Training Report on Bhushan steel private limited gzb

SUMMER TRAINING REPORT
Bhushan Steel Pvt. Ltd,Sahibabad
Duration: 07.06.2017-05.07.2017
Submitted to: Submitted By:
Mr. Bhanu Sir Ankit Gupta
HOD (Mechanical) M.E 3rd
year
1424040009
In partial fulfillment of requirements for the degree of
BACHELOR OF TECNOLOGY
IN
MECHANICAL ENGINEERING
SUNDERDEEP GROUP OF INSTITUITIONS
Dasna, Ghaziabad (U.P)

ACKNOWLEDGEMENT
This summer training is stepping stone towards the beginning of my professional
career and its satisfactory has endowed me with broader horizons of knowledge.
This training period is a fruitful culmination of my concerned affords during my
summer training at Bhushan Steels Ltd. Sahibabad.
I would like to express my thanks to Mr. Deepak Aggarwal for coordinating us
during the training. I would like to express my deep sense of gratitude to the
entire workers and technicians of various departments. Especially the HOD’s of
various departments for their inspiring guidance, continuous encouragement and
valuable suggestion.
At last but not the least, I would like to thank all personnel of Bhushan Steels Ltd,
who are directly or indirectly involved in my work for their cooperation and
precious help to complete my training successfully.

Preface
Every student of Bachelor of Technology in Mechanical Engineering has an
essential requirement to do 1 month of internship in any of the well reputed
organization. The purpose of this program is to acquaint the students with practical
applications of theoretical concepts taught to them during conduct of their course.
Really, it was a nice opportunity to have a close comparison of theoretical concept
in practical field. This report may depict deficiencies on my part but still it is an
output of a student’s efforts, for which I beg pardon.
The output of my analysis is summarized in a shape of Internship & the contents of
the report Shows the detail of sequence of these.

Abstract
The report covers the following aspects of internship:
 Table of contents.
 Introduction of Bhushan Steel Pvt. Ltd, Sahibabad.
 Departments and HODs of Bhushan Steel.
 Schedule of internship.
 My role as an internee.
 Conclusion.

Table of Contents
1. Acknowledgement ………………………………………………… Pg. no.1.
2. Preface ……………………………………………........................... Pg. no.2.
3. Abstract …………………………………………….........................Pg. no. 3.
4. Company Profile & manufacturing sites………………….………Pg. no.4-5.
5. Company’s Principle, Vision &Policies…………………………..Pg. no.6-8.
6. Finished Product & Process Layout ……………………………….. Pg. no.9.
7. Departments and their HODs ………………………….…………. Pg. no.10.
8. Safety …………………………………………...…………….. Pg. no.11-13.
9. Pickling/HRS ……………………………………...…………. Pg. no. 14-18.
10. Rolling (Hitachi mill) ……………………………..…………. Pg. no.19-21.
11. ECL …………………………………………………………. Pg. no. 22-24.
12. Annealing …………………………………….……………….Pg. no. 25-27.
13. SPM …………………………………………………………Pg. no. 28-29.
14. Finishing (CRS/CTL) ………………………………………..Pg. no. 30-32.
15. Utility …………………………………………………………Pg. no. 33-35.
16. ETP/ARP ……………………………………………………..Pg. no.
17. Electrical Maintenance ………………………………………..Pg. no.
18. Mechanical Maintenance ………………………………………Pg. no.

19. QMS …………………………………………………………….Pg. no.
20. Role of Internee during Internship …………………………….. Pg. no.
21. Conclusion ……………………………………………………… Pg. no.
22. References ……………………………………………………… Pg. no.

