turning operation on lathe for making gears blanks. 3) Milling is done on gear blanks to make spur gear or helical gear. Here there is a need of doing indexing that may be direct indexing or differential indexing. 4) Grinding for sharpening the cutting tools.

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STRUCTURAL STEEL SHOP (S.S.S) This is one of the oldest shops in VSP. The main role of this shop is welding & cutting. They do cutting with the help of a CNC machine which has the required design feeded in it. There is also a provision of doing manual cutting by using LPG-Oxygen mixture. LPG is carried in blue & Oxygen in black pipeline. In welding they use consumable electrodes (E6010) which has a flux coating on it for better & faster cutting. The work is done according to the requirement if there is a need to make a structure for any department then they plan for minimum energy utilization. Then the work design is made as per the dimensions. The work is carried out under the supervision of the manager. The different parts so produced are welded together according to the specifications. The made structure is transported to the destination to differentiate between different grades of steel, colour codes are set. Colour codes of different types of steel are : 1) Red - EN 24 2) Yellow - EN 18 3) Green - EN 19 4) Blue - C 45

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LIGHT & MEDIUM MERCHANT MILL (L.M.M.M) The mill consists of big furnaces in which billets are fed in. There are 2 furnaces working simultaneously to meet the requirements. Billets go inside the furnace through an automated process & stays inside it for few hours. Furnaces which are computer controlled are made under observation. Once the temperature crosses 1500 Celsius they are brought out & carried over to rolling process. Now a billet which is of square cross-section need to be transformed to circular shape to manufacture wire rods. Passing through rollers setup the shape slowly changes to circular one. As the process goes on the diameter slowly reduces. At last the wire rods so obtained are laid down for cooling over a large rack like structure where it cools down. The maintenance of rollers takes place frequently. Later on rods are transported to clients. The finished products include wire rods & long products like reinforcement bars, rounds, squares, flats, angles, channels, billets etc.

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WIRE ROD MILL (W.R.M) The difference between LMMM & WRM is, coiled wire rods are made in latter as the final product. The billets manufactured at SMS are transported to WRM. They are loaded near the furnace wall. They are heated & passed onto the rollers similarly as LMMM. In the immediate next stage the head & toe part of the billets are cut down. The reason behind it is to get appropriate dimensions at the end. At once 4 billets are fed inside. Inside the process there are guide valves which are used for marking a term “VIZAG TMT”. This indicates the company logo. After completion of this the coils are allowed to cool down by passing it through showers. The stating part of the coil is cut down because of its irregular shape. After cooling it’s time to mark for grade, batch, date etc. For example blue paint is marked for Fe500D grade, 621091, May 16. There are different colours for different grades of steel. Thereafter they are sealed & put in storage yard.

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STEEL MELT SHOP (S.M.S) This shop prepares steel & makes products like blooms, billets, bars etc. The process of making steel starts from heating up a iron ore in a large laddle. The next step is to add some scrap to it to make it separable from other elements. The scrap is mixed from all the departments & carried till the laddle & dropped in it. This takes some time to prepare the steel out of this. After completion of the steel it’s transported to other section where products are made out of it. The first process is an overhead job as the metal comes in a laddle. Metal is poured in the tundish which has a nozzle at its end. Beneath the nozzle there lies mould of any required shape. To maintain the temperature in tundish some additives are thrown directly inside it. After cooling the products are kept aside. The major difference between blooms & billets is cross-sectional area. The cross-sectional area of bloom is greater than 36 in2 whereas cross-section area of billet is less than 36 in2

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CONCLUSION At the end of the internship training, I could gain a lot of practical experience which cannot be found through the books. Now I could clearly relate my mechanical engineering subjects to the real life practical experience. The departments where I did my internship gave me a strong basics about foundry, wood workshop, machine design, heat transfer which I have learnt in my past 3 years and now I could clearly relate to the theory and practical due to industrial exposure.Finally this industrial internship helped me for

better understanding what I am going to face in my future as mechanical engineer and also a better understanding about my subjects and its relation to the outside world

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