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SAIL SRM UNIVERSITY

SALEM STEEL PLANT

STEEL AUTHORITY OF INDIA LIMITED SALEM STEEL PLANT SALEM INPLANT TRAINING

Department of ELECTRONICS AND COMMUNICATION ENGINEERING

SRM UNIVERSITY KAATANKULATHUR-603203 CHENNAI.

Done by GOKULNATH.B (1041210605) JAYARAGHAVENDRAN.J (1041210586) ASWINKUMAR.R (1041210595)

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SAIL SRM UNIVERSITY

SALEM STEEL PLANT

ABSTRACT

In order to study the process that takes place inside the steel plant industry we selected to do inplant training in SALEM STEEL PLANT , And we people successfully completed our inplant training on HRM , CRM, and process taking place inside those mills . The process that we understood have been submitted as the report. Hereby,we thank the HRD of SSP who gave this opportunity.

ASWINKUMAR.R(1041210595), JAYARAGHAVENDRAN.J(1041210586), GOKULNATH.B(1041210605).

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S.no

INDEX

1

Introduction

2

Industry profile

3

SAIL mission & vision

4

Company profile

5

Function of company 5.1)HRM 5.2)CRM

6

Strength Weakness & Opportunity

7

Conclusion

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SALEM STEEL PLANT (SSP) 1. INTRODUCTION Salem Steel Plant is a premium producer of international quality stainless steel in India. Commissioned in 1981, the plant has a capacity to roll 186000 tonnes of hot rolled carbon and stainless steel flat products and 70000 tonnes of cold rolled stainless steel sheets and coils per annum. Its products have become a household name “SALEM STAINLESS” in domestic market and are exported. In hot rolled special grade carbon steels, SSP has been recognized as well-known manufacturer of boiler quality steel. A Blanking Line, the first of its kind in India, was established in 1993, with an annual capacity to produce 3000 tonnes of Ferritic grade coin blanks or 3600 tonnes of utility blanks. SSP has revalorized application of stainless steel in India both conventional and unconventional area. High tech industries like atomic power station prefer ‘Salem Stainless’ .it also chosen industrial sectors like dairy and food processing, chemical and fertilizer, heavy engineering, railways, automobiles, bulk solid handling, power, value added products, etc. The building and architecture segment which is growing at rapid pace sees ’Salem Stainless’ as the most dependable companies. In architecture, building and construction, the prestigious structure where ‘Salem Stainless’ was chosen includes`The parliament house library complex-New Delhi.The worlds tallest twin building-THE PETRONAS TWIN-TOWER, in Malaysia.The retractable roofing at the Melbourne Tennis Stadium, Australia.The coaches of high speed JAN SHATABDI EXPRESS trains are furnished with modular rail marts and sub pantries made entirely of ‘Salem Stainless’SSP has developed new application of its products, viz. LPG tanks for automobile, stainless steel ceiling fans, exhaust fans, corrugated sheets, water tanks, etc.Salem Steel Plant customer spans over 37 countries worldwide. Quality

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occupies the summit of Salem Steel priorities. The products are well accepted in national and international markets for its top-notch quality. Organization Name

: SAIL - Salem Steel Plant (SSP), Salem.

Industry it belongs to

: Steel

Chairman (SAIL)

: C.S.Varma

Executive Director (SSP)

: Pangaj Gowtham

Foreign exposure

: The major exposure countries are China, United States, Australia, Singapore, Honkong, Malaysia, Indonesia, Pakistan, Srilanka.

Entry and Exit Barrier

: In 1981, the Salem Steel Plant is the only steel manufacturer in India. The price was fixed by them, but after globalization in 1995 many players entered into the market and the price was fixed by customers. The customer goes either by quality or by price.

Carrier planning

: As for the organization, establishing the new SMS (Steel Melting Shop) plant for manufacturing slabs, which is the raw material for HRM. In past the slabs are brought from their sister concern plant Bhilai, Durgapur and Bokaro. The recruitment is based on the need.

