BHUSHAN STEEL LIMITED

SHAHIBABAD GHAZIABAD UP- 201005

A REPORT OF SUMMER TRAINING ON

SUBMITTED BY
Sandeep kumar
B.TECH 3RD YEAR
NATIONAL POWER TRAINING
INSTITUTE
NEW DELHI

CONTENT

1.0 Abstract ...............

2.0 History of the company......

3.0 Company profile...

4.0 Vision of the company..

5.0 Policies of company.

6.0List of departments visited in training..

HR slitting.

Pickling.

Rolling mills.......

Electrochemical cleaning..

Annealing...

Normalization....

Skin pass mill.

Cold roll stilling/Cut to length.....

7.9 Qualitycontrol.....

Research and development..

Galvanising plant..... 7.12Rolling

grinding machine......

Narrow plant.......

Conclusion...

References.......

ABSTRACT

In 4 weeks of my industrial training I have learned about various processes such as cold
rolling slitting etc. I had a good exposure to these processes which added more to my
knowledge. I worked on galvanising plants in which galvanization process takes place,on
steel.basically zinc or aluminium coating is done on the steel,for increasing life of steel and
making it suitable for use, but at Bhushan steel they also coat steel with galume a mixture of
55% zinc + 43% aluminium + 2% silicon. Its coating is very effective and useful.silicon is
basically used just to improve adhesion of the other two material on the steel. Other products
of the industry are colour coated coil, hard tempered coil, billets, sponge iron, tubes, etc.

HISTORY OF THE COMPANY

Year events 1983 - The company was incorporated on 7thJanuary, under the name of Jawahar
Metal Industries Private Limited for the manufacture of cold rolled steel strips and steel
ingots at Sahibabad Industrial Area, District Ghaziabad.

1987 - On 14th January, Brij Bhushan Singal and his sons Sanjay Singal and Neeraj Singal
and associate companies took over the management of the company by acquiring the entire
share capital of the company.

1989 - The company undertook the setting up of a new plant for the manufacture of wide
width Cold Rolled Steel Strips with integrated plant facilities.

1992 - The name of the company was changed to the present name of Bhushan Steel & Strips
Limited and fresh Certificate of Incorporation was issued on 9th June.

1993 - The company made its maiden Public Issue of 22 lac equity shares of Rs.10 each at a
premium of Rs.55 share aggregating Rs. 1430 lacs in September/October.

1994 - The galvanising plant was commissioned in January. Presently the company has
facilities for the manufacture of 1,20,000 tonnes per' annum of wide width cold rolled steel
strips and 1,00,000 tonnes per annum of galvanised sheets.

1995 - The Cold Rolling Expansion the Company is installing state of the art 1600mm width
6HI combination Universal Crown Mill (UCM) of Hitachi, Japan with sophisticated features
for shape control and surface finish to cater to the requirements of the automobile and white
goods sector.

1996 - The Part B of 68,94,800 14% unsecured fully convertible Debentures aggregating Rs
8375 Lacs have been converted into Equity Shares w.e.f. 1st April.

1998 - With the commissioning of the new plant recently set up at company's existing site at
Sahibabad (UP), the company is now exploring further growth possibilities of setting up a

5
modern Cold Rolling cum Galvanizing Unit at West Coast of the Country.

1999 - During the year, the company has set up a dedicated service centre for large OEM
customers at Sahibabad so as to ensure supplies to them on 'just in time' concept.

2000 - The Delhi-based Bhushan Steel and Strips' to set up a Rs 750 crore cold rolled steel
plant is likely to hit a road block.

2002-Strikes an important position in the market for cold rolled steel for automobiles, feeding
over 70% of demand for car bodies.

2003-Enters into a strategic alliance with Sumitomo Metal Industries of Japan under which,
the latter has further extended process know-how for the manufacture of automotive steel
sheets for a period of six years

2004-Bhushan Steel awards Rs 36 cr order for BHEL

2006-Bhushan Steel & Strips Ltd has informed that Sh. Sanjay Singal, has ceased to be a
Director of the Company w.e.f. October 18, 2006.

