SUMMER TRAINING REPORT (BHUSHAN STEEL)

Transcription

1 SUMMER TRAINING REPORT (BHUSHAN STEEL) SUBMITTED BY, DEEPAK SHARMA ELECTRICAL AND ELECTRONICS ENGINEERING (3 rd YEAR ) HRCT GROUP OF INSTITUION Contact :

2 INTRODUCTION This entire report deals with the study of the various operations conducted in NCRM (New Cold Rolling Mill) in order to manufactured the products like cold rolled sheets, galvanized coil etc. during the entire period we deals with the various processes that are involved in the manufacturing of the above mentioned products. We visited departments like HRS, SPM, RGM, GP-1, GP-2 etc. where the various operations are conducted involved in the production of CR coils, Galvanized coil. The machines and equipment s used are of higher standard and norms which are imported from the JAPAN, GERMANY and other countries in order to maintain the accuracy and precision as well as to produce good quality products. The working environment of the company is excellent, technicians and workers are highly skilled. They work hardly to develop standards products and achieving the goals of the company. Workers are trained by the company to update their knowledge and skills. Finally it s really a great learning experience for me while working in the BSL, SAHIBABAD. This training helps me to learn the basics of the industrial work and other relevant factors which work as the stepping stone of my professional life. I am thankful to each and every one who is involved in my work and all the officials, technicians and workers which help me to learn a fruitful lesson from the working environment of the BSL, SAHIBABAD.

3 ACKNOWLEDGEMENT This summer training is stepping stone towards the beginning of my professional carrier 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. Mukesh (personal) for given me an opportunity to a part of this esteemed organization. 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 of NCRM 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.

4 COMPANY PROFILE Bhushan Steel is the largest manufacturer of autograde steel in India and is spending Rs.260 billion to expand its capacity to 12 million tones 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 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.

5 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.

6 Company s Manufacturing Sites Sahibabad Plant ( Estb ) BHUSHAN STEEL LIMITED 23, Site IV, Sahibabad Industrial Area, Distt. Ghaziabad (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 Products : Billets Sponge Iron Pig Iron Char Khopoli Plant ( Estb ) Village Nifan, Sarvoli, Kharpada Road Taluka-Khalapur, Near Khopoli Distt. : Raigad (Maharashtra) INDIA Products : Colour Coated Sheets Galume Sheets Galvanized Sheets High Tensile Steel Strapping Hardened & Tempered Steel Strips CRCA Precision Tubes

7 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 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

8 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.

9 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.

10 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

11 Current capacity of Sahibabad Plant Facility Capacity (TPA) H.R. Slitting Line(2) 2,40,000 Pickling Line (2) 9,00,000 6 Hi Hitachi Reversible Mill 3,50,000 6 Hi Flat+ Narrow Reversible Mill 1,25,000 Electrolytic Cleaning Line 3,50,000 Annealing Line Batch Type (Hydrogen) 2,76,000 Laddle Refining Furnaces 3,60,000 (Storage Capacity) 30 Bases Kathabar 180 T Roll Grinding Machine 2 Machines Roll Texturing Machine (EDT Machine) - 4 Skin Pass Cum Tension Leveling Line 3,30,000 C.R. Slitters 3,00,000 Cut-to- Length Galvanizing Line 2,25,000

12 Finished Products at Sahibabad Plant Cold Rolled Coil Cold Rolled Sheet Galvanised Plane Coil Galvanised Plane Sheet Galvanised Corrugated Sheet Process Layout

13 Various Departments and their HODs Department Safety HRS/Pickling Hitachi-Mill ECL Annealing Skin Pass Mill Finishing Colour Coating Quality NCRM GP-1 Utility Electrical Maintenance Quality System HOD Mr. Sudhir Kumar Mr. AK Dixit Mr. Neeraj Sharma Mr. SK Sood Mr. Neeraj Gupta Mr. Satyaveer Mr. AK Kansal Mr. Suresh Sharma Mr. AK Mukherjee Mr. RC Singh Mr. AK Gupta Mr. KK Mathur Mr. Deepak Aggarwal

14 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 Smust 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.

15 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.

