`

Project report
On
Zero bolt failure in steel making
MAHARISHI MARKANDESHWAR
UNIVERSITY
Submitted By:

Submitted to:

Dipankar Jha (VT20142489)

Dr N.K Batra

Roll no:11115175

HOD( ME)

CONTENTS
1. AKNOWLEDGEMENT
2. INTRODUCTION TO TATA STEEL
3. SYNOPSIS
4. SPECIFICATION OF BOLT

4
5
10

Study of bolt
Types of bolt
Types of bolt head
Property class of bolt
Bolt standard
Material of bolt
Study of bolt failure
Failure report of last 6 years
Reason of failure
Year wise failure
Department wise Failure
Grade wise failure

5. ISSUE RELATED TO SPECIFICATION

6. MINIMUM REQUIRMENT FOR CREATING NEW UMCs
7. QUALITY RELATED FAILURE
8. SOLUTION
9. ACTION POINT
10.RECOMMENDATION

24
24
26
27
28

ACKNOWLEDGEMENT
Any accomplishment, big or small, has a number of persons behind the
scene and I must acknowledge that this project was no exception.
2

I would like to take this golden opportunity to express my sincere

gratitude to the TATA STEEL Management for giving me an
opportunity to perform this project in their esteemed organization. I
would like to express my sincere gratitude towards my guide
Mr.E.G.Khan (Sr. Manager, QAG), for his consistent support during
my project. He has been an eminent source of encouragement and
provided me valuable information as well as knowledge regarding my
project.
I would also like to express my gratitude to Mr. Siddharth Roy, Mr.
Kalyaan Prasad for his support in understanding the steel making
process in Tata steel by organizing plant visit.
I feel extremely thankful to all members of MEG who helped me during
the project. Also, I must confess that this vote of thanks would be
incomplete without the mention of my friends who have also made my
work easier with their useful inputs. I am deeply indebted to them
indeed.

Dipankar jha

INTRODUCTION TO TATA STEEL

Tata Steel Limited (formerly Tata Iron and Steel Company
Limited (TISCO)) is an Indian multinational steel-making company
headquartered in Mumbai, Maharashtra, India, and a subsidiary of the
3

Tata Group. It is the 7th-largest steel producing company in the world,

with an annual crude steel capacity of 23.8 million tons, and the largest
private-sector steel company in India measured by domestic production.
Jamshetji Tata an altruistic person, a man who could translate
ideas into reality. He sowed the seeds; his successor worked untiringly to
see them bear fruits and so was born, TATA IRON AND STEEL
COMPANY (TISCO) at Bistupur, Jamshedpur on 26thAugust, 1907, the
first iron & steel industry of INDIA. The company called its first ingot in
1911 and came to function as one of the biggest producers (ingot) from
16thFebruary, 1912 and ever since has never looked back. From then
onwards, this company has emerged as an ever-growing as well as
evergreen company with no history of lock-outs in the factories. The
noble spirit was continued by his son Sir Durabji jamshedji Tata and is
been still pursued by Sir Ratan Tata.
TATA Steel is an integrated steel plant. Its main works is at
Jamshedpur, in Singhbhum district, of the state Jharkhand. TATA Steel
the leading integrated steel plant in India and is considered as the
flagship of TATA Empire.
The company has always harnessed the benefits of technical
innovations and modern infrastructure. Thus, TATA Steel has always had
a leading edge over its competitors not only in the domestic sector but
also in the global market. Technology obsolescence is an inherent
business risk in this fast changing world. The speed of change and
adaptability is crucial for survival of business. At TATA Steel, a
continuing modernization process has enabled the Company to do away
with obsolete plants/processes and emerge as one of the most modern
integrated Steel plant in the world. Steel being a capital-intensive
industry; this process has involved huge capital investment.
4

In the recent past, TATA Steel has taken major strides to adapt the
latest technology available worldwide. This has resulted in huge benefits
in the form of waste control, savings and cost of production. TATA Steel
now, can proudly boast of being the lowest cost steel producer in the
world. With this major advantage, it hopes to satisfy its valued
customers and maintain its leadership position in the world market.
Tata Steel has manufacturing operations in 26 countries,
including Australia, China, India, the Netherlands, Singapore, Thailand
and the United Kingdom, and employs around 81,600 people. Its largest
plant is located in Jamshedpur, Jharkhand. In 2007 Tata Steel acquired
the UK-based steel maker Corus in what was the largest international
acquisition by an Indian company to date.
Tata Steel is listed on the Bombay Stock Exchange, where it is a
constituent of the BSE SENSEX index, and the National Stock
Exchange of India. It is ranked 401st in the 2012 Fortune Global 500
ranking of the world's biggest corporations. It is the eighth mostvaluable Indian brand according to an annual survey conducted by
Brand Finance and The Economic Times in 2010.