2007-Company name has been changed from Bhushan Steel & Strips Ltd to Bhushan Steel
Ltd

2008-Bhushan Steel Ltd has informed that w.e.f. September 23, 2008, Sh. B B Tandon has
been appointed as an Additional Director on the Board of the Company as a Independent
Non-Executive Director.

2009-Bhushan Steel buys Aussie exploration firm

2010- Bhushan Steel Ltd has informed that Life Insurance Corporation of India has appointed
Smt. Sunita Sharma, their representative as a Nominee Director on the Board of the
Company.

COMPANY PROFILE

TYPE : PRIVATE

FOUNDED IN : 1987

HEADQAURTERS : INDIA

KEY PERSONS : Brij Bhushan Singhal (Chairperson)

Neeraj Singhal (Managing Director)

INDUSTRY : STEEL

WEBSITE : www.bhushangroup.com

LIST OF DEPARTMENT VISITED IN TRAINING

1. HR SLITTING 2.HRS/PICKLING

ROLLING MILLS

ECL

ANNEALING

SKIN PASS MILL

CRS/CTL

QUALITY

R&D

UTILITY

GP

RGM

NARROW PLANT

HR SLITTING:

DIMENSIONAL SPECIFICATION:

MIN
MAX
WIDTH
700mm
1700mm

MATERIAL I/P THICKNESS

1.8mm (HR)
7.0mm

WEIGHT OF COIL
3.0 MT
30 MT

CR THICKNESS
0.11mm
6.95mm

LINE SPECIFICATION:

MAXIMUM SPEED
1200MPM

TENSION

16 T MAX

PROCESS:

Roll slitting, also known as log slitting, is a shearing operation that cuts a large roll of
material into narrower rolls. The log slitting terminology refers back to the olden days of saw
mills when they would cut logs into smaller sections. They would also use these saw mills to
cut iron rods into smaller sections; see slitting mill. The multiple narrower strips of material
are known as mults (short for multiple) By today's definition, slitting is a process in which a
coil of material is cut down into a number of smaller coils of narrower measure. Potential
workpieces are selectively thin (0.001 to 0.215 in.) and can be machined in sheet or roll form.
Slitting is considered a practical alternative to other methods due to its high productivity and
the versatility of materials it can manage.

PICKLING:

MATERIAL SPECIFICATION (WIDER PICKLING):

A. Hot rolled steel coils:

Width : 1700 max

Thickness

: 6mm max

Weight of coil

: 35Mt max

B. Line Specification:

Maximum speed

: 120 m/min

Pickling (metal)

Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic
contaminants, rust or scale from ferrous metals, copper, and aluminum alloy. A solution
called pickle liquor, which contains strong acids, is used to remove the surface impurities. It
is commonly used to descale or clean steel in various steelmaking processes.

Process

Many hot working processes and other processes that occur at high temperatures leave a
discoloring oxide layer or scale on the surface. In order to remove the scale the workpiece is
dipped into a vat of pickle liquor.

The primary acid used is hydrochloric acid, although sulfuric acid was previously more
common. Hydrochloric acid is more expensive than sulfuric acid, but it pickles much faster
while minimizing base metal loss. The speed is a requirement for integration in automatic
steel mills that run production at high speed; speeds as high as 800 ft/min (~243 metres/min)
have been reported.

Carbon steels, with an alloy content less than or equal to 6%, are often pickled in hydrochloric or
sulfuric acid. Steels with an alloy content greater than 6% must be pickled in two steps and other
acids are used, such as phosphoric, nitric andhydrofluoric acid. Rust- and acid-resistant
chromium-nickel steels are pickled in a bath of hydrochloric and nitric acid.

