Project Report (bhushan) 2.docx

SECTOR-26, CHANDIGARH DIPLOMA ENGINEERING SESSION= 2011-2014 VOCATIONAL TRAINING PROJECT REPORT SUBMITTED BY: NAME

– SHUBHAM SHARMA

SUBMITTED TO: SMT. SEEMA SINGH

BRANCH – MECHANICAL

(TRAINING OFFICER)

ROLL NO. – 5349/10

MR. CHAMAN LAL

REGN NO. – 110095329772

(H.O.D MECHANICAL)

SEMESTER – 5th IN PLANT – BHUSHAN POWER & STEEL LTD., FACTORY NO.-22, IND. AREA, PHASE -1 CHANDIGARH.

REPORT On

One Month Industrial Training At

Bhushan Power & Steel Pvt. Ltd. (From 15 June 2012 – 14 July 2012)

CONTENTS S.NO 1. 2. 3.

4. 5. 6. 7.

TEXT

PAGE NO.

Acknowledgement Company Profile

1-4 5-10

2.1 Products

11-12

Training Report

13-32

3.1 Wire Rods 3.2 Raw Material Section 3.3 Step For Production Of Wire Rod 3.3.1 Reheating Furnace 3.3.2 Rolling Mill 3.3.3 Cooling Bed 3.3.4 Pre Delivery Inspection (PDI Section) 3.4 Wire Pointing M/C 3.5 Wire Straightening & Cutting M/C 3.6 Wire Drawing M/C 3.6.1 Medium Pulley Type Continuous Drawing M/C 3.6.2 Straight Line Wire Drawing M/C 3.7 M.S Wires 3.8 Wire Drawing Process 3.9 TOR Steel

14-15 16 17 17 18-20 21 22 23 24 25-27 25 26-27 28 29-31 32

Time Study Observation & Calculation Machinery & Tool Details Bibliography

33 34-37 38-50 51



I would sincerely like to thanks BHUSHAN POWER & STEEL LTD. for allowing me to persue 1 month Industrial Training in their esteemed organization. I would also like to thanks Mr.ROSHAN LAL (General manager) and Mr. SUNIL (Production Engineer) who guided us and told us about the various processes in the plant.

I would also like to thanks other staff members of the company who shared their great and helpful experience with me to get the useful knowledge I would like to thanks our training & placement officer for giving me a golden opportunity of Industrial training, which would help me to enhance my technical aspects.

BHUSHAN-The Beginning Brij Bhushan Singal, the prime mover, a visionary entrepreneur founded the Bhushan group than 20 years ago in Chandigarh. Making a moderate start with manufacture of hinges rail track fasteners in early 70’s with a capital less than a lakh of rupees, the group has continuously grown by modernizing, expanding and integrating its fascilities/ operations. Joined by his young and dynamic sons Sanjay & Neeraj in the 80’s and taking advantage of the liberalized environment in the steel sector, Brij Bhushan Singal has propelled the group to the success earning it a permanent place among the large players of the steel industry, with a turnover of Rs. 2200 crore, cash profit of over Rs. 180 crore and net worth of Rs. 500 crore

BHUSHAN POWER & STEEL LIMITED Bhushan power & steel limited, is an ISO 9002 certified company of erstwhile Bhushan Group, is a merged entity of Bhushan Power & steel Limited, Bhushan Mettalic Limited & Décor Steel Limited having turnover of more than INR 2000 Crores (USD 460 Million) is a leading manufacturer of Flat, Round and value added products in steel. Bhushan Power & Steel Limited has by continuation up-gradation of technology, redesigning structures, Integrating & synergizing operatios made a special place in production of various value added products in secondary Steel segment among the steel producers in India.

From production of special steel for vehicles and white goods segment to high class steel for Exports, Bhushan has made its mark. Bhushan Power & Steel Limited is having 7 World Class & state of art plant at Chandigarh, Derabassi, Kolkata & Orissa in India. A completely integrated plant is commissioned under Phase-I in Orissa and Phase-II is all set for take off. At all of these plants, technology and equipments are procured from world-renowned Companies like Luirgi from Germany, ABB limited, SMS Demag, Siemens etc. Bhushan is selling its value added range of products in Secondary Steel through a large distribution network in India ( comprising more than 25 Sales offices ) and Abroad.