SYNOPSIS

PROJECT TITLE:- Zero bolt failure in steel making

DEPARTMENT:- Maintenance Expert Group (MEG)
5

PROJECT DESCRIPTION:- Failure of bolt due to overloading and

Supply of incorrect material due to incomplete/incorrect specification in
UMC and vendor related quality issues.
OUTCOME OF PROJECT:- Sanitization of all UMC belonging to HT
bolt thereby eliminating failures caused due to incomplete/incorrect
specification in UMC. Besides identifying all the active UMCs of bolts
and studs procure through drawing route and tagging it as critical in
SAP. QAP will be prepared for all such UMCs and inspection will be
done by QAG.
BENEFITS TO TATA STEEL:-Reduction in failures and saving due to
reduction in breakdown related to bolt failure.

Study of bolts
BOLT:

A screw or bolt, is a type of fastener characterized by a helical

ridge, known as an external thread or just thread, wrapped
around a cylinder. Some screw threads are designed to mate
with a complementary thread, known as an internal thread, often
in the form of a nut or an object that has the internal thread
formed into it. Other screw threads are designed to cut a helical
groove in a softer material as the screw is inserted. The most
common uses of screws are to hold objects together and to
position objects.

Why

are

bolts

used?

Advantages:
Removable
Easy to install
Wide variety of standard parts
Disadvantages:

Loosening
Failure
Cost
High maintenance
7

 Prone to corrosion

Types of bolt:
1. Hexagonal bolt:
Description: An externally threaded fastener
with a trimmed hex head, often with a washer face on the bearing
side.
Application notes: Used in a variety of general purpose applications
in different grades depending on the required loads and material being
joined.
Reference Standard: IS 1364 (PART 1)/ISO 4014 / DIN 931 (For
standard thread length)

2. Carriage bolt :
It is distinguished from other bolts by its head:
the shank of the bolt is circular for most of its length, as usual, but the
portion immediately beneath the head is formed into a square
section. This makes the bolt self-locking when placed through a square
hole, or a round hole in most wood. This allows the fastener to be
installed with only a single tool, a spanner or wrench, working from one
side. The head of a carriage bolt is usually a shallow dome. The squared
8

section is of the same size as the diameter of the bolt shank, with a plain
unthreaded shank.
Carriage bolts were developed for use through iron strengthening plates
on either side of a wooden beam. It is commonplace though to use them
into bare timber, the squared section giving enough grip to prevent
rotation.

3. Eye bolt:
An eye bolt is a bolt with a loop at one end. They are used
to firmly attach a securing eye to a structure, so that ropes or cables may
then be tied to it.

4. Shoulder

bolt:

Shoulder bolts are screws with an unthreaded

shoulder that is larger in diameter than the threads. Also known as
stripper bolts.

9. Hex washer frame bolts:

Description: A one-piece hexwasher head bolt with a flat bearing surface, made of high-alloy steel.
Application notes: For use on truck frames. The flange eliminates
washers and helps compensate for a misaligned hole. Used with a stover
nut, the bolt system resists bolt slippage by distributing the clamp load
over a wide area.

Foundation

10.

bolt:
10

An anchor bolt is used to attach objects

or structures to concrete. There are many types of anchor bolts,
consisting of designs that are mostly proprietary to the manufacturing
companies. All consist of a threaded end, to which a nut and washer can
be attached for the external load. Anchor bolts are extensively used on
all types of projects, from standard buildings to dams and nuclear power
plants.They can also be used to firmly affix embed plates to a concrete
foundation when used with a structural steel element.

Types of bolt head :

1. Hex head
Reference std: IS 1364 (part 1)

11

2. Allen head
Reference std: IS 2269/ ISO 4762/ DIN 912

3. Countersunk head

CSK cheese
Reference std: IS 7169:1989

12

 CSK slotted
Reference std: IS 8412:1977

CSK - socket
Referance std: IS 6761:1994

6. Foundation head

13

Reference std: IS 5624

7. Low socket head

Reference std: IS 2269-2006
ISO 4762 2004 / DIN 912

8. Square head
Reference std: IS-2585

9. T- head
Reference std: IS 2014/DIN 261/DIN787
14

or

Property
class of bolt
In case of bolt, property class is designated by two digits separated
by a dot (4.6 /8.8 etc).This number indicates UTS (Ultimate
Tensile Strength) and YS (Yield Stress) value of bolt. For example,
4.6 means the UTS of bolt is 4 X 100 = 400 MPa and YS is 400 X
0.6 = 240 MPa.