2. INDUSTRY PROFILE 5

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History of the Industry The Indian steel industry is almost 110 years old now. Till 1990, the Indian steel industry operated under a regulated environment with insulated markets and large scale capacities reserved for the public sector. Production and prices were determined and regulated by the government, while SAIl and TATA steel where main producers, the latter being the only private player. In 1990, the Indian steel industry had a production capacity of 23MT. 1992 saw the onset of liberalization and the Indian economy was opened to the world. Indian steel sector also witnessed the entry of several domestic private players and large private players and large private investments flowed into the sector to add fresh capacities. Steel industry in India is on an upswing because of the strong global and domestic demand. India’s rapid economic growth and soaring demand by sectors like infrastructure, real estate and automobiles, at home and abroad, has put Indian steel industry on the global map. According to the latest report by International Iron and Steel Institute (IISI), India is the seventh largest steel producer in the world. The Indian steel industry is organized in three categories i.e main producers, other major producers and the secondary producers. The main producers and other major producers have integrated steel making facility plant capacities over 0.5MT and utilized iron ore and coal/ gas for production of steel. The main producers are TATA steel, SAIL and RINL, while the major producers ESSAR, ISPAT and JVSL. Contribution of Countries to Global Steel Industry The countries like India, china; Japan and South Korea are in the top of the above in steel production in Asian countries. China accounts for one third of total production i.e419MT, Japan accounts for 9% i.e118MT, India accounts for 53MT and South Korea is accounted for 49MT, which all totally becomes more than 50% of global production. Apart from this USA, BRAZIL, UK accounts for the major chunk of the whole growth.

Present Status of the Steel Industry 6

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 Indian economy growing at 8 to 9% is one of the fastest growing economics in the world.  The tenth plan investment in infrastructure has been envisaged at around Rs.880, 550 crores.  During eleventh plan (2007-08) to (2011-12), the projected investment toward infrastructure is likely to be Rs.2027000 crores, an increase of 180% over 10th plan. 

Per capita consumption at 35kg low as compared to world average of 150kg and 300kg for China.

 Lot of Steel project both Brown field and Green field likely to the come up and are in various stage of execution.  Due to infrastructure focus, production of long products is gradually increasing and ratio of flat to long products is narrowing.  With due focus on infrastructure on development and strong economic indicators, the demand for steel in India shall continue to remain robust. Strengths of Indian Steel Industry  Low labour wage rates  Abundance of quality manpower  Mature production base  Positive stimuli from construction industry  Booming automobile industry

Weakness of Indian Steel Industry

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 Although

India

considerably,

has

modernized

its

steel

making

however nearly 6% of its crude steel is still

produced using the outdated open-hearth process  Labour productivity in India is still very low.  Steel production in India is also hampered by power shortages.  India is deficient in raw materials required by the steel industry.  Insufficient freight capacity and transport infrastructure impediments to hamper the growth of Indian steel industry.

Indian Iron Steel Structure Indian Iron and steel industry  Steel producers  Sponge iron producers Steel producers a) Main producers i.

SAIL

ii.

RINL

iii.

TSL

b) Major producers i. JSW steel limited ii. ESSAR steel limited iii. ISPAT industries limited iv. Jindal Steel & Power limited

c) Other producers 8

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i. ii.

EAF based units: 33 working units Introduction Furnace based units: 970 working units

d) MBF-ETF based units-2units

Sponge Iron producers a) Gas based sponge iron units i.

ESSAR steel limited

ii.

ISPAT industries limited

iii.

Vikram Ispat limited

b) Coal based Sponge Iron unit.

3. SAIL VISION, CREDO, MISSION & VALUES

Vision 9

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 To be respected world class corporation and the leader in Indian steel business in quality, productivity and customer satisfaction.  A world of proven talent  Delivering break through innovation  Giving our customer a unique competitive edge  Enabling societies to master their most vital challenges.

Credo

 We build lasting relationships with customers based on trust and mutual benefit.  We uphold highest ethical standards in conduct of our business.  We create and nurture a culture that supports flexibility, learning and is proactive to change.  We chart a challenging career for employees with opportunities for advancement and rewards.  We value the opportunity and responsibility to make a meaningful difference in people’s lives.

Mission

 We will seek global market leadership.  Development and growth in oriented firms will be our focus. 10

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 We will continue to create a winning culture, operating in the highest standards of

ethics and values.

 We will strive for excellence in customer service, quality and R&D

Values

 Responsible – Committed to ethical & responsible action  Excellent –Achieving high performance & excellent results  Innovation – Being innovative to create sustainable value