Among our major and valued customers in India are Hero Honda, Honda

Scooters, Yamaha Motorcycles, JBM, BPL, HMT, GNA Group, Hero Cycles, Avon Cycles, Atlas Cycles, Delton Cables etc.

Bhushan’s products are being exported to China, Singapore, Malaysia,

Hong Kong, Indonesia, Philliphines, Dubai, Oman, Saudi Arabia, South Africa, Thailand, Korea, Mayanmar, Srilanka, Nepal, Bangladesh, Vietnam etc. and a host of African countries.

GROWING FROM STRENGTH TO STRENGTH 1970 - Started with very small initial outlay for manufacturing Door Hinges & later on, Rail Track Fasteners. 1973 - Manufacturing facilities set up for Tor Steel and Wire Rod in Chandigarh. 1981 - Rolling Mill Project commissioned at Chandigarh for Round and Narrow Strips. 1985 - Backward Integration Project for Steel Melting facilities. 1986 - Upgrading of Mini Steel Plant with continuous casting and ladle furnace facilities. 1997 - Commissioning of Narrow Width Cold Rolling Project at Chandigarh. 1998 - Commissioning of Precision Pipe Project at Chandigarh. 2001 - Commissioning of Cold Rolling & Galvanizing Complex at Kolkata. 2002 - Addition of narrow width Cold Rolling facilities at Kolkata. 2003 - Expansion of wide width Cold Rolling facilities, ERW Water Pipes & Tubes down stream facilities at Kolkata. 2004 - Further expansion of Cold Rolling facilities at Kolkata. 2005 - Commissioning of Orissa Project consisting of 4 DRI Kilns, Steel Making Facilities, Coal Washery and 100 MW Power Plant. 2007 - Commissioning of further expansion of Orissa Project consisting of HR Coil Mill, Steel making, Blast Furnance, Sinter plant, Coke oven plant, Oxygen plant and Lime & Calcining Plant.

2009 - Commissioning of 3.5 million tpa Coal Washery, 146 MW Power Plant and 0.3 million tpa Sponge Iron under Phase III of Orissa Project. 2010 - Commissioning of 130 MW Power Plant and Electric Arc Furnace under Phase III of Orissa Project and further expansion of Orissa Project under Phase IV consisting of 6 DRI Kilns, 130 MW Power Plant, Steel Making Facilities, 6th strand, 2nd CSP Caster & Tunnel Furnace, Oxygen Plant, Lime Calcining with downstream facilities - Cold Rolling, Galvanizing, Galvalume, Colour Coating, Precision Tube & Black Pipe/GI Pipe.

MISSION & VALUE Our Mission is to achieve clear identiy and leadership globally in Steel production and distribution by integration of complete chain of production starting from captive iron ore to end user Steel Products. Our revolution in Steel production has helped us to carve a niche unique only to market leader. Every year passes by with new value additions and more accolades from our customers- Locally and Globally. Our rising chart in respect of all important parameters of production and finance is a testimony to our claim. In persuing our mission, we at BHUSHAN POWER & STEEL LIMITED are guided by following values— QUALITY—To be the best in quality. We aim and achieve excellence. TECHNOLOGY—State of art technology and product enrichment by continuous Research and Development

CUSTOMER FRIENDLY— Our products are world class and more and more clients are appreciating and using our products. We also undertake customized products with values addition and enhancement.ss CORPORATE GOVERNANCE— We comply with all applicable laws and regulation. We believe in maintain clean environment and conservation of natural resources. We contribute towards betterment of our staff and provide them with best of fascilities. ENVIROMENT PROTECTION AND PRACTICE— We are adopting and implementing pollution control measures as a matter of policy. OUR COMMITMENTS—  To improve the quality of our products and complete integration of various stages of production.  To be conscious towards quality and pricing of our products. We strive by continuous research and development to make our products world class, having distinct identity and uniqueness. Our customers get best value for their money.  To run the company profitably year after year.  To workforce motivated, skilled and well looked after.

