İSDEMİR Erdi Karaçal Mechanical Engineering 3rd Year Orientation Programme Report


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İSDEMİR Erdi Karaçal Mechanical Engineering 3rd Year Orientation Programme Report.

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İSDEMİR Erdi Karaçal Mechanical Engineering 3rd Year Orientation Programme Report

  2. 2. CONTENT CHAPTER 1 PAGES 1) DESCRIPTION OF THE COMPANY…………………………...….4     1.1 NAME OF THE COMPANY………………………………………..…..4 1.2 LOCATION OF THE ORGANIZATION………………………………4 1.3 BRIEF INFORMATION ABOUT FACTORY…………………………5 1.4 COMPANY PROFILE………………………………………………….6 1.4.1 General Information About Personel………………….……….6 1.4.2 Number of Engineers Employed………………………………6 1.4.3 Operation Capacity…………………………………………….7 CHAPTER 2 INTRODUCTION……………………………………………………..8 2.1 PRODUCTS OF FACTORY………………………………….…..9 2.1.1 MAIN PRODUCTS AND WORKING AREAS……………………..9 2.1.2 BY-PRODUCTS AND WORKING AREAS………………………...10 2.2 PRODUCTION STEPS OF PROCESSES………………………..11 2.2.1 Isdemir Harbour………………………………………………………11 2.2.2 Sintering Plant and Ore Preparation…………………………………..12 2.2.3 Coke and By-Product Plant…………………………………………...13 2.2.4 Iron Making Plants (Blast Furnaces)………………………………….14 2.2.5 Steel Making Plant…………………………………………………….15 2.2.6 BOF Shop (Basic Oxygen Furnaces Shop)……………………………16 2.2.7 Continious Casting Plant………………………………………………17 2.2.8 Rolling Mill……………………………………………………………18 CHAPTER 3 3.1 SELECTION CRITERIAS OF THE FACTORY LOCATION...…20 * Aspect of raw material * Energy * Transportation * Effect of Climate 3.2 PLANT LAYOUT…………………………………………….22 2 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  3. 3. PAGES CHAPTER 4 4.1 CONTROL TECH AND PRODUCTION PLANNING……..23 4.2 ACCOUNTING………………………………………………23 4.3 PURCHASING DEPARTMENT…………………………….24 4.4 POWER PLANTS AND ENERGY FACILITIES…………...25 4.5 QUALITY AND STOCK POLICY…………………………..26 4.5.1 Definitions About Quality………………………………………26 4.5.2 Quality Control…………………………………………………..27 4.5.3 Quality Control in Production Process…………………………..27 4.5.4 Quality Policy……………………………………………………29 4.5.5 ISDEMIR Quality Management System………………………....29 4.5.6 Stock Policy………………………………………………………29 4.6 WORKERS HEALTH AND WORK SAFETY………………30 CONCLUSION……………………………………….….31 APPENDIXES……………………………………………32 3 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  4. 4. CHAPTER 1 DESCRIPTION OF THE COMPANY 1.1 Name Of The Company: 1.2 Location Of The Organization: İSKENDERUN DEMİR VE ÇELİK A.Ş. Karayılan Beldesi 31319 İSKENDERUN / TÜRKİYE Tel : +90 (326) 758 4040 (Santral-PBX) Faks : +90 (326) 755 1184 - 758 5351 - 758 3838 Web: Figure 1: General view of the İSDEMİR 4 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  5. 5. 1.3 Brief Information About Factory ISDEMIR is the biggest integrated Iron & Steel Plant of our country in terms of long product production capacity. ISDEMIR is the only integrated facility of Turkey producing long and flat product with its 5.5 million tons/year capacity. Integrated means that ISDEMIR produce its products by using iron ore as a raw material. And the output product of one department’s are used to another departments.For example when producing coil, the output of the continuous casting plant as slab is used. For example in the coke factory when coal is heated without oxygen to making coke, lots of coke gas are produced and these gases are collected, filtered and are used at another department. This is the adventure of iron ore to billet, slab, sheet metal. Long products are producing like pig iron, bloom, billet, construction steels in international quality standards. Production is made with Coke- Sinter –Blast furnace – Steel mill – Continuous Casting and Hot Rolling Processes. All of the shares of ISDEMIR are transferred to ERDEMIR by Privatization Administration with Share Transfer Agreement dated 31 January 2002 on the condition that investments shall be made towards flat product production in ISDEMIR.(3 billion dolar investments) Currently, 92.91% of ISDEMIR shares are owned by ERDEMİR, and 7,09% are owned by ISDEMIR Employees Support Foundation. ISDEMIR’s initially 2.2 million tons/year liquid-steel capacity will be increased to 5.5 million ton/year and besides long products, mainly production of flat products will be made when Modernization and Transformation investments (MTI), planned in 2003 and initiated in 2004, are completed. 5 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  6. 6. 1.4 COMPANY PROFILE 1.4.1 GENERAL INFORMATION ABOUT PERSONEL  Total Number of Employees : 5571  Top Level Managers: 7  Middle Level Managers: 49  White Collar Staff : 497  Blue Collar Staff: 4442  Contractual Personal: 36  Employees with Disabilities: 119 1.4.2 NUMBER OF ENGINEERS EMPLOYED: Man:%90 Women:%10 Blue Collar:%80.2 White Collar:%19.8 Figure 2:Graphics of the employees 6 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  7. 