4. COMPANY PROFILE The Precursor 11

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SAIL traces its origin to the formative years of an emerging nation - India. After independence the builders of modern India worked with a vision - to lay the infrastructure for rapid industrialization of the country. The steel sector was to propel the economic growth. Hindustan Steel Private Limited was set up on January 19, 1954. Expanding Horizon (1959-1973) Hindustan Steel (HSL) was initially designed to manage only one plant that was coming up at Rourkela. For Bhilai and Durgapur Steel Plants, the preliminary work was done by the Iron and Steel Ministry. From April 1957, the supervision and control of these two steel plants were also transferred to Hindustan Steel. The registered office was originally in New Delhi. It moved to Calcutta in July 1956,and ultimately to Ranchi in December 1959.The 1 MT phases of Bhilai and Rourkela Steel Plants were completed by the end of December 1961. The 1 MT phase of Durgapur Steel Plant was completed in January 1962 after commissioning of the Wheel and Axle plant. The crude steel production of HSL went up from .158 MT (1959-60) to 1.6 MT. A new steel company, Bokaro Steel Limited, was incorporated in January 1964 to construct and operate the steel plant at Bokaro. The second phase of Bhilai Steel Plant was completed in September 1967 after commissioning of the Wire Rod Mill. The last unit of the 1.8 MT phase of Rourkela - the Tandem Mill - was commissioned in February 1968, and the 1.6 MT stage of Durgapur Steel Plant was completed in August 1969 after commissioning of the Furnace in SMS. Thus, with the completion of the 2.5 MT stage at Bhilai, 1.8 MT at Rourkela and 1.6 MT at Durgapur, the total crude steel production capacity of HSL was raised to 3.7 MT in 1968-69 and subsequently to 4MT IN 1972-73.

Holding Company The Ministry of Steel and Mines drafted a policy statement to evolve a new model for managing industry. The policy statement was presented to the Parliament on 12

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December 2, 1972. On this basis the concept of creating a holding company to manage inputs and outputs under one umbrella was mooted. This led to the formation of Steel Authority of India Ltd. The company, incorporated on January 24, 1973 with an authorized capital of Rs. 2000 crore, was made responsible for managing five integrated steel plants at Bhilai, Bokaro, Durgapur, Rourkela and Burnpur, the Alloy Steel Plant and the Salem Steel Plant. In 1978 SAIL was restructured as in operating company. Since its inception, SAIL has been instrumental in laying a sound infrastructure for the industrial development of the country. Besides, it has immensely contributed to the development of technical and managerial expertise. It has triggered the secondary and tertiary waves of economic growth by continuously providing the inputs for the consuming industry.

OBJECTIVES OF IN-PLANT TRAINING

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For any MBA student, a learning combination of theory and practice is an invaluable asset, as it helps in understanding the core principles of business by way of first hand experience. This in-plant training is a stepping stone which will groom me future in the corporate world. Following are the objectives on in-plant training : To get an industrial exposure  To be aware of the happening in a particular industry  To achieve knowledge about different sectors in market for making choice as to which go for.  To learn functioning and operations of different in an organization  To get knowledge about the working culture of the organization  To have knowledge about the huge management practices and get the practical knowledge of what we have studied.

5. FUNCTIONS OF THE COMPANY 5.1 PRODUCTION DEPARTMENT

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There are two major units in Salem Steel Plant (SSP) a) HRM b) CRM

HRM: Hot Rolling Mill Input a) Carbon Steel slabs from sister steel plants viz Bhilai Steel Plant and Bokaro Steel Limited. b) Stainless Steel Slabs from Alloy Steel Plant, Durapur and from imported sources.

Output a) Hot Rolled Carbon Steel and Stainless Steel Coils and Plates. Product-Mix, Process, Equipment and Infrastructure of Hot Rolling Mill Hot Rolling Steckel Mill The Hot Rolling Mill Complex consists of a Slab Yard, a Walking Beam Reheating Furnace, a Roughing Mill, a Single Stand 4 High Reversible Steckel Mill, a Down Coiler and a Coil Yard for marking, cooling & dispatch. Product Mix With the commissioning of Hot Rolling Steckel Mill, Salem Steel Plant has also entered the market of carbon steels.

The Hot Rolling Steckel Mill is capable of

producing both stainless as well as non-stainless steels. In case of carbon steels, the minimum thickness which can be achieved is 1.6 mm and in the case of stainless steel the minimum thickness achieved would be 2.0 mm. The mill has the capacity to roll up to 1300 mm width. Process 15

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Slabs of carbon steel (or) stainless steel are received through wagons from Alloy Steels Plant, Durgapur or Bhilai Steel Plant or from abroad and stored in slab storage yard. As per the schedule the slabs are charged into the Walikng Beam Reheating Furnace and annealed to a suitable temperature. Later these slabs are discharged from furnace and sent to Roughing Mill. In Roughing Mill the slabs are rolled to transfer bar to a thickness of 25 mm and sent to the Steckel Mill for further reduction. Having achieved required thickness, the material is cooled with the system of Laminar Cooling in case of carbon steel and coiled in Down Coiler. In case of stainless steel the material is directly coiled in Down Coiler after natural cooling. From Down Coiler HR Coils are taken to CRM or customers through trucks.

