This project was prepared by me when I was doing my major training in "Bhilai Steel Plant" during my 6th semester of B.tech mechanical engineering. Our training duration :- 13 July to 9 August, 2022. In this project I have covered overview of "Bar and rod mill" and also the working of "Automated strapping machine".

1. A PROJECT REPORT ON
AUTOMATED Strapping
MACHINE
Place Of Training: Bhilai Steel Plant, Bhilai (C.G.)
Project Guide: Mr. S.K. Soni Sir
Department: Bar and Rod Mill
Training Period: 13/06/2022 to 09/07/2022
Report submitted by:-
1. Anurag Yadav
2. Prem Kumar Verma
3. Bhupesh Sahu
4. Aman Chouksey
5. Prateek Tumrali
6. Siddharth Behra

2. Acknowledgment
It gives us great pleasure to accept the opportunity to undergo Project based
training at BHILAI STEEL PLANT of SAIL for the period June 13 to July 9,
2022.This training has been a constant learning experience and we look forward
to undertake more such stimulating training in the future.
Firstly, we would like to express our deepest gratitude to our Project Guide Mr.
S. K. Soni Sir (Sr.Manager BRM, BSP), who assigned us this project and it is
solely due to him that we learn a lot. It has been a wonderful learning
experience in Bhilai Steel Plant. We would never be able to finish our
dissertation without his excellent guidance, caring, patience, and providing me
with an excellent atmosphere for doing training.
We would not forget to remember Mr. S. K. Marathe sir HRD for his
encouragement and more ever for timely support and guidance till the
completion of our project work.
The data presented in this report have been drawn from a large number of
sources and people. We shall be happy to receive criticism if thereby we may
learn more. We acknowledge our debt to all those people who helped us in
preparing this project report in its present form.

3. Abstract
Steel is an alloy, a very strong metal that is made from iron mixed with other
element like carbon manganese nickel chromium etc. There are mainly four types
of steel, Carbon steels, Stainless steel, Tool steels. Each different type of steel has
unique characteristics which lead it to being used in its respected fields.
In BSP, The production capacity of hot metal, crude steel & saleable steel after
completion of modernization & expansion programmeis as under:-HOT
METAL:- 7.5 MT, CRUDE STEEL – 7 MT, SALEBLE STEEL – 3.153 MT
Steel melting shop receives hot metal from iron making units and converts it into
various grades of steel and castes them into slabs, bloom and billets, after this
process BRM receives billet than it send to the reheating furnaces there we give
temperature at 1250°C then send to the roughing mill here we make round shape
then it pass to some more process namely cropping, finishing, flying shear, &
colling bed after this long process and hardworking we get India’s most trusted
bar TMT bars.
Then we send this bar for packaging, in packaging process we strap our bar with
the help of automated strapping machine the strapping machine compete this
process, strapping machine also play a vital role to complete the process of
making of TMT bars.

4. Content
CHAPTER 1: INTRODUCTION
1.1 Introduction 1-2
1.2 Objective of project work 2
1.3 Conclusion 2
CHAPTER 2: BAR AND ROD MILL
2.1 Introduction 3-4
2.2 Process and step involved 4
2.3 BRM Overview5
2.4 Explanation 6-7
CHAPTER 3: HUMAN PROFILE 8
CHAPTER 4: AUTOMATED STRAPPING MACHINE 9
4.1 Components working9-12
4.2 Conclusion 12
CHAPTER 5: CONCLUSION 13

