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CHAPTER 1
OVERVIEW OF JSW
JSW has an interesting history. Though a foundation stone was laid in 1971 by the then
Prime Minister Late Smt. Indira Gandhi for setting up an integrated steel plant under public
sector, the plan remained a non-starter till 1994. The public sector shelved the idea because of
resource constraints and the idea remained a distant dream for the people of Karnataka. The
floodgates were thrown open to the private sector in 1990 to have a joint venture for Integrated
Steel Plant with KSIIDC but they withdrew due to infrastructure bottlenecks. In 1994, the
Government of Karnataka approached the Jindal Group, which succeeded in starting
Vijayanagar Steel Plant in a record 33 months. The constraints were taken care of by adopting
state of the art technology. Selecting the COREX process along with the traditional blast
furnace route provided innovative solutions to power and water scarcity. Meanwhile road and
rail linkage to Goa and Chennai were improved and the Government of Karnataka assured a
steady water supply.

JSW Steel, the flagship company of the JSW Group, is the largest integrated private steel
manufacturer in India in terms of installed capacity. The Group set up its first steel plant in
1982 at Vasind near Mumbai. Soon after, it acquired Piramal Steel Ltd., The Jindals, who had
wide experience in the steel industry, renamed it as Jindal Iron and Steel Co. Ltd. (JISCO). In
1994, in order to achieve the vision of moving up the value chain and building a strong, resilient
company, Jindal Vijayanagar Steel Ltd. (JVSL) was set up, with its plant located at Toranagallu
in the Bellary-Hospet area of Karnataka, the heart of the high-grade iron ore belt and spread
over 3,700 acres of land. It is just 340 km from Bangalore, and is well connected with both the
Goa and Chennai ports. In 2005, JISCO and JVSL merged to form JSW Steel Ltd. JSW Steel
has manufacturing facilities at Toranagallu in Karnataka, Vasind & Tarapur in Maharashtra
and Salem in Tamil Nadu.

Vision
“Global recognition for Quality and Efficiency while nurturing Nature and Society”.

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Mission
“Supporting India’s growth in Steel Domain with Speed & Innovation”

Core Values
 Transparency
 Strive for Excellence
 Dynamism
 Passion for Learning

1.1 Safety at JSW

Every individual is responsible for their own personal safety and the safety of their co-
workers. It is very important that every employee work safely. Safety is protecting ourselves
from hazards existing in the workplace. All employees who are exposed to hazards are required
to use the appropriate personal protective equipment (PPE). The type of PPE used is based
upon the hazards present. Some of the mandatory PPE’s are Safety Helmet, Safety shoes,
Earplug, Goggles, Jacket.
Some of the hazards identified are Dust, Noise, Slip & fall, Confined Space, Poor illumination,
Leakage of gases, Rail wagon, Electrical shocks, Contact with hot metal.
Safety standards at JSW Permit to Work, Working at height, confined space, lock out tag out,
road safety.
Fire safety and use of fire extinguishers are as shown in the below table 1.1
Type of fire Substance Extinguisher
a) Ordinary fire Paper (A) Water
b) Liquid fire Petrol, Diesel (B) Foam
c) Gas fire LPG (B) Foam
d) Metal Metal (C) Dry Chemical powder
e) Electric (D) Carbon dioxide

Table 1.1 Fire Extinguisher Types

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1.2 Products of JSW

 Hot Rolled Coils & Sheets
 Cold Rolled Coils
 JSW NEO Steel (TMT bars)
 Wire Rods

1.3 Process Flow of JSW

The process flow at JSW for producing products is as shown in fig:1.1 below

Fig.1.1 JSW Process Flow

1.4 Major Milestones

 In 1994 The Company was incorporated on March 15, and the Certificate of
Commencement of Business was received on July 8.
 The Company undertook to set up an integrated steel plant with a capacity of 1.25
million TPA of hot rolled coils at Village Toranagallu, Dist. Bellary, Karnataka rich in
iron ore reserves.
 In 1995, the Company proposed to set up pellet plant of capacity 3MTPA
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 In 1996, the first Corex unit is slated for commissioning by October 1997. The Contract
for the second unit of Corex has been signed with VAI and this unit will be
commissioned by April-May 1998.
 In 1997 The BOF & CCP Units were to be commissioned by September/October to
synchronize with the commissioning of the first unit of Corex.
 The first phase of HSM Rolling mill was commissioned in 1997
 The Corex Plant was commissioned on Oct 5 1999, making JVSL the first company in
the world to use the technology.
 In 2004, Coke Oven 1 was commissioned with project time 14 months 17 days a
National record and Blast furnace 1 was also commissioned in the same year.
 In 2006, Coke Oven 2, BF2, Sinter plant1, were commissioned.
 In 2007, Cold Rolling Mill was commissioned and in 2008 Wire Rod Mill and in 2009
Bar Rod Mill
 In 2009, Blast furnace 3 was commissioned, largest in India having volume 4019 m3
 In 2009 JFE Steel Corporation, the world renowned Japanese steel company and JSW
Steel Ltd., India's leading private sector steel company have bonded together in a
historic collaboration agreement
 In 2014 JSW Steel inaugurates India's most modern COLD ROLLING MILL.