Functions of each unit HRM Slab Yard Slab yard is to store the slabs in a specific order. The slabs that are received either by rail or by road are unloaded in this yard.

Goliath Crane It is used to transfer the slabs from one placed to other within the range of crane movement area.

Re-heating Furnace This is a special structure constructed with firebricks to reduce heat loss. Heating is done using LPG. The temperature maintained inside the furnace depends on the type of steel in furnace. This furnace contains a walking beam to move slabs from one position to other. The main advantage of walking beam furnace is that the hot slabs are moved by one phase length without any damage (i.e., the beam will lift the entire mass of ten slabs – placed apart by a definite distance side by side – and moves one step forward and lowers them on the furnace floor and retracts back to its position.This furnace can contain ten slabs at a time. Descaler 16

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When the hot slab is discharged from the furnace, some elements in the slab will react with the oxygen in the atmosphere and forms a compound called Scales on the surface of the slabs. These scales are unwanted elements and to be removed from the surface of the slab. The hot slabs with these scales are passed through a descaler, which will break the scales. The scales so broken are wiped off the slabs with high-pressure water jets. Scale free slabs will come out of the descaler and will be forwarded to the roughing mill. Roller table enables movement of these slabs without damaging the surface Roughing Mill This is a reversible mill. The slab thickness, which enters the mill, will be of the order of 200mm.

This will be reduced down to 25-30mm depending on the final

thickness to be rolled in Steckle Mill. This thickness reduction from 200mm to 25-30mm takes place in several passes.

Crop Shear The plate from roughing mill will have minor fish tail at leading and tailing ends. This portion has to be removed in order to have a square ends. Crop shear chops off the fish tail ends.

Steckle Mill This is also a reversible mill with level 2 automation. This is the main unit of HRM Complex. The plates that enter this mill from roughing mill will further be rolled down to the scheduled/ planned thickness (as per PPC’s requirement). To compensate for the heat loss during rolling, the mandrel is housed inside reheating furnace. LPG is used for heating the strip. This helps in relieving the stress induced, to some extent, in the strip due to rolling. When the final required thickness is reached, the strip travels over a roller run table. The bring down the temperature of the strip; laminar cooling towers are installed above the run table, which showers water at rated pressure on the strip.

Down Coiler 17

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The strip from the steckel mill is wound on the mandrel and if forwarded to the Numbering/ strapping machine.

Numbering and Weighing Machine To avoid unwinding of the coils, they need to be strapped. Since the coil will be hot condition, manual strapping is not possible. Hence an automatic strapping machine which will bind the straps together over the coil. The numbering machine prints the following parameters on the strip (spray painting method):  Coil number  Grade  Thickness  Width The coil is also weighed in the weighing machine and the weight also is marked on the strip.

Transfer car The coils from the weighing machine are moved to the storage yard using transfer cars.

PROCESS

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PROCESS FLOW: HOT ROLLING MILL 1. Reheating furnace 2. Descaler 3. Edger 4. Roughing mill 5. Crop shear 6. Coiler furnace 7. Steckel mill 8. Laminar cooling 9. Pinch roll 10. Down coiler

CRM: COLD ROLL MILL

Input a) Hot rolled stainless steel coils from hrm to ssp. b) Imported source hot rolled coils (430 grade coils).

Output 19

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Stainless steel coils and sheets of various sizes as mentioned in the marketing and metallurgical services manual. The very purpose of any industry is to produce an end product that has a wide range market. As stated above ssp produces a wide range of products, which is the input of raw material for several industries of  Food processing  Utensil  Heavy engineering  Railways  Elevators  Coinage  Washing machine  Water coolers and refrigerators  Wall panelling  Interior decoration of office/house  Bus body building and so on....  To cater to the needs of industries that manufacture equipments of the kind mentioned above, Branch sales offices are established all over India at key locations. The following are the BSOs that are currently operative:  Ahmadabad  Mumbai  Kolkata  Coinage  Export-Salem  Hyderabad  Conversion- Salem  Bangalore  Chennai 20

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 New delhi-2 offices  Coimbatore  Pune  Salem The above said BSOs will interact with customers/traders in and around the place and take orders from them for our products. If the order, so taken is a standard product (as given in the product catalogue), branch will directly issue Release orders to ppc.

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Input The input slabs are stored in slab storage yard. As per the schedule the slabs are charged into the walking beam Reheating Furnace and annealed to a suitable temperature. Later these slabs are discharged from furnace and sent to Roughing Mill. In Roughing Mill the slab are rolled to transfer bar to a thickness of 25mm and sent to Steckel Mill for further reduction. Having achieved to the required thickness, the material is cooled with the system of Laminar Cooling in case of carbon steel and coiled in Down Coiler. In case of stainless steel the material is directly coiled in Down Coiler after natural cooling. From Down Coiler HR Coils are taken to CRM or customer through truck.