PRODUCTS :1. Flat Products     

Cable Tapes GP Coils Steel Coils GP Coils & Sheets Cold Rolled Sheets Narrow CR Coils

2. Long Products     

Steel Billets Alloy Steel Rounds TOR Steel Wire Rod Precision Tubes Black & Galvanized Pipes

3. Sponge iron 4. Pig Iron 5. Power Plant

PRODUCTS

` PRODUCTS PRODUCED BY BHUSHAN POWER & STEEL LTD.

(3.1) WIRE RODS— BHUSHAN POWER & STEEL LIMITED are manufacturers of IS-2062 and Electrode Quality in our Plant located at 3, Industrial Area Phase-I, Chandigarh.

WIRE RODS (3.1.1) Applications— Wire Rod is used as raw material by Wire Drawing Units, Electrodes, Wire Mesh, Fasteners, Hardware and Automobile components manufacturers. We meet stringent quality parameters. We manufacturer Wire Rod from superior quality Billets produced by our own Integrated Steel Plant situated at Jharsuguda (Orissa) to ensure high strength and long life. The sizes of Wire Rod being manufactured by us are from 7.5mm to 13mm.

3.1.2) PROCEDURE TO MANUFACTURE WIRE RODS

In Bhushan Power & Steel Ltd. Wire rods is manufactured by hot rolling process. The various steps of this process are described as followRAW MATERIAL (BILLETS) REHEATING FURNACE ROLLING MILL COILER COOLING BED FINISHING FINAL PRODUCT (WIRE RODS)

FLOW CHART TO MANUFACTURE WIRE RODS

(3.2) RAW MATERIAL SECTION This is the Section of the company where the raw materials are placed which are used in the manufacturing process of the products.

Fig 2-BILLETS Billet is used as a raw material semi finished length of Steel which can be worked in a rolling mill or for forging operations. Billet is made up of mild steel. These are also known as bloom, slab, sheet bar. Billets are available as round bar, flat bar, wire rod etc. These Billets are produced at our Chandigarh and Orissa Plants. These billets are cut according to the diameter and length of the products. For less diameter products billets are cut into three pieces and for large diameter billets are cut in two pieces. After cutting these billets are put into the furnace.

(3.3) STEPS FOR THE PRODUCTION OF WIRE RODS (3.3.1) REHEATING FURNACE Furnace is the heart of the factory. Rolling is impossible without heating the billets. Billets are heated so as to make them soft and suitable for rolling. Moreover heating also prevents residual stresses. Furnace has three parts: walls, roof and hearth (floor). Furnace is lined with several layers of refractory bricks. It is insulated by glasswool. Heating zone of the furnace has temperature of 1100 degree Celsius. Low Alumina bricks are used for this zone. Soaking zone has

Fig 3- REHEATING FURNACE temperature in excess of 1250 degree Celsius. High Alumina bricks are used for this zone.

(3.3.2) ROLLING MILL Once heated to the appropriate temperature the billet then enters the continuous bar rolling line. In basic terms the rolling line has three phases - the “roughing” stands or preliminary rolls, which do the initial rough shaping, then the “intermediate” stands which further refine the steel to a more oval shape and finally the “finishing” stands which finally shape the steel to the appropriate size, deformation pattern and shape.

Fig 4-PROCESS OF PRODUCTION OF WIRE RODS

The steel can pass through various sets of rolls to reach its final shape. As the steel billet passes through each roll it speeds up as the area of the bar gets smaller, The length gets longer and therefore it accelerates, quite like rolling out pastry.

This can be quite a sight when you see the glowing steel passing through the line. Each of the rolls are technically designed to not only produce the correct size product, But do it in a way that ensures the product quality, and considers the limitations of the way steel behaves, and the equipment that controls and drives the rolls. This process of manufacturing the wire rods is processed at such a very fast rate that a bundle of wire rods weighing 200 Kg is prepared in just approx. 42 seconds after coming out the hot billet from reaheating furnace.