5. Chapter 1: - introduction
1.1 Introduction:-
Bhilai Steel Plant (BSP) is one of the integrated steel plant units of Steel Authority
of India Limited (SAIL) which is in Bhilai, Chhattisgarh. It is the India’s one and
only sole producer & supplier of world class rails for Indian Railways including
world’s longest 130-meter rails in single piece, and a major producer of large
variety of wide and heavy steel plates and structural steel.
With an annual production capacity of 3.153 MT of saleable steel, the plant also
specializes in other product such as wire road and merchant product. The entire
range of TMT product (Bar &Rods) produced by the plant. By looking
earthquake-resisted grade and superior quality. The plant also produces heavy
structural including channel and beams. Along with these steel products it also
markets various chemical by product from its coke ovens and coal chemical plant.
It was set up with the help of USSR in 1955. The plant was commissioned with
the inauguration of the first blast furnace by the president of India, Dr. Rajendra
Prasad, on 4th
February 1959. Eleven times winner of Prime Minister’s trophy for
best integrated steel plant in the country.
BSP receives it primary raw material such high grade of hematite and magnetite
iron ore, limestone and dolomite from the respective captive mines of Dalli
Rajahra, Nandini and Hirri mines which are located at 30 to150 kms from Bhilai.

6. Inside the plant there operates: - there are 11- coke ovens there we convert coat
to coke, the first step of steel making process, 7- blast furnaces blast furnaces
produce pig iron from iron ore by making reducing action of carbon ( supplied as
coke ), 2- Steel melting shops it receives hot metal from iron making units and
converts it into various grades of steel and cast them into slabs, bloom, billet,
beam. 1-bloom and billet mill, then there is 1- bar and road mill here we make
TMT bars from billet there is 1- rail & structural mill, merchant mill and wire
road mill and other units such as 2- power plant and oxygen plants etc.
1.2 Objective of project work:-
Our project work describes the study of production of steel bars and roads
produced using continuous casting process and to maintenance of parameters
which involve in this process of production steel. In our working zone, there are
three water treatment plants (WTP-5, WTP-6, WTP-7,) used for the cooling and
reusing the water after filtration of oil and chips. And in our project, we also learn
that how the work takes process step by step in formal manner with the less
consuming time and effectively. It was great learning process.
1.3 Conclusion:-
Thus, the introduction about Bhilai Steel Plant and the process which they are
implemented in the production of higher quality steel was given along with the
details of Bar and Rod Mill highlighting the sections of BRM and WTP. The
objective of this Project work was also stated along with the details of the
organization of chapters presented.
BSP is such a great organization here the work is done in less time and here we
use every possible thing that can be used, here wastage of material is also very
less which creates a big difference. This reason makes BSP a successful
organization.

7. Chapter2 : - Bar and Rod Mill
2.1-Introduction :-
The Bar & Rod Mill (BRM) is designed to roll 0.9 MTPA of Billet (150x150mm) into
TMT bars & wire rods. The Bar & Rod Mill is equipped to produce a wide range of
products including Wire rod in Coil, TMT Rebar in Coil, TMT Rebar in Straight and
Quality Bar in Straight length in diameter ranging from 5.5 mm to 60 mm including
SAIL SeQR grades. The input material for BRM is supplied by Steel Melting Shops
#3.
The Bar and Rod mill (BRM) is one of the main production unit of the expansion
program of “Bhilai Steel Plant (BSP)”, SAIL to 7MT/year. The technology for BRM
is provided by M/s Danieli. The reheating furnace of BRM is built by M/s Fives Stein
with their latest Digital control system. The mill will have combination of one wire rod
line, two lateral bar lines and one central bar line, having wide range of products:
Wire Rod Line products –
• Quality bars & coils (5.5-22 mm)
• TMT Rebar in coils (6-12 mm)
Bar Line Products–
• TMT Rebars in straight length (8-40 mm)
• Quality Bars in straight length (16-60 mm)

8. This user-friendly automation system ensures minimization of Operating
Personnel. The high speed of rolling up to 110m/s and ready to roll concept
also ensures high productivity. The compact design of the mill and
optimization of input material temperature also results in substantial energy
Savings.
MILL: Major equipments–
• High Pressure Descaling facility
• 18 Nos. Of Mill Stands:
• 6 Stands Roughing Mill
• 6 Stands Intermediate Mill
• 6 Stands Finishing Mill
2.2 Process and steps involved :-