ROLLING MILLS(6 HI HITACHI MILL):

A. MATERIAL SPECIFICATION:

PICKLED HR COIL / ANNEALED CR COIL OF VARIOUS GRADES

B. DIMENSIONAL SPECIFICATION:

MIN
MAX
WIDTH

700mm
1700mm

MATERIAL I/P THICKNESS

1.8mm (HR)
7.0mm

WEIGHT OF COIL
3.0 MT
30 MT

CR THICKNESS
0.11mm
6.95mm

C. LINE SPECIFICATION:

MAXIMUM SPEED
1200 MPM

TENSION
16 T MAX

PROCESS:

In metalworking, rolling is a metal forming process in which metal stock is passed through
a pair of rolls. Rolling is classified according to the temperature of the metal rolled. If the
temperature of the metal is above its recrystallization temperature, then the process is termed

as hot rolling. If the temperature of the metal is below its recrystallization temperature, the
process is termed as cold rolling. In terms of usage, hot rolling processes more tonnage than
any other manufacturing process and cold rolling processes the most tonnage out of all cold
working processes.

There are many types of rolling processes, including flat rolling, foil rolling, ring rolling, roll
bending, roll forming, profile rolling, and controlled rolling.

billets. If these products came from a continuous casting operation the products are usually fed
directly into the rolling mills at the proper temperature. In smaller operations the material starts at
room temperature and must be heated. This is done in a gas- or oil-fired soaking pit for larger

workpieces and for smaller workpieces induction heating is used. As the material is worked
11

the temperature must be monitored to make sure it remains above the recrystallization
temperature. To maintain a safety factor a finishing temperature is defined above the
recrystallization temperature; this is usually 50 to 100 C (122 to 212 F) above the
recrystallization temperature. If the temperature does drop below this temperature the
material must be re-heated before more hot rolling.

Hot rolled metals generally have little directionality in their mechanical properties and
deformation induced residual stresses. However, in certain instances non-metallic
inclusions will impart some directionality and workpieces less than 20 mm (0.79 in) thick
often have some directional properties. Also, non-uniformed cooling will induce a lot of
residual stresses, which usually occurs in shapes that have a non-uniform cross-section, such
as I- beams and H-beams. While the finished product is of good quality, the surface is
covered in mill scale, which is an oxide that forms at high-temperatures. It is usually
removed via pickling or the smooth clean surface process, which reveals a smooth surface.
Dimensional tolerances are usually 2 to 5% of the overall dimension.

Hot rolling is used mainly to produce sheet metal or simple cross sections, such as rail tracks.

Cold rolling

Cold working

Cold rolling occurs with the metal below its recrystallization temperature (usually at room
temperature), which increases the strength via strain hardening up to 20%. It also improves
the surface finish and holds tighter tolerances. Commonly cold-rolled products include
sheets, strips, bars, and rods; these products are usually smaller than the same products that
are hot rolled. Because of the smaller size of the workpieces and their greater strength, as
compared to Other shapes can be cold-rolled if the cross-section is relatively uniform and the
transverse dimension is relatively small; approximately less than 50 mm (2.0 in).

12

Flat rolling:

Flat rolling is the most basic form of rolling with the starting and ending material having a
rectangular cross-section. The material is fed in between two rollers, called working rolls, that
rotate in opposite directions. The gap between the two rolls is less than the thickness of the
starting material, which causes it to deform. The decrease in material thickness causes the
material to elongate. The friction at the interface between the material and the rolls causes
the material to be pushed through. The amount of deformation possible in a single pass is
limited by the friction between the rolls; if the change in thickness is too great the rolls just
slip over the material and do not draw it in. The final product is either sheet or plate, with the
former being less than 6 mm (0.24 in) thick and the latter greater than; however, heavy plates
tend to be formed using a press, which is termed forming, rather than rolling.