1.5 CSR Activities

 The notable initiatives in improving the primary education through government schools
include establishment of Computer Aided Learning Centers (CALCs) in government
higher-primary schools, total of 25 centers are supported and providing mid-day meal
through Akshaya Patra Foundation
 To inculcate reading habit among rural children 20 mobile libraries have been set-up,
where in the educational volunteers/Balwadi teachers enroll the children as members.
 JSW Foundation has been striving hard to improve the general health conditions among
the adjoining rural community thru various initiatives. The notable ones among the
different initiatives include cataract eye care for the aged, gynecological camps for the
women, general health check-up camps, and so on through Jindal Sanjeevani Hospital.

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 Establishing a rural non-voice for educated rural young women and helping the aged
and less educated women to form into Self Help Groups (SHGs) to take up enterprises
of their choice could reach out many people, among others.
 119 women were trained on tailoring. Some of them were trained on advanced tailoring
training in association with District Industries Centre, Bellary. The trained ladies were
involved to stitch uniforms of school children and outsource employees.
 Garbage Management in six nearby villages has been taken-up to improve the local
environment and living conditions of the people.
 The local youth who find it difficult to continue their studies beyond 10th standard due
to various reasons are being trained at O P Jindal Center for Vocational Training in
different trades based on their capacity and interest to make them better employable
than taking up odd jobs. The Vocational Training is provided in Mechanical
Maintenance, Electrical Maintenance and Computer Applications

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CHAPTER 2

ABOUT ORGANIZATION DEPARTMENT

2.1 Rolling Process & Rolling Mills

The process of plastically deforming metal by passing it between rolls is known as
rolling. This is the most widely used metalworking process because it lends itself to high
production and close control of the final product. In deforming metal between rolls, the work
is subjected to high compressive stresses from the squeezing action of the rolls and to surface
shear stresses as a result of the friction between the rolls and the metal. The frictional forces
are also responsible for drawing the metal into rolls. The fig:2.1 shows the rolling process.

Fig.2.1 Rolling Process

The initial breakdown of ingots into blooms and billets is generally done by hot-rolling.
This is followed by further hot-rolling into plate, sheet, rod, bar, pipe, rails or structural shapes.
The terminology used to describe rolled products is fairly loose, and sharp limits with respect
to dimensions cannot always be made for steelmaking terminology. A bloom is the product of
the first breakdown of the ingot, generally the width of a bloom equals its thickness and the
cross sectional area is greater than 230 cm2. A further reduction by hot rolling results in billet.
The minimum cross section of a billet is about 40 by 40mm. A slab refers to a hot rolled ingot

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with cross sectional area greater than 100 cm2 and with a width that is at least twice the
thickness. Blooms, billets and slabs are known as semi finished products because they are
subsequently formed into other mill products.
Rolling mills consist basically of rolls, bearing, a housing for containing these parts
and a drive for applying power to the rolls and controlling their speed. The forces involved in
rolling can easily reach MN. Therefore, very rigid construction is needed, and very large
motors are required to provide the necessary power. Rolling mills can be conveniently
classified with respect to the number and arrangement of the rolls. The simplest and most
common type of rolling mill is two high mills. Rolls of equal size are rotated only in one
direction. The stock is returned to the entrance, or rear, of the rolls for further reduction by
hand carrying or by means of a platform which can be raised to pass the work above the rolls.
An obvious improvement in productivity results from the use of a two high reversing mill, in
which the work can be passed back and forth through the rolls by reversing their direction of
the rotation. Another solution is the three high mills, consisting of an upper and lower driven
roll and middle roll which rotates by friction.

Fig.2.2 Two High Rolling Mill Fig.2.3 Three High Rolling

A large decrease in the power required for rolling can be achieved by the use of small
diameter rolls. However, because small diameter rolls have less strength and rigidity than large
rolls, they must be supported by large diameter backup rolls. The simplest mill of this type is
the four high mills. A cluster mill in which each of the work rolls is supported by two backing
rolls. For high production it is common to install a series of rolling mills one after another in
tandem. Each set of rolls is called a stand. Since a different reduction is taken at each stand,
the strip will be moving at different velocities at each stage in the mill. The speed of each set

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of rolls is synchronized so that each successive stand takes the strip at a speed equal to the
delivery speed of the preceding stand.