7. 1.4.3 OPERATION CAPACITY Capacity of the main units are shown in below ; Table -1Units Capacity ( ton/year ) Explanation Harbor 12 million Handling - Unloading Coke Plant 2 million 6 battery (over 275 oven) Sinter Plant 2.9 million 4 Machine Blast Furnace Have 7.8 million Capacity 4 Blast Furnace Produced 4 million Aim 5 million Pig casting machine 0.7 million __ Steel Making Plant 5.5 million Pure Steel Continuous casting Plant 5 million 2 slab casting machine Coil Rolling Plant 3,5 million __ Energy Facilities 220.4 MW __ 7 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  8. 8. CHAPTER 2 INTRODUCTION Aim of this summer practice programme is to improve knowledge which we learned at the university and give us a chance for practice. Summer practices provide good opportunities to make students see the application areas of the theoretical knowledge in industry. Third Year of my education life at mechanical engineering, orientation programme ME399 covers the following topics;  Plant organisation and management like type of organisation  Factors taken into account for plant location for example due to staff, energy, raw material, sale and delivery.  Storage and stock layout, quality control applications.  Auxiliary facilities like power plant of the factory Theoretical knowledge is very important at the enginering part of a product. An engineer must know the criteria for the proper design of the product. But theoretical knowledge alone is not sufficient to manufacture a product. Some perfect desing might be developed with only theoretical knowledge, but such desing might not be manufactured because of the impossibilities on the production stage. Thus, practical knowledge has a great importance in the education Factory work introduces the engineering student to the real world and the actual problems which engineers usually encounter with on of an engineer. I have done my third orientation at Isdemir Iron and Steel Factory at the department of Study Project Directorship.I have been there 4 weeks from the date of 26/August /2013 to 23/September /2013 as 20 workday. 8 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  9. 9. 2.1 PRODUCTS OF FACTORY 2.1.1 MAIN PRODUCTS AND WORKING AREAS Main product range of ISDEMIR consists of pig iron, billet, coil, slab, hot rolled coils and plates. Besides these products, by-products such as coke, oxygen, nitrogen, argon, ammonium sulphate, granulated slag, coal tar and benzene are also obtained. BILLET Steel billets are produced via continuous casting of liquid steel, which is obtained from basic oxygen furnaces. Billet is a semi-finished product mainly used in manufacturing of wire rod, reinforcing steel bar, steel profiles and seamless pipe. WIRE ROD Wire rod is used in the production of commercial products such as mesh, wire, nail as well as it is used in the production of industrial products such as bolt, spring, electrode and welding wire. SLAB Steel slabs are produced via continuous casting of liquid steel, which is obtained from basic oxygen furnaces. Slab is a semi-finished product mainly used in manufacturing of hot rolled coil and hot rolled plate. 9 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  10. 10. HOT ROLLED FLAT PRODUCTS With the modernization and transformation investments (MTI) made, besides the long products, also flat products production started of at August 2008.ISDEMIR’s hot strip mill has a capacity of 3.5 million ton per year. Usage: Automotive industry and ship building, can and tin production, pipe and profile 2.1.2 BY PRODUCTS AND WORKING AREAS During steel production process, a variety of by-products are produced.ISDEMIR use some of them in the factory. For example in the coke factory ,when making the coal as coke so many coke gases rise.Gas holders collects these gases and pumped to another department to use. Another example is ; when producing steel ,many slags occur.Isdemir sell this slags to the cement factory. When producing steel from pig iron sulfür content must be reduced.when doing this, sulfur is collecting and ammonium sulphate is producing.Isdemir sell this products to fertilizer (gübre) factory.      Granulated Blast Slag 500.000 tons/year (is selling to the Cement Factory) Coke coal : Melting of the pig iron for casting operations. Crude Benzene(Light Oil) (ham benzol) 30.000 tons/year (chemistry sector) Ammonium Sulphate (Fertilizer) 40.000 tons/year (is selling to fertilizer factory) Tar (Ham Katran) 75.000 tons/year 10 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  11. 