Background Broad objective Specific Objectives Factory Setup Company Overview Maintenance and Operation process Quality Control Tasting Machine Problem Solution Recommendation Conclusion To study operation & maintenance activities of steel mill machineries. To study the standard process of steel production. To study Quality control testing machine. To make an analysis on the manufacturing & quality control activities through whole operation systems How to saving in raw materials Reduce manpower cost. How to reduce overall factory cost. How to Increase the production

2. Presentation Topic:
Maintenance and Operation of
Machineries at SS Steel (PVT)
LTD

3. MD. Hasibul Hasan
ID – 12207041
Department of Mechanical Engineering
IUBAT- International University of Business
Agriculture and Technology.
27.12.2016
3

4. Background
Broad objective
Specific Objectives
Factory Setup
Company Overview
Maintenance and Operation process
Quality Control Tasting Machine
Problem
Solution
Recommendation
Conclusion

5. This report structure is summarized as below: Basic portfolio of bar
production and study on machineries of SS Steel (pvt) Ltd, the company
on which the report is prepared, is presented in some next chapter. In this
report, chapter one refers to introduction which includes origin of the
report. Object of the report, , and limitations of the report. Chapter two
refers to company overview. Chapter three Reheating Furnace than
roughing Mill intermediate mill. The company is professionally managed
by a team of experienced professionals and promoted by highly qualified
and experienced personnel’s.So many skilled Engineer, technician and
labor are always present for continue the production properly. I think here
a skilled management personals are ready to work with production so that
customer can get an extra facilities from company.

6. Broad objective:
The broad objective of this project is to understanding the Operation
Maintenance of manufacturing process & quality control of SSS 500W
TMT bar.

7.  To study operation & maintenance activities of steel mill machineries.
 To study the standard process of steel production.
 To study Quality control testing machine.
 To make an analysis on the manufacturing & quality control activities
through whole operation systems
 How to saving in raw materials
 Reduce manpower cost.
 How to reduce overall factory cost.
 How to Increase the production

8. SS Steel is a fully automated
composite A to Z solution for
construction industry including
Construction Contractors,
Building Developers,
Industrialists and Individual
Home Builders.
The entire process from melting
Mild Steel Scrap in induction
furnaces to producing the end
product (Re-Bar/MS Rod) at the
Rolling Mill is conducted in our
own facility.

9.  Nearly 26 years ago an enthusiastic entrepreneur started the business that
was dedicated solely to producing reinforcement-bars from small rolling
mills. At that time; rolling mills were fed with sheered and cut plates
derived out of abandoned ships. Re-bars (Rod) were produced to meet the
needs for affordable steel and iron for the growing territories and basic
infrastructure in the newly formed Bangladesh.
 Since the inception of the company; SS Steel continued to expand its
capability in every aspects of the production spectrum. Today we narrowed
our product line to focus and become a Specialty Production Mill seeking
to service a much more selected group of demanding, quality-conscious
customers. Later the company management was taken over by the two sons
of the founder. Since then they have diversified the company’s production
and to serve the nation with great commitment.

10.  Company Name: SS Steel pvt Ltd.
 Country: Bangladesh
 Plot–4, Block–B,
 Tongi,Industrial,Area,Gazipur.
 Dhaka,Bangladesh.
Email: sales@ssSteel.biz
 Phone:01709964438

11. “Quality People, Quality Service, Quality
Product”
 Product quality is ensured throughout the manufacturing processes i.e.
Billet producing, Re-Rolling process, Cooling and stocking of finished re-
bar etc. Our production department & process has strict adherence to
follow proper quality control requirements.
A team of experienced professionals are committed to ensure customer
service through the manufacturing of quality re-bars and prompt delivery.
We believe in sustainable success through client’s satisfaction.
We care for the PEOPLE as-well-as for ENVIRONMENT. We protect the
nature through recycling used iron and steels. We ensure proper Refining
Process through state-of-the-art technology in our European Production
Plant, STS (Italy) which is the pioneer in Bangladesh.

