This document summarizes a presentation given by Akhilesh Kumar on his semester training at Tata Iron & Steel Company Limited from January to May 2014. It discusses Tata Steel's history and operations, the steel making process, hydraulics at the batch annealing furnace, and problems in the hydraulic system. Potential future advancements including the use of servo valves for more precise electro-hydraulic control are also mentioned.

1. PRESENTATION ON SEMESTER TRAINING
(JANUARY 14, 2014 TO MAY 06, 2014)
TATA IRON & STEEL COMPANY LIMITED
JHARKHAND, JAMSHEDPUR
LOVELY PROFESSIONAL UNIVERSITY
PHAGWARA, PUNJAB
AKHILESH KUMAR (VT20132839)
DEPT. OF MECHANICAL ENGINEERING

2. ABOUT TATA STEEL
• ESTABLISHED IN 1907 AS ASIA'S FIRST
INTEGRATED PRIVATE SECTOR STEEL COMPANY
• WITH A TURNOVER OF US$ 24.82 BILLION IN FY
13, HAS OVER 80,000 EMPLOYEES
• TATA STEEL GROUP’S VISION IS TO BE THE
WORLD’S STEEL INDUSTRY BENCHMARK IN
“VALUE CREATION” AND “CORPORATE
CITIZENSHIP” THROUGH THE EXCELLENCE OF
ITS PEOPLE, ITS INNOVATIVE APPROACH AND
OVERALL CONDUCT
• IN 2012, TATA STEEL BECAME THE FIRST
INTEGRATED STEEL COMPANY IN THE WORLD,
OUTSIDE JAPAN, TO WIN THE DEMING GRAND
PRIZE 2012
• TARGET OF 2 MILLION TONNES BY 2015

3. PROJECT TITLE
STUDY OF HYDRAULICS AT BATCH ANNEALING FURNACE, CRM
CONTENT OF THE PRESENTATION
• SAFTEY GUIDELINES
• STEEL MAKING PROCESS
• ABOUT CRM
• HYDRAULICS AT BAF
• PROBLEMS IN THE SYSTEM
• FUTURE SCOPE

4. SAFTEY RULES & GUIDELINES
• SAFTEY OF EMPLOYEES IS OF PARAMOUNT IMPORTANCE TO THE COMPANY.
• BREACH OF SAFTEY RULES IS AN ACT OF MISCONDUCT AND A DEALT WITH AS PER THE
PROVISIONS IN THE SERVICE RULES.
• TRAINEES SHOULD ADHERE TO THE SAFTEY GUIDELINES, PPE REQUIREMENTS AND BE
AWARE OF THE HARADOUS AREAS PRIOR TO GOING FOR TRAINING IN A DEPARTMENT
AND TAKE THE NECESSARY PRECAUTIONS.
GENERAL PPE’s
SAFTEY HELMATE SAFTEY GLASSES SAFTEY SHOES SHIN GUARD

5. STEEL MAKING PROCESS
THE PROCESS COMPLETES IN THREE STEPS:
1. IRON MAKING PROCESS
2. CONVERSION TO STEEL
3. ROLLING PROCESS

6. SINTER PLANT
• IRON ORE FINES NOT SUITABLE FOR
BLAST FURNACE
• HENCE, ARE AGGLOMERATED INTO
LARGER POROUS LUMPS, WHICH IS
SUITABLE FOR BLAST FURNACE
• HEAT GENERATED THROUGH
COMBUSTION PRODUCES LARGE
LUMPS OF HOT SINTER
• THIS SINTER IS COOLED, SIZED AND
STORED FOR BLAST FURNACE

7. COKE PLANT
• NATURALLY FOUND COAL CONTAINS
CARBON, ASH, MOISTURE AND
OTHER IMPURITIES
• UNSUITABLE FOR BLAST FURNACE;
CONVERTED INTO COKE IN COKE
OVENS
• HEATING COAL IN THE ABSENCE OF
AIR CARBONIZING IT TO FORM A
HARD POROUS MASS, DEVOID OF
VOLATILE MATTER PRODUCES COKE
• COAL AFTER CARBONISATION,
CALLED METALLURGICAL COAL

