Electrical Grade Steels (Silicon Steels)

Types of Core Losses

Hysteresis Loss:- Magnetic Hysteresis including B-H Curve - Importance of Hysteresis Loop
Hysteresis Loop
Eddy Current Losses
We can reduce the Eddy Current losses by reducing the current. The current
Reduces with increased core resistance. We can increase the core resistance by:-
Basics of Texture developments
Indices for Crystal Planes
Process Path flow - Thyssen Krupp Electrical Steel India Ltd
 Pickling Line:
Date:

Pickling is the process of removing the undesired Iron Oxides deposited on the steel surface during hot rolling at HSM.
Pickling is carried out by using Hydrochloric Acid(HCL) which reacts with iron oxides forming FeCl2/FeCl3 & water. In
this process the HCL acid is consumed & the again regenerated at Acid Regeneration Plant(ARP) by the hydrolysis of the
pickling by product i.e. FeCl2/Fecl3 dissolved in the aqueous acid.

Why Pickling is required?

 The Iron oxide patches deposited on the steel surface can affect the cold rolling process by impacting the load & the
reduction %.
 It can also led to mill work rolls skidding & can be the area of accelerated corrosion.
 It can also led to the Rolled in Scale defect on steel surface.
Type of Iron Scales deposited on the Steel surface:

Oxide % Iron(Fe) % Oxygen(O) Layer Thickness (%) Location w.r.t Sheet

Fe2O3(Hematite) 69.9 30.1 85 Outer most layer

Fe3O4(Magnetite) 72.4 27.6 10-15 Middle Layer

FeO(Wustite) 77.7 22.3 0.5-2 Inner most layer facing the steel surface

Wustite, the layer next to the steel surface is formed first & then reduced successively by the iron to form Magnetite
& then to Hematite.
 Chemical Reactions during pickling process:
Hematite: Fe2O3 + 6HCl 2FeCl3 + 3H2O
HCl
Magnetite: Fe3O4 + 8HCL FeCl2 + 2FeCl3 + 4H2O
Wustite: FeO + 2HCL FeCl2 + H2O
HC HC
l l
Use of Inhibitor:
Inhibitors reduce the pickling loss during the pickling process by HCl.
Inhibitors cover the scale free surface & avoid dissolution of metal by steel
hydrochloric acid thus prevent the over pickled surface.

Why HCL Acid is preferred over H2SO4 acid for Pickling:

 Pickling Line Specifications:
Year of Installation: 1994-95
Supplier: Nirvan Keramchemie
Type: Push Pull (Semi continuous Shallow)
Line Speed: 0 - 65 – 90 meter per minute
Thread Speed: 30 meter per minute
Strip Width: 650mm(min) - 1320mm(max)
Strip Thickness: 1.6mm(min) – 6mm(max) (Currently 2.3mm to 2.5mm generally)
Coil ID: 650mm(min) – 850mm(max) (Input): 610mm (Output)
Coil OD: 2000mm Max
Coil Weight: 24000kg Max

Pickling Line Flow Diagram:

Pickling Tanks Rinse Tanks

RT1 RT2 RT3 RT4 RT5 Air Dryer Side Pinch

Leveler Shear
PKT1 PKT2 PKT3 Shear Thickness Leveler Deflector
guide Roll Profile Roll
Uncoiler gauge
Recoiler

Sheet Direction
Pickling Process:

It is a push pull type pickling line, here each coil is fed separately from uncoiler to the recoiler and then process is started.
There are three pickling tanks which contain HCl acid with concentration 5-8%(PKT1), 8-12%(PKT2) & 12-15% (PKT3). Sheet enters
from PKT1 tank for pickling of iron oxides & exit from PKT3 after final pickling. The sample of acid concentration is taken once in a
day from each tank and as per the requirement fresh acid is added to the PKT3. Acid cascade from the third tank to first tank through
second tank & in this way acid concentration is maintained in all three acid tanks. The acid solution after pickling goes to the Acid
regeneration plant(ARP) where the used acid solution is treated with hot water to get back HCl acid for reuse.
After the picking process the sheet enters the five stage water rinsing tanks which wash out the acid carry on the sheets. pH of the final
rinse tank RT5 is maintained 6.5 to 7. The pH value of the RT5 is measured once in a day by taking sample & required pH of the fifth
Rinse tank is maintained by adding fresh water as per the requirement. In this case also the water cascade from 5th rinse tank to 1st rinse
tank through 4th, 3rd & 2nd respectively.
Now the sheet is passes through the dryer section where hot air is used to dry the sheet to avoid any rusty defect in the sheet. Thickness
profile of the sheet is measured by installed thickness profile gauge meter & then coil is recoiled at the recoiler.

Rinse Water cascading

Pickling Defects:

Acid Patches: This defect is caused by insufficient rinsing of acid at rinsing tanks. This is generally white in colour.
Water Patches: This defect is caused by water carry over due to insufficient squeezing & subsequent drying of sheet after rinsing. This is generally
blackish or brownish in colour.
Scratches: This defect is caused when running sheet touches any rough metal piece or surface at any location throughout the line.
Process Control Parameter validation at Pickling through testing at Laboratory:-
S.No Parameters to Internal process Freq. of testing Equipment of Standard / Status of tested value Actions to be taken
be checked control limits testing Method

1. Acid Conc. – 3.0 to 6.0 % Once in a day Lab – Titration As per < Control Limit  Add Acid or
PKT1 (Wt. / Vol) plant SOP reduce line speed
> Control Limit  Add water

2. Fe Content – 160 Max (g/l) Once in a day Lab - Titration As per Control limit Discard Acid or
PKT1 plant SOP reduce line speed

3 Acid Conc. – 5.0 – 9.0 % Once in a day Lab – Titration As per < Control Limit  Add Acid or
PKT2 (Wt. / Vol) plant SOP reduce line speed
> Control Limit  Add water

4 Fe Content – 130 Max Once in a day Lab - Titration As per Control limit Cascade to RC1
PKT2 ( gm / Liter) plant SOP or reduce the line
speed

5 Acid Conc. – 8.0 to 15.0 % Once in a day Lab – Titration As per < Control Limit  Add Acid or
PKT3 (Wt. / Vol) plant SOP reduce line speed
> Control Limit  Add water

6 Fe Content – 100 Max (g/l) Once in a day Lab - Titration As per Control limit Cascade to RC2
PKT3 plant SOP or reduce the line
speed

7 Rinse Water > 6.5 Once in a day Conductivity Measureme < Control Limit Add fresh water
PH – RT5 meter nt with
calibrated
PH meter
 Reversing Mill 01:
Date:

Rolling can be defined as the process of reduction of thickness of the steel sheet by applying a continuous load with the help of a
specific arrangement of Rolls. Rolling is the plastic deformation of metal done by applying load through Hydraulic cylinders on the
chokes of backup rolls. It is carried out below the recrystallization of the steel 727℃. It is the economical way of obtaining a desired
thickness with better surface finish, better shape as well as dimensional control and uniform mechanical properties.

Theory Part:
What is Cold Rolling?
It’s a basic method of shaping metals by:

WITHOUT HEAT APPLICATION

Cold Rolling:-
Process by which hot rolled strip or stock is introduced between a set of rotating rollers and then squeezed or
compressed to the desired thickness.

This is achieved either in:

Reversing Cold Rolling Mills : Thickness achieved by repeated passes through the same rolling stand back and forth
Or in,
Tandem Cold Rolling Mills : Thickness achieved through series of rolling stands in tandem
Principle Applied to Cold Rolling:
•The combined Tensile and Compressive Load on the material causes it to
W
1
deform permanently.
•Optimum compressive load prevents the material from narrowing
substantially across the width. (W1 = W2).

•Since width has no change after permanent deformation, elongation effects

a proportionate change in length and thickness of material.