12. 12

13. Grade Yield
Strength
N/mm2(Ma
p)
Tensile
Strength
N/mm2(Ma
p)
Ratio
(UTS/YS)
Elongation
(%) GL
300 300 330 1.10-1.20 16
400/400W 400 440 1.10-1.20 15
500/500W 500 550 1.10-1.20 14
13

14. Grade Yield
Strength
Psi
Tensile
Strength
Psi
Ratio(UTS/Y
S)
Elongation
(%)
GL-203.2mm
40 40,000 70,000 1.75 11-12
60 60,000 90,000 1.50 7-9
14

15. Grade Carbon(C) Manganese
(Ma)
Silicon(Si) Sulphur(S) Phosphoru
s(P)
500W 0.18-0.24% 0.60-0.75% 0.20-0.30% 0.05%Max 0.05%Max
60 0.30-0.34% 1.10-1.40% 0.15-0.30% 0.05%Max 0.05%Max
40 0.22-0.26% 0.60-0.85% 0.15-0.30% 0.05%Max 0.05%Max
15

16. 16

17. steel mill section
 Electric induction furnace
 CCM-Continuous Casting Machine
Re-rolling mill
 Reheating Furnace
 Roughing Mill
 Intermediate Mill
 Finishing Mill
 TMT-Thermo Mechanical Treatment
 Flying Shear
 PLC
 Cooling Bed

18.  Electric Induction Furnace
 CCM-Continuous Costing Machine
Electric Induction Furnace:
The electric induction furnace is a type
of melting furnace that uses electric
currents to the metal. Induction furnaces
are ideal for melting and alloying a wide
variety of metals with minimum melt
losses, however, little refining of the
metal is possible.
Fig: Induction furnace

19. Induction Heating:
Induction heating is a form of non-contact heating for conductive materials. The
principle of induction heating is mainly based on two well-known physical
phenomena.
Electromagnetic Induction:
The energy transfer to the object to be heated occurs by means of
electromagnetic induction. Any electrically conductive material placed in a
variable magnetic field is the site of induced electric currents, called eddy
currents, which will eventually lead to joule heating.
Fig: Electromagnetic Induction
19

20. Continuous casting may
be defined as teeming
metal in short mould
with a false bottom
through partially
solidified ingot is
continuously withdrawn
at the same rate at which
metal is poured in the
mould.
Fig: CCM
20

21. 1) Ladle turret
2) Tundish
3) Tundish car
4) Mold
5) Mold vibration device
6) Vibration drive device
7) Universal joint
8) Pinch roll
9) Dummy bar
10) Hydraulic system
11) Pendulum shear
21

22. 12) Roller table
13) Hydraulic billet pusher
14) Flame cutting machine/hydraulic shear (determined
by customers)
15) Electrics control system
16) Steel structure
17) Hydraulic system
18) Cooling water
22

23. Ladle Turret: Ladle
turret plays the role of
move the molten steel from
ladle to pouring position. It
consists of Rotary arm,
rotary bearing, and
transmission device
Tundish: The tundish holds
enough metal to provide a
continuous flow to the
mold, even during an
exchange of ladles, which
are supplied periodically
from the steelmaking
process
Fig: ladle turret
Fig: Tundish
23

24. To begin with the bottom of the
mould is temporarily closed by
what is known as dummy bar. It
is meant to lead the product
though the roller apron and
withdrawal rolls. In a curved
mould machine the plug bar is
flexible
24
Fig: Dummy Bar

25.  The main function of the mold is to
establish a solid shell sufficient in
strength to contain its liquid core upon
entry into the secondary spray cooling
zone. Key product elements are shape,
Billet etc
Fig: mold tube