Output Hot Rolled Carbon Steel and Hot Rolled Stainless Steel Coils and Plates.

Reheating Furnace The furnace section consists of a)Slab Yard b)Re-heating Furnace The walking beam type Reheating furnace is hydraulically operated, top and bottom fired and has a flat roof. The combustion system is of recuperative type designed for firing LPG or natural gas. The Reheating furnace has been designed and supplied by M/S Italiampianti, Italy and Erected by M/S Wellman Incandescent, India. Furnace capacity For Stainless Steel: 55 T/hr (For a reference slab of 170 mm thick) For Carbon Steel : 70 T/hr (For a reference slab of 170 mm thick)

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The different types of material that can be processed are: Stainless Steel: AISI 200 & 300 Series (Austenitic) AISI 400 Series (Ferritic & Martensi tic) Carbon Steel:

IS 1079 D, IS 1079 DD, and IS 1079 EDD IS 2062B, IS 10748, E38, E34, SAILCOR, IS 6240.

The slabs are uniformly heated in the Re-heating furnace so that they are brought to the discharge temperature of 1150 ˚C to 1250˚C. No of burners installed: 56 Fuel used: LPG; Calorific value – 22,000 Kcal/NM. No of combustion blowers installed: 2 Recuperator: Metallic type to recover the waste heat from flue gases. Slab temperature is measured by the radiation pyrometer installed in the furnace roof of discharging side. Oxygen analyser is provided in the recuperative zone of charging side to measure the oxygen percentage in waste gas.

Reversing Roughing Mill The Roughing Mill is a 4 hi Reversing Mill. Supplied by M/S Schloemann Siemag (SMS), Germany. Automation supplied by M/s Siemens, Germany. Rouging Mill is controlled by Level 1 Automation.

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The Roughing Mill housing accommodates two work rolls and two supporting rolls called Back-up rolls. Max Dia

Min Dia

Length

Work roll

1050 mm

950 mm

1475 mm

Back up roll

1350 mm

250 mm

1425 mm

In Roughing Mill the thickness of Reheated and Descaled (Primary scales) slab is reduced to 20 - 32 mm by rolling process in 3,5,7 or 9 passes depending on the input slab size by controlling the width during rolling in Edger. The complete rolling and edging operation is carried out as per the proper selection of pass schedule.

Discharge temperature of slabs 1. Carbon Steel: 1200 - 1280˚C 2. 200 Series

: 1190 ±20˚C

3. 300 Series

: 1220- 1280˚C

4. 400 Series : 1140 ±20˚C. The temperature of the Transfer bar (T-bar) after the last pass rolling in Roughing Mill: 950˚C - 1100˚C. The fish tails formed at head end and tail end of the T-bar during edging and roughing process is removed in Drum Shear and the final reduction in thickness is achieved by rolling in Steckel Mill.

a. Equipment from Reheating Furnace Upto Roughing Mill 25

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 Slab reject roller tables  Furnace delivery roller table  Descaler connecting and descaler roller table  Primary descaler  Roughing mill approach roller table  Front mill roller table  Roughing mill feed rollers  Roughing mill entry side guides  Vertical edger

b. Roughing Mill Equipment  Roughing Mill Screw Down System  Un-jamming device  Roughing mill guides  Lifting rails  Work roll cooling system  Back up roll balancing  Spindle balancing  Back up roll changing sled  Work roll change cover plate, tilting flap  Roll change car c. Systems  Hydraulic system  Booster pump system (Centralised for Steckel Mill and Roughing Mill)  High pressure water system  Morgoil system (Centralised for Roughing Mill and Steckel Mill)  Oil lubrication system (Centralised for Roughing Mill and Steckel Mill areas) 26

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 Pneumatic system  Grease systems Steckel Mill Steckel Mill is a 4 hi Reversing Mill Supplied by M/S Schloemann Siemag (SMS),Germany. Automation supplied by M/S Siemens, Germany. The Steckel Mill housing accommodates two work rolls and two supporting rolls called Back-up rolls.