ROLLERS USED IN ROLLING MILL The rollers in the rolling mill are mounted in a stand, ready to be installed in the rolling mill has a series of differently shaped grooves and the material pass them in a predetermined sequence in order to get a thoroughly worked material.

Fig 5-ROLLING STAND WITH REVERSIBLE ROLLERS

The intermediate and final pairs of rollers are mounted in line, one after the other. After the very final pairs of rolls the wire rod is laid by a laying head in coil form on a conveyor and transported to cooling and heat treatment, if any. (3.3.4) COOLING BED After the steel leaves the rolling line it goes on cooling bed, as the name suggests, is where finished bars are placed for cooling. Cooling bed is simply a raised platform with chains ‘wrapped’ round it. Chains roll on sprockets.

Fig 6-COOLING BED These sprockets are mounted on a shaft, which rotates very slowly. Slow speed is maintained to allow time for bars to cool down. These chains carry the bars from one end to the other, from where it is dropped on to a conveyor. Once on the cooling bed the bar cools to a manageable state and is then further processed at a cold shear where it is cut to the customer required length.

(3.4) PRE DELIEVERY INSPECTION (PDI SECTION) In this section, the product(WIRE RODS) is checked / tested after manufacturing against its various characterstics like shearing, hardening, bending, breaking etcbefore dispatch.

All the finishing processes are completed by this department. When the products are inspected that they are ok for use then these products are transported to their packaging section. (3.5) FINISHED PRODUCT

Fig 7- WIRE RODS

(3.6) WIRE POINTING MACHINE— This machine is suitable for pointing different types of materials like Mild Steel, High Carbon Steel, Aluminium, Copper, etc. The pointing rolls are made of EN-31 material and are ground finished. They are

driven by power as well as by hand. The machine is mounted on 4 wheels, thereby making it mobile and useful to serve several drawing machines. The machine is of a swiveling type with12mm0.8mm thickness of wires.

Wire Pointing Machine

(3.7) WIRE STRAIGHTENING MACHINES & CUTTING MACHINES— Wire Straightening and Cutting Machines are used to straighten & cut wires to make cut length rods out of coils. This machine is used wherever wire is further processed in form of Rods and where

accurate straightening of coiled wire with clean cut, tolerances and high outputs are of importance. The wire is drawn from the Coil Payoff Stand through the Driven pinch rollers having grooves of different diameters & passed through the high speed rotating spinner, which is equipped with five numbers of quickly and easily adjustable dies of different material like carbide, Cast Iron, Cast Nylon etc depending on the material to be straightened. Finally passing through the cutter, actuated by the push rod fitted on the conveyor, the length required can be adjusted as desired on the conveyor gauge. The straightened and cut - to - length wires are collected on the wire collector at the bottom to be removed manually.

Wire Straightening Machines & Cutting Machines

(3.8) WIRE DRAWING MACHINES— (3.8.1) Medium Pulley Type Continuous Wire Drawing Machine

Medium Pulley Type Continuous Wire Drawing Machine

Our pulley type continuous wire drawing machine has the characteristics of simple structure, low cost, and easy operation, and it is suitable for drawing a variety of medium and thin fiber material, especially for mild steel wire, galvanized iron wire, steel head wire, stainless steel wire, rubber hose steel wire, spring steel wire, rod welding wire and copper wire aluminum rod, etc. Scope of application: gas-protection welding wire, welding electrode, stainless steel wire, galvanized iron wire, bullet and hard wire, copper wire, and metal product wire, etc

(3.8.2) Straight Line Wire Drawing Machine

Straight Line Wire Drawing Machines were developed for straight or deflection free drawing of wire to provide better drawability lower frictional contact and lower operator interference.

Straight Line Wire Drawing Machine These heavy Straight Line Wire Drawing Machines provide remarkable drawing performance for Low, Medium and High Carbon Steel Wire, Stainless Steel Wire and special Alloy Steel Wire and Non-Ferrous Alloy Steel Wire. This machine has a sensor roller between the drum and the next die such that the wire passes in contact with this roller.