• This aforesaid characteristics is the foundation of the MASS

FLOW EQUATION which is t1v1 = t2v2 W
• 2
t1 & t2 – Thickness(Entry & Exit)

• v1 & v2 – Speed(Entry & Exit)

Shape Control: Basic Type of Sheet Shape
Shape is controlled by means of:
Roll coolant sprays
Roll bending
Roll shifting
Operators display and control
Necessity of Roiling oil(Coolant) during cold rolling:
Rolling oil present in the coolant considerably reduce the Rolling force required for reduction, lessen the Roll wear,
reduces the roll & strip temperature and also serves as lubricating media.
i.e. It is applied to control friction, wear and surface damage of the rolls and strip.
- To maintain optimal frictional force during rolling.
- To help in improving surface quality of rolled strip.
- To help in removing heat, dirt from roll surface and strip.

Backup Roll spray header

BR
Backup Roll& Work Roll bite spray header
Work Roll spray header WR

Work Roll spray header WR

Backup Roll& Work Roll bite spray header

BR

Backup Roll spray header

 Mill 01 Line Specifications:
Year of Installation: 1994-95
Supplier: FPE(Flat Products of India Ltd)
Type: 4Hi Reversing cold rolling mill
Line Speed: 0 - 600 – 1200 meter per minute
Roll Data: Work Roll: Barrel Diameter-430mm – 455mm; Barrel Length-1420mm
Backup Roll: Barrel Diameter-1162mm – 1295mm; Barrel Length-1420mm
Strip Width: 650mm(min) - 1320mm(max)
Strip Thickness: 0.15mm(min) – 3.15mm(max) (Currently 2.3mm to 2.5mm generally)
Coil ID: 610mm (Output)
Coil OD: 1830mm Max
Coil Weight: 23000kg Max

Mill 01 Line Flow Diagram:

Pinch
Flattener Shear Anti Thickness Deflector
Roll Deflector Thickness Anti
gauge flutter flutter gauge
Cum Cum
Pay of Roll Roll
Pinch Roll Pinch Roll DTR
Reel ETR

4Hi Mill

Odd Pass Even Pass

Sheet Direction
Rolling Process:
Hot rolled & pickled coil is feed at POR & then the head end of the coil is feed to the recoiler 01 passing through the work roll. Now, tension
is provided at the recoiler & load is provided from top of the backup roll. Due to this applied load the thickness if the coil is reduced & full
coil is recoiled at the recoiler. This is the 1 st pass reduction. Now the tail end of the coil is feed to the recoiler 2 & again load is applied. This is
the 2nd pass reduction. In this way coil is rolled up to the desired thickness as per the rolling schedule.
Shape is controlled by roll bending & tilting so as to get a flat sheet free from centre buckling, quarter buckling & edge waviness.
Rolling arrangement Roll bending

Important requirement of Inter pass Ageing:

Generally, grain oriented electrical steel is cold rolled by reversing mill and maintained a few minutes between cold rolling passes. The
use of short time inter-pass ageing treatment has been reported to improve the magnetic properties in the high permeability grain
oriented electrical steel by increasing the amount of 110 〈001 〉 component in the primary recrystallization texture.

The inter-pass ageing through the effects of static strain ageing, influences the plastic deformation due to pinning action of solute C and
N on dislocations formed during the cold rolling. This fact favors the occurrence of shear bands when coil is further rolled. The Goss
oriented grains nucleate in these shear bands which enhance the development of this component in the primary recrystallization.
During secondary recrystallization there is more favorable site for the nucleation of the secondary recrystallized grains i.e. rate of
nucleation is more then the rate of grain growth. So, it helps in refining the grain size after secondary recrystallization and ensuring high
performance to the final product due to the reduction of core loss.
Important requirement of Inter pass Ageing:
Observations (Based on literature / paper surveys) :
1) Inter-pass ageing treatment at 200 °C during cold rolling reduces the grain size of Fe-3%Si grain oriented electrical steel after secondary
recrystallization and improves its core loss.

Final grain size is reduced by inter-pass ageing, being minimum around 200 °C, which can be attributed to the
largest volume fractions of 110〈001〉 and 012〈001〉 orientations at this temperature after primary recrystallization Core loss as a function of final grain size

2) The largest variation in yield stress took place at the temperature of 200 °C in all evaluated thicknesses, showing that strain ageing is more
effective at this temperature. The strain ageing effect is more pronounced in the thickness of 0.70 mm, 70 % reduction.
3) Inter-pass ageing treatment during cold rolling increases 110〈001〉 and 012〈001〉 components on the primary recrystallization texture.
The sum of volume fraction 110〈001〉 plus 012〈001〉 orientations after cold rolling reaches a maximum at inter-pass ageing temperature of
200 °C.

Effect of inter pass ageing on the magnetic Primary recrystallization texture as a function of Cold rolled texture as a function of pass
properties inter-pass ageing temperature 012〈001〉 and
ageing temperature
110〈001〉
Process Control Parameter validation at Reversing Mills through testing at Laboratory:-
Mill coolant parameter validation – Mill # 1 and Mill # 2
S.No Parameters to be Internal process Freq. of Equipment of testing Standard / Status of tested Actions to be taken
checked control limits testing Method value

1. pH value 5–8 Once in a PH meter As per < Control Limit  Pkl rinsing to be
day plant SOP improved. Inform
line incharge
> Control Limit  Drain out rinse
water and add
fresh water

2. Conductivity 1 mSiem Max Once in a Conductivity meter As per > Control limit Add fresh water
day plant SOP

3 Total Oil 0.60% - 8.0% Once in a Conc. HNO3, Cassia Flask, As per < Control Limit  Add fresh Oil
Content (TOC) day Brine water, water bath / Oven plant SOP > Control Limit  Add water
4 Scum Oil 1.0 % Max Once in a Same as above for Total Oil As per > Control limit Skimming of Scum
day concentration measurement plant SOP

5 SAP Value > 120 mg KOH Once in a NaCl, Beaker, Hot Plate, Water As per < Control Limit Add fresh oil
/ g of oil week Bath, separating flask, Methyl plant SOP
Ethyl Ketone, filter paper, 0.5N
KOH, 0.5N Hcl,, Erlenmeyer
flask, pipette, 0.5N Alcoholic
KOH, Condenser flask,
phenolphthalein indicator, 0.5N
Hcl, Burette

6 Tramp oil < 39% Once in a Same as above for SAP value As per > Control limit Add fresh oil and
week measurement plant SOP check for any
leakages

7 Chlorides < 100 PPM Once in a 0.0564N AgNO3, 0.0564N As per > Control Limit Drain the water and
week NH4SCN, 0.0564N NaCl, plant SOP add fresh water
Conical Flask, Conc. HNO3,
Hot Water Bath, Filter Paper,
Nitrobenzene, Ferric Alum
indicator, Burette

8 Fe. Content < 300 PPM Once in a Erlynmeyer flsk, measuring As per > Control Limit Check magnetic
day cylinder, Conc. HCl, Hot Plate, plant SOP separator and ensure
Al foil, Phosphoric Acid, 0.01 N it is operational
Potassium dichromate
Process Control Parameter validation at Reversing Mills through testing at Laboratory:-
Mill coolant parameter validation – Mill # 1 and Mill # 2
S.No Parameters to be Internal process Freq. of Equipment of testing Standard / Status of tested Actions to be taken
checked control limits testing Method value

9 Free fatty acid > 8% Once in a 0.1 N KOH, Ethanol or Iso As per < Control limit Add fresh oil
week Propyl Alcohol, Oven, plant SOP
Phenolphthalein indicator,
Burette,

Impact of various oil parameters on rolling / product quality

Parameters High Low Parameters High Low
pH Higher emulsion stability Lower emulsion stability Fe content Surface contamination Inadequate lubrication

Higher Roll force
Lower Mill speed
Lower lubrication
Gauge Variation
Skidding Higher oil consumption Higher roll force
due to magnetic
Higher plateout separation and draining
Higher corrosion tendency
Chloride content Higher corrosion Desirable
tendency

Conductivity Lower emulsion stability Higher foaming tendency Higher oil consumption

