Summer Training Project

Report

Merchant mill
21st May – 1st July

Department: mills mechanical maintenance

Project Guide: mr . Manish Kumar
SR.Manager mechanical
maintenance
Submitted by: kaushik sheet
3rd year (b.tech)
Mechanical engineering

Acknowledgement
 ----------------------------
--------
Every project big or small is successful largely due to the effort of a
number of wonderful people who have always given their valuable
advice or lent a helping hand. I sincerely appreciate the inspiration,
support and guidance of all those people who have been instrumental
in making this project a success.
I, KAUSHIK SHEET, student of B.A.College of Engineering &
Technology (Mechanical Engineering), am extremely grateful to “Tata
Steel Limited” for the confidence bestowed in me and entrusting my
project.
At this juncture I feel deeply honoured in expressing my sincere
thanks to Mr. Manish Kumar, Sr.Manager (Mill Mechanical
Maintenance) for making the resources available at the right time and
providing valuable insights leading to the successful completion of my
project.
I express my gratitude to the entire team, especially Mr. Arbab, and
Mr. A Soren for guiding me through the entire project.
I am very grateful to the HR Department (Capability Development),
especially Mr. Saket Kumar (Sr.Manager Recruitment) for providing
me this opportunity to work in this prestigious organization.
I especially thank to Mr. Rohit Khullar who have been very
cooperative.
Last but not the least, I place a deep sense of gratitude to my fellow
trainees and my family who gave me insights into the working of all
the departments in the plant and therefore helped me better
understand the ways of the company.

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 About the
company
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 Tata Group.
It is one of the top steel producing companies globally with
annual crude steel deliveries of 27.5 million tonnes (in
FY17), and the second largest steel company in India
(measured by domestic production) with an annual capacity
of 13 million tonnes after SAIL.
Tata Steel operates in 26 countries with key operations in
India, Netherlands and United Kingdom, and employs
around 80,500 people.]Its largest plant (10 MTPA capacity)
is located in Jamshedpur, Jharkhand. In 2007, Tata Steel
acquired the UK-based steel maker Corus.
It was ranked 486th in the 2014 Fortune Global 500
ranking of the world's biggest corporations. It was the
seventh most valuable Indian brand of 2013 as per Brand
Finance.

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 History
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

Tata Steel's
plant at night
Tata Iron and Steel Company was founded by Jamshedji
Tata and established by Dorabji Tata on 26 August 1907,
and began producing steel in 1912 as a branch of Jamsedji's
Tata Group. By 1939, it operated the largest steel plant in
the British Empire. The company launched a major
modernization and expansion program in 1951. Later, in
1958, the program was upgraded to 2 million metric tonnes
per annum (MTPA) project. By 1970, the company
employed around 40,000 people at Jamshedpur, and a
further 20,000 in the neighbouring coal mines. In 1971 and
1979, there were unsuccessful attempts to nationalise the
company. In 1990, the company began to expand, and
established its subsidiary, Tata Inc., in New York. The

PAGE 3
company changed its name from TISCO to Tata Steel Ltd.
in 2005.

CONTENTS

 About Merchant Mill

 Charging Bed

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 About Merchant Mill

A. Overview of Merchant Mill

This Merchant Mill was installed during T.M.P.(Two Million-Ton Programs)

of TISCO
The mechanical equipment was supplied by schloemann A.G. of Germany:
electrical equipment by
Brown Bovary of Switzerland and reheating furnace by OFU Germany.
The mill is served on the charging end by billet yard gantry and crane
facilities.
The mill is served on the charging end by billet yard gantry and crane
facilities.
The main building is 1416 ft long X 100 ft wide and the height to the top of
the monitor is 80 ft. The building is designed to ensure proper ventilation.
The crane span of the building is 95ft and 5 cranes serve the main building
The loading bay consists of an open gantry. The rolled products from the
mill building are transferred to the loading bay with the help of 2
electrically operated cars. A depressed loading dock track enters the
loading bay from the south.
The electrical station is situated on the west of the mill. The building houses
the major part of electrical equipment such as transformers, rectifiers and
high tension switch gear and control panels.
The motor house consists of an enclosure within main building and only the
rotating machinery such as main drive motors; exciter and converter sets
are housed in the motor house.
The roll and bearing shop building are provided with two 5-ton capacity
floor cranes.

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A layout of the plant hazardous area marked in red is enclosed to facilitate
safe movement in the plant.