11. 2.2 PRODUCTION STEPS OF PROCESS 2.2.1 ISDEMIR HARBOUR We can say that production starts with the raw materials which are transported to factory by means of Harbour Isdemir harbour is very important for loading export products that are produced by the plants as well as unloading iron ore which is main raw material of factory, pollet ,coal and fuel oil.Moreover ,Isdemir makes significant income from loading and unloading of third party cargoes (another factory’s cargoes).Isdemir serve to customers from cities such as Antakya, Adana, Mersin, Kayseri, Nevşehir, Niğde, Ankara, Gaziantep, Kahramanmaraş, Malatya and Elazığ. Furthermore, loading/unloading, terminal and warehousing services could be provided for transit trade customers. Figure-3: Cranes and Coils Figure-4:Capacity of Harbour Required improvement on the existing harbour is made to load products (billets ,slab ,coil ,wire road and pig iron), which will be sent to domestic and foreign markets and to unload raw materials required by increase in productions. Today,Isdemir harbour has 2 unit 50 tons unloading cranes, 5 unit 15 tons cargo crane ,4 unit 10 tons cargo cranes,2 unit 50 tons cargo cranes will be purchased and builded at Dock no.4 ISDEMIR use long converyors to transport to raw material from harbour to departments. 11 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  12. 12. 2.2.2 SINTERING PLANT AND ORE PREPARATION The main aims of the plant are unloading and stocking the raw materials like iron ore, pellet, dolomite, limestone etc., reclaiming, grinding and screening of these materials, preparing sintering mix and producing sinter, supporting Blast Furnaces and BOF Shop with these materials. Figure-5:General view of the sinter furnace Ore Preparation and Blending (Mixing) Facilities enable raw materials that are brought to Isdemir to be taken to stocks, to be ground and to be blended and the user units to be fed by the prepared raw materials. Ore preparation facilities consist of open stocking areas with capacity of 700,000 tons, 160,000 tons capacitated pellet stocking pool, 2 x 40,000 tons blending yards and other stocking yards. There are 4 stocker/reclaimed machines on open stocking areas and 4 stockers in stoking yards. 12 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  13. 13. 2.2.3 COKE AND BY-PRODUCT PLANT The main function of coke factories is to produce metallurgical coke for the blast furnaces. The plant consists of coal preparation facilities, coke oven batteries and by-products. Figure-6: Coke plant Coal preparation facilities (tesis) consist of open stocking areas with capacity of 480.000 tons, 4 stocker/reclaimed machines that work on stock areas, 12 coal silos that have a total capacity of 29.600 tons, coal crashers and mixers. The total capacity of coke batteries is 2.000.000 tons/year in dry base. Coke factories consist of 6 batteries each has 69 furnaces. There are one coke wet (with water)quenching station and one coke dry(with nitrogen) quenching (söndürmek) plant in order to quench the hot coke. Crashed coke then screened and classified according to the dimensions as metallurgical coke, coke nut(ceviz) and coke breeze (kül). The coke gas that is produced during coking process of the coal is treated in the byproducts plant, and products such as pure benzene, pure xylene, pure toluene, solvent naphtha, ammonium sulphate, coal tar and electrode pitch are produced. The coke gas that is cleansed at the end of these processes is used as fuel in coke batteries and in the other units. Coke ovens and by-products plants are intended (designed) for the production of metallurgical coke to be used in Blast Furnaces. 13 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  14. 14. 2.2.4 IRON MAKING PLANTS ( BLAST FURNACES ) Figure-7: Molten metal The main task of this unit is to produce hot metal. There are 4 blast furnaces in Isdemir namely Cemile, Ayfer, Gönül and Dilek.As it seen that furnace’s names are woman’s name.The aim of these is; women can bring a child to the world and this event liken to making iron from raw material.Production capacities of Cemile and Ayfer is 2.000 tons/day for each and the production capacity of Gönül is 3.000 tons/day, so the total production capacity is 7.000 tons/day and 2.450.000 tons/year. In order to get hot metal, sinter, pellet, lump ore and metallurgical coke are charged into the blast furnace. Also, supplementary materials that help slag (cüruf) formation such as limestone, quartzite, and dolomite are charged into the furnace. Figure-8: Molten metal is poured into ladle 14 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  15. 