Higher ash content Lower emulsion stability

Higher corrosion tendency SAP Desirable Poor lubrication
Oil % Skidding Poor lubrication Higher roll force
Higher plateout Higher roll force Increases oil consumption
Gauge variation
Tramp Lower SAP number Desirable
Lower mill speed
Higher Fe generation
 Induction Training at TADL:
Date:

After cold rolling, coil is processed at Tandem Annealing and Decarburization line(TADL) for Decarburization Primary recrystallization annealing
and Nitriding. In decarburization carbon content in steel is reduced in a humid Hydrogen & Nitrogen atmosphere by reacting carbon with oxygen
forming carbon monoxide gas & subsequently removing the gaseous product through vent. On the other hand cold rolled grains of the steel
recrystallize and the grain growth of the recrystallized grains is pinned by aluminum nitride(AlN) formed during the nitriding process of steel. The
final structure of the steel is fine equiaxed grains which is the prime requirement for the secondary recrystallization of the steel.
Why Decarburization is required?
Decarburization is carried out to reduce the carbon content in the GO electrical steel. This is because carbon causes magnetic ageing when it
slowly leaves the solid solution and precipitates as carbides at the grain boundaries. This hinders the passing path of the current when subjected to
electricity and thus increases the eddy current losses. The main chemical reaction occurring during decarburization process are:-

C + H2O CO + H2 eqs(1)
C + CO2 2CO eqs(2)
C + 2H2 CH4 eqs(3)
C + 1/2O2 CO eqs(4)
The rate equation for the reactions C+H2O «CO+H2 (eq1) and C + CO2 « 2CO (eq2) depends on the local carbon activity of the steel, the partial
pressure of water vapour and carbon dioxide, temperature and the thickness of the oxide
layer formed on the surface. The relevance of eqs (3) and (4) can be considered negligible if the PH2O/PH2 ratios are high (>0.1).

Why Nitriding is done?

In Electrical steel most important factors are low core loss & high magnetic permeability. This can be achieved by large grain size
structure obtained by secondary recrystallization at higher temperature. The criteria for secondary recrystallization is a small and
uniform primary grain structure which can be achieved through the inhabitation of normal grain growth during primary
recrystallization. For this inhabitation steel is treated with Nitrogen to from AlN which precipitates at the grain boundaries to retard the
grain growth & thus small & uniform primary grain structure is obtained.
TADL Line Flow Diagram: Sheet Direction

Zone 01 to 09 Zone10 to 11
Deflector
Briddle Roll
Roll 2A

Sheet Direction
Seal Seal Seal Pinch
Entry Exit
Seal Gate1 Gate3 Air Cooling Jet Seal Roll
Gate2
Cooling
Decarburizing Zone 01 to 11 Nitriding Zone- 15 to
Zone-20
19
Zone- 12 to 14
Sheet Direction

Deflector Deflector
Recoiler Deflector
Roll Shear Roll
Roll Briddle
Briddle Roll 03
Roll 04 Exit Looper

Sheet Direction

Shear

Water ECL Briddle Deflector

Air Dryer Rinsing Cleaning Roll 01 Pinch Pay of Pay of
Seam Roll Shear
Entry
Roll Reel 01 Reel 02
Briddle Looper Welder
Roll 02

Sheet Direction
TADL Equipment & Process description:

Entry Section- Uncoiling of coil is done at the entry section with the help of 2 Pay off reals (POR01 & POR02), other parts are shear
for cutting the sheet and a pinch roll set for moving the sheet forward and reverses direction.

Welding and looper section- Since TADL is a continuous type line, after end of Payoff real 01 coil, we have to weld the head end of
coil from Payoff real coil 2. Welding is done by seam type welder in which 9500A current is given. Lapping of sheet is maintained
around 5 mm.
 2 Loopers are provided at TADL, One in the Entry section and another one in the Exit section. The loopers act as a buffer stock &
feed the sheet to the furnace when entry is stopped for welding work & store the sheet when the exit is stopped for coil unloading.
The filling capacity of entry Looper is 228 metre & exit lopper is 214 meter and we can use 90% of it.

Electrolytic cleaning (ECL) – Here degreasing of sheet is done with the help of alkaline solution (NaOH).
Important points of ECL:
 It is a method of removing oil, dirt, coolant patches and some extraneous material stick or carried over to the surface of sheet
while Cold rolling process.
 A DC current is applied between an insoluble electrode and the steel sheet to be cleaned. 4 electrodes are provided to supply max
3000A current. As a set up when electrodes act as anode the sheet is cathode & vice versa.
 Chelaclean (NaOH) is use as alkaline agent in the bath. The changeover of a bath consist of 6-7 drums (1 Drum =45Ltr) of
chelaclean and 7.5KL water. The bath changeover frequency is in every 24Hr.
 The alkali % of bath should be in the range of 2.5%-2.7%
 Temperature (70 degree Celsius) is maintained continuously to ensure an optimal pre-cleaning.
 In the cleaning section, projection of recycled heated water is used.
 Four different tanks are provided- Circulation tank, sludge tank, Line tank and Preparation tank. Circulation tank and preparation
tank is heated by steam and the temperature is 70 degree Celsius maintained.
Electrolytic cleaning (ECL)
TADL Equipment & Process description:

Scrubber section- After ECL section, Wringer rolls are provided to stop alkaline bath carry over from the surface of the sheet. Then the surface
is introduced to Scrubber section in which water at high pressure is provided to clean the alkaline surface of the sheet.
Vital points of Scrubber section
 The temperature of scrubber section is around 70 degree Celsius
 10 Headers are provided to spray water on the surface of the sheet, 5 in Top and 5 in bottom, which is more categorized in Fresh and
Recirculating.
 The water flow in scrubber section is maintained at 10 M3/hr at >4bar pressure
 3 Squeezing rolls are provided to remove water from the surface of sheet
 
 
Humidifier section- This section is very critical to maintain Mix Gas atmosphere in the furnace. The mixture of N2 and H2 gas is provided in
the form of steam in furnace through headers. There are 2 Humidifiers located; 1st is in the furnace zone in Zone 4 and 5, and other one is for
Zone 7 and 9.The Water flow of both the humidifiers is set at 1.5KL/Hr.
Humidifier section Consist of 3 main sections.

 Gas heater- The set temperature of this station is 100 degree Celsius
 Water heater- The set temperature of a Normal grade is 80 degree Celsius and for CSM grade it is set at 86 or 88 degree Celsius.
 Wet gas heater- The set temperature of wet gas heater is 140 degree Celsius.
 Whenever the dew point is getting low, then water heater temperature increase. Dew point is very necessary to create moisture on the sheet.

Ammonia Tonner Section-

This section includes Ammonia vaporiser and ammonia tonners. The liquid ammonia in the ammonia tonner is converted into gas state by the
use of Ammonia vaporiser and then it is utilizing in Nitriding section of the furnace. The temperature of ammonia vaporiser is maintained at
75 degree Celsius. 1 Ammonia tonner contains 400 kg of liquid ammonia 
 
TADL Equipment & Process description:
Furnace Pressure- Currently Furnace pressure is maintained around 3.5 – 4.5 mmWC. Furnace pressure is maintained in following zones.

It is very important to maintain Furnace pressure in the appropriate range, but sometimes Entry seal 3.5-4.5
it fluctuates because of some reasons:-
 If the temperature of decarb zone is changing Z#1 3.5-4.5
 If the line speed increases/ decreases. Z#10 4.0-4.5
 If there is change of H2 flow, N2 flow, H%. Z#14 4.0-4.5
 Changing the position of old vent valve. JC 4.0-4.5
 Changing the position of entry and exit seal.
Exit Seal 4.0-4.5
 Sudden change in Ammonia flow.
Old vent 1 30%

Seal gates- Seal gates are provided in the furnace to insure there will be no mixing of atmosphere from decarb zone to nitriding zone. There
are 3 seal gates provided. Currently Seal gate 1 is open and other two seal gates are closed. Seal gates are provided between zone 9 & 10,
then zone 11 & 12 and then between zone 14 & 15.