B. SAFETY INSTRUCTIONS FOR MERCHANT MILL

1. Do not go to hazardous and lonely places within the department or section

unaccompanied.
2. Do not go in the immediate vicinity of a permanent or working electrical magnet.
3. Do not remove or disregard safety WARNING instructions or Safety Signals.
4. Do not go on the E.O.T. Crane, Crane Track Line, crane Gantry platform for any
purpose without permission from Unit Manager/Officer/Shift Supervisor.
5. Do not ride on tractor & trailor unless it is required and has operator’s permission.

6. Do not operate E.O.T cranes, Tractor & Trailors and any other moving or stationary
equipment unless it is part of job requirement.
7. Do not stand, move or walk underneath moving E.O.T. cranes carrying load by
magnets, slings or chains.
8. Do not clean clothes or any part of body by compressed air.
9. Do not indulge in horseplay or fights.
10. Do not smoke in the plant.
11. Do not go near gas burners, gas flow controlling valves, explosion caps
unaccompanied.
12. Do not go on the shop floor under the influence of drugs or alcohol.
13. Do not go very close to High Pressure hydraulic system pipe joints, hoses etc. as any
leakage of oil can cause injury.
14. Do not go near electric panels, cables, Sub-stations and control rooms unless
required.
15. Do not touch any roll product or billet with bare hands even if appearance is steel
gray. They may be hot.
16. Do not trespass into areas where overhead repair work on equipment, EOT cranes,
Building Structure, Pipelines and roof sheeting changing job is being carried on.
17. Do not take vehicles to the shop floor. Always park vehicles near Main office building
at designated places.
18. Do not go inside furnace that has been shut down for repair or to the furnace
basements without authorized escorts and taking clearance.
19. Do not walk on drain covers.
20. Do not go near moving machinery.

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21. Use all safety appliances provided.

Schematic diagram of merchant mill

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 MERCHANT MILL LAYOUT

Charging Bed:
It is an inclined bed made of Beams. Billets loaded on it by E.O.T. crane
and charged into

furnace one by one with the help of

Moving Racks, Finger Rolls, Charging Bed Rolls and
Furnace Approach Rolls.

List of equipment:-

1. Fixed Rack (10 no.) – There are 10 nos. of Fixed Rack Beams. These beams are locked
at the center by a pin and placed all along the charging bed. It provides
support to billets loaded on it by the E.O.T crane.
2. Moving Rack (5 no.) - There are 5 nos. of moving rack beams. Its upper part is locked
by a lever and pin and its lower part is connected to a gear box (driven by an
electric motor) through eccentric hood bearing and eccentric shaft. This
drive moves the moving racks up and down and the billets are shuffled
and gradually moved forward. The billets are allowed to fall one by one
on charging table rolls through cam and disc.
3. Eccentric Hood Bearing – It connects eccentric shaft to moving rack. It also translates
rotary motion of line shaft to reciprocating motion and moves moving racks
up and down.
4. Eccentric Shaft – It is a straight line shaft in two halves which connects gear box to
moving rack through eccentric hood bearing. It is held in position by means of
pedestal and bearings.
5. Finger rolls and Slide rails – 5 nos. of finger rolls are fitted on fixed beams and 5 nos.
of slide rails are fitted on alternate fixed rolls. Finger rolls holds the billet and
does not allow falling whereas slide rails allow the billets to fall on rolls

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with less impact.
6. Charging Bed rolls – There are 11 nos. of rolls with individual drive which moves the
billet to furnace approach rolls for charging into furnace.
7. Buffer – One Buffer is situated at extreme north of charging table rolls to absorb the
shocks of billet movement in reverse direction.
8. Billet Ejector – It is a pneumatic cylinder operating device. The billets not suitable for
rolling are thrown out into a cradle by this device.
Hazards – Falling of billets from EOT crane, Electric Shock and injury due to movement
of billets and moving machinery.
Lubrication – Lubricate moving rack lever pin at every s/d. Lubricate all charging bed
rolls at every s/d.
9. Furnace approach rolls – There are 15 nos. of individual driven rolls to move the
billets for charging into the furnace.
Hazards – Injury due to movement of billets.
10. Furnace conveyer rolls (6 no.) – There are 6 nos. of conveyer roll individually driven
by electric motor and gear box. Gear boxes are assembled with one roll and
mounted on furnace back wall through bolts. Both gear box and roll are
water cooled. Water is supplied from a 10mm common header laid just
above it on furnace back/stay beams.

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