16 Pickling line Mainly pickling of coil is used to remove corrosion or rust, which is produced on coil surface due to interaction of coil surface with air and moisture. This may form an oxide layer on coil surface, which may cause of reduction of metal and improper surface finish. Pickling in a solution of hydrochloric or sulphuric acid. The acid dissolute the oxide scales from the strip surface according to the reaction: Fe2O3 + 6HCl = 2FeCl3 + 3H2O. Rinsing and passivation of the strip. At this stage the acid residuals are washed by water from the strip. Passivation film is formed on the strip surface providing corrosion protection. Drying. Edge Trimming. Oiling. Recoiling.

17 Specification: Type of Line Material Strip Thickness Strip Width Coil O.D. Coil Wt. Pickling Rinse Push Pull Hot Rolled M.S. 6.0 mm 1700 mm 2000 mm 30 MT. Cascade with 2/3/4 tanks Multi stage cascade hot rinse Pickling Medium HCL

18 Online Side Trimming. Oiling. Roll Bending. Quick Work Roll Change. Additional Features These pickling lines can process strips varying from 1.0mm to 12.0mm thick and 200mm to 2000mm wide. Picking lines process one coil at a time, therefore eliminating the need for joining strips. This process allows immense flexibility of operation & also ensures easy operation and maintenance. As accumulators are not required in these lines, thus making them cost effective in nature. These pickling lines are capable of producing between 200,000 to 1,000,000 Tons per annum.

19 Hot Rolled Slitter This process is performed for removing unwanted material, giving fatness, 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 Recoiling Removal of coil Stepping & labeling of output material Storage of output material

20 Slitting Lines Slitting Lines, Slitting Lines have been successfully put into operation in well-known production plants & service centers. These lines have the capability to meet client's demand for minimum burr, no damage to the surface, high production capacity etc., to the fullest. The high automation level of the lines reduces the need for operator attendance and ensures economy of operation. Characteristic Features: High automation level to achieve high economic efficiency Minimum burr on strip edges due to high running accuracy of knife arbors No manual interferences required as the edge scrap baller is pit mounted Additional Features : Quick Slitter Head Change with Standby Slitter Head. Dual speed lines to cover wider range of thickness.

21 Specification: a) Type of Line Loop / Pull Thru'. b) Material Hot Rolled M.S. c) Strip Thickness 10.0 mm. d) Strip Width 2000 mm. e) Coil O.D mm. f) Coil Weight. 3MT. g) Line Speed 200 mpm. H.R.Slitter Additional Features: Quick Slitter Head Change with Standby Slitter Head. Specification: C.R.Slitter 1. Type of Line Single / Double Loop. 2. Material CR FH / CRCA / GALVANIZED / COLOUR COATED. 3. Strip Thickness 3.0 mm. 4. Strip Width 1650 mm. 5. Coil O.D mm. 6. Coil Wt. 3MT. 7. Line Speed 250 mpm.

22 Galvanizing Line We offer hot-dip galvanizing lines. The lines manufactured by us are furnace type, heat to coat type or wet flux type. Efficient air-knives control the thickness of coating with great precision, either through manual settings or through automatic coat control systems. The materials can be pickled hot rolled steel, cold-rolled steel of CQ, DQ quality & full hard in nature. Specification: Additional Features: On Line Skin Passing. On Line Tension Leveling. Double Recoiler on Exit Side

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26 GP1 A. WORK INSTRUCTION FOR ENTRY SECTION APPROVED PROCESS APPROVED MACHINERY Coil loading Coil car & uncoiler Welding unit B.LINE SPECIFICATION MONITORING OF PROCESS PARAMETERS SPEED Entry speed 15 20mpm TENSION Entry (POR) mpm Entry accumulator 105 TO 1050 Kg POSITION Entry accumulator1 90% Filled POR initial data 500mm 600mm C.OLD ROLED MATERIAL SPECIFICATION Hardness of material HRB Thickness of strip mm Width mm Weight0.5MT (min.), 22MT (max.) Initial diameter of coil 500 mm 600mm

27 D. COLD ROLLED MATERIAL INSPECTION Preferably coil should be free from edge cut & saw edges. Shape & surface finish of the cold rolled coil is inspected by entry operator & also enters the same in log book. E. INTRODUCTION FOR ENTRY SETUP Made entry section ready by pressing switch. Make accumulator tension on by pressing switch. Make POR tension on by pressing switch. Make entry start by pressing switches. F. COIL LOADING Coil is loaded with the help of coil car.