COMPANY PROFILE
Bhushan Steel is the largest manufacturer of auto-grade steel in India and is
spending Rs.260 billion to expand its capacity to 12 million tons annually, from the
present installed capacity of around one million tones.
It was the vision of the founder; Brij Bhushan Singal, that the first stake was driven
into the soil of Sahibabad (Uttar Pradesh) in 1987. His vision helped BSL overcome
several periods of adversity and strive to improve against all odds.
The company has three manufacturing units in the state of Uttar Pradesh (Sahibabad
Unit), Maharashtra (Khopoli unit), and Orissa Plant (Meramandali unit) in India and
sales network is across many countries.
The company is a source for vivid variety of products such as Cold Rolled Closed
Annealed, Galvanized Coil and Sheet, High Tensile Steel Strapping, Colour Coated
Coils, Galume Sheets and Coils, Hardened & Tempered Steel Strips, Billets,
Sponge Iron, Precision Tubes and Wire Rod.
As one of the prime movers of the technological revolutions in Indian Cold Rolled
Steel Industry, BSL has emerged as the country’s largest and the only Cold Rolled
Steel Plant with an independent line for manufacturing Cold Rolled Coil and Sheet
up to a width of 1700mm, as well as Galvanized Coil and Sheet up to a width of
1350 mm.
The dynamic reason of awesome and unparalleled growth of BSL is rapid
integration on the Steel value chain; conceivably, it would be its unwavering focus
on acquiring the latest technology and know-how, also the BSL’s commitment to
provide its customers with the best quality products.
Given a vibrant Steel industry dynamics in India, we are on a course to become a
fully Integrated Steel & Power Company with market leading offerings in value
added Steel in Automotive and White Good Segment with the quality been
approved by ISO 9001:2008 & ISO 14001:2004.

Company’s Manufacturing Sites
 Sahibabad Plant ( Estb. 1987 )
BHUSHAN STEEL LIMITED
23, Site IV, Sahibabad Industrial Area,
Distt. Ghaziabad – 201010 (U.P.)
INDIA
Products :
• Cold Rolled Coil
• Cold Rolled Sheet
• Galvanized Plane Coil
• Galvanised Plane Sheet
 Meramandali Plant
Narendra Pur
P.O. Shibapur, Meramandali
District - Dhenkanal - 759 121
Products :
• Billets
• Sponge Iron
• Pig Iron
• Char
 Khopoli Plant ( Estb. 2004 )
Village Nifan, Sarvoli, Kharpada Road
Taluka-Khalapur, Near Khopoli
Distt. : Raigad - 410203 (Maharashtra)
INDIA
Products :
• Colour Coated Sheets
• Galume Sheets
• Galvanized Sheets
• High Tensile Steel Strapping
• Hardened & Tempered Steel Strips
• CRCA

PRINCIPLE
―Our mission is to grow our company by providing innovative strong
and high-performance products and solutions to meet our global customer
needs.‖
Bhushan Steel Ltd formerly known as Bhushan Steel & Strips Ltd. is a globally
renowned one of the leading prominent player in Steel Industry. Backed by more
than two decades, of experience in Steel making, Bhushan Steel is now India’s 3rd
largest Secondary Steel Producer Company with an existing steel production
capacity of 2 million tons per annum’s (approx.).
It was the vision of the founder; Brij Bhushan Singal, that the first stake was driven
into the soil of Sahibabad (Uttar Pradesh) in 1987. His vision helped BSL
overcome several periods of adversity and strive to improve against all odds.
The company has three manufacturing units in the state of Uttar Pradesh
(Sahibabad Unit), Maharashtra (Khopoli unit), and Orissa Plant (Meramandali unit)
in India and sales network is across many countries.
The company is a source for vivid variety of products such as,
Galume Sheets and Coils , Hardened & Tempered Steel Strips , Billets, Sponge,
Iron, Precision Tubes and Wire Rod. As one of the prime movers of the
technological revolutions in
Indian Cold Rolled Steel Industry, BSL has emerged as the country’s largest and
the only Cold Rolled Steel Plant with an independent line for

manufacturing Cold Rolled Coil and Sheet up to a width of 1700mm, as well as
Galvanized Coil and Sheet up to a width of 1350 mm. Vision of company:-
―The vision of evolving into totally Integrated Steel Producer by
committing to achieve the highest standards of Quality through Cutting-
Edge Technology.”
The key to Vision is to use rigorous conceptual framework and to understand
how that framework connects to the underlying DNA of enduring great
companies. A well-conceived vision consists of two major components
—―CORE IDEOLOGY and an ―‖ ENVISIONED FUTURE . A good‖
vision builds on the interplay between these two complementary Yin-and-Yang
forces; it defines ―What we stand for and Why we exist that does not change‖
the Core Ideology and sets forth ―What we aspire to become, to achieve, to
create that will‖ require significant change and progress to attain the Envisioned
Future.