15. 2.2.5 STEEL MAKING PLANT Steel Making Plant accomodates (barındırmak) two mixers where molten metal from blast furnaces is poured. Also employed are 200 tonnes LD converters where conversion into steel is accomplished . Converters are first charged with steel scrap then with molten metal from mixers in ladles (pota) . On completion of charging ,oxygen is blown into the converter and lime as well as other flux material are added . After accomplisment of required steel chemistry and temperature ,molten metal is trapped into steel ladles .Meanwhile ,alloying and deoxidation elements are added. There are two ladle metallurgy stations ,a chemical station and a electrical station which are both used for further refining and adjustment of steel composition and temperature. Figure-9:Loading of Melted Pig Iron 15 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  16. 16. 2.2.6 BOF SHOP (BASIC OXYGEN FURNACES SHOP) The hot metal transferred from blast furnaces to BOF shop in ladles is fed into 2 mixers, each having a capacity of 1.300 tons, using 200 ton cranes. The mixers provide buffer (tampon) storage of hot metal from blast furnaces and a homogeneous composition suitable for the operation conditions of the converters. The hot metal in the mixers is heated by coke oven gas to maintain its temperature. Each mixer is provided with a weighbridge (kantar) and a slag removal apparatus. Steel is produced in 3 top-blown basic oxygen furnaces (BOF), each having a charging capacity of 130 tons. Having an annual capacity of 2.2 million tons. The converter is first charged with steel scrap and then liquid metal transferred from the mixers in ladles. Such elements as carbon, sulfur, silicon, manganese and phosphorus contained in liquid metal are reduced to required levels by blowing oxygen for 17-20 minutes and adding other supplementary materials (calcinated lime, dolomite, coke breeze, fluorite, etc.). Lime (kireç) calcinations plant produce the calcined lime used in BOF shop. There are 6 vertical (fixed) kilns each with a capacity of 100 tons/day, all designed to obtain metallurgical lime by calcinations of limestone. Dolomite and meerschaum are also treated in these kilns. The Scrap Manipulation Unit has been established to prepare and store the internally produced and purchased scrap for use in the converter. 16 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  17. 17. 2.2.7 CONTINIOUS CASTING PLANT There are one electrical and one chemical ladle metallurgy stations to adjust the quality and temperature of liquid steel tapped from the converter at required levels. The liquid steel from the converters is poured into ladles, and directly treated in ladle metallurgy stations (chemical and electrical), and then sent to radial continuous billet casting machines. Figure-10: Billets There are 2 radial continuous billet casting machines, as replacement of vertical bloom casting machines installation in October 2003. These casting machines has square cross sections and the billet length is torch-cut.The total capacity of the machines is 2.5 million tons/year. In continuous billet casting machines, the steel is fed into the tundish, where it is poured through water-cooled copper crystallizer moulds. The steel is cooled down and solidified in the mould and the second cooling zone of the machine and shaped into billets. There is a schematic view about continuous casting at the Appendix. 17 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  18. 18. 2.2.8. ROLLING MILL In Rolling Mills, the billets from continuous casting are passed through rolling stands to obtain semi-finished and finished products in desired cross sections and dimensions. There is one rolling mill in Isdemir, namely Wire Rod Mill. Figure-11: Wire Rods The billets coming to the Wire Rod Mill are rolled into finished products (round bars). The billets are first heated in the reheating furnaces (annealing) with a capacity of 130 tons/hr, and then passed through the rolling stands. The capacity of the Wire Rod Mill is 500.000 tons/year wire rods of 5.5-16 mm in coils. The length of billets is limited with 12 meters due to the reheating furnace dimensions; the mill can roll maximum 130x130 mm billets; consequently maximum coil weights are 1.5 tons. 18 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  19. 19. Also in sheet metal producing plant the figure shows us the manufacturing steps of production Figure-11: Flow Chart of Hot Rolling 19 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  20. 