8. THE BLAST FURNACE
• HEART OF THE STEEL PLANT
• MAGICAL TRANSFORMATION OF
DARK IRON ORE INTO GLOWING HOT
LIQUID IRON
• COKE IS USED FOR COMBUSTION TO
ATTAIN THE HIGH TEMPERATURES
REQUIRED FOR REDUCTION
• FLUXES ARE USED TO MAKE LOW
MELTING SLAG AND CONTROL THE
QUALITY OF HOT METAL
• THE BLAST FURNACE REACH UP TO
1,500°C
• WORKS ROUND THE CLOCK

9. CONVERSION TO STEEL

10. LINZ DONAWITZ SHOP #1
• NAMED AFTER THE TOWNS IN
AUSTRIA WHERE THE TECHNOLOGY
WAS COMMERCIALISED
• MOLTEN IRON IS REFINED INTO
STEEL USING THE “BASIC OXYGEN
FURNACE”
• OXYGEN REMOVES CARBON,
SILICON, SULPHUR AND
PHOSPHORUS CONTENT FROM
MOLTEN IRON
• ONE ‘HEAT’ TAKES 45-50 MINUTES &
PRODUCES 158 TONNES OF MOLTEN
STEEL
• LD #1 FOR IRON RODS

11. LINZ DONAWITZ SHOP #2
• TEMPERATURES REACHES 1,700°C
• FROM EVERY HEAT, A SAMPLE OF
THE MOLTEN STEEL IS ANALYSED TO
SEE IF IT MEETS THE REQUIREMENT
• ANY VARIATION, A ‘CORRECTION
BLOW’ IS ORDERED
• STEEL GOES THROUGH FURTHER
REFINING, DEPENDING ON
REQUIREMENT, AT THE ONLINE
PURGING STATION
• LIQUID STEEL FINALLY TAKES SOLID
FORM AND IS SHAPED
• LD #2 FOR SLABS & THEN TO HSM

12. LINZ DONAWITZ SHOP #3
• FOR PRODUCTION OF SLABS,
OUTPUT NEITHER SENT TO HSM NOR
CRM
• LADLES WITH A HOLDING CAPACITY
OF 160 TONNES CARRY THE LIQUID
STEEL TO THE CONTINUOUS CASTER
MACHINES
• FERRO-ALLOYS AND ALUMINIUM
ARE ADDED DIRECTLY INTO THE
STEEL LADLE FOR ALLOYING AND
DEOXIDISATION

13. STEEL ROLLING PROCESS
HOT STRIP MILL
• FLAT STEEL IS FURTHER PROCESSED
AT HSM DEPENDING ON END USE
• PRIMARY FUNCTION OF THE HOT
STRIP MILL IS TO REHEAT SEMI-
FINISHED STEEL SLABS OF STEEL
NEARLY TO THEIR MELTING POINT,
THEN ROLL THEM THINNER AND
LONGER
• 12 SUCCESSIVE ROLLING MILL
STANDS DRIVEN BY MOTORS
TOTALING 77,000 hp

14. COLD ROLLING MILL
HR COILS COMING FROM HSM ARE
COLD ROLLED BECAUSE
1. SHAPE AND PROFILE ARE BETTER IN
CR AS COMPARED TO HR COILS.
2. SURFACE FINISH IN HR COIL IS NOT
GOOD.
3. GAUGE ACCURACY OF HR IS NOT
GOOD.
4. SOME OF THE PHYSICAL PROPERTIES
WHICH ARE INVARIANT UNDER HEAT
TREATMENT PROCESSES CAN BE
ONLY MODIFIED BY THIS PROCESS.

