MANUFACTURING OF 140 T LADLE

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7/7/2017
SUMMER INTERNSHIP
REPORT 2017
By: ASHISH JAISWAL | USN: 1DS15ME019
Department of Mechanical Engineering
DAYANANDA SAGAR COLLEGE OF ENGINEERING
Shavige Malleshwara Hills, Kumaraswamy Layout, Bangalore-78

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ACKNOWLEDGEMENT
I am greatful to acknowledge the continuous encouragement, invaluable
supervision, timely suggestions and inspired guidance offered by
Mr. Rajesh Thakur , DGM , I-SHOP where students rarely get a chance to intern .
Mr. Ajeet Yadav , Senior Engineer and Mr. Saurabh Bagad and Mr. Prabhakar
Yadav Department - I SHOP, JSW Steel LTD. in bringing this report to a successful
completion. I consider myself extremely fortunate to get a chanceto work under
the guidanceof such a dynamic personality.
Last but not the least; I extend our sincerethanks to all other faculty members at
JSW Steel Ltd. for their help and valuable advice in every stage for successful
completion of this case study as a project report.
Iwould like to express my special thanks of gratitude to Mr. Dipansu Laskar (AGM
,HR) and Mr. Sourav Bagchi(Senior Officer ,HR) who gave me the golden
opportunity to do this wonderfulprojecton the topic "Manufacturing of ladle ”,
which also helped me in doing a lot of depth search in field and I came to know
about so many new things and I am really thankfulto them.

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PROJECT: MANUFACTURING OF A LADLE
MANUFACTURING PROCESS :
 RE-ENGINEERING DEPARTMENT
 PLANNING DEPARTMENT
 FABRICATIONDEPARTMENT
 MACHINING
 ASSEMBLY
 FINAL INSPECTION
 SURFACEINSPECTION
 DISPATCH
 REFRACTORY INSTALLATION

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RE-ENGINEERING & DRAWING DEPARTMENT
1. The drawings areissued from the Design department which are taken from
that particular department
2. The design department ( DRAWING STUDYDEPARTMENT)
3. Model view creation in SOLIDEGEsoftware
4. All the views of each items are prepared
5. Assembly of all the models
6. detailing of assembly drawings
7. Available drawings will be used for BOM preparation of SFGs(semifinished
goods)
8. total raw material required and thickness required
9. based on detailing cutting plan is made
10.procurementdrawing is also made ( pre-machined indent )
11.If Drawings arenotavailable ReverseEngineering for thoseitems at
customer site
12.BOM is forwarded for costestimation of the project. Estimated costis
reviewed and approved by project planning and the same amountis
mentioned to the user department
13.Drawing received from the user dept. is photocopied and distributed as
follows-
a) Production - 03 copies d). Quality - 03 copies
b) Machining - 02 copies c) Planning - 01 copy

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BILL OF MATERIALS FOR 140T LADDLE

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PLANNING OFFICE
 This department handles the availability of raw material , Gradeof raw
material required according to job
 Head will allocate job to a Projectmanager(PM)
 Based on BOM PurchaseRequisition (PR) is raised for boughtout items (Z
spares)
 After technical evaluation of items file sent to PurchaseDept. for ordering
of Z spares
 Job Card will be generated against different POs for respectiveproject
 Routing of job will be allocated to different work centers as per operations
involved
DOCUMENTATION:
 Document verification - Review the approved drawing fromdesign
department .
 Raw material certification by MTC ( material Testing Certificate)
 Verification of WPS (Welding ProcedureSpecification) and WPQ (Welder
PerformanceQualification).
 Calibration report for calibrating equipments
 Drawing review as per QAP (QUALITYASSUARANCEPLAN)

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FABRICATIONPROCESS :
 Shell plate marking and correlate the heat number and plate number,
which is hard punched during marking inspection.
 Now the raw material is sentto cutting department where CNC Oxy-
Acetylene & Plasma cutting machine cut the plates according to the cutting
plan (TEMP-2882deg Celsius neutralflame)
 CNC machines receive their programfromDesign department and is
automatically feed into machine when Heat number and batch number is
entered in machine program
 Marking of holes on plate and edge preparation

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 Rolling the plate into a shell by rolling machine
 Setup /Fit up/ box up : refer figure 1
 Preheating the job whereever required
 check up all fit up joints for root gap and welds and dimension
 NDT(Non DestructiveTest) is carried out :as per ASME SEC- V
1. DPT (Deep Penetration test) - carried out on all back
chipping of groovejoints cleaner and developer
2. UT (Ultrasonic test) - carried out on all butt welds of
ladle (inthe range between0.5and15 MHz)
3. RT (Radiography Test) - carried out on all joints and
dish to shell butt joints
We also refer SN- 200
ASME- SEC IX
ASME SEC- VIII
AWS D1.1