These rollers have sensors to detect the position of the arm and maintain tension on the wire by regulating speed of the drums. The drums of this machine are inclined to the vertical axis to effect fill on the drums. Principally this machine is best suited for thick wires. Features of Straight Line Wire Drawing Machine:- Machines are built on modular structure, in combination of Blocks and do not require any special foundation.  Better productivity due to higher drawing speeds due to twistfree operation.  Easy operation and faster threading.  High pressure Narrow gap, internal water cooling for high efficiency cooling of wire.  High degree of reliability - low downtime due to lower no of wear parts.  Much better finish wire quality due to a gentler handling of the wire during the drawing process (Less wire deviations, low torsion etc.) As well as an optimized wire cooling.

(3.11) MS WIRES

MS wires are the strong mild steel wires which is available in different sizes of dia (ranges from 2.00mm to 6.00mm) which are used in various engineering applications. MS wires is produced by BHUSHAN POWER & STEEL by wire drawing process in Plant located at 3, Industrial Area Phase-I, Chandigarh.

MS WIRES (3.10) VARIETY OF M.S WIRES MANUFACTURED— M.S Wires are produced from hot rolled product Wire Rods. These Wires are manufactured in different sizes and quality as per requiring conditions. The Sizes Available in following Diameters:-     

3.0mm 3.6mm 4.2mm 5.0mm 6.2mm 7.0mm Etc. (as per requirement)

(3.9) WIRE DRAWING PROCESS—

Raw Material: Hot rolled steel bar or wire rods coils are used as raw material. Because the hot rolled products are produced at elevated temperatures (1700 - 2200 Deg. F. i.e. hot rolling), they generally have a rough and scaled surface and may also exhibit variations in section and size.  Cleaning: Abrasive scale (iron oxide) on the surface of the hot rolled rough stock is removed.  Coating: The surface of the bar or coil is coated with a drawing lubricant to aid cold drawing. RAW MATERIAL CLEANING COATING POINTING DRAWING FINISHED PRODUCT

FLOW CHART TO DRAW MS WIRE

 Pointing: Several inches of the lead ends of the bar or coil are reduced in size by swaging or extruding so that it can pass freely through the drawing die. Note: This is done because the die opening is always smaller than the original bar or coil section size.  Drawing: In this process, the material being drawn is at room temperature (i.e. Cold-Drawn). The pointed/reduced end of the bar or coil, which is smaller than the die opening, is passed through the die where it enters a gripping device of the drawing machine. The drawing machine pulls or draws the remaining unreduced section of the bar or coil through the die. The die reduces the cross section of the original bar or coil, shapes the profile of the product and increases the length of the original product.  Finished Product: The drawn product, which is referred to as Cold Drawn or Cold Finished, exhibits a bright and/or polished finish, increased mechanical properties, improved machining characteristics and precise and uniform dimensional tolerances.  Drawing: In this process, the material being drawn is at room temperature (i.e. Cold-Drawn). The pointed/reduced end of the bar or coil, which is smaller than the die opening, is passed through the die where it enters a gripping device of the drawing machine. The drawing machine pulls or draws the remaining unreduced section of the bar or coil through the die. The die reduces the cross section of the original bar or coil, shapes the profile of the product and increases the length of the original product.

 Multi-Pass Drawing: The cold drawing of complex shapes/profiles may require that each bar/coil be drawn several times in order to produce the desired shape and tolerances. This process is called multi-pass drawing and involves drawing through smaller and smaller die openings. Material is generally annealed between each drawing pass to remove cold work and to increase ductility  Annealing: This is a thermal treatment generally used to soften the material being drawn, to modify the microstructure, the mechanical properties and the machining characteristics of the steel and/or to remove internal stresses in the product. Depending on the desired characteristics of the finished product, annealing may be used before, during (between passes) or after the cold drawing operation, depending on material requirements.