26. Reheating Furnace:
Reheating Furnace is the heart of any hot rolling mill where in the charge is
heated to rolling temperature. The charge could be in the form of billets,
blooms, slabs or ingots.
 Furnace Size: 61ft*11ft
 Capacity=12 ton per hours
 Billet Size=100*100*3000mm
 Billet space= 183 pitch
 Parts of the furnace:
 Peshawar- 10 ft
 Charging- 20ft
 Heating- 27ft
 Chouking-11ft
 Scale-3
Fig: Reheating
furnace 26

27. This is the first stage of reduction in area of bar further elongation the 19 inch
roughing mill consist of
 One A/C Motor of 1120 KW
 Motor RPM (741)
 One set fly wheel
 Reduction gear
 Pinworm Gear
 Spherical Roller (22318 B)
 Inner Die (90 mm)
 Universal coupling- 7
 Roll RPM (107)
 Stand- 3
27

28. Roughing mill 3 stand
1st Stand:
Roll Diameter: 480 mm
 Length: 1200 mm
 Roller : 3
 Weight: 2.5 ton
 Roll pass: 5
 2nd Stand:
 Roll Diameter: 480 mm
 Length: 800 mm
 Roll pass: 2
 Roller :2 Fig: Roughing mill roll
28

29.  3rd Stand:
 Roll Diameter: 480 mm
 Length: 800 mm
 Roll pass: 1
 Roller :2
29

30.  In intermediate mill is 280 mm
size powered by 800 HP AC
motor having 4 stands with speed
increase.
 An intermediate mill is a
reducing unit of the products of
roughing mill.
Fig: Intermediate
Mill

31.  In finishing mill the finished profile shape
is made. It takes metal from intermediate
stands as its input. The reduction given in
these stands is lesser as compared to
roughing and intermediate mill. Finishing
mill has 6 stand.
 Finishing mill consist of DC
motor(1000rpm), Gear Box, Delivery pipe,
Two Star, Oil Tank, Gear Box. There are 6
stand here every stand have 2 roll.
 Gear ratio:
 C1=2.7, C2=2.29, C3=1.8, C4=1.5,
C5=1.2, C6=1
31
Fig: Finishing Mill

32. 8mm
mill
speed
C1 C2 C3 C4 C5 C6
Motor
rpm
1179 1293 118 1254 1122 1192
Mill
speed
6.27 8.26 9.69 12.12 13.69 17.47
Roller
Length
427 563 600 827 926 1192
32

33. 10mm mill
speed
C1 C2 C3 C4
Motor rpm 1184 1331 1208 1256
Mill speed 6.29 8.50 9.84 12.09
Roller
Length
629 579 671 824
12mm mill speed C1 C2
Motor rpm 1193 1305
Mill speed 6.33 8.34
Roller Length 432 568
33

34. SS Steel TMT 500W bars are
produced from the world-
renowned TMT technology. TMT
stands for Thermo – Mechanical
Treatment. It is a specially
designed heat treatment process
involving quenching and
tempering of steel.
Fig: TMT
34

35. Quenching is a metallurgical process involving the rapid cooling of the
steel to strengthen and harden the steel. Although quenching makes the
steel stronger and harder, it also makes the steel brittle. To eliminate this
brittleness, the material is tempered after quenching.
The key feature of the TMT technology is that it converts a low carbon,
low strength steel to low carbon but high strength steel
35

36. Crank Shear and/or Rotary
Flying Shear Convertible
(multifunction). Advanced Start-
Stop type technology
High cutting force for bar and
section steel
Cutting movement Horizontal
component Velocity equal to
rolled piece speed
Fig: Flying Shear
36

37. PLC means Programmable logical control. This plc is
mainly time sequence basis. It means all equipment
which is connected with plc. Work in a time signal. In SS
steel Pvt Ltd. use scads type plc.
37

38.  H.M.D & pyrometer
 Pinch roll – 1
 Pinch roll – 2
 Tail break – 1
 Tail break – 2
 Fly shear
 Twin channel
38

39. Cooling bed is utilized
to handle bars in high
speed operation & for
allowing bars to cool
down in ambient
temperature
Fig: Cooling Bed
39

