SUMMER TRAINING REPORT

Sahibabad
Duration :20-05-2024 to 18-06-2024

Submitted by:
Harshit Tiwari
MME 3rd year

MAULANA AZAD NATIONAL INSTITUTE OF

TECHNOLOGY, BHOPAL

Acknowledgment
I would like to express my sincere gratitude to Mr. Deepak
Aggarwal for his invaluable coordination during my summer
training program at Bhushan Steels Ltd., Sahibabad. I am also
grateful to the workers and technicians of various departments
for their support and assistance. Special thanks to the Heads of
Departments (HODs) for their guidance and encouragement.
Finally, I extend my heartfelt thanks to all personnel at Bhushan
Steels Ltd. for their cooperation and help in making my training
a success.

Abstract
The report covers the following aspects of internship:
 Table of contents.
 Introduction of Bhushan Steel Pvt. Ltd, Sahibabad.
 Departments and HODs of Bhushan Steel.
 Schedule of internship.
 My role as an internee.
 Conclusion.

CONTENTS
1) Acknowledgment
2) Abstract

3) Company Profile & Manufacturing sites

4) Finished Product & Process Layout

5) Departments and their HODs

6) Safety

7) Pickling /HRS

8) Rolling

9) ECL

10) Annealing

11) SPM/FINISHING

12) QMS

13) Role of Internee during Training

14) Conclusion

COMPANY PROFILE
Bhushan Steel is the largest manufacturer of auto-grade steel in
India and is spending Rs. 260 billion to expand its capacity to 12
million tons 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 1987. 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.

Company's Manufacturing Sites

Sahibabad Plant (Estb. 1987)
BHUSHAN STEEL LIMITED 23, Site IV, Sahibabad
Industrial Area, Distt. Ghaziabad – 201010 (U.P.) INDIA
Products:
 Cold Rolled Coil
 Cold Rolled Sheet
 Galvanized Plane Coil
 Galvanized Plane Sheet
Meramandali Plant Narendra Pur P.O. Shibapur, Meramandali
District - Dhenkanal - 759 121 Products:
 Billets
 Sponge Iron
 Pig Iron
 Char
Khopoli Plant (Estb. 2004) Village Nifan, Sarvoli, Kharpada
Road Taluka-Khalapur, Near Khopoli Distt.: Raigad - 410203
(Maharashtra) INDIA
Products:
 Colour Coated Sheets
 Galume Sheets
 Galvanized Sheets

Finished Products at Sahibabad Plant

  Cold Rolled Coil
 Cold Rolled Sheet
 Galvanized Plane Coil
 Galvanized Plane Sheet
 Galvanized Corrugated Sheet

Process Layout
 SAHIBABAD PLANT
Hot Rolled Coils -> Pickling Line -> Cold Rolling - Wider
-> 6 HI Hitachi Mill, Japan -> Electro Cleaning Line
->Annealing Furnace (Batch) -> EBNER, Austria ->
Kathabar Cooling & Storage -> 4 HI Skin Pass Mill ->
DMS, France -> SERVICE CENTER -> CR Slitter / Cut to
Length -> Bihler, Home, & Georg, Germany

Cold Rolling - Local ->1200 / 1450 / 1650 mm ->GP / GC

Sheets -> OEM / EXPORT / WHITE GOODS

Cold Rolling - Narrow -> OEM

 Various Departments and Their HODs

| **Sl. No.** | **Department** | **Incharge** |

|-------------|----------------------------|--------------------------|
|1 | SAFETY | Mr. Ramakant Patel |
|2 | PICKLING/HRS | Mr. LR Singh |
|3 | ROLLING | Mr. Abhishek Sinha |
|4 | ECL | Mr. Manish Sirisikar |
|5 | ANNEALING | Mr. Vivek Kaushik |
|6 | SKIN PASS MILL | Mr. Mahesh Bhatt |
|7 | FINISHING | Mr. Ajay Verma |
|8 | QA | Mr. Manish Arora |
|9 | UTILITY | Mr. KK Shukla |
| 10 | ETP/ARP | Mr. MK Rawat |
| 11 | ELECTRICAL MAINTENANCE | Mr. Rajesh Gupta
|
| 12 | MECHANICAL MAINTENANCE | Mr. Amit Sharma
|
| 13 | QMS | Mr. Ankur Shrivastava |

SAFETY
The service provider and his men should comply with personal
protection equipment (PPE) requirements decided by the
organization's safety department, such as Cut Resistance, Hand
Gloves, Safety Helmets, and Safety Shoes.
 All the PPEs must be worn while working on the 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 an authorized engineer.
 Service Provider must not go near any equipment while it is
moving.
 No person is allowed to stand on the coil car/slitting line.
 No bypassing of interlocks and no pre-assumptions for any
equipment operation.
 Use proper PPEs and safety platforms while packing.
 Ensure that fingers are away from the strapping procedure
and while working with the tensioner.

PICKLING
WHAT IS STEEL PICKLING?