Gas flow parameters- Zone Nitrogen Hydrogen Hydrogen %

1 to 3 35-45 70-80 60+/- 2
6 to 9 35-45 75-85 60+/-2
10 to 11 0 0 -
12 to 14 30-40 0 60+/- 2
15 to 19 0 30-40 30-40
Jet cool 55-65 0 0
Entry seal 30-40 0 -
Exit seal 40-50 0 -
Entry snout flow 25-35 0 -
Exit snout flow 110-130 0 -
TADL Equipment & Process description:

Dew point and ammonia flow- Dew point plays a vital role in decarburization process. Dew point is checked manually by dew cup method
in zone 2,8,10,11. The range of dew point is 60-70 degree Celsius.
Ammonia flow is maintained in nitriding zones and output nitrogen is controlled by the ammonia flow (Kg/Hr). Ammonia is transferred to the
furnace via headers. Total 12 headers and provided 6 top & 6 bottom.

Entry and exit seals, Vent valves- Entry and exit seals are closed to maintain pressure inside the furnace. There are six vents provided in the
furnace.

Bouncy betty and Necking of sheet- Bouncy betty is necessary because of the furnace tension so that it provides the balancing of sheet and it
is maintain in the range of 25-42 Psi.
Necking of sheet is also depends on furnace tension.  

Furnace zones and Speed (Decarburization zones and Nitriding Zones), Cooling section - Furnace is having 19 zones and Jet cooling
section. Decarburization (Removal of carbon) is done in zone 1-11, and Nitriding is done in Zone 12-14 where ammonia is provided. The
speed of the line is 60 MPM. Cooling is done by indirect cooling. Cooling section starts from zone 15, slow Cooling is done in zones 05 to 19
with air & finally in zone 20 rapid cooling is done with the help of water. In jet cooling 12 blowers are provided.
 
Exit- At exit, the TADL operation is maintained. Different kinds of defects like Alkali patches, coolant marks, scratches, white patches etc. are
observed and controlled by the pulpit incharge. Removal of welding is done.
Process Control Parameter validation through testing at Laboratory:
S.N Parameters to Limits as per ISO Internal process Freq. of testing Equipment of Standard / Status of tested Actions to be taken
o be checked spec control limits testing Method value

1. Alkali % in 0.7- 2.0 % 2.5 % (Trias Once in a day Lab – Titration Internal < Control limit Add fresh Alkali
tank (NaOH) with higher with 0.N HCl Standard
conc. Of 5%
under > Control limit Add fresh water
progress)

2 % O2 0.03 – 0.12 % 0.10 – 0.115 % Every coil LECO ON736 ASTM < Control limit or 1. Check one
E1019 > Control limit dummy sample
2. If variation
3 % N2 0.015 – 0.04 % 0.0220 – Every coil < Control limit or found in
0.0260 % > Control limit dummy
sample, check
4 %C NA < 30 ppm Min. one coil LECO CS230 ASTM with standard
per shift E1019 samples
5 %S NA NA Min. one coil 3. Callibrate
per shift equipment,
with results of
standard
samples
4. Again check
line sample
5. If still values
found out of
control limits,
inform process
and check
process
abnormalities
LECO ON736 – For O2-N2 measurement

Theory of operation and measurements:-

 The ON736 system is designed for measurement of O2 ad N2 of steel and other inorganic
materials
 Pre weighed sample is placed in a graphite crucible which is heated in impulse furnace to release
analyte gases
 Oxygen in the sample reacts with the graphite crucible to form CO and CO2.
 Inert gas , Helium sweeps the liberated gases out of the furnace, through a Mass Flow Controller
 The gas then flows through a heated reagent (Cuprous Oxide), where CO from the gas is oxidised
to form C02 and H2 is oxidised to form H2O
 The O2 is detected as CO2, using a Non-Dispersive Infrared Cell (NDIR Cell)
 CO2 and H2O are then scrubbed out of the carrier gas
 A thermal conductivity (TC) detector, is then used to detect the remaining N2
 The detection system is comprised of both NDIR and TC detectors.
NDIR cells are based on the principle, that analyte gas molecules absorb, Infra Red (IR) energy
at unique wavelength within the IR spectrum. Incident IR wavelengths is absorbed as the gases
pass through the IR absorption cells.
TC detection measure the N2 content, through measurement of difference in thermal conductivity
between the carrier gas (Helium) and the analyte gas (CO+CO2+H2+N2).
Resistive TC filaments are placed in a flowing stream of carrier gas and heated by a bridge
circuit. As the analyte gas is introduced into the carrier gas, the rate at which the heat transfers
from the filaments, will change producing a measurable deflection in the bridge circuit.
The concentration of the unknown sample is determined relative to the calibration standards.
Prior to each analysis, reference measurements of pure gas are made to reduce any interference
from instrument drift
LECO CS230 – For C-S measurement

Theory of operation:-
 The CS230 Carbon/Sulfur determinator is a microprocessor based, software driven
instrument for measurement of carbon and sulfur content in metals, ores, ceramics, and
other inorganic materials.
 It uses an induction furnace and measures carbon and sulfer by infrared absorption.
 1 g nominal weight of sample is kept into a ceramic crucible, preheated to 1000 Deg C &
kept in a decicator after heating . Accelerator material (LECO EL Mesh – 20+40) is added
and the crucible is placed on the loading pedestal.
 Check and ensure the O2 level above the Red Line and maintain @ > 40Psi through
adjustment of O2 cylinder valve
 After O2 level is maintained, analyse key pressed to start analysis. Furnace closes
automatically, then the combustion chamber is purged with oxygen to drive off residual
atmospheric gases. After purging, oxygen flow through the system is restored and the
induction furnace is turned on.
 The inductive elements of the sample and accelerator couple with the high frequency field
of the furnace. The pure oxygen environment and the heat generated by this coupling
cause the sample to combust.
 During combustion, carbon bearing elements are reduced, releasing the carbon, which
immediately binds with the oxygen to form CO and CO2, the majority being CO2.
 Also, sulfur-bearing elements are reduced, releasing sulfur, which binds with oxygen to
form SO2.
 Sample gases are swept into the carrier stream. Sulfur is measured as sulfur dioxide
(SO2) in the first IR cell. SO2 is converted to SO3, and removed from the system in a
cellulose filter.
 Carbon is measured as carbon dioxide in the IR cell as gases flow through the IR cells.
LECO CS230 – For C-S measurement
Mechanism of measurements in the IR cell
 The infrared (IR) source consists of nichrome wire that is resistance-heated to 850 Deg C. The
IR source radiates visible energy as well as all wavelengths in the infrared spectrum.
 Carbon dioxide absorbs IR energy at a precise wavelength within the IR spectrum. Energy from
the IR source is absorbed as the gas passes through the cell, preventing it from reaching the IR
detector. All other IR energy is prevented from reaching the IR detector by a narrow bandpass
filter. Because of the filter, the absorption of IR energy can be attributed only to carbon dioxide
(CO2). The concentration of CO2 is detected as a reduction in the level of energy at the
detector.
 One IR cell is used as both a reference and for measurement. The total carbon, as carbon dioxide, is
detected on a continuous and simultaneous basis. The cell consists of an IR source, chopper motor, a
narrow bandpass filter, a condensing cone, an IR energy detector and the cell body.
 Radiated energy is chopped at a rate of 87.5 Hz. before it enters the cell body. The chopped energy enters
the cell body through a window, travels through the cell body, then exits through a second window and a
precise bandpass filter.
 The selective filter passes only the CO2 absorption wavelength into a condensing cone that concentrates
the energy on the detector. The solid state detector is AC coupled to a preamplifier. As the gas
concentration increases, the voltage to the preamplifier decreases.
 The starting reference level, or baseline, for the detector is established by running 100% oxygen through
the cell. The pure oxygen environment permits the maximum amount of energy to reach the detector.
This maximum energy level is AC coupled to the preamp where it is amplified, rectified, and filtered. It is
then sent to an A/D converter where the analog signal is converted to a digital signal. The nominal
voltage read at the cell output, via the Ambient Monitor, is 8.500 VDC.
 During every analysis, the computer reads the baseline. This level is then adjusted digitally until a nominal
level is achieved.
 As analysis begins, the cell output decreases with the amount of carbon (as CO2) present in the cell. The
computer reads the cell output 20 times per second and produces data points that are stored in memory.
The computer then processes the curve or graph formed by these data points. The curve or graph is then
used by the computer to calculate the element weight percent of an unknown sample.
 Induction Training at MgO Coating Line:
Date:
At TADL, coil has gone through decarburization & nitriding process generating a primary recrystallized structure. Now for getting
excellent magnetic properties & lower core loss the coil has to be processed through high temperature annealing section for
obtaining large secondary recrystallized grain structure. So, to avoid the wraps getting welded or stick to each other during high
temperature annealing MgO coating is applied on both surface of the coil & dried subsequently.