15. BATCH ANNEALING FURNACE

16. FURNACE DESCRIPTION

17. FURNACE HOODS

18. PROCESS DESCRIPTION

19. HYDRAULICS IN BATCH ANNEALING
FURNACE

20. HYDRAULIC CYLINDERS
• MAINLY USED FOR CLAMPING & DE-
CLAMPING PURPOSE OF HOODS
• TOTAL OF 8 CYLINDERS IN A BASE
• 4 NRV & REST NON – NRV
• CYLINDERS ARE OPERATED BY A CENTRAL
CONTROL ROOM
MODLE NAME SURD-202
S- SWING TYPE
U- UPPER FLANGE
R- RIGHT SWING
D- DOUBLE ACTING
20- RATED CAPACITY OF 18.8 kN
CLAMPING FORCE

21. HYDRAULIC CIRCUIT

22. CIRCUIT AT BASE

23. MAINTENANCE OF SYSTEM
SCHEDULED ROUTINE MAINTENANCE
• ALINGNMENT
• MONITORING OF THE NITROGEN
CHARGE PRESSURE OF ACCUMULATOR
• FILTERS
• FLUID LEVEL
• CHECKING OF OIL LEVEL
• PIPING SYSTEM
SCHEDULED PERIODICAL MAINTENANCE
• GENERAL MAINTENANCE
• DAILY TO WEEKLY MAINTENANCE
• WEEKLY TO MONTHLY MAINTENANCE
• QUARTERLY TO SIX-MONTHLY
MAINTENANCE
• YEARLY MAINTENANCE

24. PROBLEM IN THE SYSTEM
PROBLEM 1: CYLINDER LEAKAGE
PROBLEM 2: CYLINDER NRV O-RING DAMAGE
PROBLEM 3: LEAKAGE FROM FITTINGS
PROBLEM 4: DAMAGE HOSE
PROBLEM 5: INTERNAL LEAKAGE IN PISTON
PROBLEM 6: ACCUMULATOR PUNCHER
PROBLEM 7: PRESSURE RELIEF VALVE NOT WORKING
PROBLEM 8: DIRECTION CONTROL VALVE DAMAGE
PROBLEM 9: MINIMESH POINT LEAKAGE
PROBLEM 10: PRESSURE SWITCH MALFUNCTION

25. PROBLEM 1: CYLINDER LEAKAGE
CAUSE: CYLINDERS NEAR THE HH, TEMPERATURE IS ABOUT 850 °C.CYLINDERS GET WORN OUT
EFFECT: LEAKAGE INCREASES
CONTAMINATION OF FLUID
REMEDY: DEFECTIVE CYLINDER IS REMOVED & REPLACED & SENT TO THE WORK SHOP FOR REPAIR WORK

26. PROBLEM 2: CYLINDER NRV O-RING DAMAGE
CAUSE: THE ONLY REASONIS HUMAN ERROR.DUE TO IMPROPER FITTING OF O-RING
EFFECT: PRESSURE DROP IN CYLINDERS
REMEDY: CHANGE OF O – RING

27. PROBLEM 3: LEAKAGE FROM FITTINGS
CAUSE: DUE TO CONTINOUS OPERATION AND FREQUENT VIBRATION, SOMETIMES THE FITTINGS GETS
LOOSEN
EFFECT: LEAKAGE FROM THE SYSTEM
CONTAMINATION OF FLUID
DETORIATES SYSTEM PERFORMANCE
REMEDY: LOCATE THE LOOSEN FITTING AND TIGHTEN THE PART; SURGE THE PRESSURE TO AVOID
ACCIDENTS

28. PROBLEM 4: DAMAGE HOSE
CAUSE: DUE TO CONTINOUS OPERATION OR LONG TIME IT BECOMES HARD AND GETS DAMAGED
EFFECT: LEAKAGE IN THE SYSTEM
CONTAMINATION OF FLUID
REMEDY: REMEDY IS TO SURGE THE PRESSURE FROM THAT HOSE AND CHANGE IT WITH A SUITABLE ONE

29. PROBLEM 5: INTERNAL LEAKAGE IN PISTON
CAUSE: DUE TO CONTINOUS OPERATION OF THE SYSTEM, SEAL OR O-RING GET DAMAGE
EFFECT: PRESSURE DROP
CONTAMINATION OF FLUID
REMEDY: DISMANTEL THE CYLINDER AND CHANGE THE PISTON OR THE SEAL, O-RING