Our Vision
 About Culture: -To make it a place where all the people can thrive living,
learning and working in a clean, safe and healthy environment.‖
 About Values:-To corporate values as ―the rules or guidelines by which a
corporation exhorts its members to behave consistently with its order,
security and growth.‖
 About People: - See the good in people and try to develop those qualities‖
i.e. preparation and grooming of the next generation of the young thinkers.
 About Customers: - Sell good merchandise at reasonable price; treat our
customer like we would treat our friends and the business will take care of
itself. Bhushan Steel’s endeavor is to attain the highest level of Customer
Satisfaction.‖
 About Products: - We should always be the pioneers with our products –
out front leading the market.‖

Policies
INTEGRATED QUALITY, ENVIRONMENT, OCCUPATIONAL
HEALTH & SAFETY MANAGEMENT SYSTEM POLICY:
Bhushan Steel Ltd. commits to produce cold rolled and galvanized steel sheets of
world class quality in a safe, healthy and clean environment by involving
employees with continual improvements in system implementation, technological
advancement, operational integration, prevention of pollution & hazards
maintaining
Legal compliance and satisfying needs & expectations of Customers:-
For Environmental Management System we have ISO 14001:2004 Certification
For Quality System we have ISO/TS 16949:2002 Certification
For Safety Management System we have OHSAS 18001:2007 Certification

Finished Products at Sahibabad Plant
 Cold Rolled Coil
 Cold Rolled Sheet
 Galvanized Plane Coil
 Galvanized Plane Sheet
 Galvanized Corrugated Sheet
Process Layout

Various Departments and their HODs
Sl. No. Department Incharge
1. SAFETY Mr. Ramakant
Patel
2. PICKLING/HRS Mr. LR Singh
3. ROLLING Mr. Abhishek
Sinha
4. ECL Mr. Manish
Sirsikar
5. ANNEALING Mr. Vivek
Kaushik
6. SKIN PASS MILL Mr. Mahesh Bhatt
7. FINISHING Mr. Ajay Verma
8. QA Mr. Manish Arora
9. UTILITY Mr. KK Shukla
10. ETP/ARP Mr. MK Rawat
11. ELECTRICAL
MAINTENANCE
Mr. Rajesh Gupta
12. MECHANICAL
MAINTENANCE
Mr. Amit Sharma
13. QMS Mr. Ankur
Shrivastava

SAFETY
The service provider and his men should comply with personal protection
equipment (PPE) requirement decided by the organization safety department like
Cut Resistance, Hand Gloves, Safety Helmets and safety Helmets and Safety
Shoes.
➢ All the PPE’S must be worn while working on job.
➢ The service provider should be competent enough to supervise his men.
GENERAL SAFETY GUIDELINES:
➢ Service Provider must not operate any equipment in
manual mode without permission from authorized
engineer.
➢ Service Provider must not go to any equipment while
moving.
➢ No person is allowed to stand on coil car / slitting
line.
➢ No By-passing of interlocks and no pre assumptions for any equipment
operation.
➢ Use Proper PPE’S& Safety platform while packing.
➢ Ensure that, fingers should be away from strapping procedure and while
working with tensioner.
➢ Service Provider trained operator should handle consumables for packing of
Coils.

➢ Operators should be away from under crane, while crane carrying the Coil/
Plates to packing saddle/ packing area.
➢ Service Provider must remove the waste consumables immediately
➢ Specified scrap bin and keep the area neat &clean.
➢ Service Provider must keep only good quality wooden logs for packing.
➢ Service Provider must always wear sufficient PPE’s inside the plants.
➢ Service Provider must keep safe distance to the coils & packs while packing.
➢ Service Provider must not modify any tools or equipment’s.
➢ Service Provider must not touch any movable parts.
➢ Service Provider must riggers must be alert while pack stacking procedure in
yard.
➢ Extra care to taken while packing with fork lifter. The signal to be given to fork
lifter driver by standing at least one meter away from pack.
➢ Service Provider must keep the packs stack height maximum 6 feet and must
not stack the packs more than 6 feet height.
➢ Rigger must ensure as coil properly gripped in sling-gofer/c-hook than after
give the signal to the crane operator.
➢ Service Provider must not put wooden blocks for packing while the crane is
moving with load.