20. CHAPTER 3 3.1 SELECTION CRITERIAS OF THE FACTORY LOCATION Figure-12: Factory Location İSDEMİR is located in Yakacık, 17 kms to İskenderun, the center of the Southern Anatolia Industrial Zone, near to highways, railways and marine transportation facilities in one single point. Its surface is 16.75 million m together with social facilities (plant surface is 6.8 million m2). İSDEMİR is located on İskenderun Industry Region and there are many factories and corporation with it. These provide good interaction opportunities between companies and many chances at production levels. 20 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  21. 21. In addition to, İskenderun near to market of Middle East is advantage.  Aspect of raw material: İsdemir uses pellet,lump iron,concentrated iron and iron ore as raw material.This type of materials are produced in Divriği/Sivas,Hekimhan/Malatya and Russia. It can easily transport by big harbor railway and highway.  Energy: İsdemir does not have any problem about energy such as electricity from Çukurova Company and self plant production, sea water from Mediterranean sea, coke and natural gas. ln Industrial Region, these are enough infrastructure to get these type of energy and the public has taken necessary precautions .In this way, İsdemir has suitable place for continuous production.  Transportation: İsdemir Region has highway, railway and big one harbor. İsdemir usually sent its products by big these ways.In the factory 80 km railway are built and this railways are used to transport materials departments to departments.And also these railways connecting to TCDD line.  Effect of climate: Climate of İskenderun have advantage and disadvantage. Hot weather is advantage to storage of raw materials. As well as, this weather is disadvantage for workers in working facilities. Products of Isdemir are sold in domestic markets and exported to Middle East, Europe, Asia, Africa countries and to the USA. 21 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  22. 22. 3.2 PLANT LAYOUT The plant layout facilitates the arrangement of machines, equipment and other physical facilities in a planned manner.Plant layout differs from plant to plant, from location to location and from industry to industry. But the basic principles governing plant layout are more or less same. Isdemir is designed according to Process Type of Layout because in this factory they are producing a lot of type products. In this type of layout ,machines of a similar type are arranged together at one place. ISDEMIR have lots of departments. Totally we can accept the factory has process type of layout. But when we analyse the departments individually, They are arranged to another type of layouts.For example when we analyse the sheet metal production unit we can say that this department is producing one type of product as called sheet metal in totally one long line. The grouping of machines according to the process has to be done keeping in mind the following principle:  The distance between departments should be as short as possible for avoiding long distance movement of materials.In Isdemir railways help the movement of materials. Advantages: Process layout provides the following benefits;  The overhead costs are relatively low  Breakdown of one machine does not result in complete work stoppage 22 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  23. 23. CHAPTER 4 4.1 CONTROL TECHNIQUES AND PRODUCTION PLANNING Plans and procedure of the all applications which are done in this organization, are created by planning department. The production plan of the order, which is coming from selling department, is done by the planning department. The production plan includes what kind of raw material needed, calculation of the amount of needed raw material, package material; to produce the order. Calculation of production time or how many machines and which ones in the production line must be used according to the delivery period; are included in the plan. The hardware and software settings accordindg to the order are contained in the plan. Planning department not only plans the production activities but also plans the maintenance activities,quality control activities and general medikal check up activities. Every kind of controls are done according to an annual plan which was done beforehand.Controls are classified like these daily, weekly, monthly from the point of view of the time. Some controls that are done in this organization are; Software settings of the machines on the production line, Hardware settings of the machines like, gear’s number, roller’ number, Machine’s output data sheets, Imperfection of the raw material, Wasted material at the production time, 4.2 ACCOUNTING The accounting department maintains this company’s financial records. Also, it provides information and services on the followings; 1. Cost accounting 2. Financial reports Financial reports generally include financial position of the organization and the process of the getting money from a bank or somewhere for a new project. 