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
 Job is send for SR ( Stress Relieving ) and visualinspection done for
welding bur and scales.
 Remove high points or burs by grinding and again straightness to be
checked.
 Shot Blasting to be carried out, touch up to be done for welding break-up,
undercuts and grind finish the job
2 vertical
plates
Lower
bendring
Paws
Ladle rest
pin
FIG.1

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 Final inspection for internal cracks doneusing Radiography Test &
Ultrasonic Test
 Primer to be applied on the fabricated job and sent for machining and
assembly

MACHINING PROCESS:
 Fabricated items and casted items for machining are received with
Production Order no.
 Job loading on machining centers as per plan and route card
 All types of machining operations like milling , drilling , boring etc are done
 Machining hours to be recorded manually in excel sheets for actual
machining cost
 Inspection is carried out and recorded by QA (Quality Assurance) to check
dimensional accuracy after machining
 Dispatch the job to assembly section
ASSEMBLYPROCESS:
 All the parts of job are assembled in the assembly zone with the help of
over head cranes (100T)
 This is the most critical process in this job preparation
 components of job are joined by bolts and welding
 Duration of assembly is usually 8 hrs .

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FINAL INSPECTION:
 Final dimension check with drawing as a reference
 Cross check of items with Bill of materials (VISUAL CHECK)
SURFACEINSPECTION :
 Shot blasting - shall be carried with monochromeballs for surface
preparation , removes all dustan gives a good surfacefinish to job
 Painting - Primer and Heat resistantcoat shall be done as per customer
requirement
DISPATCH :
 Placing of I-SHOP logo
 Packing the job and dispatching it to its client
REFRACTORY INSTALLATION:
 This process is done at clients side
 then ladle is ready to use
9.1 HOT METAL LADLES
 Refractory Bricks of various shapes areused for laying along the shell.
 Nature of slag is Acidic, Si, P, S and C are inclusions.
 Refractory lining includes:
o SAFETY LINING

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o WORKING LINING.
IS-8 QUALITYBricks areused in safety lining.
TYPES OF REFRACTORY BRICKS
 ACIDIC, BASIC AND NEUTRAL
 ALUMINA
 SILICA
 CHECKER BRICK
9.2 CHARGING LADLES
 Condition of the Refractoriness being subjected to Transfer Ladles are
same as that of Corex Ladles in terms of inclusions, except desulphurised
metal being poured to Mixer (homogenization) later poured to Charging
Ladles.
 Hot Metal Temperature is low, appr: 1300-1350 deg Cthan that of COREX
Ladles whereappr. Tapping Temp. Will be 1500 - 1550 deg
 Hot Metal retention time is less. Hot Metal Weight is high about 127 - 135
MT.
 Impactof Hot Metal is from height of around 9 meters at Bottom Impact
and Striker regions, whereas Impactis on Bottom Conical in case of Corex
Ladles.
 Side Wall and Bottom Safety Lining is IS-8 quality bricks.
 Side Wall Working is HG Bricks. Bottom Impactand Striker region is 80%
Alumina bricks. Bottom is lined with 70% Alumina bricks.
 Repairs include: Spout Repairs, Impactand Striker Repair
9.3 STEEL LADLES
 Temperature of Operation is very high than that of Hot Metal and Charging
Ladles. Subjected Temp.will be around 1630 - 1680 deg C. Dueto Agitation
or homogenization of steel by Bottom Purging, bricks areprone to abrasion
 Basic MgO-Ccomposite bricks areused.
 Superior quality 97% MgO based bricks used in Slag Line.

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INNERREFRACTORY LINING :

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PROJECT : MANUFACTURINGPROCESS OF 140T STEEL LADDLE
JOB CARD NO : ISMR-SMS1-00161
DRAWING NO : BT-1100 Z008001-R3
BUDGET ALLOCATED : 32 LACKS
TIME OF COMPLETION : 85 DAYS
GRADE OF RAWMATERIALS USED : STEEL Gr-2 IS:2002-1992 or
SA516Gr.70
DEFINATION : Ladles are the means of transportation of Hot metal from area of
manufacture like Blast furnace/ COREX to areas of conversion
 Hot metal to Steel – Charging Ladles
 Steel to Slabs/Ingots/Billets – Steel Ladles
 Ladles used for transportation of hot metal fromIron making units
may be HM ladles/Torpedo ladles

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DETAILED DRAWINGS OF LADLE

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COMPONENTS OF A LADLE :
PAW
MAIN
SHELL
SPOUT
DISH
END
TILTING PIN
LALDE REST
PIN
FLANGES
TRUUNI
ON PIN

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MAIN SHELL
MAIN SHELL
(OD=3754)
(ID=3722
(THICKNESS=32)
(HEIGHT = 2473)
OD=3754
DEPTH= 2505
THICKNESS= 32