 FIRE HAZARDS AND ITS SAFETY:
FIRE MATERIAL FIRST AID
CYLINDERS
A Solid Water.
B Liquid Mechanical form.
C Gas CO2.
D Metal Dry Chemical Powder
(D.C.P).
E Electrical CO2

PICKLING
WHAT IS STEEL PICKLING?
A Scaly Crust
When steel is cooling, after hot-rolling, the oxygen in the atmosphere
chemically reacts with the hot surface iron on the steel and forms a compound
normally referred to as SCALE.
Chemically speaking, this scale can be made up of one or any or all of these
separate compounds:
Iron Oxide - scale (black, scaly)
Ferrous Oxide - rust (brown, powdery)
Ferric Oxide - magnetite (blue black, magnetic)
This scale, no matter what proportion of the three above compounds it
contains, is generally a very hard, brittle coating, from between paper thick to
1/32” thick, adhering to the surface of the steel.
No ‘foreign’ material can be present when the steel is further processed such
as in sizing by cold rolling or drawing or forming by stamping etc. This means
that the scale must be removed prior to this processing.
Mechanical scale removal methods such
as: Shot Blasting, Brushing, Grinding,
Scraping.
damage the surface of the steel. In addition, the processes are usually self
destructive and a constant maintenance headache.
As an alternative, chemical processing allows for quick, clean removal of
scale, without mechanical damage to the steel surface and without using self-
destructing equipment.
This method of scale removal is commonly referred to as ‘STEEL PICKLING’.

Although it bears no relationship to ‘pickling’ in the general sense of the word,
it does, however, imply the use of acid as the main process medium, which in
turn leads us to chemical processing.
This means that the scale is being removed using chemical reactions with acids
such as sulfuric or hydrochloric.
The Acids
The difference in attack mechanism affects other aspects of pickling such as:
Surface finish: Because the sulfuric acid has to attack the metal to
remove scale, a sulfuric finish is usually more etched than a hydrochloric
finish.
Inhibitors: Because sulfuric has to attack the metal to remove scale,
inhibitor cannot completely stop base metal attack. In hydrochloric acid,
very effective inhibitors almost completely stop attack on base metal.
Scale breakers: Hydrochloric acid dissolves scale, so no breakers are
needed. In sulfuric acid the scale must be cracked to allow acid to
penetrate beneath it.
Tank Sludge: Sulfuric acid attacks scale very slowly, so removed
scale collects in the bottom of the pickle tanks. Hydrochloric acid
dissolves scale rapidly, so these accumulations do not occur. Also, at
high temperatures, in sulfuric acid, ferrous sulphate monohydrate forms
and settles out in the tanks, due to decreasing solubility at higher
temperatures; this does not happen with hydrochloric acid.
Of course, hydrochloric acid has its disadvantages too:
 it is much more corrosive than sulfuric acid, which means pickle lines
cost more
 it gives off choking fumes when hot, so very good fume exhaust systems
are needed

 it is about 2 1/2 times as expensive as sulfuric acid

MATERIAL SPECIFICATION: Hot Rolled Steel Coils.
DIMENSIONAL SPECIFICATION (old):
Width 1700 max.
Thickness 6 mm max.
Wt. of coil 35 MT max.
LINE SPECIFICATION:
Maximum Speed 120 m/min
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.

 The activities involved in pickling are:
A. Loading of Coil.
B. Acid treatment of the I/P Material.
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)
C. Hot Water Rinsing.
D. Drying.
E. Oiling.
F. Re-Coiling.
G. Removing of Coil.
H. Strapping & Labelling.
I. Transfer of O/P Material.