Max dia

Min dia

Length

Work roll

760 mm

680 mm

1825 mm

Back up roll

1350 mm

1250 mm

1425 mm

A. Steckel Mill Specifications Type: Single stand, 4 Hi reversible Mill, provided with one coiler furnace on each side to wind the hot strip just after rolling in each pass and also to maintain the strip temperature suitable for hot rolling. Steckel Mill is built with sophisticated facilities & control systems to obtain high quality flat product such as  HGC – Hydraulic gap control  AGC – Automatic Gap Control  MON - (Thickness monitoring system)  RAC – Roll alignment control  CVC and Work roll bending system 27

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 PGM – Profile Gauge Meter  Model Server

The state-of-the-art automatic pass schedule calculation facility (model server) is installed to have trouble free rolling. Automatic work roll change facility is provided for quick and easy changing of work rolls. Main drive capacity: 4500 KW each for



top and bottom work Back up roll is friction driven. 

Maximum roll force: 30,000 KN



Maximum rolling speed: 10 M/sec



Maximum bending force: 3,000 KN



CVC shifting range: -200 mm to +200 mm



CVC crown values: -0.7 mm to +0.3 mm



Pass line deviation allowed: -10 mm to +10 mm

COILER FURNACE  Temperature maintained : 950˚C - 1000˚C  Fuel used: LPG  Air/gas ratio: 28 – 32  Number of burners: 6 for each furnace  Coiler Drum diameter: 1350 mm  Coiler Drum drive capacity: 650 KW  Combustion air pressure for coiler furnace: 800 mm wc  LPG working pressure: 800 mm wc

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Technical Details Material Specifications: Transfer bar thickness: 20mm - 32 mm (carbon steel) : 20mm - 28 mm (Stainless steel) Transfer Bar Width

: 600mm – 1300 mm

T –Bar temperature

: 1020 - 1100˚C

Strip thickness for Carbon Steel: 1.6 mm – 12.7 mm for Stainless steel: 2.0 mm – 10.0 mm Systems  Auxiliary hydraulic system  Servo hydraulic system  Booster pump system (Centralised for Steckel Mill and Roughing Mill)  High pressure water system  Morgoil system (Centralised for Steckel Mill and Roughing Mill)  Oil lubrication system (Centralised for Steckel Mill and Roughing Mill)  Laminar cooling system  Pneumatic system  Grease systems  Re-circulating water system

B. Air Compressors 4 Nos. of Air compressors are installed to meet compressed air requirement for the Hot Rolling Mill complex.

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C. Model Server The Model Server is the Level 2 automation system consisting of a mill process computer. The mill process computer based on mathematical models and strategies, calculates the set up values for the mill like roll gap, roll force, CVC position, bending values etc., (in association with the slab data and transfer bar data). Finally the set up values allow for an accurate control of strip thickness, profile and flatness. The area of the model server is restricted to the Steckel Mill stand and coiler furnace. The primary data is transmitted by the production control PC to furnace PLC. When a slab is discharged from the furnace, furnace PLC transmits the primary data of this slab and the next slab to Roughing Mill PLC. After acknowledgement from Roughing Mill operator, Roughing Mill PLC transmits the primary data to model server. With the completion of the last pass in the Roughing Mill, Roughing Mill PLC transmits the actual values of the last pass in the Roughing Mill, (Width, last pass roll force, roll gap, temperature and speed) to model server. The availability of primary data and T-bar data enable the model server to calculate the pass schedule. After the calculation, the set up values are transmitted to the Steckel Mill PLC. The Steckel Mill PLC will do the sequence control of the process in Steckel Mill. During the pass in Steckel Mill, actual values like roll force and strip temperature are measured by Steckel Mill PLC and sent to Model server. After 35-50% of that pass length is rolled the model server will process the measured values sent by Steckel Mill PLC. Based on this feed back, the models will re-calculate an improved set up for the remaining passes. However, the thickness distribution, speed, tension values will not be changed. This process will be repeated pass by pass until the last pass is reached.

The model server has the following automation functions: 30

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1. Strip tracking 2. Pass schedule calculation 3. Acquisition and processing of measured values 4. Dialogue and display 5. Logging function. Roll shop Roll Shop caters to the  Work rolls and back up roll requirements of Roughing Mill and Steckel Mill by supplying rolls with chocks assembled with bearings as and when required.  Turning and assembling of Edger rolls.  Grinding of Pinch rolls of Steckel Mill and Down Coiler.