Fig.2.4 Tandem Mill

Hot rolling is the process of rolling a metal above its recrystallization temperature. Cold
rolling is the process of rolling metals below recrystallization temperature.

2.2 Salient Points about Rolling

 Rolling is the most extensively used metal forming process and its share roughly 90%
of the product.
 The material to be rolled is drawn by means of friction into the two revolving roll gap
 The compressive forces applied by the rolls reduce the thickness of the material or
changes its cross sectional area.
 The geometry of the product depend on the contour of roll gap
 Hot rolls are generally rough so that they can bite the work and cold rolls are ground
and polished for good finish.

2.3 Hot Rolling

For hot rolling of steels, the ingot (billet) is reheated in a furnace to a temperature
around 1150o C and located on roller table. These rollers feed into roll stands. In hot rolling,
when metal heated above its recrystallization temperature is passed through the roll stands, the
section thickness is reduced and is accompanied with grain refinement. In hot rolling, the
original coarse grain structure of the material is broken up and elongated by the rolling action
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under compressive forces. Since, the temperatures is above the recrystallization point, the
fragments of crystals act as nuclei and form new small grains as the metal comes out of the
rolls. The crystals continue to grow if the temperature is high enough and if no further
deformation is carried out. The grains become more finer with increasing number of passes.
Fine grained structure will give improved toughness and strength. A satisfactory grain size
with equi-axed grains can be obtained by maintaining the finishing temperature very close to
recrystallization temperature.

Fig.2.5 Micro Structural Changes in Hot Rolling

2.4 Important Terms & Factors in Rolling Mills

 Stock size: Maintaining required stock size from the respective stand will help in
matching the correct speed to achieve tension free rolling. Uneven stock size will also
result in varying shape and size of finished product.
 Temperature: Temperature control from furnace exit to cooling bed becomes very
critical for all grades of re-bar. High temperature of billet causes more wear out and
low temperature becomes critical causing unwanted looping and load on stands.
 Wear out: Uneven wear out in mill causes disturbance in mill by causing disturbance
in front end flow resulting in cobble.
 Equipment Health: Performance of all equipment to its optimum level will result in
better repeatability and continuity of Rolling.

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 Equipment Alignment: It is important parameters to run the mill continuously proper

alignment is required.
 Scale: A complex iron oxide formed on the steel surface during the hot rolling
operation or formed on steel parts which are heat treated in the presence of oxygen.
 Scrap: Material unsuitable for direct use but usable for reprocessing by re-melting.
 TMT Process: The processing of reinforcing steel is usually through one or
combination of processes which may include hot rolling after micro alloying, hot
rolling followed by controlled cooling (TMT process) and hot rolling followed by cold-
work. Heat treatment is a thermal process undergone by the steel in the solid state, the
most common practice is finishing online heat treatment while rolling, commonly
known as thermo-mechanical treatment (TMT) process. After leaving the last stand of
the rolling mill, the bars are quenched (rapidly cooled) in water from a final rolling
temperature of about 950°C. The quenching is partial, only until a surface layer has
been transformed from austenite (a steel phase stable only at very high temperatures]
to martensite (stable at temperatures below 350°C). This controlled quenching is
achieved in one or more online water cooling devices through which the steel passes at
a very high speed before reaching the cooling bed.

2.5 Rolling Mill Practices

 Stock size inspection in Roughing Mill, Intermediate Mill, and Finishing Mill in regular
intervals in a shift and correcting the stock in stands accordingly.
 Monitoring of Furnace exit temperature and Pyrometer reading in mill, adjusting the
water box accordingly to maintain the desired temperature.
 Observing the Re guide roll play and wear out is very critical and should be done in
every shift religiously.
 Static guide inserts also to be observed for wear out for uneven wear out.
 Observe for any metallic shavings or chips in the guide mounting area.
 During pass change of stands, observe the alignment of entry and delivery guide to the
pass
 Pass grinding should be done uniformly to avoid front end bite slippage

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 During Ring change, Shaft should be cleaned with acetone and ring to be placed with
clean hands for dust and dirt free.