HOT ROLLED SLITTER
This Process is performed for removing unwanted material , giving flatness,
side cutting to get desired shape or width, remove side bending, defects like
notches etc.
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.

ROLLING (HITACHI MILL)
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.
The gap between the rotating rolls is less than the thickness of the entering work
piece , therefore a friction force is necessary in order to bite the work piece and to
pull it through the rolls.
A steel work piece passing through the rotating rolls is squeezed, and it elongates
while it cross section in area decreases.
Rolls must be made of materials with high strength and resistance to wear.
Common materials include cast iron, cast steel & forged steel. Rolls are polished for
cold working and special applications.
Rotating Rolls perform two main functions:
• Pull the work piece into the gap between them by friction between work
piece and rolls.
• Simultaneously squeeze the work piece to reduce its cross-section .
Rolling mill stand is used for housing the rolls for rolling of the work piece.
A typical rolling mill stand consist of a pair of rolls driven by an electric motor
transmitting a torque through a gear and pair of cardan shafts. The rolls are
equipped with bearings and mounted in a stand with a screw-down mechanism.
Hitachi mill is used for the reduction of thickness of the sheets.
 MATERIAL SPECIFICATION: Pickled HR coils.
 DIMENSIONAL SPECIFICATION:
MIN. MAX.
Width 750 mm 1700 mm
Material i/p thickness 1.8 mm (HR) 7.0 mm

Wt. of Coil 3.0 MT 30 MT
CR thikness 0.11 mm 6.95 mm
• LINE SPECIFICATION:
Max. Speed 1200 MPM
Tension 16 T MAX.

• Steps applied during Rolling:
1. Production scheduling.
2. Loading of coil.
3. Feeding of coil.
4. Rolling of coil.
5. Inspection of material rolled and action for defects.
6. Unloading.
7. Strapping of Coil.
8. Material storage and transportation.

Electrolytic Cleaning Line
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.
 MATERIAL SPECIFICATION:
(1). Cold rolled steel strips.
(2). Dimensional Specification:
MIN. MAX.
Thickness 0.20 mm 3.20 mm
Max. Coil Wt. 30 MT

 LINE SPECIFICATIONS:
(a) Threading speed 26 MPM (MIN).
(b)Max Speed 300 MPM
(c) Max Re-Coiler Tension 4000 KGF.
(d)Min. Re-Coiler Tension 1500 KGF.
(e) Max. Un-Coiler Tension 2000 KGF.
(f) Capacity 52 MT PER HOUR WITH AVERAGE
SIZE OF 0.50*1250 MM.
 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.

ANNEALING
Annealing is a process by which the properties of steel are enhanced to meet
machinability requirements. Annealing is a process of heating the steel slightly
above the critical temperature of steel (723 degrees Centigrade) and allowing it to
cool down very slowly.
 MATERIAL SPECIFICATION :
Low carbon non alloy steel of CQ, DQ, DDQ, EDDQ, SEDDQ, & IF steel
used in automotive applications including outside body panel application.
 DIMENSIONAL SPECIFICATION:
MIN MAX
WIDTH 700 mm 1710 mm
THICKNESS 0.15mm 4.10 mm
CHARGE WEIGHT _ 110 MT
 The steps involved in the process are:
PROCESS EQUIPMENT /
ATMOSPHERIC MEDIA
(a) Coil Transfer Coil car, Coil lifter, Crane.
(b) Charging Coil lifter, Inner Cover, Work
Base.
(c) Leak Test Nitrogen, Hydraulic Power Pack
For Clamping.
(d) Safe Purge 1 Nitrogen.
(e) Heating NG, Electrical control system,
Heating Bell, Hydrogen Gas.