Why MgO Coating is required?

At the MgO coating line, a Magnesium oxide coating layer is applied on the decarbed steel, by the application of a water based
Magnesium Slurry through coater rolls and then removing the excess moisture in the coating by passing through gas fired infrared
burners .
This layer of Magnesium Oxide (MgO) is needed on the strip, so that in the next secondary recrystallization process at the next
annealing line (Tunnel furnace or MBAF), this MgO coating can react with the fayelite (Fe2SiO4) present on the strip to form a
layer of forsterite (Mg2SiO4). This layer of forsterite coatings are commonly known as “Glass Film” or “Mill glass”or “Mill anneal”
coatings and defined as C-2 insulation coating layers in IS 3024 standards

This forsterite coating (Mg2SiO4) formed after secondary recrystallization also acts as a binder between the base metal and
another tension coating (Phosphate+colloidal silica based coating) applied, after the secondary recrystallization process, to provide
insulation and reduce core losses.

De-scaling – pickling
Fayelite – Fe2SiO4 Cold reduction
Decarb annealing
Amorphous Silica

MgO Coating MgO Coating

Fayelite – Fe2SiO4

Amorphous Silica

Recrytsllisation Annealing @ Tunnel furnace or MBAF

Forsterite - Mg2SiO4

Phosphate Coating
Forsterite - Mg2SiO4
MgO Coating Line Flow Diagram:

Gas fired Infrared Burners

Kriton MgO
Uncoiler Pinch Exit Shear Recoiler
Seam Briddle Coater Dryer area Air Cooling Pinch Deflector
Roll Welder Roll
Zone Roll
Roll

Sheet Direction

Preparation of the MgO slurry Batch

 800 L of DM water @ 5 Deg C
 Add additives (TiO2 – 4.8 Kg and SbCl3 – 43.2 g) and stir the mixture for 3 minutes
 Add MgO powder in the preparation tank
 MgO powder is added in proportion of Scora – 56 Kg and Tateho – 24 Kg. Total of 80 Kg in the batch. Stir the
mixture well for 1.5 hours
Now the slurry is ready for use
Process Control Parameter validation through testing at Laboratory:-

S.No Parameters to Internal process Freq. of testing Equipment of testing Standard Status of tested Actions to be taken
be checked control limits / Method value

1. Weight of 2 to 8 Min one coil per Punching Press Internal <2  Inform line to
MgO coating day SOP increase coating
(GSM) Analytical weigh balance weight
>8
(weight loss method of  Inform line to
100mm dia circular reduce coating
samples O/S,C & D/S)) weight

2. Loss of 2 to 9 One sample per ELTRA – Internal >9 Inform line process
moisture on shift Thermogravimetric SOP incharge to check
ignition (%) at Analyzer firing and temperatue
1000 Deg C at dryer

Weight Loss method for checking

coating weight
Thermogravimetric Analyzer – for checking LOI
*** Tunnel Furnace – Details of Process and Parameters yet to be obtained
HFCL Line Flow Diagram:
HFCL Line Description:
HFCL (Heat Flattening & Coating Line) is a continuous processing line. Here the coating of CRGO (Cold Rolled Grain Oriented Electrical
steel) coils is done after High Temperature annealing at Tunnel Furnace. This type of electrical steel is used for DISTRIBUTION
TRANSFORMER.
First step is to load WIP coil on entry payoff for processing CRGO coil on HFCL, then threading to stitch the leader end of fresh coil with tail
end of running coil. Then sheet goes to the scrubbing section for scrubbing of sheet with brush roll & rinsing with water for removing MgO
powder. Now sheet go for pickling with H3PO4 (Ortho-Phosphoric Acid) for roughness/etching & brightness. Thereafter sheet is rinsed with
water (hot & cold) to remove traces of acid before coating.

Now the coating is done with the mixture of Kromal-2034 & Colloidal silica with DM water. Kromal-2034 is a complex mix of 50-55% Tri
Aluminium Phosphate + 5-10% Hexavalent Chromic Acid and the rest is water. After coating, sheet passes through drying furnace for curing.
Then it passes through electrical heating for stress relieving and thermal flattening (if required) by flattening rolls which are in the furnace.
After healing & flattering section, sheet is cooled by Jet cooling blowers before going to the leaser section for laser scrubbing. At the end
sheet passes through the on line tester (Watt-loss Tester) for checking Permeability & Core loss. Finally the quality inspection of the sheet is
carried out before the sheet gets recoiled into a coil on Recoiler for CRS (Cold Rolled Slitter).
ENTRY:
1. Payoff:- There are 02 payoffs for coil loading / processing for coils coming from Tunnel
Furnace.
2. Shear:- shear is used to cut the damaged / waste sheet which is not useful.
3. Stitcher:- Stitches the back end (tail end) of the coil already processed and the front end
(head end) of the coil which is to be processed.
All above equipment (Payoff, Shear, Stitcher) are operated by Hydraulic Power Packs. Hydraulic
power packs keep 50 kg/cm2 (approx.) pressure and uses the EP-46 brand hydraulic oil.
Safety:- All above jobs must be done with safety precautions as per JSA (job safety analysis) as
fingers may be pinched @ the time of coil loading on payoff, saddle, and pinch rolls. Fingers may
be cut in shear and Stitcher.
Environment:- At entry area removes MgO powder which is applicable on CRGO Raw
material. Report any leakages (like:- oil, steam, air etc.) to respective department.
Auxiliary equipment:- In this area many pinch rolls like:- Upper pinch roll # 01 & # 01A for
travelling sheet from payoff # 01; Lower pinch roll for travelling sheet from payoff # 02; and Pinch
roll # 01 for travels sheet from payoff to Shear / Stitcher. Pinch roll # 02 for pinching the stitch.
Above all pinch rolls operate by compressed air at 1-2 kg/cm2 (approx.) pressure .
HFCL Line Description:
4. Scrubber:- Main Input which are used in this section - Brush roll, Water, Compressed air
Function:- In this section scrubb the sheet by the help of Brush roll & spray nozzle with cold water. There removes the MgO (which is applicable on CRGO
raw material) without damage glass film (which is generated @ Tunnel Furnace) with water.
In this section, Squeeze rolls are also use for squeezing the water. Use compressed air for up-down movement of brush roll.
BRUSH ROLL SPECIFICATION:
ID OD Length Type

150 mm 305 mm 1308 mm Tungston Carbide Impregnated

3 inch 12 inch 500 mm Tungston Carbide Impregnated

3 inch 10 inch 75 mm Nylone-66

Compressed air keeps 2-4 kgs (approx) pressure.

Brush roll function:- For top surface scrubbing, one brush roll on top and one steel roll on bottom touches the sheet by compressed air and scrubb
with water. For bottom surface, one brush roll on bottom and one steel roll on top touches the sheet by compressed air and scrubb with water.