Oftentimes the rolls are heated to assist in the workability of the metal. Lubrication is often
used to keep the workpiece from sticking to the rolls. To fine tune the process the speed of the
rolls and the temperature of the rollers are adjusted.

13

ELECTROCHEMICAL CLEANING

MATERIAL SPECIFICATION

COLD ROLLED STEEL STRIPS

DIMENSIONAL SPECIFICATION

MIN
MAX
WIDTH

800 MM
1705 MM
THICKNESS
0.20 MM
3.20 MM
MAX COIL WEIGHT
------30 MT
B. LINE SPECIFICATION:

1.
THREADING SPEED

: 27MPM(MIN)
2.
MAX SPEED

: 300 MPM
3.
MAX RECOILER TENSION
: 4000 KGF
4.
MIN RECOILER TENSION
:1500 KGF
5.
MAX UN-COILER TENSION
:2000 KGF
6.
CAPACITY

: 52 MT / HOUR

with everage size

of 0.50 * 1250

mm

14

SM

Electrochemical Cleaning (ECC) is a very effective process using the same physics,
equipment, and chemicals we use in our proprietary "spot" electropolishing technique.
Discovered when a customer had a product residue issue that looked like classic "rouge" yet
when industry accepted de-rouging chemical applications were tried they proved completely
ineffective. In an experiment we used the spot electropolish procedure whereby electrolyte
was applied to the stained surface and the DC current was activated and the "hand tool" was
applied to and moved over the surface the stain was removed immediately. Because of this
discovery we were able to completely clean 5,10,15K GALLON & larger vessels in hours
instead of days.

Once discovered this method has found several very cost effective applications where ECC
can be used in place of more expensive and less effective chemical or manual processes while
delivering a micro surface improvement to the area being cleaned where optional processes at
best do nothing to improve and at worst can etch the micro surface.

Applications:

De-rouging: ECC has been found to be very effective for removing rouge for both
electropolished and non-electropolished surfaces. An added benefit observed on items derouged using ECC is the rouge is very slow to return. Though conventional de-rouging and
passivation methods would yield a clean product contact surface the rouge would begin to
reform in a matter of hours. Equipment de-rouged using ECC has shown the rouge resisted
returning for months and in some cases years.

Grey Residue: On equipment with a sanded or mechanically polished stainless steel surface
only it is common to find a grey residue present when the surface is wiped with an alcohol
soaked cloth. In many instances the entire surface of a vessel, as an example, will be hand
wiped for hours using "clean wipes" until all of the grey residue has appeared to have been
removed. The vessel may then be passivated or cleaned in place and allowed to dry only to
have the grey residue return at visibly the same concentration as observed before the cleaning
operation.

It is believed this grey residue is made up of stainless steel powder created by the sanding
process and electrostatically adhered to the mechanically polished surface (PIC). No amount

15

of wiping or chemical cleaning has proven to completely remove this residue.

Understandably Quality Control personnel find this condition unacceptable concerned if the
grey residue can be wiped off, it stands to reason it can come loose during product processing
and become an undesirable additive.

ECC can completely remove this grey residue in one application by electrolytic action as
metal is removed ion by ion with the very outermost surface and any residue being removed.
In dozens of applications this condition has successfully been treated in one application
eliminating grey residue from the equation.

Weld Scale and Discoloration: Prior to successful use as a de-rouging or surface

contaminant removal process, ECC was developed specifically for removing weld
discoloration directly on a weld or in the heat affected zones adjacent to the weld.

The process utilizes a mild acid electrolyte solution and DC current that when applied to a
weld or heat affected zone (HAZ) very rapidly removes discoloration. On large construction
projects utilizing austenitic, super-austenitic or nickel alloys, weld discoloration has
historically been removed by mechanical polishing, blasting or a harsh chemical application,
all of which alter the appearance when compared to untreated surrounding surfaces. The
process has also been shown to improve corrosion resistance in these areas comparable to that
of the surrounding base metal.