A Scaly Crust

When steel is cooling, after hot-rolling, the oxygen in the

atmosphere chemically reacts with the hot surface iron on the
steel and forms a compound normally referred to as SCALE.
Chemically speaking, this scale can be made up of one or any or
all of these separate compounds:
 Iron Oxide - scale (black, scaly)
 Ferrous Oxide - rust (brown, powdery)
 Ferric Oxide - magnetite (blue black, magnetic)
This scale, no matter what proportion of the three above
compounds it contains, is generally a very hard, brittle coating,
from between paper thick to 1/32” thick, adhering to the surface
of the steel.
No ‘foreign’ material can be present when the steel is further
processed such as in sizing by cold rolling or drawing or
forming by stamping etc. This means that the scale must be
removed prior to this processing.
Mechanical scale removal methods such as: Shot Blasting,
Brushing, Grinding, Scraping.As an alternative, chemical
processing allows for quick, clean removal of scale, without
mechanical damage to the steel surface and without using self-
destructing equipment.
COMPONENTS OF PICKLING LINE:
 Coil Car
 Un-Coiler
 Out Support
 Sniper Roll
 Peeler Table
 Pinch Roll (2)
 Flat Roll (2+3=5)
 Guide
 Shear
 Squeeze Roll
 Acid Tanks (4)
 Hot Water Rinsing Tank (5)
 Dryer (temp. 95°C)
 Shear
 Tension Unit
 Deflector Roll
 Re-Coiler
 HOT ROLLED SLITTER
This Process is performed for removing unwanted material,
giving flatness, side cutting to get desired shape or width,
removing side bending, and defects like notches etc.
Various Processes involved are:
 Loading of coil
 Feeding of coil
 Setting of cutter
 Trimming
 Re-Coiling
 Removal of coil
 Stepping and labeling of O/P material
 Storage of O/P material
 ROLLING (HITACHI MILL)

Rolling is a plastic deformation process of reducing the

thickness or changing the cross-section of a long workpiece by
compressive forces exerted by two opposing rolls. The rolls
rotate to pull and simultaneously squeeze the workpiece between
them.
 The gap between the rotating rolls is less than the thickness
of the entering workpiece, therefore a friction force is
necessary in order to bite the workpiece and to pull it
through the rolls.
 A steel workpiece passing through the rotating rolls is
squeezed, and it elongates while its cross section in area
decreases.
 Rolls must be made of materials with high strength and
resistance to wear. Common materials include cast iron,
cast steel, and forged steel. Rolls are polished for cold
working and special applications.
Rotating Rolls perform two main functions:
1. Pull the workpiece into the gap between them by friction
between the workpiece and rolls.
2. Simultaneously squeeze the workpiece to reduce its cross-
section.
The rolling mill stand is used for housing the rolls for rolling the
workpiece. A typical rolling mill stand consists of a pair of rolls
driven by an electric motor transmitting a torque through a gear
and pair of cardan shafts. The rolls are equipped with bearings
and mounted in a stand with a screw-down mechanism.
Hitachi Mill is used for the reduction of thickness of sheets.
 Material Specification: Pickled HR coils.
 Dimensional Specification: 1.2 mm to 2.0 mm thickness.

Electrolytic Cleaning Line

The main purpose of electrolytic cleaning is to remove the
lubricant oil and dirt left on the cold rolled strip before
annealing. All traces of surface oil are removed using
mechanical and electrolytic chemical reactions while the cold
rolled coil passes through an alkaline solution between high
voltage electrodes.
The removal of residual roll coolant on the surface of cold-rolled
strip by the electrolytic cleaning process includes alkaline water
immersing, brushing, electrolyzing, rinsing, and drying to
improve cleanliness of the strip surface before annealing.
Process Flow:
1. PAY-OFF REEL
2. SHEAR
3. WELDER
4. H.C.T Hot Caustic Tank
5. E.C.T Electric Cleaning Tank
6. H.R.T Hot Rinse Tank
7. T.B.R Tension Bridle Roll
 8. SHEAR
9. TENSION REEL

The Process Being Carried Out at ECL

Involves Following Steps:
 Loading of Coil.
 Feeding & Welding Of Strip.
 Primary Cleaning Of Strip.
 Electrolytic Cleaning Of Strip.
 Hot Water Rinsing Of Strip.
 Drying Of Strip
 Inspection.
 Filter Paper Test.
 Pickle lag test.
 Recoiling Of Strip.
 Unloading Of Coil.
 Storage & Transfer Of Processed Coil.

Annealing

Annealing is a process by which the properties of steel are

enhanced to meet machinability requirements. It involves
heating the steel slightly above its critical temperature (723°C)
and allowing it to cool down very slowly.
Material Specification:
 Low carbon non-alloy steel of CQ, DQ, DDQ, EDDQ,
SEDDQ, and IF steel used in automotive applications
including outside body panel application.
Dimensional Specification:
Minimum Maximum
Width 700 mm 1710 mm
Thickness 0.15 mm 4.10 mm
Charge Weight - 110 MT

The Steps Involved in the Process Are:

Process Equipment/Atmospheric Media
Coil
Coil car, Coil lifter, Crane
Transfer
Charging Coil lifter, Inner Cover, Work Base
Leak Test Nitrogen, Hydraulic Power Pack for Clamping
Safe Purge 1Nitrogen
NG, Electrical control system, Heating Belt,
Heating
Hydrogen Gas
 Types of Annealing
There are various types of annealing:
1. Full Annealing
o The process involves heating the steel to 30 to 50

degrees Centigrade above the critical temperature of

steel and maintaining the temperature for a specified
period of time, then allowing the material to slowly
cool down inside the furnace itself without any forced
means of cooling.
o Hot Worked sheets, forgings, and castings made from

medium and high carbon steels need full annealing.