(f) Soaking -DO-
(g) Warm Leak Test -DO-
(h) Cooling Cooling Hood.
(i) Safe Purge 2 Nitrogen.
(j) Unloading, Storage&
Transfer
Coil Lifter, Crane.
(a) Types of Annealing
There are various types of annealing.
1. Full Annealing - The process involves heating the steel to 30 to 50 degrees
Centigrade above the critical temperature of steel and maintaining the temperature
for a specified period of time, then allowing the material to slowly cool down inside
the furnace itself without any forced means of cooling. Hot Worked sheets,
forgings, and castings made from medium and high carbon steels need full
annealing.
2. Process Annealing - This process is mainly suited for low carbon steel. The
material is heated up to a temperature just below the lower critical temperature of
steel. Cold worked steel normally tends to posses increased hardness and decrease
ductility making it difficult to work. Process annealing tends to improve these
characteristics. This is mainly carried out on cold rolled steel like wire drawn steel,
etc.
3. Stress Relief Annealing - Large castings or welded structures tend to possess
internal stresses caused mainly during their manufacture and uneven cooling. This
internal stress cause brittleness at isolated locations in the castings or structures,
which can lead to sudden breakage or failure of the material. This process involves
heating the casting or structure to about 650 Degree centigrade. The temperature is
maintained constantly for a few hours and allowed to cool down slowly.
4. Spherodise Annealing - This is a process for high carbon and alloy steel in order
to improve their machinability. The process tends to improve the internal structure
of the steel. This can be done by two methods
a. The material is heated just below the lower critical temperature about 700 Degree

centigrade and the temperature is maintained for about 8 hours and allowed to cool
down slowly.
b. Heating and cooling the material alternatively between temperatures just above
and below the lower critical temperature.
5. Isothermal Annealing – This is a process where is steel is heated above the
upper critical temperature. This causes the structure of the steel to be converted
rapidly into austenite structure. The steel is then cooled to a temperature below the
lower critical temperature about 600 to 700 Degree Centigrade. This cooling is done
using a forced cooling means. The temperature is then maintained constant for a
specified amount of time in order to produce a homogenous structure in the
material. This is mainly applicable for low carbon and alloy steels to improve their
machinability.
 Advantages of Annealing:
The following are some of the advantages of annealing.
· It softens the steel.
· It enhances and improves the machinability of steel.
· It increases the ductility of steel
· It enhances the toughness of steel
· It improves the homogeneity in steel
· The grain size of the steel is refined a lot by annealing
· It prepares the steel for further heat treatment.

SKIN PASS MILL
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 SPECIFICATIONS:
MIN MAX
Thickness 0.15 mm 3.50 mm
Coil Wt. 30 MT
Coil OD 2000 mm
Coil ID 610 mm

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.

FINISHING
 It has two section lines:
1. C.R.S ( Cold roll slitting ).
2. C.T.L ( Cut –to-length ).
 COLD ROLL SLITTER LINE (FIMI- ITALY):
Dimensional specifications:
Max. Speed 400 mpm
Min. Width 25 mm
Max. Width 1700 mm
Work Instructions:
A. Loading of coil: (1) CR, Skin passed coil is loaded on the coil car by
crane.
(2) The coil is loaded to the un-coiler through coil car and it should be
centrally loaded.
B. Feeding of coil: (1) The coil is fed from un-coiler using peeler table.
(2) The coils outer 2/3 damaged wraps are cut by shear.
(3) The coil is feed from slitter to re-coiler through looping table in
tension unit.
(4) The tension unit is providing back tension before coil is being re-
coiled.
(5) The feed coil is slitted and its scrap is allowed to fall in scrap pit,
where is balled by scrap baler.
(6) The slitted strips are kept separated by line separator before tension
unit.

C. Setting of slitter and slitting of coil: (1) The cutters and spacers set up is
prepared as per the planning sheet for slitting of coil.
(2) The cutters must be properly cleaned & should have right cutting edge.
 CUT –TO – LENGTH (GEORG-GERMANY):
WORK INSTRUCTIONS:
A. Loading of coil: The coil after slitting are loaded on the coil skid by crane
under a skilled person & then with the help of car coil is loaded on the un-
coiler centrally.
B. Setting of length: (1) Coils are cut to length as per planning after feeding the
necessary data in computer (i.e. length to cut).
(2) Gap between the two shear blades is set about 10% of thickness of sheet
for proper cutting.
C. Feeding of coil: The coil feeding is done with the help of snubber roil, peeler
table & entry pinch roll up to the feeding pinch roll in such a fashion that
sheet with respect to line should remain in center.