28 Electrolytic Cleaning Line Utilizing a performance enhanced, low temperature, high volume, updraft re-circulating hot air design, the Electrolytic cleaning line is ideal for refreshing steel products and other metallic mater. The Electrolytic cleaning lines are the ideal wet cleaning complement for advanced Electrolytic components. Specification: Additional Features: On line trimming

29 Electrolytic Cleaning is required in case material rolled with high percentage of oil while reduction in mills goes for annealing in furnace. Oil free base material is essential for the production of bright and corrosion resistant steel. Sodium Orthosilicate is used as cleaning agent in ECL. Tension is given according to thickness, width based on customer requirement. The installed production capacity of the line is MT/Annum.

30 ROLL GRINDING MACHINE:- It is a three rolled grinding machine. It is basically used to treat the roll which are used continuously in certain machines like Hitachi Mill, Pickling line etc. In this machine we use two categories of rolls namely Intermediate Rolls Back Up Roll PROCESS FLOW DIAGRAM FOR RGM 1 Pre inspection of roll: In this step the rolls are inspected in order to identify their defects. 2 Loading of roll: In this step the rolls which are found defected ones are load with the help of coil car. 3 Selection of Machine Control Program (MCP): In this step particular computer operated programs are selected to operate on the loaded roll. 4 Rough Cutting of Roll: In this step rough cutting of rolls are done with the help of shear. A shear cutting oil is used in order to control friction and to reduce the temperature develop on the surface.

31 5 Inspection of roll: This step is performed to find the any defects or extra material attached to the surface of the rolls. If any defect is found then the roll is sent for the cutting operation to remove those defects. 6 Finishing of rolls: After the inspection process finishing operation is done on the roll. Now the rolls are ready to use for their operation in the machines like Hitachi Mills, SPM etc. 7 Texturing (only for W/R) : In this process Electric discharge is used in order to provide the desired Roughness to the rolls so that they perform their function satisfactorily If this operation is not conducted then roll will not perform its work properly and hence the product formed will not be of good accuracy and precision. 8 Unloading, storage & Transport: Finally the defect free roll is obtained.now it is ready for reuse. Now it is unloaded with the help of coil car and sent back to the different mills for use. DEFECTS OF ROLLS Roll Bite Pinchers Chattering Marks Floppers (Pinching Marks)

32 Annealing Line Annealing Line: The demand for better annealed stainless steel has increased. Annealing is a heat-treating process conducted under controlled-atmosphere furnace to minimize oxidation, so that the product surface remains clean. It is very common for continuous annealing of strip products and stainless steels. Type of Line Material Strip Thickness Strip Width Coil O.D Coil Wt. Line Speed Horizontal Tight Line Stainless Steel. 1.5 MM. 660 MM MM. 10 T 30 MPM Additional Features: Tension control in closed loop. Annealing For Stainless Steel:- The heat treatment has to be specific in annealing and pickling line to find the best compromise between strength and ductility without neglecting the surface finish. Annealing and pickling lines (APL's) are used for the treatment of hot rolled (HR) and cold rolled (CR) stainless steel strips. HR Austenitic & CR strip is annealed and pickled continuously in an APL and HR ferric strip is only pickled. Lines for HR & CR, as well as dedicated APL's process the majority of the stainless steel production.

33 Annealing at a temperature ºF ( ºC) in a controlled reducing atmosphere (commonly a mixture of Hydrogen and Nitrogen) preventing oxidation of the steel surface. Annealing results in recrystallization of the steel Grain structure and in stress relief. There are two alternatives of annealing process continuous annealing line and batch annealing furnace. In the continuous annealing line (see the picture below) steel strip passes annealing furnace at a controlled speed. In the batch process steel strip coils are stacked on top of each other in the bell type furnace. Batch annealing allows to achieve lower hardness and higher ductility of the steel than in alternative continuous annealing. Batch Annealing Furnace The process of annealing of cold rolled coil is carried out to obtain the desired properties in the finished coils. For this, the material is heated to predetermined temperature in a protective atmosphere and soaked for a specified time before it is put to room temperature. Optimum condition with annealing atmosphere, annealing cycle, sealing and purging have to be maintained to obtain a finished product with bright surface, desired micro structure and uniform properties throughout the coil. HSD is used for heating the surface. Nitrogen is purged inside the inner cover. Nitrogen is obtained from PSA Unit. The installed production capacity of the line is MT/annum.

