The document provides information about Ankit Gupta's internship project at Bhushan Steel Limited. It includes sections on company profile, safety procedures, processes like pickling, rolling, electrolytic cleaning, annealing, skin pass milling, and maintenance activities. Pickling involves using hydrochloric acid to remove rust and scale from steel coils. Rolling is used to reduce thickness using opposing rolls. Safety is emphasized, including wearing protective equipment and avoiding moving machinery.

1. SUBMITTED BY:
ANKIT GUPTA
M.E. (4th year)
1424040009

2.  Company profile.
 Safety.
 Pickling.
 Rolling (6HI Hitachi mill).
 ECL (Electrolytic cleaning line).
 Annealing.
 Skin Pass Mill.
 Finishing.
 Electrical Maintenance.
 Mechanical Maintenance.
 Quality management.

3.  TYPE:- PRIVATE
 FOUNDED IN:- 1987
 FOUNDERS:-BRIJ BHUSHAN SINGHAL(Chairperson)
 INDUSTRY:- STEEL
 WEBSITE:-www.bhushangroup.com

4. 1) ALWAYS WEAR SAFETY EQUIPMENTS LIKE HELMET AND
GLOVES.
2) NEVER MOVE UNDER THE CRANE.
3) BE CAREFULL OF THE WORKING MACHINERY.
4) NEVER TOUCH THE MACHINERY WITHOUT PROPER
KNOWLEDGE.
5) KEEP KNOWLEDGE OF THE EMERGENCY EXIT IN CASE OF
ANY ACCIDENT.
6) KNOW HOW TO OPERATE A FIRE EXTINGUISHER TO PUT
OFF FIRE WHEN NEEDED.
7) NEVER WEAR TIE IF YOU ARE WORKING ON A MACHINERY.
8) DO NOT WALK ON THE RAIL SET FOR TROLLEYS.
9) REMAIN ALERT OF THE SURROUNDINGS.

5.  Pickling line is basically meant for removal of
rust and dust from the surface of HR coils.
 Acid used for pickling is HCL.
 COMPONENTS OF PICKLING LINE: Coil Car, Un-Coiler, Out
Support, Sniper Roll, Peeler Table, Pinch Roll(2), Flat
Roll(2+3=5), Guide, Shear, Squeeze Roll, Acid Tanks(4),
Hot Water Rinsing Tank(5), Dryer(temp. 95 degree
Celsius), Shear, Tension Unit, Deflector Roll, Re-Coiler.

6.  Chemical Reactions In Pickling: When steel is
immersed in hydrochloric acid in a pickle tank, two
reactions take place.
 Scale is dissolved:
 FeO (scale) + 2HCl(acid) = FeCl2(ferrous chloride) +
H2O(water)
 If there is rust or magnetite on the steel, these will
produce ferric chloride (FeCl3), thus:
 Fe2O3(rust) + 6HCL(acid) = 2FeCl3(ferric chloride) +
3H2O(water)

7.  Various Process involved are:
 Loading of coil.
 Feeding of coil.
 Setting of cutter.
 Trimming.
 Re-Coiling.
 Removal of coil.
 Stepping and labeling of O/P material.
 Storage of O/P material.

8.  Rolling is a plastic deformation process of reducing the
thickness or changing the cross-section of long work piece by
compressive forces exerted by two opposing rolls. The rolls
rotate to pull and simultaneously squeeze the work piece
between them.
 Hitachi mill is used for the reduction of thickness of the
sheets.
 MATERIAL SPECIFICATION: Hot Rolled Coils.
 DIMENSIONAL SPECIFICATIONS:
DIMENSIONS
SPECIFICATION
MINIMIUM MAXIMUM
WIDTH(mm) 700 1700
THICKNESS(mm) 1.6 7.0
WEIGHT OF COIL 3.0 MT 30 MT

9.  LINE SPECIFICATIONS:
LINE SPECIFICATION
SPEED 1200 MPM
TENSION 16T(MAX)

10.  The main purpose of electrolytic cleaning is to
remove the lubricant oil and dirt left on the cold
rolled strip before annealing. All traces of surface
oil is removed using the mechanical and electrolytic
chemical reactions while the cold rolled coil passes
through alkaline solution between High Voltage
electrodes.
 The removal of residual roll coolant on the surface
of cold-rolled strip by electrolytic cleaning process
include alkaline water immersing, brushing,
electrolyzing, rinsing and drying to improve
cleanliness of the strip surface before annealing.

11.  The Process Being Carried Out At ECL Involves
Following Steps:
 Loading of Coil.
 Feeding &Welding Of Strip.
 Primary Cleaning Of Strip.
 Electrolytic Cleaning Of Strip.
 Hot Water Rinsing Of Strip.
 Drying Of Strip.
 Inspection.
 Filter Paper Test.
 Pickle lag test.
 Recoiling Of Strip.
 Unloding Of Coil.
 Storage & Transfer Of Processed Coil.