2. Process Annealing
o This process is mainly suited for low carbon steel.

o The material is heated up to a temperature just below

the lower critical temperature of steel.

o Cold worked steel normally tends to possess increased

hardness and decreased ductility making it difficult to

work.
o Process annealing tends to improve these

characteristics.
o This is mainly carried out on cold rolled steel like wire

drawn steel, etc.

3. Stress Relief Annealing
o Large castings or welded structures tend to possess

internal stresses caused mainly during their

manufacture and uneven cooling.
o This internal stress causes brittleness at isolated

locations in the castings or structures, which can lead

to sudden breakage or failure of the material.
 oThis process involves heating the casting or structure
to about 650 degrees Centigrade.
o The temperature is maintained constantly for a few

o hours and allowed to cool down slowly.

4. Spheroidise Annealing
o This is a process for high carbon and alloy steel in

order to improve their machinability.

o The process tends to improve the internal structure of

the steel.
o This can be done by two methods: a. The material is

heated just below the lower critical temperature about

700 degrees Centigrade. b. The material is heated just
above the critical temperature and held at the
temperature for several hours, followed by slow
cooling.
5. Isothermal Annealing
This is a process where steel is heated above the upper critical
temperature. This causes the structure of the steel to be
converted rapidly into an austenite structure. The steel is then
cooled to a temperature below the lower critical temperature,
about 600 to 700 degrees Centigrade. This cooling is done using
a forced cooling means. The temperature is then maintained
constant for a specified amount of time in order to produce a
homogeneous structure in the material. This is mainly applicable
for low carbon and alloy steels to improve their machinability.
Advantages of Annealing:
 It softens the steel.
 It enhances and improves the machinability of steel.
  It increases the ductility of steel.
 It enhances the toughness of steel.
 It improves the homogeneity in steel.
 The grain size of the steel is refined a lot by annealing.
 It prepares the steel for further heat treatment.

SKIN PASS MILL

4 HI SKIN PASS MILL: 4 HI stands for four horizontal insert
skin pass mill.
OPERATING MODE: Two Operating modes, namely (1)
Force mode (mostly preferred), (2) Elongation mode.
MATERIAL SPECIFICATION: Carbon steel strips.
PURPOSE OF USING SKIN PASS MILL:
 For proper graining structure.
 To remove yield point.
 Remove light I/P defects like marks, dents etc.
 To maintain the shape.
 For reducing the use of R.P.O i.e. rust protect oil spray

FINISHING
Cold Roll Slitter Line (FIMI-ITALY)
Dimensional Specifications:
 Max. Speed: 400 mpm
  Min. Width: 25 mm
 Max. Width: 1700 mm
Work Instructions:
Loading of Coil:
1. CR, Skin passed coil is loaded on the coil car by crane.
2. The coil is loaded to the un-coiler through the coil car and
it should be centrally loaded.
Feeding of Coil:
1. The coil is fed from the un-coiler using the peeler table.
2. The coil's outer 2/3 damaged wraps are cut by shear.
3. The coil is fed from slitter to re-coiler through looping table
in tension unit.
4. The tension unit provides back tension before the coil is re-
coiled

QUALITY MANAGEMENT SYSTEM

(QMS)
A quality management system (QMS) is a set of internal rules
that are defined by policies, processes, documented procedures,
and records. This system defines how a company will achieve
the creation and delivery of the product or service to the
customer.
Components of QMS:
1. Quality Control (QC):
o Focuses on product characteristics through a reactive

approach by line function to identify defects using

operational activities such as testing and
measurements.
2. Quality Assurance (QA):
o Focuses on processes through a proactive (preventive)

approach by staff function to prevent defects using

systematic activities such as assessments and audits.
QMS = QC + QA

Role of trainee during the training period

"I learned how to adjust myself in the work environment, how to
deal with people at work - from the boss to the janitors. It’s a
good and quality experience; the necessary kind of experience as
it helps you realize what you want in the future. Also got the
opportunity to evaluate myself under these stressful conditions."
 CONCLUSION
From this summer training, I concluded that:
 In Bhushan Steel Sahibabad plant, steel undergoes different
processes like pickling, rolling, ECL, annealing, skin pass
mill, and then finishing.
 Pickling is a process of removing the oxide scale from hot
rolled steel.
 Rolling is a process of reducing the thickness of HRS coil
(from pickling) with the help of 6HI Hitachi Mill.
 Electrolytic cleaning line is used to remove the oil film
from the surface of cold rolled steel coils.
 Annealing is a heat treatment process used to soften the
steel.
 Skin pass mill is used to give the proper grain structure to
steel coils (from annealing) and also to remove the yield
point.