16

ANNEALING:

Annealing, in metallurgy and materials science, is a heat treatment wherein a material is

altered, causing changes in its properties such as strength and hardness. It is a process that
produces conditions by heating to above the recrystallization temperature, maintaining a
suitable temperature, and then cooling. Annealing is used to induce ductility, soften material,
relieve internal stresses, refine the structure by making it homogeneous, and improve cold
working properties.

In the cases of copper, steel, silver, and brass, this process is performed by substantially
heating the material (generally until glowing) for a while and allowing it to cool. Unlike
ferrous metalswhich must be cooled slowly to annealcopper, silver and brass can be
cooled slowly in air or quickly by quenching in water. In this fashion the metal is softened
and prepared for further work such as shaping, stamping, or forming.

Thermodynamics:

Annealing occurs by the diffusion of atoms within a solid material, so that the material
progresses towards its equilibrium state. Heat is needed to increase the rate of diffusion by
providing the energy needed to break bonds. The movement of atoms has the effect of
redistributing and destroying the dislocations in metals and (to a lesser extent) in ceramics. This
alteration in dislocations allows metals to deform more easily, so increases their ductility.

The amount of process-initiating Gibbs free energy in a deformed metal is also reduced by
the annealing process. In practice and industry, this reduction of Gibbs free energy is termed
"stress relief".

The relief of internal stresses is a thermodynamically spontaneous process; however, at room

temperatures, it is a very slow process. The high temperatures at which the annealing process
occurs serve to accelerate this process.

The reaction facilitating the return of the cold-worked metal to its stress-free state has many
reaction pathways, mostly involving the elimination of lattice vacancy gradients within the
body of the metal. The creation of lattice vacancies is governed by the Arrhenius equation,
and the migration/diffusion of lattice vacancies are governed by Ficks laws of diffusion.

Mechanical properties, such as hardness and ductility, change as dislocations are eliminated
and the metal's crystal lattice is altered. On heating at specific temperature and cooling it is

17

possible to bring the atom at the right lattice site and new grain growth can improve the
mechanical properties.

Stages:

There are three stages in the annealing process, with the first being the recovery phase, which
results in softening of the metal through removal of crystal defects (the primary type of which is
the linear defect called a dislocation) and the internal stresses which they cause. Recovery phase
covers all annealing phenomena that occur before the appearance of new strain-free grains. The
second phase is recrystallization, where new strain-free grains nucleate and grow to replace those
deformed by internal stresses. If annealing is allowed to continue once recrystallization has been
completed, grain growth will occur, in which the microstructure starts to coarsen and may cause
the metal to have less than satisfactory mechanical properties.

Controlled atmospheres:

The high temperature of annealing may result in oxidation of the metals surface, resulting in
scale. If scale is to be avoided, annealing is carried out in a special atmosphere, such as with
endothermic gas (a mixture of carbon monoxide, hydrogen gas, and nitrogen gas).

The magnetic properties of mu-metal (Espey cores) are introduced by annealing the alloy in
a hydrogen atmosphere.

Setup and equipment:

Typically, large ovens are used for the annealing process. The inside of the oven is large enough
to place the workpiece in a position to receive maximum exposure to the circulating heated air.
For high volume process annealing, gas fired conveyor furnaces are often used. For large
workpieces or high quantity parts Car-bottom furnaces will be used in order to move the parts in
and out with ease. Once the annealing process has been successfully completed, the workpieces
are sometimes left in the oven in order for the parts to have a controlled cooling process. While
some workpieces are left in the oven to cool in a controlled fashion, other materials and alloys are
removed from the oven. After being removed from the oven, the workpieces are often quickly
cooled off in a process known as quench hardening. Some typical methods of quench hardening
materials involve the use of media such as air, water, oil, or salt.

18

Normalization:

Normalization is an annealing process in which a metal is cooled in air after heating in order
to relieve stress.