The used work rolls, back up rolls of Roughing Mill and Steckel Mill, Edger rolls and Pinch rolls of Steckel Mill and Down Coiler are reground in the Roll grinding machine. Roll grinding m/c is supplied by M/S Toshiba machine company, Japan. State – of –the- art CNC roll grinder is working on Level -3 automation which ensures fully automatic grinding where special functions like wheel quick approach, Automatic roll alignment and wheel surface speed control are done by machine itself. Overhauling and maintenance of all Work roll and Back up roll bearings are taken up on a regular basis. The chocks earmarked for overhauling are dismounted from rolls. Then the bearings, seals and chock internals are taken out, cleaned and checked for any mark or wear and tear. Based on the condition, the bearings and chock internals are either replaced with new or are put back after thorough cleaning and removal of marks. 31

SAIL SRM UNIVERSITY

SALEM STEEL PLANT

Roll Grinding Machine (RGC 1400 x 5000 CNC grinding machine) Hot Rolling Mill (HRM) of Salem Steel Plant have different rolls like Breakup Rolls, Work rolls, Edger Rolls and Pinch Rolls. All these Rolls in HRM need grinding after a stipulated tonnage of rolling for better surface finish. So, these rolls are being ground by CNC grinding machines. In HRM, in addition to the existing CNC grinding machine supplied by M/S Toshiba, a new Roll grinding machine of Type: RGC 1400 x 5000 CNC, [supplied by M/S World Machinery Works (WMW), Romania] was also commissioned in July 2009 to grind HRM rolls for production of 3,70,000 t of Slabs per year. The main equipments and automation of this new Roll Grinding Machine a. CNC

: SINUMERIK 840D

b. MIDA

: Roll Alignment System

c. MARPOSS

: Wheel Balancing and auto wheel touching

d. LISMAR

: Flaw detection

e. Meas4 Roll

: Profile measurement

f. Wheel measurement and dressing g. PLC

: SIMATIC S7-300

This machine consists of mainly 9 axes. The details are as follows C1

: Roll drive rotation

C2

: Wheel Rotation

Z

: Longitudinal Movement of the Carriage

X

: Traverse Movement of grinding wheel (coarse)

X1

: Traverse Movement of grinding wheel (fine)

B

: Wheel assembly swiveling 32

SAIL SRM UNIVERSITY

SALEM STEEL PLANT

A

: Diameter measurement arm rotational movement

Y

: Diameter measurement

U

: Roll alignment

Special features of RGC 1400 x 5000 CNC grinding machine  The roll grinding machine RGC 1400 x 5000 CNC type performs grinding, measuring and testing E.C cylindrical surfaces, Plane or Cambered (concave or convex).  Highly productivity output ranges, optimal machine accuracy and decreasing preparation period.  All types of profile can be ground Viz. Straight, Taper, Concave, Convex, Radius, CVC etc.  Backup Rolls and Edger Rolls can be ground with chocks  Roll diameter can be measured during grinding  Grinding accuracy - Roundness

: 0.002 mm

- Cylindricity

: 0.002 mm

- Crown profile

: 0.0025 mm

- CVC profile

: 0.0025 mm

Down coiler The finished strip from Steckel Mill rolling is coiled around the Down Coiler mandrel. The finish strip thickness: For Carbon steel : 1.60 mm to 12.7 mm For Stainless steel: 2.00 mm to 10.0 mm The equipments are supplied by M/S Schloemann Siemag (SMS), Germany. The automation is done by M/S Siemens, Germany. 33

The Down Coiler is controlled by

SAIL SRM UNIVERSITY

SALEM STEEL PLANT

Level -1 automation. The walking beam conveyor is used for the transportation of coils to the Coil Yard. The coil is strapped by a single band circumferencial automatic Strapping machine, weighed in the weighing m/c and marked by an automatic marking machine supplied by M/S Infosight Corporation, USA. Down Coiler consists of a.

Run out Roller table (RORT): This consists of 184 rollers (Roll dia: 300 mm) separated into six groups. This helps in transporting the finished strip from Steckel Mill to Down Coiler

b.

Side Guides: Side guides are provided for guiding the strip straight into the Coiler.

c.

Hold Down Roll: The main function of the hold down roll (Roll dia: 300 mm) is to avoid fluttering in the strip. This roll will be in the up position when the strip is coming and will get down when the strip enters the pinch roll.

d.

Pinch Roll: The function of the pinch roll is to guide the strip into the mandrel Max

Min

:

900 mm

880 mm

Bottom Roll:

400 mm

370 mm

Top Roll

e.

Strip Switch: The strip switch guides the strip to the mandrel. During coiling it opens and it allows the strip to the mandrel and afterwards it closes the way to the mandrel.

f.

Chute Plate: The chute plate feed the strip to wrapper roll 1 which makes the strip to wind on the coiler

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SAIL SRM UNIVERSITY

g.

SALEM STEEL PLANT

Wrapper Rolls: Three wrapper rolls are provided for wrapping the head end of the strip into the mandrel. The wrapper rolls will get retracted after the mandrel expanded and tension built.

h.