23 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  24. 24. 4.3 PURCHASING DEPARTMENT This department aims to procure materials at required time and place, with minimum stock level, reasonable cost, sustainable competitive approach and long-term cooperations. Accordingly, Purchasing Department operates procurements covering all of the following processes excluding raw material and service:   Procurement of steel scrap, refractory materials, ferroalloys, fuel-oil products, mineral oil, dyes-chemical materials, machine components and other general consumables from domestic and foreign resources. Domestic and international transportation of materials, customs clearance and warehousing operations, delivery to our plant. Raw Materials Purchasing Raw Material Purchasing Department is working with a head of Vice President Purchasing for purchasing raw material as iron ore, coal, manganese etc. Raw materials as iron ore, coking coal, metallurgical coke, manganese, manganese with iron, quartzite, dolomite, limestone, silica send, dunite, magnesite, metallurgical lime are purchasing from domestic or imported resources with sea way, rail way or high way transportations. Raw Material Purchasing Department also making deals with contracting firms for exploiting licenced mines of ISDEMIR. Raw Material Purchasing Department work in a coordination with concerned departments in order to take necessary precautions while purchasing, using and stocking of raw materials and auxiliary raw materials. Stock levels and analyses values of raw materials and auxiliary raw materials are followed up constantly. All prepared reports are submitted to concerned departments. Raw material and auxiliary raw material requirements of ISDEMIR;      Iron ore are purchased from foreign countries and domestic suppliers. Our domestic supplier are; ERDEMIR Maden and other companies which have licence belong to third people. Coking coal, metallurgical coke, pulvarised injection coal and anthracite are purchased from foreign countries (Australia, China, U.S.A., Russia, Canada, Poland) Limestone, dolomite, quartz, dunite and silica sand from ISDEMIR’s licenced mine areas. Manganese, ferromanganese and magnesite from domestic suppliers Metallurgical lime from domestic rolling mills and factories near surroundings of ISDEMIR. 24 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  25. 25. 4.4 POWER PLANTS AND ENERGY FACILITIES In these plants, distilled water, steam and electricity, blast air, oxygen, nitrogen, compressed air requirements of production facilities are produced, blast furnace gas is cleaned, blast furnace and coke oven gas are distributed. LPG, argon, nitrogen and oxygen are procured and stored in liquid phase, and distributed in gas phase. The annual installed capacity of power station generating electricity is 1.1 billion kWh. Furthermore, the power station is also designed so as to be supplied by national interconnected network. The power station is equipped with 2 x 25 MW, 3 x 55 MW and 1 x 5.4 MW turbo-generators. The steam required for the generators is supplied by 5 steam boilers each with a capacity of 220 tons/h.The blast air for blast furnaces is supplied by 3 turbo blowers each with a capacity of 2,900 m3/min. and 2 turbo blowers each with a capacity of 3,600 m3/min. The oxygen plants consist of 5 oxygen blocks each with a design capacity of 4.850 m3/h. Oxygen production up to a purity of 99.5% is mainly transported to the converters in BOF shop department and other units of the facilities through pipelines, but may also be contained in oxygen cylinders to meet the requirements of the works and market. Besides, nitrogen is also obtained in the plants up to a purity of 99. Water Facilities Fresh water from Mersin çayı 5500 m3/hour Fresh water from Aslantaş barajı 3500 m3/hour (since 2009) Drinkable water 400 m3/hour Sea Water 57500 m3/hour 25 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  26. 26. 