2.6 Hot Strip Mill-II

 A slab is passed or deformed between a set of work rolls and the temperature of the
metal is generally above its recrystallization temperature, as opposed to cold rolling,
which takes place at room temperature. Hot rolling is primarily concerned with
manipulating material shape and geometry together with desired mechanical properties.
This is achieved by heating a component or material to its upper critical temperature
and then applying controlled load which forms the material to a desired specification
or size. Hot strip mills must: Roll a wide range of width & slab thicknesses, Process
numerous grades of steel, simultaneously govern both width and thickness, and
continuously operate for extended periods of time.
 The Hot Strip Mill II in JSW has a high technology and high efficiency steel
manufacturing and processing capabilities supplied by Mitsubishi – Hitachi Metals and
Machinery Inc. JSW is an Integrated Steel Plant and the new rolling mill HSM II has
a fully computerized dynamic sequence process control system capable of producing
various steel grades at an annual production of 3.5 million tons per annum in phase 1
and it has an expansion of product range and production capacity up to 5 million tons
per Annum with provision of R1 (Roughing Mill 1), F7 Finishing Stand and Down
Coiler 3
 In phase 2 modernization. Fig:2.6 Shows the Hot Strip Mill 2 Overview with Phase 2.

Fig.2.6 HSM II Mill Overview

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CHAPTER 3

TASKS PERFORMED IN THE INDUSTRY

3.1 Features of Hot Strip Mill 2

Now the Hot Strip Mill 2 is operating with a production capacity of 3.5 million tons
per annum. It has an expansion of product range and production capacity up to 5 million tons
per annum with provision of Furnace 3, Roughing Mill 1, F7 Finishing Stand and Down Coiler
3 in phase 2 modernization as summarized in the below table 3.1

Table 3.1: HSM-2 Mill Features

Area Phase Supplier Features
1 M/s LOI 2 x 350 Tons/Hr, Gas fired
Furnace
2 Italimpianti, Italy 1 x 350 Tons/Hr, Gas fired
Hydraulic Scale De scale Pressure 200 Bar with
1
Breaker height adjuster
2 Hi, Slab Sizing Press
Roughing Mill (R1) 2
Motor power-AC 3200 KW x 20/40
M/s Marubeni-
4 Hi Reversible
Mitsubishi Hitachi
Motor power-AC 8000 KW x 55/85
Metal Machinery,
Roughing Mill (R2) 1 Transfer Bar - 25 mm to 65 mm
Inc, Japan
Vertical Edger with Automatic
Width Control
Finishing Mill Scale De scale Pressure 200 Bar with
1
Breaker height adjuster

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Area Phase Supplier Features

4 Hi, 6 stands
All Stand Automatic Gauge
Control
F1-F4, Pair Cross with
Stabilizers
F5-F6, Work Roll Shifting
1 Automatic Profile and Flatness
Finishing Mill
Control
Motor power-AC 10000 KW x
240/620

M/s Marubeni- Max Strip Rolling Speed 1200

Mitsubishi Hitachi Metal mpm
Machinery, Inc, Japan Descale Pressure 100 Bar

2 7th Stand

Run Out Laminar Cooling system with

Cooling 1 length of 150 m applicable for
System Dual Phase and TRIP Steels
DC # 1, 2. Heavy Duty Dual
Speed Hydraulic Coiler
1 QOC with Non step Expanding
Down Coiler
Mandrel
Motor power- 1300 KW
2 DC # 3
Electrical and
Automation M/s TMEIC-GE, Japan
Civil and
Structural M/s GDC, India
Engineering
Consultant M/s ESPIC, India

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3.2 Reheating Furnace

The slabs from the slab yard of continuous casting plant are received and stored in the
slab yard of Hot Strip Mill. Then according to the schedule planned by the production planning
and control department the slabs are fed into the reheating furnace. There are two furnaces,
each with a capacity of 350 T/Hr. Corex and mixed gas is used as the fuel for these furnaces.
The slabs are moved in the furnaces by the help of a walking beam which is hydraulically
operated. The slabs are gradually heated in the different zones of the furnace maintained at
different temperatures. There are ten zones in each furnace and the zones are,

 Zone 01 - Top pre-heating zone

 Zone 02 - Bottom pre-heating zone
 Zone 03 – Top 1st heating zone
 Zone 04 – Bottom 1st heating zone
 Zone 05 – Top 2nd heating zone
 Zone 06 – Bottom 2nd heating zone
 Zone 07 – Top soaking right zone
 Zone 08 – Top soaking left zone
 Zone 09 – Bottom soaking right zone
 Zone 10 – Bottom soaking left zone

Capacity of Reheating Furnace:

 Slab size 220 mm thickness x 11 m length max.

 Discharging Temperature 1,200 - 1,250 °C
 Capacity 350 T/Hr per furnace (cold charge base)

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Fig.3.1 Reheating Furnace

3.3 Hydraulic Scale Breaker (HSB)

Hydraulic Scale Breaker Table (hereinafter HSB Table) is located at the entry side of
fill-in table for sizing press after the furnace delivery table. HSB table is operated in
combination with the HSB which is applied to remove the primary scale on slab surfaces and
HSB table transfers the slab from furnace delivery table to fill-in table for sizing press through
the HSB.