Bolt standard:
15

Reference Standard:
1. IS 1364 (PART 1)/ ISO 4014 / DIN 931 (For standard thread
length, hexagonal head bolt)
2. IS 1364 (PART 2)/ISO 4017/ DIN 933 (For full length threaded
screw, hex head bolt )
3. IS 3640/ DIN 609 ( Hex fit bolt)
4. IS 5624 ( Foundation bolt)
5. IS 2269-2006 / ISO 4762-2004/ DIN 912 ( Socket head bolt)
6. IS 2585 (square head bolt)
7. IS 2014 / DIN 261/ DIN 787 ( T-head bolt)
8. IS 1363(PART 1):2002/ISO 4016 : 1999

Bolt materials :
Most are steel alloy, although occasionally you may find brass or
aluminium or plastics used.
Stainless steel used in cases where extreme corrosion resistance is
needed.
Screws and bolts are made from a wide range of materials, with
steel being perhaps the most common, in many varieties. Where
great resistance to weather or corrosion is required, stainless steel,
titanium, brass, bronze, monel or silicon bronze may be used, or a
coating such as brass, zinc or chromium applied. Electrolytic

16

action from dissimilar metals can be prevented with aluminium

screws for double glazing tracks.
e.g. : some types of plastic, such as nylon,
polytetrefluoroethylene(PTFE), can be threaded and used for
fastening requiring moderate strength and great resistance to
corrosion or for the purpose of electric insulation.

a) Low or medium carbon steel

b) Medium carbon cold drawn steel
c) AISI 501
d) AISI 140
e) AISI 4140, 4142, 4105
f) Alloy steel
g) AISI 347
h) Medium carbon steel, Quenched and tempered

STUDY OF BOLT FAILURE

17

Scientific services report of last six years shows that there have been
maximum failures in case of bolt.

The major contribution of failure is due to failure of bolt and stud (28%
) so a project was taken under MEG as a campaign for Zero Bolt
Failure.
The scientific services report of last 6 year was studied for bolt and stud
related failure.
The findings tabulated in excel sheet for analysis of data. Following are
the findings.

18

Failure report of last 6 years:

Approach
Span of Analysis-Failure reports of 6 Years(2008-2013)

Source of Data- Sc. Services Archived report and Field failure

reported by Sc. Services of 2011, 2012 and 2013

Scope of study- Tata Steel Jamshedpur works

Data capturing Format:

Reason of bolt failure :

Quality
Overloading
Design
19

 Over torquing
Fatigue
Maintenance

ANALYSIS

* Quality related failure and Overloading during operation are

the two major reason of fail.

Year wise failure:

ANALYSIS
20

3 MTPA Failure 8 Nos.

Department wise failure:

ANALYSIS
21

Four most contributing Dept:

1. LD1
2. HSM
3. CP
4. LD2

5. Grade wise Failure:

22

50% 0f Total Failure(10.9

&12.9)

23

ISSUE REALTED TO SPECIFICATION

To deal with quality issues related to specification, study of existing
database of UMC for its completeness and uniqueness is required. For
this one has to understand the meaning of complete specification.

WHAT IS COMPLETE SPECIFICATION?

Complete specification refers to the inclusion of all such parameters
which
is
necessary
to
define
any
item.
In the creation of any UMC all the parameters has to be clearly
mentioned and thus understanding of complete specification is very
important.

MINIMUM REQUIREMENT FOR CREATING A

NEW UMC IN BOLT:

Head type
Diameter of bolt (mm/ inch)
Length of bolt (mm/ inch)
24

 Thread (metric/BSW/UNF/UNC)
Thread length (full/standard/ std mentioned)
Thread pitch (as per std mentioned)
Material of construction (MS/ HT/brass)
Property class (grade) : 8.8/8.9/10.9/12.9
Surface coating : galvanized/ blackened/any specific
Reference Standard(IS 6761,IS 1364(PART 1)/ISO
4014/DIN931)
Part route
Make/manufacturers name
Drawing number/part no.

25

Quality Related Failure:

Reason of Failure
40
35
30
25
20
15
10
5
0

Quality

Overloading

Design

26

Overtorquing

Fatigue

maintenance

*Quality related issue is the main reason for failure of bolt.

The three main reason for quality related failure are:
1. Incomplete specification resulting in wrong material supply by the
vendors.
2. No inspection of standard bolts supplied by the approved vendors
resulting in field failure due to quality related reasons like improper
hardness or chemistry.
3. Improper quality of material supplied by the unapproved vendors
approached through drawing route.

SOLUTION
1. Sanitization of UMCs of HT bolt.
All the UMCs of HT bolts (2700 ) no. were downloaded from SAP and
through analysis in excel was done for its completeness in specification.

Followings are the findings:

27

WRONG SPECIFICATION IN PO TEXT

54

34
22
19
WRONG SPECIFICATION IN PO TEXT

16
6

ACTION POINT:
28

 Block the incomplete UMCs.

Correct the wrong UMCs if possible.
RECOMMENDATIONS
1. Inspection of standard bolts supplied by the approved vendors to
eliminate the field failure due to quality related reasons like
improper hardness or chemistry.
2. Tagging of material in SAP as Critical, supplied by the vendors
procured through drawing route.

29