Safety:- Fingers and Hand may be pinch @ the time of Brush rolls & Squeeze rolls setting.
Environment:- In this section removes MgO coating material in form of slurry. This slurry disposes as per Environmental norms (Disposal norms). Report
any leakages (like:-water, air etc.) to respective department.
HFCL Line Description:
5. Dryer:- Main Input which is used in this section - Steam

Function:- Its main function is dry the sheet which comes out from scrubber by
steam. It keeps above 1000c temperature for drying.

Safety:- Skin may be burn after touching this equipment. Report any leakage of
steam to respective department.

6. Looper:

Function:- At the end of running coil accumulates 140 (approx.) meters

material in looper area. When Entry stops @ the time of stitching the sheet, @
that time accumulated material (which are in looper) run through process.

Length of Looper is 74 Mts (approx.). Min. 03 minutes require for stitching. So,
do the stitch @ the 30 - 40 mpm

PROCESS:
1. ATS (Acid Treatment Section):- Main Inputs - Ortho-Phosphoric Acid
(H3PO4), Steam, Compressed air, Water.
Function:- H3PO4 acid is used with 6 - 8% conc. for Roughness / Etching and Brightness
of sheet. Conc. May kept up to 25 % depending on input raw material quality so that glass
film does not get damaged.
In this section, Squeeze rolls are also use for sequeezing the acid.Do up-down movement
of squeeze roll by compressed air
In this section, keeps 500C temperature for heating the acid by Steam.
Safety:- Fingers and Hand may be pinch @ the time of Squeeze rolls up-down.
Environment:- Acidic fumes hazards to health. So, there is a acid fumes scrubber. In
this scrubber acidic fumes suck by motor and dissolves in water by spray pump and mix
with water and send to ETP / ARP.
HFCL Line Description:
2. Rinse Tank:- Main Input - Water, Steam, Compressed air
Function:- Its main function is Rinse / Wash the sheet (which comes
from ATS) with water by spray nozzle as acid gives red / brown patches
after quering.
In this section temprature kept 500 - 600C by using steam.

In this section, maintain the PH value above 05.

In this section, Squeeze rolls are also use for squeezing the water
Do up-down movement of squeeze roll by compressed air
Safety:- Fingers and Hand may get pinch @ the time of Squeeze rolls
operation.

3. Dryer:- Main Input which is used in this section - Steam

Function:- Its main function is dry the sheet which comes out from
Rinse Tank by using steam & air combination. Dryer temprature is kept up
to 1200c temperature for drying.

Safety:- Skin may be burn after touching this equipment.

Report any leakage of steam to respective department.

4.Coater:- Main Input - Coating rolls, Coating chemicals, Compressed air

Safety:- Fingers & Hand may be pinch @ the time of gap setting. Chemical may be damage the skin & eyes. So,
use rubber hand gloves, gum boot, goggles etc.

Environment:- Coating chemicals hazardous to health & environment. So, spent / waste solution collect in a
separate place and send to ARP / ETP through pump.
HFCL Line Description:

5. FURNACE:-
i) Drying Furnace:- In this section, qure the coated sheet which comes from coater. There are four (04) zones
and having total 38 Naptha Burner for the require temperature. Use LPG for Ignition of Naptha burner.

There are two (02) combustion blowers to provide O2 for burning burner which pressure is 500 mmWC. If pressure goes
below 300 mmWC, all burners have been tripped automatically.

Require Temperature for CRGO grade

Z # 01
Z # 02 Z # 03 Z # 04

5600C 5870C 7000C 8000C

Electrical Heating:- In this section, heat the sheet by heating element for Flatness & Stress releasing. There are
four (04) zones and having heating element for require temperature. Use flattening rolls (02) for Thermal Flatness.

Require Temperature for CRGO grade

Z # 05
Z # 06 Z # 07 Z # 08 Z # 09

8500C 8500C 8500C 8500C 8500C

HFCL Line Description:

Exit:

1. Laser Scrubber:- The sheet from the furnace is then gets scrubbed with laser so as to reduce the core loss
due to fine cutting of the secondary recrystallized grains.

2. Exit accumulator :- When stitch comes and stop at the exit for removal of sample & stitch the material
starts accumulating in looper to remain process running continuously.
Looper length is 58 Mts (approx.).
HFCL Line Description:
3. Watt Loss Tester:-
Function:- After all previous process like- coating, heating, cooling etc. sheet passes through the watt loss tester for checking the Permeability of
Magnetic properties. This tester generates CST (continuous strip test) chart.

4. Shear:- Shear is used to cut the stitch / damage material which comes from entry / furnace.
5. Recoiler:- At the final stage of HFCL line sheet is recoiled in the coil form at the recoiler. After the coil is recoiled then it is taken out from the
mandrel by the coil car & kept at the saddle. The exit operator to paste the identification sticker containing the coil no & other details. Then the coil is kept in
the designated yard for the next process CRS.
Process Control Parameter validation through testing at Laboratory:-

S.N Attributes Parameters Limits as per Internal Freq. of testing Equipment of Standard / Status of Actions to be taken
o to be ISO spec process testing Method tested value
checked control
limits
1. Density 1.25 + / - 0.10 Once in a Day of Gravimetric Internal < Control Resample and
Line Run Flask standard Limits reconfirm
> Control If deviation found
Coating Limts then change batch
material (C5 and give feedback to
Coating) – supplier
Kromal +
2. colloidal Viscosity 15 +/- 5 Sec Once in a Day of B4 size Internal < Control Check stirring & use
silica Line Run viscosity cup standard Limits fresh batch. If
(110ml) > Control Viscosity is beyond
Limts acceptance criteria,
prepare new batch.
3. Acid in Acid conc. 3 – 20 % 6–8% Once in a Day of Lab – Titration Internal < Control  Add Acid or
Pickling % Line Run with 0.5N Standard Limit reduce line speed
tank Na2CO3
(Orthophos  Add water
phoric > Control
Acid) Limit
Laboratory Testing Facilities – for Product Validation
Final Product Quality assurance through testing at Laboratory:-
S. Parameter Acceptance Freq. of Sample Size No. of Equipment of testing Reference Testing Status of Actions
No s to be criteria testing samples Standard Standard tested to be
checked (Min) value taken

1 Insulation > 10 Ohm Every T x 50mm x 250mm 05 Donart IR tester – SRT1 IS 3024 IS3024 / < Control Adjust
Resistivity cm2 / alternate OR IS 648 IS649 Limit coating
Lamination coil Epstein samples Brockhaus IR tester - 6929 IS 649 ASTM A717 thickness
(As per (with mutual agreement)
IS3024)

Test method and principle:-

 This test is a measure of the insulation quality of the electrical steel and specifies
about the procedure of testing the Insulation resistivity of a single strip of flat rolled
electrical steel under predetermined conditions of
(i) Voltage and (ii) Pressure. The apparatus is popularly known as the Franklin
Current Tester
 It is the effective resistivity, of a single insulative layer tested between the applied
bare metal contacts and the base metal of the insulated test specimen
 10 numbers of metallic contact buttons of fixed area, are applied to one surface of
the specimen, and electrical contact with the base metal is made by two twisted
Brockhaus IR tester - 6929 drills of carbide tips or hardened or pointed rods of 3mm Dia.
 The effective surface insulation is then indicated by measurement of the average
electrical current flowing between the 10 metallic contacts and the base metal,
under a specified applied voltage and specified load
 The voltage in the circuit is maintained at 0.5 V and the contact area of each of the
10 metallic contact buttons, is 6.45 cm2. The pressure at which the test is
performed is to be maintained at 2.1 Mpa or 21 Bars
 A 5 Ohm (+/- 1 %) Resistor is connected to each contact buttons. Contacts with
their individual resistors shall be connected in parallel
 The resistivity is given by the formula:-
Ri = ( 6.45/I ) – 6.45
Where:-
Ri = average surface resistivity in ohm-cm2 per lamination (two surfaces), and
I = ammeter reading Amp
Donart IR tester – SRT1
Final Product Quality assurance through testing at Laboratory:-
S. Parameters Freq. of Sample Size No. of samples Equipment of Acceptance / Testing Status of tested Actions to be taken
No to be checked testing (Min) testing Reference Standard Standard value