34 Rewind cum Trimming Line Built from the basic elements of the compact trimming line, the modular line mechanically trims the edges through chip removal process. Any desired dimension is possible depending on strip width and thickness. The number of tools operating simultaneously is variable. It is frequently used in the welded tube production. Additional Features: Two - speed arrangement.

35 Coil build-up Lines The coil build-up lines are used for side-trimming of the strips and also provide the coils with leader strips that can be reused for optimization of the yield. With suitable inclusion of welder, these lines can be used for building up bigger coils from small coils, with roll-able weld. 1. LOADING OF COIL Cold Rolled (CR),GP Coil or skin passed coil is loaded on the coil car/turnstile by crane. 2. FEEDING OF COIL o The coil is fed from uncoiler using Peeler Table. o The coils outer 2/3 damaged wraps are cut by shear. 3. SETTING OF SLITTER & SLITTING OF COIL o Proper set of cutters and rubbers to be used for setting of slitter. o During slitting the operator must check the back tension & regulate it properly. o The pneumatic pressure on pressure pad should in between bar. 4. CLEANING OF MACHINE All rotating parts & rolls should be cleaned regularly. Line should be cleaned regularly after processing of approx MT of material.

36 5. RECOILING &UNLOADING. 6. PACKING OF COIL COLD ROLLED SLITTER MINIMUM Speed Coil width Strip thickness Coil weight MAXIMUM 400 mpm II400 mm1700 mm 0.10mm3mm 3 MT

37 COLD ROLLING MILL:- There are two types of Cold Rolling Mills operates, which are 6 Hi Cold Rolling Mill and 4 Hi Cold Rolling Mill. Pickled Hot Rolled Coils of higher gauges are reduced to required thinner gauges by passing through the Mills. In 6 Hi Mill the reduction achieved is up to 0.13mm ultrathin gauge whereas 4 Hi can reduce the thickness up to 0.25mm. The computer controlled rolling process ensures closure thickness tolerances and perfectly flat strips. The installed production capacity of 6 Hi Mill is 23,856 MT/annum and 4 Hi Mill is 43,502 MT per annum. Cold Rolling Mills our cold rolling mills are specifically designed for breakdown rolling of ferrous/ non-ferrous sheet & strip. The rolls are manufactured from alloy steel, having high hardness of about HRC. The produced steel is considered to be "full hard". Cold-rolled steel products begin as hot rolled pickled and oiled coils. These coils are "cold-reduced" by passing them through a cold reduction process on a reversing mill under high tension and pressure. Mill Specification:

38 Additional Features: Hydraulic Automatic Gauge Control. Thickness Gauges. Roll Bending. Quick Work Roll Change.

39 Skin Pass Mill:- Skin Pass Mill These skin pass mills are specifically designed for manufacturing sheet / strip of medium hardness or to provide finish pass. The Rolls are made of alloy steel & have high hardness, which is generally up to 65 HRC or more. For increasing demands with respect to strip flatness, elongation and roughness, especially for hard material grades, skin-pass mill is an ideal solution due to higher rolling forces and torques that can be achieved in this case.

40 Temper rolling (skin pass rolling) - final cold rolling operation with low thickness reduction conducted in order to impart to the steel required levels of hardness, evenness and surface finish. Four-high rolling mill is used for tempering. Most of annealed low carbon steel strips are tempered since they are too soft (HV<110) in annealed condition. Bending and deep drawing operations of soft annealed steel may cause formation of kinks (cross breaks) and stretcher strains, which are the result of localized stretching of the strip at low cold deformation beyond the yield point. Light tempering of annealed strip (non-kinking temper, pinch pass) produces strip surface conditions, which do not cause formation of cross breaks and stretcher strains. Hardness of pinch passed steel is about 115 HV. Other temper conditions of steel strip are: eighth hard (105<HV<125), quarter hard (115<HV<130), half hard (130<HV<160), three quarter hard (150<HV<185).

41 Quality control: BSL have fully fledged laboratory with test equipment s such as Emission spectroscope for the chemical analysis, computerized Universal testing machine with stress-strain graph for tension tests, surface finish tester, Hardness testers using both Vickers and Rockwell scales, LFQ testing machine, Cupping tester, on line Radiometric and off line chemical lab for coating mass, salt spray tester for corrosion resistance, and Humidity chamber. o For Environmental Management System we have ISO 14001:2004 Certification o For Quality System we have ISO/TS 16949:2002 Certification o For Safety Management System we have OHSAS 18001:2007 Certification The main concern of the company is to Maintain the international norms of steel industry to develop the accurate and precise products by preserving the environmental balance and constituting an ecofriendly environment by utilizing modern and advanced techniques available in the market.