12.  LINE DIAGRAM :

13.  ANNEALING IS A PROCESS OF HEATING, SOAKING AND
CONTROLLED COOLING OF COIL IN A NON OXIDIZING
ATMOSPHERE.
 ANNEALING IS DONE TO REFINE THE GRAIN STRUCTURE
 AND REDUCE HARDNESS OF SHEET.
 ANNEALING IS DONE AT A TEMPERATURE OF 575-650°C.
 BELL TYPE ANNEALING IS DONE FOR ROLLED SHEETS.
 KATHABAR BELL IS USED FOR COOLING OF ROLLED SHEET SO
THAT THE STRIP DOES NOT STUCK WITH EACH OTHER.
 OXYGEN GAS IS REMOVED BY FILLING UP NITROGEN GAS
INSIDE THE BELL.
 NITROGEN GAS IS REMOVED BY FILLING HYDROGEN GAS.
 AIR COOLING IS DONE TILL THE TEMPERATURE REACHES 250°C
 WATER COOLING IS DONE TILL THE TEMPERATURE REACHES TO
125°C
 AFTERWARD COOLING IS DONE BY DRY AIR WHICH IS FORMED
ON KATHABAR BELLS

14. ANNEALING OF ROLLED SHEETS

15.  4 HI SKIN PASS MILL: 4 HI stands for four horizontal
insert skin pass mill.
 OPERATING MODE: Two Operating modes, namely (1)
Force mode (mostly preferred) ,(2)Elongation mode.
 MATERIAL SPECIFICATION: Carbon steel strips.
DIMENSIONAL
SPECIFICATION
MINIMUM MAXIMUM
WIDTH 800MM 1705MM
THICKNESS 0.15MM 3.50MM
COIL OUTER DIAMETER 2000MM
COIL INNER DIAMETER 610MM
WEIGHT 30MT

16.  PURPOSE OF USING SKIN PASS MILL:
 For proper graining structure.
 To remove yield point.
 Remove light I/P defects like marks, dents etc.
 To maintain the shape.
 For reducing the use of R.P.O i.e. rust protect oil
spray.

17.  It has two section lines:
 1. C.R.S ( Cold roll slitting ).
 2. C.T.L ( Cut –to-length ).
CUT –TO – LENGTH (GEORG-GERMANY):
 IN THIS LINE SHEETS ARE CUT ACCORDING TO THE
REQUIREMENT OF THE CUSTOMER.
 SHEAR BLADES ARE USED FOR CUTTING OF THE
SHEETS.
 SHEETS ARE DISPATCHED FOR COLORING OR
POLISHING.

19.  UTILITY DEPARTMENT HAS 4 SUB DEPARTMENT
UNDER IT:
 RO PLANT.
 BOILER.
 AIR COMPRESSOR(CENTRIFUGAL TYPE).
 A.C PLANT.

20.  It Uses the Reverse Osmosis Process to filter the
water.
 LAYOUT OF R.O. PLANT:

21.  THE BOILER CHANGES THE FORM OF WATER FROM
LIQIUD TO VAPOUR. FIRST A SMALL DIA PIPE SUPPLIES
GAS TO THE FURNANCE NOW A SPARK IS GIVEN TO
BURN THE GAS AFTER THAT A LARGE DIA PIPE SUPPLIES
THE GAS TO THE BURNERS AND THE SMALL DIA PIPE IS
SWITCHED OFF.
 THE STEAM GENERATED IS NOW SUPPLIED TO THE
PLANT WHERE NECESSARY.

22.  A centrifugal compressor is a type of dynamic
compressor, or turbo-compressor, with a radial
design.

23.  IN INDUSTRY IT IS UNDERSTOOD THAT PEOPLE
WORKING IN THE INDUSTRY NEED SOME COMFORT
WHILE WORKING THEREFORE A.C PLANT IS
INSTALLED TO GIVE THEM A COMFORTABLE WORKING
ENVIRONMENT.

25.  A.R.P Stands for Acid Regeneration Plant. It is
operated by PLC system. In ARP, spent acid from
pickling collects in two yellow color spent acid
tank each of 30 ton. Now these spent acids get
heated at 850 degree Celsius in a Roaster then
after several processes the acid regenerates.

26.  IT INVOLVES FAULT DIAGNOSIS, ROUTINE CHECKUP,
SERVICING AND REPAIRING OF ELECTRICAL COMPONENT
OF MACHINES.
Types of elec-
trical
maintenance.
PREVENTIVE PREDICTIVE BREAK DOWN

27.  Mechanical maintenance means the steps taken
to prevent any mechanical equipments and
machines from any kind of damages.
 Types of mechanical maintenance:
1. Preventive maintenance.
2.Predictive maintenance.
3. Breakdown maintenance

28.  A Quality Management System, often called a QMS, is a
set of internal rules that are defined by a collection of
policies, processes, documented procedures and records.
This system defines how a company will achieve the
creation and deli very of the product or service they
provide to their customers.
 For simplicity, QMS=QC+QA
 QC: Quality Control that focuses on product
characteristics through a reactive approach by line
function to identify defects using operational activities
such as testing / measurements.
 QA: Quality Assurance focuses on processes through a
proactive (preventive) approach by staff function to
prevent defects using systematic activities such as
assessments / audits.