2 Stacking Epstein Samples As per IS 649 TEMACO IS 3024 IS 649 < Acceptance Adjust coating
Factor T x 30mm x 305mm TESTER IS 648 criteria thickness

Test method and principle:-

 This test is also known as Lamination factor and is essential in the quality
evaluation of Silicon grade magnetic steel strips for rotating and static electrical
machines.
 The stacking factor is the ratio of the calculated Volume from the Weight-Density
of the stack of specimens, to the measured volume obtained from the stacking
height of the stacked specimen under a specified pressure.
 The difference in the volume arises mostly due to the presence of Oxides,
Roughness, Insulation coatings and other surface conditions affecting the surface
of the specimen strip
 The number of specimens taken in the stack is to be taken as per IS 649
(Depends on the nominal thickness of the strip)

 During the test, the applied pressure on the stack is to be maintained at 3.5
Kgf/cm2.
The effective area of application of the pressure = 64.5 cm2
Width of specimen (30mm) x Length of the Load cell (215mm)

 Hence, the force as indicated on the display should be maintained at 226 kgf
(3.5 Kgf/cm2 X 64.5cm2)

 The stacking factor is calculated by the formula:-

% S = ((1000 x M) / (Width x Length x D x H)) x 100
Where,
S = Stacking factor; M = mass of test specimen in gm.
D = Density of specimen material, gm / cm3. (7.865–0.065x(%Si+1.7%Al))
H = Measured average separation of plate, faces, or Stack height in mm.
Final Product Quality assurance through testing at Laboratory:-
S. Parameters Acceptance Freq. of Sample Size No. of Equipment Testing Standard Status of tested Actions to be taken
No to be criteria testing samples of testing value
checked (Min)

3 Coating 1 To 4 Every 50mm x 50mm 01 Fischer IS649 / DIN EN ISO < Control Limits  Increase coating
Thickness Microns alternate (Min) Deltascope 2178 / ASTM B499 / thickness
coil MP30 BS 5411/11 > Control Limits  Decrease coating
thickness

Test method and principle:

 The Fischer Deltascope is used to measure the thickness of any non-
ferromagnetic or non-conductive coatings applied on steel or Iron
 The principle or test method is magnetic induction method according to DIN
EN ISO 2178, ASTM B499 or BS5411/11 standards

 During the test, the probe is brought in contact with the magnetic material
with a non magnetic coating on it

 Low frequency voltage is developed causing magnetic flux to be induced

within the probe

 The thickness of the non magnetic coating is thus equal to the magnetic
resistance of the induced flux lines developed

 The electronic circuit of the instrument, thus converts the resistance to the
thickness, and displays on the screen
Final Product Quality assurance through testing at Laboratory:-

S.No Property to Specific attributes to be Acceptance Freq. of Equipment of Testing Sample Size / Nos. and treatment Status of tested Actions to
be checked checked / Reference testing testing Standard value be taken
Standard

4 Magnetic For CRGO – As per All BROCKHAUS For Epstein Specimen:- If actual Investiga
Properties IS 3024 samples of MPG 100D IS 648 tested value tion of
(1) Max Specific finished IS 649 1. Sample size 30 x 305mm of Core loss is process
Core losses (Ps coils Epstein Test not as per paramete
– W/kg) at Peak processed Frame 2. No. of samples > 12 and target value, rs
values of at Multiples of 4 gradation to
magnetic flux Finishing OR (Depending on thk.) as per be done as
density of 1.5 T Lines Test method and principle:- IS 649 per tested
and 1.7 T at (CRS 1, 2, SST (Single IEC values of Core
frequency of 50 4,6) Sheet Test) Test 60404-3 3. Direction of samples Loss (either
Hz frame – For should be along the rolling Epstein or
Domain Refined direction SST – after
(2) Max magnetic grades through converting to
permeability at Laser Scribing 4. Stress Relief Annealing @ Epstein
peak value of 800 +/- 20 Deg C in Non-Ox equivalent)
Magnetic field atmosphere, for 15 mis
strength of 800 and cooled in furnace
A/m, in an AC below 100 Deg C before
magnetic field at removal
50 Hz – B800
5. After SRA, ageing to be
done @ 225 Deg C +/- 5
Deg C for 24 hours and
cooled to room temperature

For SST Specimens:-

1. Sample size 500 x 500 mm

2. Direction of samples should
be along rolling direction
Brockhaus MPG 100D – For measurement of magnetic properties of electrical steels
25 cm Epstein test frame
Sample mass – 1 Kg max
Primary windings – 4x25=100
Secondary windings – 4x25=100
Meas. freq. – 150Hz to 1.5 KHz
Field strength – 1A/m to 3,000 A/m
Polarization – 0.001T to 2 T

SST Test Frame

Sample mass – 1.5 Kg
5 x Primary windings – 400
1 x Secondary windings – 400
Meas. freq. – 3 Hz to 100 Hz
Field strength – 1A/m to 30,000 A/m
Polarization – 0.001T to 2T

25 cm Epstein test frame

Sample mass – 1Kg max
Primary windings – 4x175=700
Secondary windings – 4x175=700
Operating principle of Brockhaus MPG 100D :- Meas. freq. – 1Hz to 150 Hz
Field strength – 1A/m to 30,000 A/m
Polarization – 0.001T to 2 T

 In order to measure the magnetic properties of electrical steel sheets, a sample of material is prepared as per defined size, and
exposed to defined magnetic field in an appropriate coil system, to create a magnetic flux in the steel sheet
 The coil system consists of a primary winding for the creation of a magnetic field, which then creates a magnetic flux in the metal
sheet.
 The magnetic field created is determined by the (i) Current (ii) The number of windings (iii) The magnetic length of the coil.
It is given by the formula:-

H(t) =(N1 x I1) / Lm

Where:-
H(t) – rms value of magnetic field strength
N1 - Number of turns in the primary winding
I1 - rms value of the current in the primary winding
Lm – conventional effective magnetic path length

 The number of windings and the magnetic length of the coil is determined by the geometry of the coil system
Operating principle of Brockhaus MPG 100D :-

 The necessary current is provided by an amplifier and is measured by means of a precision resistor, which is unaffected by
temperature changes and is free of induction from field coils

 The voltage is digitized with a data capture system via a sufficient number of support points on the path of the primary signal

 An automatic dynamic adjustment enables exact measurement of the voltage with a digital resolution of 16 Bit. This 16 Bit
processor of the measuring CPU converts the voltage measured into the magnetic field strength, or alternatively, the magnetic
field measured into the primary current.

 The peak value of magnetic field strength is given by:-

Where:-
Hm – Peak value of the magnetic field strength in amperes per meter
N1 – No. of turns in the turns in the primary winding
Rn – Resistance value of the precision resistor
Lm - Conventional effective magnetic path length
Um - Peak voltage drop across Rn

 The polarization (J) is determined by measuring the voltage induced in the Secondary winding of the coil system.
The peak value of the magnetic polarization is derived from the average value of the rectified secondary voltage measured at the
secondary winding.

It is given by the formula:-

Where:-
J – Peak value of magnetic polarization in Tesla
f – Frequency in Hertz
N2 – No. of turns in the Secondary winding
A – Cross section area of the test specimen
U2 – Average value of the secondary rectified voltage, in Volts
Operating principle of Brockhaus MPG 100D :-
 After several groups of parallel recording, conversion and integration of values of J (Magnetic Polarization) and H (Magnetic field
strength), have been done by the 16 bit processor system, the magnetization curve of J and H is given by the equipment.