D. Cropping of coil: (1). For adequate cropping the conveyor should be in good
condition.
(2). The cutting edge of the shear blade found damaged it must be in good
condition & always checked by shift in-charge before operation.
(3). The load provided to the leveler must be adequate regarding to material.
(4). While cropping the material ensures that gap between the shear blades
should be minimum 10% in order to maintain the cutting edge quality.
E. Stacking and unloading: (1). The sheet which has been cut to require
length moves ahead with the help of conveyor belt on stacker unit where
sheet get stacked in form of pile on wooden pallet.
(2). Before packing oiling must be done on each packet.
(3). After packing identification sticker or tag must be pasted properly on
every packet & also be ensure by shift in-charge.

UTILITY
Utility generally Comprises of 4-Sections:
• R.O Plant.
• Compressor.
• Boiler.
• A.C. Plant.
R.O. PLANT:
Osmosis: It is the flow of solvent particles from lower concentration of solution to
higher concentration of solution through semi-permeable membrane.
Or,
It is the flow of solvent particles from higher concentration of solvent to lower
concentration of solvent through semi-permeable membrane.
Osmotic pressure: It may be defined as the pressure which is required to prevent
the osmosis.

Reverse Osmosis: The process of Osmosis can be reversed if a pressure applied
on the solution is larger than the Osmotic pressure. As a result the solvent starts
moving from the solution towards the pure solvent through SPM.
LAYOUT OF R.O. PLANT:
 APPLICATIONS:
• Cooling water make-up.
• Drinking purpose.
• De-mineralized plant feed.
• Other purposes.

CENTRIFUGAL COMPRESSOR: A centrifugal compressor is a type of
dynamic compressor, or turbo-compressor, with a radial design. Unlike
displacement compressors that work at a constant flow, dynamic compressors work
at a constant pressure and the performance is affected by external conditions such as
changes in inlet temperatures.
So, how does a centrifugal compressor work?
Air is drawn into the center of a rotating impeller with radial blades and is pushed
toward the center by centrifugal force. This radial movement of air results in a
pressure rise and the generation of kinetic energy. Before the air is led into the
center of the impeller, the kinetic energy is also converted into pressure by passing
through a diffuser and volute.
Each stage takes up a part of the overall pressure rise of the compressor unit.
Depending on the pressure required for the application, a number of stages can be
arranged in a series to achieve a higher pressure. This type of multi-stage
application is often used in the oil and gas and process industries. Alternately, in
wastewater treatment plants, low pressure, single-stage applications are used to
achieve the desired pressure ratio.
In modern configurations of centrifugal air compressors, ultra-high speed electric
motors are used to drive the impellers. This results in a compact compressor
without a gearbox and associated oil-lubrication system, thus making it oil-free and
appropriate for applications that require 100 percent oil-free air.

EFFLUENT TREATMENT PLANT
Equalisation
Tank
Equalisation
Tank
Reaction TankReaction Tank Agitation Tank with
Agitator
Tank
Agitation Tank with
Agitator
Tank
Dosing of Lime
Sol.
Dosing of Lime
Sol.
ClarifierClarifier
PE
Dosing
PE
Dosing
Clarifier Outlet Sludge Pit
Sand
Filter
Sand
Filter
Filter
s

Three Storage Tanks
Another Storage Tank
Sump Pit
Checking of COD & BOD
NaOcl
Equalisation
Tank
Equalisation
Tank

ACID REGENERATION PLANT
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.

ELECTRICAL MAINTENANCE
Electrical maintenance means the care and checklist of electrical
equipments/instruments to avoid any breakdown or fault. To tighten all electrical
connections, to upgrade the power rating of safety switches is also a part of
Electrical maintenance.
Electrical maintenance engineer look after AC motors, DC motors, Transformer,
Electrical switch gears (Air Circuit breakers, relays etc); Electronics ( PLC, drives);
Line instruments ( Proximity switch, level switch, RTD ).
Preventive maintenance: A preventive maintenance is a schedule of regularly
planned maintenance testing and actions with the intent of preventing breakdowns
and failures. Finding and replacing worn components before they can actually fail is
the goal of preventive service, as well as predicting useful life of existing
equipment.
Types of elec-
trical
maintenance.
Types of elec-
trical
maintenance.
PREVENTIVEPREVENTIVE PREDICTIVEPREDICTIVE BREAK DOWNBREAK DOWN