(3.12) TOR STEEL Tor Steel is the strong steel bar which is used in various engineering applications like Construction activities Buildings, Roads, Bridges etc to provide more strength where it is used for Concrete Reinforcements The product finds its uses in manufacturing various types of CTD wires MS wires, wire rods & many others products.

Fig 1-TOR STEEL 3.3 TWISTING SECTION After manufacturing of TOR STEEL bars they have to be twisted. The twisting machines carry out twisting. Finally the ends of twisted bars (and the untwisted ones) are sheared off by a shearing machine. Ends are sheared because they are often cracked. The finished product is then loaded on to trucks and weighed on weighbridge. The product is then bundled and labeled to provide its unique identity and send for the inspection before delivery.

(4.2) TIME STUDY Time Study is defined as work measurement technique recording the times and rates of the working for the elements of specified job carried out under specified condition and analyzing the data so as to obtain the time necessary for carrying out the job at defined level of the performance The instruments required for time study are1. Stop Watch 2. Time study forms The Basic Steps in the Time Study are1. Obtain & Record all the information about the job, operator and surrounding conditions. 2. Record the description of the method and break operations into elements. 3. Examining the breakdown to ensure the most effective method is used. 4. Note down the time consumed in each step with the help of stop-watch. 5. At the same time, assess the effective speed of working operator corresponding to the steady rating. 6. Find the basic time from the observed time. 7. Give the required allowances. 8. Determine the standard time for the complex operation.

(4.3)

OBSERVATION & CALCULATIONS:-

Weight of 1 full billet (11m) 420kg (Before cutting)

Weight of 1 half billet (5.5m) 210kg (After cutting)

Total Men Power Required 32

I prepared the time study on the production of tor steel by taking the average weight is 200 kg.

OBSERVATION TABLE:Time consumed in marking, cutting & putting the billet into 00:26:00 furnace (20 Billets) Average Time Consumed in marking, cutting & putting the 00:01:09 billets into the furnace (1 Billet)……….(A) Time used For Starting/heating he Furnace ( once in shift 01:10:00 )……….(X)

Time consumed in Rolling Mill -----(B) Time Consumed in First set of 3 Multi-pass Rollers(1 00:00:09 Billet)……….(a) Time Consumed in other 14 Types of Rollers ( 1 Billet ) 00:00:22 ……….(b) Time Consumed for cutting the tor steel upto desired 00:00:16 length….(c) Total Time Consumed on Rolling Mill …..(B=a+b+c) 00:00:47 Time Consumed for Cooling ( once in Shift ) ……….(Y) Time Consumed for Twisting (for 200kg)……(C) Total time consumed to get tor steel (for 200kg) ( excluding heating & cooling ) i.e A+B+C

02:12:00 00:06:19 00:08:15

Heating (X) & Cooling (Y) are Carrying out for just once in shift (8 hrs)

So, Total time consumed in Heating + Cooling (X+Y) = 3:22:00

Now we have to calculate the production for the remaining time

Period of the shift i.e for

= ( 8:00:00-3:22:00 ) = 04:38:00

Amount of tor steel /shift = (04:38:00/00:08:52) ×200=32 ×200=6400kg (approx.)

Allowances (Relaxation, contingency, breakdown etc. ) = 8.%

Resultant production of tor steel /shift = 5960kg

Total working shifts in a day = 3 (8 hrs. each)

Production of tor steel per day = 5960×3=17880kg=17.8 tonnes Production of tor steel per month = 17.8×30 = 534 tonnes

(4.4) Suggestions on the basis of time study to improve the production rate:Steel yard should be near to the rolling area to get the material as soon as possible; which would save the time

Use of conveyor system to lift and transportation of the rolled material to the racks would greatly reduce in time.

Automation of the machine can save the time.

If we concentrated on these points, then we can save the time & our average production will rises.

BIBLIOGRAPHY ONLINE SOURCES:  www.bhushansteel.com For Information on Company Profile  www.assomacmachine.com For Information on Machines  www.answer.com For definatio & diagrams/sketches

THANK YOU !!