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TOP SPOUT FABRICATION
TOP SPOUT
(HEIGHT =584)
(DIAMETER = 3754)
FISH LIP
OPENING
TOP SIDE
FLANGE

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BOTTOM OF THE LADDLE OR DISH END
DISHEND FOR
BOTTOM
TILTING PIN
3 (placedat
120◦)
SUPPORTING
PLATES FOR
WEIGHT
SUPPORT

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TRUUNION PIN & LADDLE REST PIN
LALDE REST
PIN
TRUNION
PIN

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TECHNICAL DATA OF A LADLE:
 SPECIFICATIONS
 LADLECAPACITY 140T
 HOTMETAL VOLUME 20.67mm3
 DENSITYOF HOT METAL 6.8t/m3
 CENTRE OF GRAVITY OF LADLE IN DIFFERENT LOAD CONDITIONS
CONDITION DISTANCE FROM TRUNION CENTER
(mm)
Ladle empty condition 515
Empty condition with refractory 656
50T hot metal 1034
100T hot metal 902
140T hot metal 803
 LOAD DATA
Weight of ladle 30.5T
Ladle vessel + refractory 71.5T
Weight of full ladle 211.5T
Weight of full ladle + slag buildup 216.5T
 TOTAL HEIGHTOF LADLE: 3593+50 =4003

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OPERATIONS ON A LADLE :
1) Material Identification: Identify the material, the grade as per given
drawing Punch the Project no: on material.
2) Cutting Plan of Items: Prepare the cutting plan (nesting) for all the
items to be cut from the plate as per detailed dwg. no BT-1100
Z008001-R3 with considering shrinkage and machining allowances.
Shell plate should be cut in rolling direction of the plate.
3) Inspection of Nesting: Check the nesting or cutting plan , punch the
item identification no. on each item as per standard format. Heat no. to
each item. Software used is Nanocad
4) Preparation of Dish end
4.1)Dish End Cutting: Prepare cutting plan(Nesting)for dish end
with a single plate or welded plate (if reqd.) considering
shrinkage, forming and machining allowance.
CUTTING PLAN OF ONE
OF THE SHEETS OF A
LADLE

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4.2)Inspection of Dish End: Conduct NDT of dish end. If not OK,
repair and to same. Follow QAP
4.3) Forming of Dish End: Form the dish end as per given
dimensions.
4.4) Inspection after forming : Check visually and dimensionally
the dish end.
4.5) Edge preparation of dish end: Maintain the height of dish
end create WEP on open end as mentioned in Drg.
4.6) Inspection of dish end after WEP: Check visually and
dimensionally the WEP and height of the dish end.
4.7)Drilling of dish end: Mark & Drill the vent holes dia.10mm as
per center distance given
5) Preparation of Main shell
5.1) Rolling of shells: Bending of the shells body must be done in
the rolling direction(longitudinal direction ) of the plate.
5.2) Inspection of shell after rolling: check the diameter of the
shell after rolling. If not OK re roll the same. 1st the 2 vertical
plates are welded temple like structure is welded
5.3) then lower bend ring is welded to provide support
5.4) then a spider web is welded to prevent shrinkage in shell
during welding
5.5) Vent hole drilling on shell plate: Mark for the vent holes as
per center distance given in the Dwg. Drill holes Ø10mm as per
marking.

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5.6) Dressing of items: Remove slag and dress all the items.
6)Main top shell & spout bottom flange :
6.1) flange plate marking & cutting
6.2) flange plate individual setup & inspection
6.3) but welding of individual flange joint
7)Top shell :
7.1) shell plate marking and drilling and edge preparation
7.2) top shell top flange marking cutting and edge preparation fit
up and welding
7.3) rolling of plate (OD=3754mm) set up and welding
7.4) flange fit up in topside and welding
7.5) mouthpiece plat cutting /bending& fit up with main shell and
drilling
7.6) mouthpiece welding with main shell
7.7) opening cutting in main shell and grinding
8) 60mm thick main shell and top shell flanges:
8.1) both flanges are combined up to get 60 mm thick shell in
middle section of ladle
9) Flange &n main shell
9.1) flange setup with main shell
9.2) flange welding with main shell

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10) Trunnion:
Marking: Mark the center line of the ladle to setting on the
machine and check the machining allowances on trunnion & hook
holes.
10.1) Trunnion hole machining: Finish the Bore Ø560 H7 (see
detail Dwg. of trunnion) . Put chamfer on all chamfer edges as per
Dwg. make drill through hole dia 65mm and C/bore dia 80x20mm
deep for trunnion sleeve fitting.
10.2) Trunnion Pin Machining: Finish the trunnion as per size
Ø580 H7 (trunnion) . Put chamfer on all sharp edges as per drg.
make drill through hole dia 65mm and C/bore dia 80x20mm deep
for trunnion sleeve fitting.
11) Inspection After Machining: Check the bore diameter of the
trunnion holes/trunnion diameter and make a report of interference.
12) Trunnion Assembly: Check the bore diameter of the trunnion
holes/trunnion diameter and the pin is fitted by a shrinkage fit (0.1 to
0.25) the hole is heated and pin is fitted into the hole and further
welded and back chipping is done
13) Welding of Trunnion: Preheat the welding area and weld the
trunnion circular seams as per specified in the Dwg.
15) Paw arrangement :
15.1) paw plate cutting marking and edge preparation
15.2) fit up and welding with main shell
15.3) assembly send for bore machining in flanges