HSB Table consists of two sections, of which Section 1 has nine individually driven
rollers and Section 2 has ten individually driven rollers. Each roller will be mounted in
antifriction bearings located in bearing cages and bolted to the table beam. The slab discharging
from furnace acts with the air present in the atmosphere, so the primary oxide scale is
generated. This scale is removed by Hydraulic Scale Breaker (HSB) at a descaling pressure of
200 bar. It consists of two high-pressure top spray headers rigidly mounted above table rollers
and top bottom spray headers. The purpose of the slab descaling system is to remove heavy
scale formed on the slab before sending it to reversing roughing mill.

Specification:

 Type : High pressure water spray type

 Number of headers : Two top and two bottom headers
 Descaling spray valve : One each for entry and delivery
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 Descaling hood lift cylinder : One hydraulic cylinder operated by one double
solenoids valves
 Flapper lift cylinder : Two pneumatic cylinders operated by one double
solenoids valve
 Header lift cylinder : Four hydraulic cylinders operated by one double
solenoids valve
 Header liner shift cylinder :Four hydraulic cylinders operated by one double
solenoids valves

3.4 Reversing Roughing Mill

Four-high Reversing Roughing Mill will be provided for reducing slab thickness to the
required transfer bar size in nominal five or seven passes. The mill will operate in tandem with
the Attached Vertical Edger (E2) during forward passes. The mill housing will be of welded
and closed type with mountings for the screw down gear housing at the top and for the edger
on entry side. The mill housings will be mounted on shoe plates which will be fastened to the
foundation.

The roll gap will be adjusted by two motors through high-speed screw down system.
Gap adjust hydraulic cylinders regulated by the electric hydraulic servo control will be
provided under the bottom back up roll chocks to make fine zeroing of work roll gap, leveling
of screw down, unjamming on the occasion of emergency jamming, quick opening for
emergency. Load cell will be provided under the screw of screw down device to prevent the
influence of the mill hysteresis to the roll force measurement.

Top backup roll will be balanced by hydraulic cylinders mounted in the project block
fixed on mill housing posts. Top and bottom work rolls will also be balanced by hydraulic
cylinders mounted in the project blocks fixed on the mill housing posts. Therefore, there will
be no hydraulic hose to be connected to work roll chock. The stripper guides will be provided
at both sides of work roll, and retractable at work roll changing. The wiper is attached on the
stripper guides to contact to the work roll for the prevention of the water leakage on the rough
bar.

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A pair of work rolls will be retracted by hydraulic cylinder at work roll changing. The
bottom back-up roll chocks will be retracted on the sled by hydraulic cylinder. A pair of back-
up rolls can be retracted by the hydraulic cylinder with stool between top and bottom chocks
for back-up roll changing.

Work rolls will be direct driven type with twin main motors through cross pin type
universal spindles. By adjusting. The speeds of the upper and lower rolls independently, the
turned up and down for head end of bar will be reduced.

Fig.3.2 Roughing Mill

Specification:

 Type Four high reverse type - twin motor drive

 Rolling load Approx. Max. 42,000 kN
 Reduction capacity Max. 50mm at low carbon steel
 Work roll size 1,200/1,100 mmdia.X2,250 mm
 Back up roll size 1,550 /1,400 mm dia. X 2,230 mm

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3.5 Heat Holding Covers

To prevent the temperature drop of transfer bar, heat holding covers are located above
delay table. Heat shielding apron will also be furnished between table rollers, where an opening
for scale will be provided. These holding covers with insulator can be opened and closed by
hydraulic cylinders. Fix type entry guide will be installed to prevent the holding cover against
up-bend transfer bar.

Specification:

 Quantity :Eight Heat holding cover

 Type :Hyd. cylinder tilted type
 Tilting cylinder :Two Hydraulic cylinders/cover

One Approx. 4160 mm x 112 x 1,110mm stroke

One Approx. 160 mm x 112 x 110mm stroke

 Heat holding cover with insulator :Fabricated steel, Stainless steel sheet for cover
inside
 Total length :Approx. 7,000 mm/pce
 Inner width : Approx. 2,430 mm
 Inner height :Approx. 470 mm (From the roller surface)

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Fig.3.3 Heat holding cover

3.6 FSB
Finishing Mill Pinch Roll Scale Breaker (FSB hereinafter) is located at the entry side
of Finishing Mill Fl after the Crop Shear. FSB is arranged to remove secondary scale on a
transfer bar from its top and bottom surfaces with using high pressure water prior to the
threading into Finishing Mill Fl.