9. 2.3 BRM overview { Level-2 Automation } :-
Manually
BILLET STORAGE AREA
CHARGING BED AND
QUALITY CHECK
REHEAT FURNACE WITH WALKING BEAM MECHANISM
ROLLING
MILL
18
STANDS
FFB
QTB
DOG
HOUSE
TAIL
BREAKER
COOLING BED WITH
WALKING
BEAMMECHANISM
AUTO
STRAPPER
MACHINE

10. 2.4 Explanation:-
1) The billets of 150 × 150mm cross-section and 12m length is transferred to the charging
bed by means of a magnetic crane and the manual work is done here, now the further
processes will begin in full automation.
2) Before charging to the furnace, billet is checked by the camera sensors.
3) If in case any defect is found in the billet, it will be rejected.
4) Only the billets with no any defects are charged inside the furnace.
5) The furnace consists of 24 burners, which are fired with the help of gases being produced
and stored by BSP itself during various steel and coke making process from BF, LD-
converter and coke oven.
6) The burners are perfectly managed by the furnace itself according to different billet input
temperatures.
7) The furnace consists of a walking beam system, on which billet travel from inlet to outlet
of the reheating furnace.
8) After coming out of the furnace, the billet temperatures are around 1150-1250℃.
9) The billets coming out after reheating from the furnace are cleaned by means of a water
jet with around 250 bar pressure. This process is necessary in order to remove any
particle/impurities which can be deposited within the material during the rolling process.
10) Now after reheating and cleaning process, its time to pass the billet through the mill, for
rolling purpose.
11) The rolling mill consists of total 18 stands (9 vertical and 9 horizontal set of rollers).
12) After passing through 7 stands the billet cross-section is now reduced to approx 71-73
mm, and the billet tends to get its circular cross-section after further rolls.
13) As the billet cross section reduces, its length increases.
14) Now at the 15th
stand, the billet gets its dog-bone ( ∞) shape, which is then splitted from
center at the 16th
stand and converted into two rods which are further rolled in 17th
and
18th
stand.
15) Now our billet is converted into two rods.
16) These rods further go to the Fast Finishing Block (FFB).

11. 17) The FFB consists of tungsten-carbide rings , which gives the rod its specific TMT shape,
and also quality and SAIL logo are given to the TMT Bar.
18) Now the TMT is passed through Quenching and Tempering Box (QTB), where the TMT
get its properties. The QTB consists of several numbers of water sprays which effectively
cools down the outer surface of the TMT bar, making it Martensite structure.
19) The inner core/surface of the TMT bars are kept unquenched and kept cooling under
atmospheric air in order to make the inner material ductile in nature.
Martensite (HARD)
Pearlite (DUCTILE)
20) Then the TMT’s are send to Dog House where its front ends are cut and removed away.
21) The Dog House is a perfect example of Artificial Intelligence because it cuts the TMT
very precisely into 84 m pieces without disturbing the rolling speed.
22) The Tail Breaker reduce the speed of fast moving TMT BAR and put it on the walking
beam type cooling bed.
23) After shearing the bars in cold shear into 12 meter length, a bundle of 4 ton of TMT Bar
are made with the help of strapping machine and these bundles are ready to be dispatched.
Fig :- Cross-sectional view of a TMT bar

12. Chapter 3 : - human profile
BSP currently has nearly 55, 000 permanent workers on its direct payroll, of
whom approximately three-fifths work inside the 17 square kilometer plant and
the remainder for its associated mines and quarries, and for the purpose-built BSP
township. A handful of managers, and a significant proportion of the contract
labour force, are women, all the regular BSP workers assigned to duties inside
the plant are men. About 18,500 employees and 2,500 contractual workers are
imparted training every year at Human Resource Development Centre (HRDC).
Training also imparted to MSMEs, Academic Institutions, Vocational Trainees,
Apprentices, and Fresh Entrants. Central and Public Library with approx. 80,000
books, journals, magazines, newspapers and Technical Standards is run by HRD
Dept.