4.5 QUALITY AND STOCK POLICY 4.5.1 DEFINITIONS ABOUT QUALITY Isdemir uses some terms when defining the problem. K1 Quality: Products should be equivalent to products in Isdemir cataloque which is designated the criterias of national and international quality standars. Also products should meet the expectations (beklenti) of buyers. Tolerance values, limits and specifications can be changed from one buyer to another one. Divert: Deviation (sapma) of specification values while producing steel. Dispose: Deviation of specification values while block or wire rod is being checked. Quality Stoppage: Loss of feature on product’s surface compared with specification values, standarts and tolerances. K2 Quality: Deviations of specification values, standarts, and tolerance of products on surface, body or modal. K3 Quality: If any dimension of the product is not proper to tolerance values or any problem of K2 included to this. Manufacturing Practice Code ( MPR ): Special number given to products while quality control process. 26 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  27. 27. 4.5.2 QUALITY CONTROL Quality control management makes the quality control in Isdemir. They are responsible for: analysis and control of raw material, semi products, and final products according to standarts. Also they do phsical and chemical tests.Preparation of specification cards of final products coordinated with related department.Preparation of manufacturing process cards of alloys, pigs, and steel. 4.5.3 QUALITY CONTROL IN PRODUCTION PROCESS Sulphur removal-- Pig Casting--Steel Production--Continuous Casting--Control Area--Wire Rod Mill( Bobbin )-- Storage/Delivery Production process is carefully controlled for best quality from start to delivery of product. If any problem occur in process , this is reported to quality control engineers and then precautions are taken. After final product produced its either checked without destruction or a sample is taken for physical and chemical tests. If there is not any problem on products quality it is delivered to buyers else it is used as second quality or recycle material. I have also been at the quality control labrotary.They use very long steel pipe which are built from department to department.This pipe is used to send the specimen to labrotary with Pneumatics pipeline.This is very useful for shorten the controlling time of specimen. 27 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  28. 28. ISDEMIR laboratories operates internationally to service specializing in the analysis of a variety of sample types (soil, sediment, rock cuttings, raw materials, lime stone, iron ore, slags, sinter, ferro alloys, refractories, coal, initial product, in-process product and finished product steel). ISDEMIR plants provides to companies and customers with a broad range of laboratory services from raw material to finished product analysis. ISDEMIR laboratories have TSE Laboratory Certificate of TS EN ISO/IEC 17025 that is; the general requirements for the competence of testing and calibration laboratories. ISDEMIR laboratories provide following list of services: Raw Materials Analysis       Lime stone Iron ore Coal, slags Ferroalloys Refractories Fe-Ti & Ca-Si cored steel Initial - In process - Final Products Analysis       Pig iron Billets Wire rods Slab Coil Hot rolling roll and plate These analysis are made by using XRF spectrometer, ICP & AAS machines. These analysis are made by using Optical Emission Spectrometers and also N-H-O elements can be determined by LECO. Physical & Mechanical Tests Technological & Metallurgical Tests Physical Tests Technological Tests      Breaking Grinding Elimination Resistance Density     RUL test LTD test RDI test FSI test Metallurgical Tests Mechanical Tests      Pull Tilt Hardness Press Shock Physical & mechanical tests are made according to the type of the material.      Microhardness Grain size Inclusions Impact Ultrasonic Technological tests are made by RUL test, LTD test, RDI test and FSI test machines. ISDEMIR provide a comprehensive range of metallurgical and mechanical testing services with a dedicated machine shop to provide specimen preparation. 28 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  29. 29. 4.5.4 QUALITY POLICY  Improve company to produce best goods by using Total Quality Management System.  Manage the company by targets and use sources effectively.  Focus on work based on consumer.  Consider about education and innovation.  Try to be different. 4.5.5 ISDEMIR QUALITY MANAGEMENT SYSTEM Isdemir use 5S for better working conditions, higher work safety, lower technical problems, lower expenditure, and to include every personnel to specific steps of every work. 5s name coming from Japanese; Seiri – clearing up Seiton—organization Seiso – cleaning Shitsuke – discipline Seiketsu – standardizing They use this in every work area of the company. A comission from general management control every deparment. They look at cleaning, check stored paper if they are in order or not, in work areas if kits are in order or work safety is done or not, etc. Then every worker are taken into an exam. After this successful departments are taken gold and silver flags. 