It can also be referred to as: Heating a ferrous alloy to a suitable temperature above the
transformation temperature range and cooling in air to a temperature substantially below the
transformation range.

This process is typically confined to hardenable steel. It is used to refine grains which have
been deformed through cold work, and can improve ductility and toughness of the steel. It
involves heating the steel to just above its upper critical point. It is soaked for a short period
then allowed to cool in air. Small grains are formed which give a much harder and tougher
metal with normal tensile strength and not the maximum ductility achieved by annealing. It
eliminates columnar grains and dendritic segregation that sometimes occurs during casting.
Normalizing improves machinability of a component and provides dimensional stability if
subjected to further heat treatment processes.Process annealing

Full anneal:

A full anneal typically results in the second most ductile state a metal can assume for metal alloy.
It creates an entirely new homogeneous and uniform structure with good dynamic properties. To
perform a full anneal, a metal is heated to its annealing point (about 50C above the austenic
temperature as graph shows) and held for sufficient time to allow the material to fully austenitize,
to form austenite or austenite-cementite grain structure. The material is then allowed to cool
slowly so that the equilibrium microstructure is obtained. In some cases this means the material
is allowed to air cool. In other cases the material is allowed to furnace cool. The details of the
process depend on the type of metal and the precise alloy involved. In any case the result is a
more ductile material that has greater stretch ratio and reduction of area

19

properties but a lower yield strength and a lower tensile strength. This process is also called
LP annealing for lamellar pearlite in the steel industry as opposed to a process anneal which
does not specify a microstructure and only has the goal of softening the material. Often
material that is to be machined, will be annealed, then be followed by further heat treatment
to obtain the final desired properties.

Resistive heating:

Resistive heating can be used to efficiently anneal copper wire; the heating system employs
a controlled electrical short circuit. It can be advantageous because it does not require
atemperature-regulated furnace like other methods of annealing.

The process consists of two conductive pulleys (step pulleys) which the wire passes across
after it is drawn. The two pulleys have an electrical potential across them, which causes the
wire to form a short circuit. The Joule effect causes the temperature of the wire to rise to
approximately 400 C. This temperature is affected by the rotational speed of the pulleys, the
ambient temperature, and the voltage applied. Where t is the temperature of the wire, K is a
constant, V is the voltageapplied, r is the number of rotations of the pulleys per minute, and ta
is the ambient temperature:

The constant K depends on the diameter of the pulleys and the resistivity of the copper.

Purely in terms of the temperature of the copper wire, an increase in the speed with which the
wire passes through the pulley system has the same effect as an increase in resistance.
Therefore, the speed with which the wire can be drawn through varies quadratically as the
voltage applied.

20

SKIN PASS MILL (4HI Hitachi mill):

DIMENSIONAL SPECIFICATION:

MIN
MAX
WIDTH
700mm
1700mm

MATERIAL I/P THICKNESS

1.8mm (HR)
7.0mm

WEIGHT OF COIL
3.0 MT
30 MT

CR THICKNESS
0.11mm
6.95mm

LINE SPECIFICATION:

MAXIMUM SPEED
1200MPM

TENSION
16 T MAX

After annealing, coils may require a final rolling called a temper pass, skin pass or planish
pass. This involves a controlled light reduction to establish the final thickness, impart the
desired surface finish, flatten the strip to improve shape and create the required hardness or
temper the mate

21

COLD ROLL SLITTING / CUT TO LENGTH

Some customers require a steel to be of a particular thickness other than the general increment
sizes rolled in the hot mill or thinner than the minimum thickness rolled in the mills. These steels
are processed in the cold roll reduction mill. These mills are capable of rolling steel to the precise
thickness that the customer orders and are a major part of the steel strip production process. The
reduction mill in the plant I worked had four rolls in the mill that were stacked upon each other.
This arrangement is known as a two high mill. There are two working rolls between which the
strip is passed and two large back-up rolls, one on top of the working rolls and one on the bottom.
The back-up rolls apply the tremendous pressures required to cold roll (reduce) the strip between
the working rolls. The working rolls are usually about two to three feet in diameter while the
back-up rolls are about seven to eight feet in diameter. The rolls are made of high alloy steel so
they can withstand the tremendous pressure they are under while