FSB essentially consists of two pinch roll units, five bottom individual driven table
rollers, two top descaling headers, two bottom descaling headers, two tilting aprons driven by
one pneumatic cylinder and necessary accessories enclosed in a pivoting spray hood. FSB is
equipped with two pairs of descaling headers, of which each the pair consist of one top and
one bottom headers and turned on/off with individual spray valve (2 Valves for two pairs).
FSB operates with a Descale Pressure of 200 Bar with height adjuster.

3.7 Finishing Mill

HSM II is four high six stand finishing mill in (Phase 1) and seven stands in (Phase 2)
to further reduce the thickness of the strip after it gets reduced to the specific thickness in the
roughing mill. The problem of thermal crowning of rolls is mainly encountered by the rolls in

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finishing mill. The mill is highly automated with all the operations being monitored in the
control room itself.

The work rolls of the finishing mill are continuously exposed to the high temperature
of the strip. This results in the increase of work roll temperature with each passing strip. With
increase in roll temperature thermal stresses are developed in the roll. Due to the roll wear and
this thermal stresses, if the rolls are not changed frequently there is a high probability of roll
breakage which again is highly undesirable. Keeping this in mind the work rolls are changed
frequently depending on the rolling schedule. The work rolls after being removed from the
stands are brought back to the roll shop where grinding operations are carried out.

Specification:

Type: Four-high non-reversing mill.

Fl-F4: PC (Pair Cross) mill

F5-F6: WRS (Work Roll Shift) mill

Fl-F6 stands are equipped with positive work roll bending system.

Maximum cross angle: Max. 1.2 degrees (Normal operation)

1.5 degrees (Mechanical limit)

Work Roll Shift Stroke: ±100 mm/roll

WR bending force: Fl through F4: Max. 1,176 kN/chock

F5 through F6: Max. 1,470 kN/chock

Rolling force: Fl - F4: Max. 42,000 kN

F5, F6 Max. 35,000 kN

Roll force measurement: Two load cells per stand, mounted in the back-up roll change sled.

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Capacity: Fl through F4: 25,000 kN/load cell

F5 through F6: 20,000 kN/cell

Table 4.1 Mill Stands and Motor Specification

Fig.3.4 Finishing Mill

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3.8 Run Out Table

Run-Out Table will be located between the finishing mill F6 and number one down
coiler pinch roller stand. This roller table will be designed to carry a strip after rolling toward
down coiler with strip cooling. The hollow steel table rollers individually driven will be
supported by anti-friction bearings. There are 404 rolls individually driven by AC motors for
better speed control. The basic speed reference to all the sections is given by the last stand exit
speed.

However each section may have an additional speed reference, which can be positive
(leading speed) or negative (lag speed). Leading speed is applied when the head of the strips
is moving towards the coiler, lag speed when the tail of the strip is leaving the finishing mill.
Their function is to keep tight the strip.

The hot strip as it comes out of the sixth stand of finishing mill is cooled with water on
the Run-Out Table to the required coiling temperature. The water is sprayed from the top
through a number of headers and bottom by nozzles. The cooling of the strip is controlled
automatically by the computer controlled coiling temperature control (CTC) modules based on
the preset temperature segment.

Fig.3.5 Run Out Table

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3.9 Down Coiler

The hot strip after getting cooled on the run out table has to be coiled. For this purpose
two down coilers are provided to coil the strip. The two down coilers receive strips alternatively
to reduce the time. The coils from the down coiler are selected randomly for quality check.
The coils are allowed to cool in the coil yard having a storage capacity of 12,000 MT.

The down coiler coils the strip coming out of the finishing mill. The down coiler is
equipped with a pair of entry guides to guide the strip centrally into the coiler. Two hydraulic
down coilers are equipped with out-board bearing supports to take care of heavy coil windings.
The finished coil in the down coiler is taken by stripper car provided at the coiler and that coil
was carried to the fixed saddle placed at the exit of the coiler. Then from the fixed saddle coil
is lifted by a delivery car to the coil conveyor system. Finally this coil is placed at the walking
beam 1 first saddle. There are 6 walking beams in the coil yard area to transfer the coils to the
coil yard. The coils are then lifted by the cranes in the coil yard and placed in the hot zone area.

Then the coils are sampled, marked and packed after 12 hours of storage and released
after testing from the QA department for the final dispatch.