4.5.6 STOCK POLICY Isdemir uses two kind of storage policy. Reserved and unreserved raw materials.First demand is created by the organization for unreserved materials. Storage control management to this job. Then demand for buying is created. After Material management leader confirm this, department of purchasing take the control. They search the market and at least 10 offers are taken. The best offer hitch is economic and has enough quality standards. After this purchasing finish and materials transfer to the related unit. In reserved materials first material is taken from the storage and stock control is done. According to number of materials stored they decide to buy or not to buy another one instead of used one. Then demand for purchasing is created by stock control management. Department of purchasing take the control after confirm of material management leader. Again market search is done and material is purchased. At least material is stored again. 29 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  30. 30. 4.6 WORKERS HEALTH AND WORK SAFETY As ISDEMIR Their Occupational Health and Safety Policy is;  To recognize our employees as the most valuable resource of our company by adopting the “Human First” and “Zero Accident” concepts, to provide a healthier and safer work environment.  To obey the current laws, rules and regulations in the scope of “Occupational Health and Safety”.  To implement TS 18001 Occupational Health and Safety Systems that set in ISDEMIR and to assure the sustainability of this system.  To consider the “Occupational Health and Safety” concept as a first priority in all activities.  To enhance the consciousness level of our employees by realizing training and other improving activities and to progress behaviour change in a positive way in the scope of Occupational Health and Safety matters.  To cooperate with the companies in our region, to be involved in an organization which enables common interference to the disasters and emergency situations.  To minimize the occupational health and safety risks and to prevent occupational injuries and illnesses in our company and improve the system in a continuous way by utilizing new technologies and using resources efficiently. 30 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  31. 31. CONCLUSION I completed my orientation programme at ISDEMIR which is one of the biggest and integrated factory in Turkey..ISDEMIR has huge production area.I have never been such a big factory before.Over 5000 people are worked there.Their coordination is very hard.Lots of department and lots of people focus on production.I am very happy to been there.Twenty day was not enough to travel all of the departments.Isdemir is huge factory. I have done my orientation programme at the department of Project Directorship and as a unit of Mechanical Spare Part. In my department 7 mechanical engineers work.I also realize that in Isdemir about 40 percent of engineers are graduated from Gaziantep University.Wherever I went in the factory there was an engineer who is graduated from Gaziantep University.I am very lucky because there is 4 engineer who are graduated from my university in my department.So many times I talked with them.This is very strange because they are graduated from my university before 10 years or 15 years and they recognize our teacher.One of engineers said me IS MR. BAYSEC is stil there I said him yes he is stil there.  They give me good advice about my future life after graduation from my university. I have been lots of departments due to chance of been Project Directorship.Engineers who work in this department is improved themself about design and development.I also improve myself about computer programming which they use there, like Solidworks and Autocad Mechanical.I have drawn lots of mechanical parts which are comes from departments.They are drawn in my department to make mechanical spare part.Engineers in my department make analyses and they work on how to improve the design. I think this orientation programme will be very useful for my future life.I also realize that each lessons which we learn in university connect with practical area. 31 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  32. 32. APPENDIX Production of Molten Steel Schematically 32 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  33. 33. Principle of Continuous Casting 33 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  34. 34. Figure:- Dust collector Fan of Coke Factory 34 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship
  35. 35. 35 Checked By VEYSEL ÇELİK (Mechanical Engineer MSC) İSDEMİR Project Directorship