30. PROBLEM 6: ACCUMULATOR PUNCHER
CAUSE: DUE RUBBER TUBE INSIDE THE ACCUMULATOR GETS DAMAGE
EFFECT: PRESSURE DROP
INCREASE IN VIBRATION
REMEDY: THE ACCUMULATOR IS REPLACED WITH A NEW ONE

31. PROBLEM 7: PRESSURE RELIEF VALVE NOT WORKING
CAUSE: DUE TO CONTINOUS OPERATION, SPRING INSIDE IT GETS LOOSE OR DAMAGE; OTHER REASONS
CAN BE CONTAMINATION OR O-RING DAMAGE OF THE VALVE
EFFECT: SAFTEY PARAMETER OF THE SYSTEM IN DANGER
REMEDY: IMMEADITE REPLACEMENT OF THE PRESSURE RELIEF VALVE WITH A NEW ONE

32. PROBLEM 8: DIRECTION CONTROL VALVE DAMAGE
CAUSE: CONTINOUS OPERATION OF THE SYSTEM OR THE CONTAMINATION OF THE HYDRAULIC FLUID
EFFECT: NO CLAMPING & DE-CLAMPING IN THE SYSTEM
REMEDY: CHANGE THE DIRECTION CONTROL VALVE AS SOON AS POSSIBLE

33. PROBLEM 9: MINIMESH POINT LEAKAGE
CAUSE: DUE TO PIN DAMAGE OR FITTING LEAKAGE AT MINIMESH POINT, OR DUE TO CONTINOUS
OPERATION; OR DUE TO SPRING DAMAGE
EFFECT: PRESSURE DROP IN THE SYSTEM
REMEDY: CHANGE THE MINIMESH, AS IT CAN’T BE REPAIRED

34. PROBLEM 10: PRESSURE SWITCH MALFUNCTION
CAUSE: DUE TO IMPROPER PRESSURE IN THE LINE OR DUE TO ELECTRICAL FAULT
EFFECT: NO PROPER INFORMATION ABOUT THE CLAMPING & DE-CLAMPING PRESSURE
REMEDY: CHANGE THE PRESSURE SWITCH AS SOON AS POSSIBLE

35. PROBLEM: LEAKAGE IN THE HYDRAULIC PIPE
REMEDY: TO FIND THE LEAKAGE AND TIGHTEN
THE LOOSE PARTS OR CHANGE THE PIPE,
ACCORDING TO THE SITUATION.
CAUSE: HUMAN ERROR
MISTAKE: NO PRESSURE SURGE FROM THE
LEAKAGE PIPE OR AREA
NO USE OF SAFTEY GLOVES
RESULT: HYDRAULIC FLUID AT PRESSURE OF 110
bar PENETRATED INTO WORKERS HAND.
AWARD: TWO DAYS SUSPENSION.
HOLE DUE TO FLUID
PENETRATION
MAJOR ACCIDENTS

36. PROBLEM: CYLINDER LEAKAGE
REMEDY: TO OPEN THE HYDRAULIC
CYLINDER FROM THE BASE AND
FIX IT AGAIN
CAUSE: HUMAN ERROR
MISTAKE: OVERCONFIDENCE
RESULT: HYDRAULIC CYLINDER’S
SWING MOVEMENT SMASHED HIS
HANDS
AWARD: FIVE DAYS SUSPENSION
HANDS IN CYLINDER

37. FUTURE ADVANCEMENT
SERVO VALVES
• “ELECTRO-HYDRAULICS”, DONE TO
ACHIEVE A VERY HIGH DEGREE OF
SOPHISTICATION AND AUTOMATION
• SERVO VALVE IS MECHANICAL –
ELECTRICAL COMBINATION OF ALL THE
VALVES USED IN A CIRCUIT
• ACCORDING TO THE NATURE OF THE
OPERATION AND GIVES THE PROPER
FEEDBACK TO THE CONTROL SYSTEM OR
THE SERVER
• MULTISTAGE SERVO VALVE SYSTEMS ARE
USED
• HAS THE ABILITY TO RESPOND MORE
QUICKLY AND HANDLE LARGER FLOW
RATE