Some of the preventive maintenance are:
1. To change the carbon brush of DC motors.
2. Tightness of Electrical connections.
3. To clean the dust is AC motors so as to prevent from heat.
Predictive maintenance: Predictive maintenance techniques are designed to
determine the condition of in-service equipment in order to predict when
maintenance should be performed. The main promise of predictive maintenance is
to prevent unexpected equipment failures. The key is -right information in the right
time.
Breakdown maintenance: Breakdown maintenance is maintenance performed on
equipment that has broken down and is unstable. Better the preventive maintenance,
lesser chance of breakdown.

MECHANICAL MAINTENANCE
Mechanical maintenance means the steps taken to prevent any mechanical
equipments and machines from any kind of damages.
Mechanical Maintenance engineers carry out planned or unplanned maintenance
and repair activities on a wide range of equipment e.g. pumps, engines,
compressors, turbines etc.
Types of mechanical maintenance: 1. Preventive maintenance.
2. Predictive maintenance.
3. Breakdown maintenance.
Preventive maintenance: It is a daily maintenance ( cleaning, inspection, oiling,
and re-tightening) , design to retain healthy condition of equipment.
Some of the preventive maintenance are:
1. To check the alignment.
2. To tight the nut and bolt.
3. Proper lubrication.
Predictive maintenance: This is a method in which the service life of important
part is predicted based on inspection, observation or diagnosis.
Prediction and observation of temperature, vibrations, level of oil, pressure etc.
Breakdown maintenance: Breakdown maintenance is a maintenance performed
on equipment that has broken down or damaged. Better the preventive maintenance
lesser the chances of breakdown.

QUALITY MANAGEMENT SYSTEM
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
Where, QMS: Quality Management System.
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.

Role of trainee during the training period
“I learned how to adjust myself in the work environment, how to deal with people
at work - from the boss to the janitors. It’s a good and quality experience; The
necessary kind of experience as it helps you realize what you want in future. “Also
got the opportunity to evaluate myself under these stressful conditions”.
CONCLUSION
From this summer training, I concluded that:
• In Bhushan steel Sahibabad plant , steel undergoes different processes like
pickling , rolling, ECL, annealing, skin pass mill then finishing.
• Pickling is a process of removing the oxide scale from hot rolled steel.
• Rolling is a process of reducing the thickness of HRS coil ( from pickling)
with the help of 6HI HITACHI MILL.
• Electrolytic cleaning line is used to remove the oil film from the surface of
cold rolled steel coils.
• Annealing is a heat treatment process used to soften the steel.
• Skin pass mill is used to give the proper grain structure to steel coils (from
annealing) and also to remove the yield point.
• Finishing carries two section lines, first one is Cold Rolled Slitter where Cold

Rolled steel coils are slitted according to the customers needs. And, second
one is Cut-to-length where steels coils are cutted into sheet form having some
length based upon customer requirement.
REFERENCES
1. https://en.wikipedia.org/wiki/Pickling_(metal)
2. http://www.bhushan-group.org/historynew.html
3. http://www.bhushan-group.org/company.html
4. https://www.google.co.in/search?
biw=1366&bih=623&tbm=isch&q=pickling+metal&sa=X&ved=0ahUK
EwjwhtaqrYvOAhVMwI8KHTwgBvUQhyYIIA&dpr=1&cad=cbv&bvc
h=u&sei=xlaUV9zYCYnnvgS1qav4Cw
5. https://www.delstar.com/metal-pickling

Training Report on Bhushan steel private limited gzb

Recommended

Recommended

More Related Content

What's hot

What's hot (20)

Similar to Training Report on Bhushan steel private limited gzb

Similar to Training Report on Bhushan steel private limited gzb (20)

More from Ankit Gupta

More from Ankit Gupta (6)

Recently uploaded

Recently uploaded (20)

Training Report on Bhushan steel private limited gzb