Measurable magnetic parameters with MPG 100D :-

 Specific Core Losses (W/Kg) - Ps
 Specific Hysterisis Losses (W/Kg) -
 Peak value of Polarisation (T) - Jmax
 Effective Polarisation (T) - Js
 Peak value of field strength (A/m) - Hmax
 Effective field strength (A/m) - Hs
 Residual magnetism (T) - Jr
 Coercive field strength (A/m) – Hc
 Specific apparent power (VA/kg) – Ss
 Permeability - mur
 AC/DC Hysteresis curves
 Reading and interpretation of the results

 SST (Single sheet test) specimen of dimension 500 x 500mm has been exposed to the magnetic field of frequency 50 Hz, inside the Brockhaus 100 MPG D
 In first AC magnetization cycle, at peak magnetic field strength of 43.974 A/m (Hmax) and effective magnetic polarization of 1.5 T (Js), the peak magnetic
polarization achieved in the sample is 1.5001 T (Jmax)
The residual magnetic polarization induced in the sample is 1.082 T (Jr). The magnetic field strength required to demagnetize this residual magnetic
polarization is 16.559 A/m which is the Coercive field strength (Hc).
The specific core loss obtained in W/Kg, in this cycle, to magnetize and demagnetize the sample under the sinusoidal AC magnetization field strength is
0.60641 W/kg (Ps)
 Again in the Second AC magnetization cycle, at peak magnetic field strength of 96.084 A/m (Hmax) and effective magnetic polarization of 1.7 T (Js), the peak
magnetic polarization achieved in the sample is 1.6999 T (Jmax)
The residual magnetic polarization induced in the sample is 1.2929 T (Jr). The magnetic field strength required to demagnetize this residual magnetic
polarization is 18.164 A/m which is the Coercive field strength (Hc).
The specific core loss obtained in W/Kg, in this cycle, to magnetize and demagnetize the sample under the sinusoidal AC magnetization field strength is
0.84137 W/kg (Ps)
 Under the same AC magnetization condition, the peak magnetic polarization (Jmax) that can be achieved by the sample at the effective magnetic field strength
of 800 A/m (Hs), will be 1.8938 T
Final Product Quality assurance through testing at Laboratory:-

S. Parameters to Acceptance Freq. of Sample Size No. of Equipment / Method of testing Reference Testing Status of Actions to
No be checked criteria testing Samples Standard Standard tested value be taken
(Min)

5. Thermal Effect As per IS 3024 Once in 50mm x 12  12 Samples to be kept in oven IEC 60404 IS 649 Not as per Check
on Coating for Insulation every 250mm Min @ 150 Deg C for 7 Days acceptance quality of
Resistivity batch  After 7 days, samples to be IS 3024 criteria Coating
removed and cooled to Room IS 648 chemical
Tempr. and IR to be checked, IS 649 and
after discarding first and last inform
samples supplier

6. Resistance to No flake off or Once in 30mm x 12  12 samples to be clamped and IS 3024 IS 649 Burn off or Check
Heat Burn off every 125mm Min put in high tempr. furnace @ IS 648 flake off quality of
batch 800 Deg C for 2 hours. IS 649 observed Coating
 After 2 hours remove the chemical
samples and check for burn off and
or flake off inform
supplier

7 Resistance to After heating Once in 30mm x 2  2 beakers filled with equal IS 3024 IS 649 Not as per Check
Solvents there should be every 125mm Min quantity of Xylene to be taken. IS 648 acceptance quality of
batch One sample to be weighed and IS 649 criteria Coating
(Xylene) 1) No colour immersed in one beaker and chemical
change heated till boiling (139 Deg C) and
2) No weight for 6 hours inform
difference  After 6 hours, compare both the supplier
3) Coating not beakers for any colour change
loosened and any loose coating on the
immersed sample beaker
 Calculate the weight difference
of the immersed sample after 6
hours
Final Product Quality assurance through testing at Laboratory:-

S. Parameters to be Acceptance criteria Freq. of Sample Size No. of Equipment / Method of testing Reference Testing Status of Actions to be
No checked testing Samples Standard Standard tested value taken
(Min)

8 Resistance to After heating Once in 30mm x 2  2 beakers filled with equal IS 648 IS 649 Not as per Check
Degreasing Agent there should be every 125mm quantity of Trichloroethylene to IS 649 acceptance quality of
(Trichloroethylene) batch Min be taken. One sample to be IS 3024 criteria Coating
1) No colour weighed and immersed in one chemical
change beaker and heated till boiling and inform
2) No weight (87.2 Deg C) for 6 hours supplier
difference  After 6 hours, compare both the
3) Coating not beakers for any colour change
loosened and any loose coating on the
immersed sample beaker
 Calculate the weight difference
of the immersed sample after 6
hours

9 Resistance to After heating Once in 30mm x 2  2 beakers filled with equal IS 648 IS 649 Not as per Check
Transformer Oil there should be every 125mm quantity of Transformer Grade IS 649 acceptance quality of
(IS 335 Grade) batch Min (IS335 Grade) to be taken. One IS 3024 criteria Coating
1) No colour sample to be weighed and chemical
change immersed in one beaker and and inform
2) No weight heated to 100-120 Deg C and supplier
difference kept for 8 hours
3) Coating not  After 8 hours, compare both the
loosened beakers for any colour change
and any loose coating on the
immersed sample beaker
 Calculate the weight difference
of the immersed sample after 8
hours
Final Product Quality assurance through testing at Laboratory:-
S.N Parameters Acceptance criteria Freq. of Sample Size No. of Equipment / Method of testing Reference Testing Status of Actions to
o to be testing Samples Standrd Standard tested be taken
checked (Min) value

10 Ductility For CRGO:- Once in For 1– Apron brake or Thinners IS 3024 IS 649 No. of Check
Transverse bend face to every CRGO:- transverse brake equipment IS 648 breaks process
be checked for surface batch Full width direction (910mm width, 0.90mm IS 649 are abnormali
breaks and assigned x 76mm (full width) opening and 0.80mm bend more ties
class of ductility as (Length) radius) than
below:- one Check
Bending a full width sample quality of
Class 1 - Max 1 break or through 160 Degree in the coating
fracture, of length < = Apron Brake, across the chemical
8mm, transverse direction and and
recording the number of inform
Class 2 - Max 2 breaks breaks or fractures along the supplier
or fracture, of length bend
<=15mm

Class 3 - > 3 breaks

For Bend tester of 5mm radius IS 649 Not as Check
CRNO:- 10 jaws and clamping tool. per process
30mm x (5 – Rolling accepta abnormali
For CRNO:- Min. one 152mm Direction.) Counts of number of bends nce ties
bend, before crack (in Min 5– and reverse bends through criteria
parallel direction of Transverse 180 Deg (Including the first 90
rolling) Direction) Deg bend), till first crack or
complete rupture, is to be
recorded as ductility value of
that sample

Average of all the samples is

recorded as the ductility of
the coil
Final Product Quality assurance through testing at Laboratory:-
S. Parameters to be Acceptance criteria Freq. Sample No. of Samples Equipment / Referen Test Status of Actions to be
No checked of Size (Min) Method of ce Stand tested value taken
testin testing Standar ard
g d
10 Adherence Test For CRGO:- Every Full width 1 Bend tester of IS 3024 IS 649 Classificatio Check process
Classification from coil x 76mm 20mm IS 648 n as per abnormalities
Class 1 to 6 as per length diameter rod IS 649 Adherence
Adherence Class Class Table Check quality
Table of coating
chemical and
For CRNO:- 30mm x Bend Tester inform supplier
Surface coating shall 125mm of 5mm
not detach after Min radius jaws
reverse bending test and clamping
through 90 Deg tool

11 Grain Viewer –to Uniform grains Every 500 x 2– Grain Viewer NA As Mixed grain Reworking at
check grain throughout the width coil 500mm 1 - O/S to machine per band at CRS line to
uniformity across of the sheet from (SST center intern various salvage the
the width CRS samples) (500mm) Special Ink al locations mixed grain
line 1 – D/S to solution used SOP across portion
center (00mm) as viewing width. Check process
agent Small abnormalities
grains

Adherence Tester
and Adherence
Class table for
CRGO sheets
Grain Viewer – For assessment of Grain Size uniformity across full width of the coil

Uniform and large grains across full width Mixed grain structure across width