40.  DC Motor-
 Gear
 Shaft (72 meter)
 Cooling rack
 Roller Table( Forward
/Reverse)
 Roller-48
 Roller Length-700mm
 Roller Dia-254mm
 Fixed Rack
 Moveable Rack
 Bearing Model (22312B)
 Cooling Bed are two
roller used
 Hanger
 Twin Chanel – 72 Meter
 Twin Chanel Shaft-2
 Twin Chanel Stand-24ft
 Hydraulic Jow-2
 Flat from
 Gear Ratio 1:1
40

41. The purpose of the quality control team in SSS is to ensure the
quality of the product by raw material inspection, process
control
and final inspection.
1. Spectrometer
2. UTM- Universal testing Machine
3. Steel bar bending and Re-bending testing Machine
41

42. Spectrometer:
The major raw material is
high quality billets sourced
from Turkey, South Korea,
Taiwan, India, and China.
Random samples from the
imported billets are checked
by Spectrometer for chemical
composition and compared
against specifications.
42

43. Random samples are
collected hourly/per 50
billets from the cooling
bed and tested for surface
quality, chemical
composition, physical and
mechanical properties.
43

44. Physical properties
− Unit weight
− Actual diameter
− Core diameter
− Transverse rib height
and width
− Longitudinal rib
height and width
Mechanical
Properties
− Yield strength
− Ultimate tensile
strength
− Bend test
Fig: Result
44

45. The steel bar bend testing
machine can be used to do
bend and re-bend test for steel
bars. It is an important
equipment to test the re-
curveting character of screw
thread steel bar in steel
factory and architectural
company. It can be used to
bend the steel bar on-site so
that test and construct can be
done in one machine.
45

46.  Main Technical Specifications:
 Angle of steel forward bend: 0°-180°at will
 Angle of steel backward bend: 0°-90°at will
 Rotating speed of working plate: ≤ 3.7 r/min
Fig: Working
table
46

47. List of the problems:
 Suddenly stop the operation.
 Wastage Hague amount of scrap.
47

48. Root causes are:
1. Guide box broken.
2. Roll pass is decay.
3. Reheating furnace temperature up down.
4. Mill speed is high.
5. TMT water pressure high or low.
6. PLC will not be under control.
48

49. 1.Before start working, should be checked everything properly.
2.Roller pass should be changed, When decay.
3.Skill operator is needed for fixing temperature.
4.Mill speed will be fixed properly

50. Root causes are:
1.When reheating temperature up down.
2.Rollers pass design incorrect.
3.Raw material dose not well.

51. 1.Good raw materials import.
2.Temperature must be limited.
3.Roller pass must be right design.

52.  SS steel mill is contributing in our society by producing the material things.
There is some problem what we have seen in our internship period it has
been mentioned on our analysis. We also suggested them some solution
against those problem. We hope, they will overcome their problem and
industry will be more productive.
 I recommend that suddenly stop the operation and disconnect power reduce
this problem must be increase the production.
 Roller can be broken for rising temperature so try to increase adequate
water cooling system.

53.  Demand of bar is increasing day by day, we daily consume huge amount of
bar to perform our regular work. There are different types of the steel mill,
re-rolling mill is the one of the popular mil in Bangladesh.
 During the practicum training period in SS steel pvt ltd, I have gathered
knowledge about the induction furnace, CCM-continuous casting machine,
and re-rolling mill. I learned lot of thing about practical knowledge in SS
steel mill .Finally I worked about mechanical maintenance and operation
procedure of bar in SS steel mill. I have analysis the problem and given
some suggestion. This steel mill is used PLC modern technology. I am very
glad that I have done my internship in such field where I learned many
things about steel mill and re-rolling mill, which will be very helpful in my
professional life.

54. 54

55. 55