Mandrel: The finished strip from Steckel Mill winds on the mandrel The diameter of the mandrel: Collapsed

: 727 mm

Pre-expanded : 738 mm Fully expanded: 762 mm i.

Outboard Support Bearing: Two support bearings are provided, one in right and the other in the left side to hold the mandrel during rolling.

j.

Coil Car: The coil car transports the finished coil from the mandrel to the walking beam conveyor. It has a lifting table which is provided with two rollers and locking provision for the rollers.

5.2CRM-COLD ROLLING MILL Input 35

SAIL SRM UNIVERSITY

SALEM STEEL PLANT

Hot Rolled Stainless Steel Coils from HRM of SSP. Imported source Hot Rolled Coils (430 grade Coils). Process SSP employs the latest technology in cold rolling and incorporates the most modern equipment supplier by the leading machinery manufacturer all over the world. The raw material for CRM is HR Stainless Steel Coils, called hot beams. These coils are processed in Coil Built-up Line (CBL). Coils from CBL are softened and descaled in Annealing and Pickling Line (APL. From here they are sent for cold rolling in Sendzimir Mill (Z-Mill) to the descried final thickness. The cold Rolled Coils are again softened and descaled to obtain the optimum finish and mechanical properties. These are passed through the Skin Pass Mill (SPM) to give a bright finish and necessary flatness. The coils are ultimately either slit or sheared into finished products in the form of slit/divided coils or cut-lengths. The special surface finishes are obtained in the Sheet Grinding and in the form in the Strip Grinding Line (SGL).With the special feature of the computerized gauge control in Sendzimir Mill, it is possible to obtain very close gauge tolerances. The Ruthner neutral electrolytic pickling process in the APL ensures excellent surface finish and minimum environmental pollution.

Units in CRM

          

Cold build up line Bell annealing furnace Annealing and pickling line no:2 Annealing and pickling line no:1 Strip grinding line Sendzimir mill no:1 Sendzimir mill no:1 Roll grinding shop Skin pass mill Slitting line Shearing lineStrip grinding and polishing line 36

SAIL SRM UNIVERSITY

SALEM STEEL PLANT

PROCESS FLOW :COLD ROLL MILL 1. Hot rolled coil 2. Coil buildup line 3. Annealing & pickling line 4. Bell annealing furnace 5. Sendzimir mills 6. Strip grinding line 7. Skin pass mill 8. Sharing line 9. Slitting line 10. Coil inspection & dividing line 11. Sheet grinding & polishing line 12. PVC coating unit 13. Sheet packing line 14. Strecher leveler 15. Requiring shear 16. coil packing line

A- Annealing B- Pickling C- Shot Blating

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SAIL SRM UNIVERSITY

SALEM STEEL PLANT

17. blanking line

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SAIL SRM UNIVERSITY

SALEM STEEL PLANT

Output Stainless Steel coils and sheets of various sizes as mentioned in the marketing and metallurgical service. The purpose of any industry is to produce an end product that has a wide range market. SSP provide wide range of products, which is the input raw material for several industries of: Food Processing-Utensil Heavy Engineering-Railways Elevators-Coinage Washing Machine-Water Coolers and refrigerators Wall Paneling-Interior Decoration for Office/House Bus Body Building and so on…

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SAIL SRM UNIVERSITY

SALEM STEEL PLANT

6.STRENGTH,WEAKNESS &OPPORTUNITY OF SAIL

STRENGTH 

High Quality products



Experienced and skilled personnel



Customer Satisfaction



Leader of Indian Steel Business Effective innovative skills



Employee participation in Decision Making



World Class Respected Company

WEAKNESS Due to high quality prices are high which can be based on

 demand.

The advantage of competition

 OPPORTUNITY

 To increase steel , coils & steels & other products  Globalization of market is the best way to access the whole world  Salem Steel Plant can better exploit the cheep resources as well as the skilled employees.  To huge width in India & a number of plant are to formed

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SAIL SRM UNIVERSITY

SALEM STEEL PLANT

7.CONCLUSION For an Engineering student a learning combination of theory and practice is an valuable asset which helps in understanding the core principles of business by the way of first hand experience

This in plant-training in Salem Steel Plant has given me such a

great experience about all the managerial functions, which is going on in the company. It also helped me to understand the exact mechanism of working of the various departments. After completing this in plant-training I could be able to understand much more about the Salem Steel Plant the MNC which is the most reputed name in the corporate world. Salem Steel Plant known for its quality products. This knowledge will help me well to establish myself in the corporate World after completing my academic session.

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