13. Chapter 4 : - automated strappingmachine
It is a machine which is used to prepare a bundle of desired quantity of TMT
bars with the help of straps.
It is hydraulically operated, and the major components of machine are:-
⮚ PLC (Programmable logic control unit)
⮚ Power pack
⮚ Strap dispenser
⮚ Strapping head
4.1 Componentsworking:-
1)PLC:-
• The “Auto strapping machine” is controlled and operated with the help
of PLC.
• It stands for programmable logic control.
• It operates the components of strapping machine according to the input
and output signals received from the control room.
2)HYDRAULIC POWER PACK :-
• All the hydraulic operations being performed on the head is powered
by the hydraulic power pack only.
• It maintains the hydraulic pressure and proper flow of the working fluid
in order to operate the machine.

14. • The picture given below is showing the hydraulic power pack.
MOTOR – Creates hydraulic pressure
RADIATOR – Cool down the heated fluid
OIL FILTER – Removes the contaminants
OIL TANK – Stores the working fluid
3)DISPENSER:-
• It is also the one of the major components of strapping Machine which
feeds the strap into strapping head.
OIL TANK
MOTOR
RADIATOR
DISPENSER
MOTOR
1431 JUMBO STRAP

15. • The strapping material (1431 jumbo strap) is loaded on to the dispenser.
• The dispenser rotation can be done by means of a motor.
4) STRAPPING HEAD :-
• Driver no-1 sends the strapping reel to the feeding unit via strap
guide. It is also known as feed wheel.
• Driver no-2 rotates in the reverse direction and tightens the
strapping reel around the batch of TMT.
• Driver no-3 performs the cutting task of strapping reel.

16. • The equipment no-4 is known as sealing unit. Its purpose is to
punch seal the strapping reel around the batch of TMT by
converting hydraulic energy into mechanical punching work. This
system consists of several no of cylinders, which can be operated
by the hydraulic energy supplied by the hydraulic oil via hydraulic
power pack.
• The flow of the hydraulic valve is controlled by means of a
solenoidal valve provided on top of the cylinder assembly of the
equipment.
• The combined apparatus of all the equipments explained above is
known as head or carriage.
• The whole head apparatus is designed to move back and forth
vertically, or we can say adjustable for punching purpose.
5) PUNCHING MECHANISM :-
4.2 Conclusion :-
• It uses1431jumbo strap for packaging with Thickness 0.79mm and 31.75mm
width.
• There are total seven straps in the bundle TMT Bars which machine uses to
punch.
• The distance of the straps are determined by the Different sensors which is
fitted in the strapping Machine which also gives the signals to PLC.

17. CHAPTER 5:- CONCLUSION
The project work at SAIL Bhilai Steel Plant in the time period of 4 weeks gave
us an intense industrial exposure and helped us to know more about our
theoretical skills we have learnt in our curriculum in the real industry work to get
optimum solution of the problem.
We learned about the practices and operations performed for production of good
quality steel. The management of the plant is excellent and taught us many things
apart from the project. Since the beginning of this training, we started working
on it with great enthusiasm, discipline & punctuality.
We have also visited other plants as to gain more knowledge and to understood
different processes going in that plant like Coke Oven, Blast Furnace 8, SMS-3,
URM & WRM.
We were assigned the project of studying the “AUTOMETED STRAPING
MACHINE” in Bar & Rod Mill, its functions and maintenance. We have watched
each and every process in BRM especially AUTOMATED STRAPING
MACHINE’s major processes. It is important that for efficient output each and
every system has a major and crucial role to play.
In our project we learnt that the overall efficiency of a process can be altered by
proper maintenance of all the components of system. Even if a minor defect
occurs, we have to detect & solve it as soon as possible in the running time so
that the process cannot be affected. The plant is run for 365 days constantly every
day & is a great example of balance between machines and humans