22

rolling without deforming. Because of this the rolls are ground in a large lathe using a very
large grinding wheel on a movable carriage. Depending on the surface finish required of the
strip the working rolls will either have a highly polished (mirror like) finish or a dull finish on
them. All working rolls are ground on the lathe in the mill to a highly polished surface
periodically. The rolls that have a dull finish on them are shot blasted after grinding to
produce surface.

After grinding to a polished surface the rolls that need a dull finish are placed on a large carriage
which has a set of rubber rolls on it. The carriage then travels on a small rail track into a large
enclosure and the door is closed down. On top of this enclosure is a large hopper filled with fine
steel balls called shot. This shot is very small in diameter (about half the size of a BB or smaller)
and is very hard. It is fed down a chute and using either compressed air or a impeller type system
it is accelerated to high speed (in excess of a hundred miles per hour) and blasted against the
surface of the roll. The rubber rolls on the carriage rotate causing the steel roll to rotate so all its
surface is exposed to the shot blast. The shot comes in a variety of sizes and hardness grades and
different types are used depending on the type of surface finish required on the rolls. After a
predetermined cycle time the roll is removed from the Wheelabrator, as it

A saddle type conveyor runs along the side of the reduction mill. Steel coils are place on this
conveyor by overhead cranes using the same C hook as at the entry and exit ends of the pickle
lines. This saddle conveyor moves the coils along to the reduction mill where they are lowered
onto a frame at the entry side of the mill. A transfer saddle operated by the mill operator moves
out to the frame and picks up the coil and moves it back into the feed mandrel on the entry side.
The operator cuts the strap, freeing up the loose end of the coil. He opens a space between the
work rolls and feeds the end of the exit side. On the exit side is another expandable mandrel the
same as the catcher mandrels of the hot mills and pickle line. The entry operator feed the strip
until the exit operator can catch the end in the open segment of his mandrel, expanding it and
trapping the end of the strip. The entry operator then closes the gap in the working rolls down on
the strip. Pressure (thousands of tons) is applied by the back-up rolls by means of hydraulically
operated screws, to the working rolls and the reduction rolling process begins. If the thickness of
the steel needs to be greatly reduced, the strip will be passed back and forth between the rolls a
number of times with the rolls adjusted for each pass. Due to the great amount of pressure exerted
in the reduction process the steel strip becomes very hot. In order

23

to prevent the steel from becoming too hot and sticking to the work rolls, the rolls are flooded
with a coolant consisting of 95% water and the other 5% water soluble oil. The end of the
strip that is in the exit mandrel is not released in the multiple pass process nor is it completely
unwound from the entry mandrel. In the final pass through the reduction mill, the portion that
was not reduced from the entry end is trimmed off in a set shears just before they enter the
work rolls to the exit side. A transfer saddle on the exit side then moves the coil back onto the
conveyor that runs beside the mill.

QUALITY CONTROL

Quality control is a process by which entities review the quality of all factors involved in
production. This approach places an emphasis on three aspect

Elements such as controls, job management, defined and well managed processes,
performance and integrity criteria, and identification of records

Competence, such as knowledge, skills, experience, and qualifications

3. Soft elements, such as personnel integrity, confidence, organizational culture,

motivation, team spirit, and quality relationships.

The quality of the outputs is at risk if any of these three aspects is deficient in any way.

Quality control emphasizes testing of products to uncover defects, and reporting to

management who make the decision to allow or deny the release, whereas quality assurance
attempts to improve and stabilize production, and associated processes, to avoid, or at least
minimize, issues that led to the defects in the first pun For contract work, particularly work
awarded by government agencies, quality control issues are among the top reasons for not
renewing a contract.