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14) Stress Relieving: Relieve stress from the trunnion welded area by
local SR.
16).Dish end setup with main shell:
16.1)dish end setup & welding & back chipping & final welding
17).Spout set up with main shell:
17.1) complete assembly of main shell with spout part bolting in
flange of spout
17.2) 10.Nos shear block fit up & welding with main shell top
flange
18) Stress relieving: After all welding work the ladle has to be annealed
as one piece. Heating Rate: 50°C/hr, Annealing temp: 550°C - 620°C,
Hold time : 6 hr, Cooling Rate : 45-50°C/hrs as per standard SR graph (
AWS D1.1)
19) Shot Blasting: Shot blast the component with suitable shots (Cu
slag) unless and until not mentioned any specific shots for any
As a sample of STRESS
RELEIVINGGRAPH OF LADLE

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components. Here steel grade G-24 is used
as a sample of shot blasting surface grit
20) Primer Painting: After cleaning the shots apply primer paint /red
oxide on the ladle.
19) Final Inspection: Check all the activities visually and dimensionally
prior to paint the ladle.
20) Final Painting: Clean all the surface prior to apply paint, paint up to
required ladle. Paintings should be checked by DFT (dry film thickness)
AFTER SHORT BLASTING
WITH MONOCHROME
BALLS

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21)Packing and Identification: All Item shall be securely packed and
items shall be adequately marked for identification at site.

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SEQUENCE OF ASSEMBLY
1. DISHEND is grounded
2. MAINShell is placed and then welded
3. Top Spout is bolted

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DISTPATCH

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WELDING TYPES DURING FABRICATION:
SUBMERGED ARC WELDING (SAW) is used it comprises of consumablewire and
flux.
 1G WELDING: This type of welding is done on plates lying on floor
 2G WELDING: This type of welding is done in vertical direction of the
job(left to right)
 3G WELDING : This type of welding is done on straight standing plates and
curved surfaces (down to up )
 4G WELDING: This type of welding is done underneath surfaces to join 2
plates.
 Welding electrodes as per standard IS-814 or AWS 5.1
 PROCESS OF SAW WELDING

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ELECTRODE CONSUMPTION SHEET
Total Electrode Consumption = 1.1 tones
WELDING ELECTRODE AND WIRE :7018-A1H4R(4 & 3.15) and E312-
16(2.5)

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CHALLENGES FACED DURING MANUFACTURING :
 Lack of information in the detailed drawing which causes
following problems :
o Dimensional relatable problems of the job
o Sometimes drawing is too complex for the contractor to
understand
o Faults in setup of job
 During Welding :
o No information in detailed drawing regarding support
positioning before welding
o Defects :
 Undercut
 Lack of fusion
 Cracks ( longitudinal and transverse)
 Porosity
 Deep penetration
o Mismatch in joints
o Temperature should be maintained while welding
otherwise cracks and holes are formed
o Proper usage of consumable electrodes so that their
properties do not change
o If electrodes are not used within 8 hrs then should be
returned to stores for baking into oven

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 Preheating & Post heating :
o This is done to remove the moisture from plate which
done prior to welding
o If welding is done directly then Austenite phase form of
Iron plate will be formed , small pores will be formed
 Post welding (if required) when there is a distortion in plates
and dissimilar metals
 Ovality :
o During welding due to lack of support the metal tends to
shrink inwards which causes change in shape
( circular --> oval )

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 During Assembly :
o When different components are assembled by bolting
then some holes do not match up between spout & main
shell
o Mismatch of holes between bottom shell & main shell
SOLUTIONS FOR CHALLENGES
 Updating the missing data in the detailed drawing
 Up gradation or revision in drawings prevent the
misunderstanding
 Giving the job as per clients requirements with 99%-99.8%
match as per issued drawing
 Welding to be done accordingly as per drawings
 Preheating the job for removal of HYDROGEN which is trapped
in austenite phase and to remove moisture content
 Proper dimensional checks to prevent dimensional related
errors
 Proper supports to prevent shrinkage as well change in shape
 In case of mismatch during assembly , JACKING is done and
bolts are bolted in their places

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THANK YOU!!!
BY: ASHISH JAISWAL
USN: 1DS15ME019