42 Hardness is a surface property. HARDNESS TEST: - It is defined as the resistance of a material against permanent deformation of the surface in the form of scratch, cutting, indentation, or mechanical wear. BRINELL HARDNESS TEST:- This test is conducted for the specimen with range 0 to 10. In this test hardened steel ball is used as an Indenter. Indenter is used to introduce indentation on the surface. This machine is called push-pull button type machine because the indenting load is applied by pushing a button. Before conducting the test, the surface of specimen is made free from oil, grease, dust and dirt. FORMULA:- BHN = Indenting load in (kgf)/spherical surface area of indentation in (mm2)

43 VICKERS HARDNESS TEST This test is similar to Brinell s test but uses a different type of Indenter. A Square based Pyramid Indenter of cone angle (=136 degree Celsius) between opposite faces of pyramid is used. The applied loads may be 5, 10, 30, 50, 50, 100 or 120 kgf. FORMULA:- VICKERS HARDNESS = P/d2 (for cone angle = 136) This test is performed for smaller cross sections, very hard materials, polished and nitride surfaces, and very thin test pieces. TENSILE TEST This test is performed on machines such as given below. 1. Hounsfield Tensometer, 2. Universal Testing Machine(UTM) 3. Instron or other Material Testing Machine (MTS). 4. Universal Testing Machine (UTM)

44 The UTM have large load capacity, generally ranging from 0-4 Tonne. Materials with large sections and high tensile strength such as steel bars are tested on them. Tensometer is generally mechanically operated while UTM s are hydraulically operated. They can be controlled by computers or can be operated manually. R & D department : For continuous bench marking of our product quality, we keep carrying out testing from outside laboratories. This has resulted in continuous upgrading of the process parameters confirming to any international standards. Further, we have online backup SGS inspection for all test parameters up to the point of dispatch. We are IS0 900l certified. Our products are accompanied with mill test certificates and packing lists. Following tests are conducted in order to maintain the accuracy and precision and standardization of the products manufactured in the plants according to international norms of the steel market.

45 Conclusion Cold Rolling Mill Complex (CRM) The various processing units involved in the CRM complex and their functions are given below: The waste liquor from pickling line, recoiling line are treated in effluent treatment plant ensuring pollution free environment. The acid regeneration plant ensures regeneration of hydrochloric acid from waste pickled liquor for reuse in pickling line. Continuous Pickling Line (Cpl): The HR Coil, which is the basic raw material, is passed through CPL to remove the oxides or scales from strip surface to enable further reduction of thickness to desired level in Cold Rolling Mills. This processing is required since rust is formed on the surface of the coils at room temperature whereas scales are formed at high temperature during rolling in Hot Strip Mill. Cold Rolling Mill Pickled Hot Rolled Coils of higher gauges are reduced to required thinner gauges by passing through the Mills. In 6 Hi Mill the reduction achieved is up to 0.13mm ultra-thin gauges whereas 4 Hi can reduce the thickness up to 0.25mm. The computer controlled rolling process ensures closure thickness tolerances and perfectly flat strips. Electrolytic Cleaning Line Electrolytic Cleaning is required in case material rolled with high percentage of oil while reduction in mills goes for annealing in furnace. Oil free base material is essential for the production of bright and corrosion resistant steel. Sodium Orthosilicate is used as cleaning agent in ECL. Tension is given according to thickness, width based on customer requirement.

46 Annealing Furnace The process of annealing of cold rolled coil is carried out to obtain the desired properties in the finished coils. For this, the material is heated to predetermined temperature in a protective atmosphere and soaked for a specified time before it is put to room temperature. Optimum condition with annealing atmosphere, annealing cycle, sealing and purging have to be maintained to obtain a finished product with bright surface, desired micro structure and uniform properties throughout the coil. HSD (High Speed Diesel) is used for heating the surface. Nitrogen is purged inside the inner cover. Skin Pass Mill In this process the cold rolled annealed strips are given a desired surface finish. It improves the flatness and suppresses the yield point elongation. Anti-rust oil is used on strip surface as protection from rust. Bibliography 1. Wikipedia wiki Bhushan Steel 2. Bhushan Steel Official Website