Fig.3.6 Down Coiler

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CHAPTER 4
REFELECTION NOTES

4.1 Internship Experience

Internship work carried out at JSW Steel Limited, Bar Rod Mill-1 was a good
experience. Most of the things which were studied as a part of academics could be practically
experienced. At the initial stage of internship understood briefly the steel making process, all
the departments involved and their contribution in steel making. During the department
allocation for internship I was allotted to Bar Rod Mill, were in billets are rolled to get TMT
bars which are mainly used in construction. Practically observed the rolling mill stands, rolling
process, water quenching involved for TMT process, reheating of billet at furnace, use of
hydraulic and pneumatic cylinders across all the mill line.
Opportunity to compare most of academics part with the practical situation like
operating of hydraulic cylinders, components of hydraulic system like pump, filter, direction
control valves, flow control valves, flow distributors. Exposure to material handling systems
at industry level.
Improvement in verbal and written communication, enhancing knowledge,
presentation skills, decision making and problem analysis skills, mail communication.
The most important outcome of Internship is the need for safety at industry, and industry safety
should be taken seriously. Any person entering the industry should have a basic knowledge of
safety. Different safety standards practiced at industry level.
Improvement in problem solving skills with the task performed at industry during the
Internship. Use of QC tools to determine the area contributing most for mechanical delays,
performing this task has helped in learning MS Excel, usage of Excel for plotting graphs, usage
of logic in Excel which makes calculations and tabulations easier and faster in MS Excel.

4.2 Importance of Industrial Safety

 The most important factor or the context to be understood is safety and should have
brief knowledge of industrial safety before entering into any industry.

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 Before starting the Internship at JSW Steel Ltd, mandatory training was provided on
Industrial Safety.
 It is mandatory to wear all the Personal Protective Equipments (PPE’s) which include
Safety helmet, Safety Shoes, Ear Plug, Goggles, Dust mask and Safety jacket.
 Understood different hazards in the work location which include hot rolling material,
hot surface, rotating equipment, electrical shocks, slip and fall, noise.
 Important to carry CO (carbon mono-oxide) Monitor when working at furnace area as
there could be danger in leakage of CO gas.
 Safety procedure under practice before starting of job is to take “Permit To Work” and
to isolate the equipment were the job is to be carried out.
 Different types of Fire extinguisher and how to operate them during Fire incident.
 Location of Assembly point, idea about unsafe act and unsafe condition.
 Important steps to be checked while working at height (above 1.8m from ground)
 Steps followed to avoid accidents are to follow the Standard Operating Procedure
(SOP) and Stand Maintenance Practices (SMP).
 Road Safety Standards followed to avoid road accidents, limits on Speed of vehicles,
regular road safety inspection to check for any violations, good condition of vehicle,
use of helmet and florescent jackets on bike.
 Employees are given First Aid training, and availability of First Aid Kit at all the work
location
 Employees and all the outsource technicians should undergo medical checkup as twice
a year.
 Regular safety trainings carried out at JSW are Road Safety, Permit To Work, Lock
Out Tag Out, Work At Height, Confined Space Entry.
 All the persons are trained for any new safety standards implemented.
 Display of boards which create awareness regarding safety at work location
 Display of emergency contact numbers for Ambulance, Fire Safety, Safety Office
 Visitors are not allowed at worksite for safety reasons and there is separate pathway for
visitors to view the rolling process

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4.3 Technical Outcomes

 During the course of Internship had a good exposure to Rolling Process.
 As Metal Forming Process (Rolling) being part of academics, could compare most of
the things studied, into a practical situation.
 Surface oxidation results in Scale formation and is removed off at Descaler, if the scale
is not removed at the exit of furnace then it may lead in accumulation near rolling stands
and Guide rollers may jam and face difficulties during rolling.

4.3.1 Industrial Ergonomics

 Ergonomics is the scientific discipline concerned with the understanding of
interactions among humans and other elements of systems in order to optimize human
well-being and overall system performance.
 Training conducted for employee’s and associates regarding safety, operating
procedure, maintenance practices to enhance the knowledge
 Display of sign boards, standard operating procedures, standard maintenance
practices, equipment name display boards.

4.3.2 Brief Understanding of Industrial Procurement Process

 The end user gives the list of requirements to the planning cell
 Planning cell consolidate the requirements, create the item code for the same
 Purchase requisition will be raised based on the requirement and is processed for
approval as per the hierarchy

4.3.3 Wide Applications of Hydraulics & Pneumatics

 During the Internship, came across wide range of applications on Hydraulics &
pneumatics.
 Almost all major equipments in the Rolling Mill we can find the hydraulic and
pneumatic actuators out of which most are cylinders.
 Various components which make up a hydraulic system are Oil tank, Pump, Filter,
Pipeline, Valve Stand, and Cylinders in general..