"Total quality control", also called total quality management, is an approach that extends beyond
ordinary statistical quality control techniques and quality improvement methods. It implies a
complete overview and re-evaluation of the specification of a product, rather than just considering
a more limited set of changeable features within an existing product. If the original specification
does not reflect the correct quality requirements, quality cannot be inspected or manufactured into
the product. For instance, the design of a pressure vessel should

includenot only the material and

dimensions, but also operating,

GALVANISING PLANT:

Galvanizing plant
WORK INSTRUCTION FOR ENTRY SECTION

A. APPROVED PROCESS
APPROVED MACHINARY
1.
COIL LOADING
COIL CAR AND COUNTER FOIL
2.
WELDING
WELDING UNIT

B. LINE SPECIFICATION

SPEED

ENTRY

15 to150 m/min

TENSION

a) ENTRY (POR) 50 TO 570 kg

b) ENTRY ACCUMULATOR 105 to 1000 kg

28

Metal protection:

In current use, the term refers to the coating of steel or iron with zinc. This is done to
prevent galvanic corrosion (specifically rusting) of the ferrous item. The value of
galvanising stems from the relative corrosion resistance of zinc, which, under most service
conditions, is considerably less than those of iron and steel. The effect of this is that the zinc
is consumed first as a sacrificial anode, so that it cathodically protects exposed steel. This
means that in case of scratches through the zinc coating, the exposed steel will be
cathodically protected by the surrounding zinc coating, unlike an item which is painted with
no prior galvanising, where a scratched surface would rust. Furthermore, galvanising for
protection of iron and steel is favoured because of its low cost, the ease of application, and
the extended maintenance-free service that it provides.

The term galvanizing, while correctly referring to the application of the zinc coating by the
use of a galvanic cell (also known as electroplating), sometimes is also used to refer to hot
dip zinc coating (commonly incorrectly referred to as hot dip galvanizing). The practical
difference is that hot dip zinc coating produces a much thicker, durable coating, whereas
genuine galvanizing (electroplating) produces a very thin coating. Another difference, which
makes it possible to determine visually which process has been used if an item is described as
'galvanized', is that electroplating produces a nice, shiny surface, whereas hot dip zinc coating
produces a matte, grey surface. The thin coating produced by electroplating is much more
quickly consumed, after which corrosion turns to the steel or iron itself. This makes
electroplating unsuitable for outdoor applications, except in very dry climates. For example,
nails for indoor use are electroplated (shiny), while nails for outdoor use are hot dip zinc
coated (matte grey). However, electroplating and subsequent painting is a durable
combination because the paint slows down the consumption of the zinc. Car bodies of some
premium makes are corrosion protected using this combination.

Nonetheless, electroplating is used on its own for many outdoor applications because it is cheaper
than hot dip zinc coating and looks good when new. Another reason not to use hot dip zinc
coating is that for bolts and nuts size M10 or smaller, the thick hot-dipped coating uses up too
much of the threads, which reduces strength (because the dimension of the steel prior to coating
must be reduced for the fasteners to fit together). This means that for cars, bicycles and many
other 'light' mechanical products, the alternative to electroplating bolts and nuts is not

CONCLUSION

IT GIVES ME IMMENSE PLEASURE TO SAY THAT I HAVE SUCESSFULLY

UNDERGONE 4 WEEKS OF INDUSTRIAL TRANING IN BHUSHAN STEEL LTD. IT
WAS A LIFETIME EXPERIENCE . I LEARNED A LOT OF NEW THINGS ,AND LOT OF
NEW WAYS OF SOLVING A PROBLEM. I WANT TO CONCLUDE MY REPORT ON A
POSITIVE NOTE AND I HOPE THAT THE EXPERIENCE WHICH I GOT WILL ALSO B
FRUITFUL IN MY CAREER AHEAD.