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4.3.4 Maintenance Practices

 Maintenance is the regular activity which is carried out to have good healthiness of
equipments and higher equipment availability.
 Monthly two or three shutdowns are planned to carry out the maintenance activities.
 Exposure to different type of maintenance practices like Preventive maintenance,
corrective maintenance, breakdown maintenance, opportunity based maintenance,
condition based maintenance.

4.3.5 Exposure to Material Handling System

 Exposure to various kind of material handling systems in the industries.
 Use of hand trolley for shifting small components within assembly sections
 Use of forklifts and Overhead cranes to carry heavier components to different location
in industries.
 Roller conveyor for transfer of billets into the furnace and discharging from the
furnace. Also to transfer bar layer from cooling bed to stacker, and in bundling area.
 Chain conveyor in finishing area and bundling area.
 Walking beam mechanism to transfer billets within the furnace.

4.3.6 Importance of Lubrication

 Lubrication is the most important factor for healthy running of equipments
 Because of the high temperatures in Hot rolling mill all the equipments are exposed to
high temperatures, it becomes every important for retaining grease or oil at those
temperatures.
 Exposure to centralized grease systems, Air Oil system, centralized lubrication
system across the rolling mill
 Use of Water resistant and high temperature grease.

4.3.7 Importance of Documentation

 Activities/Jobs which are carried out in every shift are recorded into Log Books
available with all the sections, and control pulpits.

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 Mill speed, Stock size, water flow and pressure, billet temperature, cooling bed bar
temperature, roll parting details are also noted down.
 Running status, standby status of all pumps like hydraulic pump, water pumps,
lubrication pumps are also listed out.

4.3.8 Exposure to Control Pulpit and Human Machine Interface (HMI)

 Human Machine Interface (HMI’s) are the screens available at every control pulpit and
Electrical Control Room
 Control pulpit is the location where the operator will be available to control, switch ON
and OFF the equipments of some particular area from a single place.
 HMI shows the whole process on the screens, the operators gets access to control the
process through HMI.

4.4 Non-Technical Outcomes

 Exposure to problem analysis, in case of any problem during rolling process how
actually the persons deal with the problem. The approach to the problem, finding the
root cause and taking corrective actions hence rectifying the same. Also regular check
for any deviation or abnormal such that the problem should not repeat.
 Use of Process Data Acquisition (PDA) in problem analysis.
 For every problem in the rolling line, we can analyze with the help of PDA. There are
signals for every particular parameter for example torque of mill stands, actual and
reference speed of equipment, operating feedback of cylinders, loop height in case of
loopers, presence of material at particular location by the feedback of Hot Metal
Detector.

4.4.1 Improvement in Verbal Communication

 During the course of Internship, discussing the daily tasks with the external guide, also
day progress reporting, and communication with line Engineers helped to improve my
verbal communication skills.
 Monthly Internship Progress presentation at Industry and Colleges.

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 Discussion with internal guide.

4.4.2 Improvement in Written Communication
 Preparation of Weekly and Monthly Reports of task assigned at industries.
 Mid- Internship Report preparation and submission at college.
 Final Internship Report

4.4.3 Improvement in Presentation Skills

 Presentation of weekly and monthly reports of internship at industry
 Mid Internship Presentation at college
 Attending some of the presentation given at industry level also enhanced my
presentation skills

4.4.4 Improvement in Time Management Skills

 Clear understanding between important and urgent tasks and executing accordingly
 Understanding clearly the problems importance and its effect on production,
prioritizing the time and problem to solve the problem.
 Proper scheduling of activities required to complete the task at the earliest.

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CHAPTER 5
CONCLUSION

The implementation of all the parameters described below was carried out from the
month of March 2012. From the observations made it was concluded the following points plays
an important role for the better strip shape control.

 The effect of roll cooling time before grinding for thermal stabilization of work rolls.
 Periodic inspection of work rolls cooling nozzles.
 Effect of rundown pattern.
 Roll force distribution in the finishing stands.
 Roll crown (Standard Operating Practices)
 Work roll shifting pattern in thinner gauges for better leveling.
The observations after these implementations have given better results compared to
previous month’s data. Such modification would not require large capital investments and the
yield of prime product would increase. The rolling conditions will not be the same every time,
they may vary depending on the type of work rolls used, rolling speed and wear out of back up
and work rolls. This leads to change in the thermal crown of the work rolls. HSS rolls may
require more time for thermal crown development whereas ICDP rolls require less time for
thermal crown development. HSS rolls cost more in comparison with ICDP rolls. So there is
scope for further improvement by studying thermal crown for different type of rolls used, rate
of rolling and wear pattern for backup and work rolls in finishing stands.

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