Quality Presentation-1

Quality Assurance
Kapil Kapoor - Nashik
Developing the future.

Quality Assurance – An Overview
• Understanding Quality Assurance
• Quality Assurance Functions
• Test Equipment and Details & Lab Accreditation
• Overview of Production process for Electrical Steel
• Electrical steel – Applications and contribution
Theme Quality Assurance Department

Date : Friday, July 10, 2015
Speaker : Kapil Kapoor
2 ThyssenKrupp Electrical Steel India
Quality
Quality in business or manufacturing is a pragmatic interpretation of

conforming and non conforming of activity process or product. It can
also defined as fitness for use.
Quality is a perceptual, conditional, and somewhat subjective attribute
and may be understood differently by different people.
Consumers may focus on the specification quality of a
product/service, or how it compares to competitors in the marketplace.
Producers might measure the conformance quality, or degree to
which the product was produced correctly and is reliable,
maintainable, or sustainable. A quality item has the ability to perform
satisfactorily in service and is suitable for its intended purpose.

So what exactly is Quality Assurance?
• The maintenance of a desired level of quality in a service or product, especially by
means of attention to every stage of the process of delivery or production.
• Quality assurance (QA) is a way of preventing mistakes or defects in manufactured
products and avoiding problems when delivering solutions or services to customers; "part
of quality management focused on providing confidence that quality requirements will
be fulfilled".
• Empowering the Process to produce consistent product each time and every time


Quality Assurance Functions
Quality Assurance functions Lab testing facilities
• Control – Specification for Hot rolled coil & • Core loss
Coating chemical
• Incoming Checks - Raw material , Coating • Magnetization
In Coming Control Chemical , Consumables Magnetic • Permeability
• HR- CR Matrix
• Supplier Rating , Supplier feedback
• Process Parameters & Defining of Rules / • Strength

Guidelines • Hardness
• Process Checks i.e. Water , Alkali , Oil , VCI
Process Control paper , Acid Conc. , coating etc. Mechanical • Ductility
• Failure Analysis , Metallography , SQC Methods
• Continuous improvement
• Product Development • Insulation Resistivity

• Coating Development • Coating Thickness
Research & • Customisation of product
Coating • Coating adherence
Development • Product specification (TDC)
• Interaction with mother plant and exchange of
best practices
• Microstructure Analysis
• Magnetic , Mechanical & Chemical Testing
• Bench Marking
• Chemistry Analysis
Product Testing & • Inspection Norms
Metallogra • Carbon and Sulphur Analysis
Inspection • Acceptance Criteria phy
• Out Side Testing - NABL


ThyssenKrupp Electrical Steel India Testing Laboratory Accreditation

ThyssenKrupp Electrical Steel India Testing Laboratory
Lab Overview
Electrical Testing
• Core Loss Measurement
• A.C. Magnetisation
• Permeability
• Anisotropy
• Aging test
• Coating Thickness
• Insulation resistivity
• Stacking Factor
• Coating Adherence
• Thermal Effect on coating
• Resistance to Solvents & Oils
• Sheet Thickness
• Ductility

Tensile testing
Mechanical Testing
• Yield strength
• Tensile Strength
• % Elongation
Hardness
Testing
• Rockwell Hardness - HRB
HV 1 & HV 5
• Rockwell Hardness – HR 30 T
Hardness • Vickers Hardness - VPN

testing Sample Press
Chemical Testing
• Manganese in Steel
• Silicon in Steel
• Aluminium in Steel
• Phosphorus in Steel
C & S Analyser
• Copper in Steel
• Chromium in Steel
• Nickel in Steel
• Carbon in Steel
• Sulphur in Steel
Spectrometer • Purity of Copper Wire


Production of Steel upto Hot Rolled coil
Converter
Hot
Metal
Transfer
Degassing
Continuous slab casting (CSC) Thin slab casting (CSP)
250 2-6 mm 60 mm 2-6 mm

mm

Production of Electrical Steel from Hot Rolled to Cold Rolled
NGO FF
Hot Rolled Coil Pickling Cold Rolling Decarburization, Annealing and Coating Side Trimming and Slitting Shearing
Re-crystallization
Annealing Testing
GO
Hot Rolled Coil Pickling Cold Rolling Intermediate Annealing Cold Rolling Decarburization, Annealing and MgO Coating
High Temperature Annealing Heat Flattening and Coating Laser scribing Side Trimming and Slitting
Optional
Testing

NGO FF – Covers all segments & applications
Max. Core Loss Insulation Coatings Widths (mm)

Thickness (mm)
W 15/50
0.35 2.35 C3ML C3M C6W 30 to 1250 mm
0.35 0.50 2.50
0.35 0.50 2.70 C6A C3Y C6U
0.50 2.90
0.35 3.00 Length (mm)
0.50 3.10 600 to 4000 mm
0.35 0.50 0.65 3.30
0.50 0.65 3.50
0.35 3.60
0.50 0.65 4.00 Shape of sheets
0.50 0.65 4.70
0.50 0.65 5.30 - Square
0.50 0.65 1.00 6.00 - Rectangle
0.50 6.30 - Parallelogram
0.50 0.65 1.00 7.00
Max. Core
0.50 0.65 1.00 8.00 Permeability Option
Loss
0.50 9.00
0.50 9.40 2.35 to 3.3 Standard
0.50 0.65 1.00 10.00
3.5 to 8.0 Standard High
1.00 13.00
9.0 to 13.0 Standard

GO – Sole producer in India
max. core loss W 17/50 Thickness [mm] Insulation coatings Widths
Conventional grades C5/C2

100 to 1000 mm
1.1 0.23*
1.2 0.23* 0.27 0.30*
1.3 0.27 0.30*
1.35 0.35*
1.4 0.27 0.30*

1.45 0.35*
High permeability grades
0.90 0.23*
0.95 0.23* 0.27
1.00 0.23* 0.27
1.05 0.30*
1.10 0.27 0.30*
1.20 0.30*
1.25 0.35*
Note: *technical capability in place

Pole & Rim Sheets – Key ingredient for Large Machines
Min Yield Strength Insulation Coatings Widths (mm)
Thickness (mm) 2
N/mm
0.65 1.00 2.00 250 Uninsulated C6W 100 to 1250 mm
0.65 1.00 2.00 300
0.65 1.00 2.00 350
0.65 1.00 2.00 400
0.65 1.00 2.00 450 Length (mm)
1.00 2.00 500
1.00 2.00 550
600 to 4000 mm
1.00 2.00 600
Shape of sheets
Applications: As pole and rim of
Wind mill generators, Hydro and - Square
turbo generators, Large DC - Rectangle
motors.


What is associated with electrical steel
Applications of electrical steel
as electromagnetic
operational material

Electrical steel in electric motors
Big motors
Standard motors
Hermethic
motors
Special motors Small-

(p.e. for pumps) and
servo motors

What is associated with electrical steel – Future
Application of electrical steel at Transrapid and for long distance travelling

Water power generators
Application of electrical steel in generators
Turbo generators
Mobile
generators Wind energy
generators

Distribution
What is associated with electrical steel Transformers
Application of electrical steel in Transmission
Power
Transformers
Large UPS
Wound Core
Transformers
Rectifiers

CONTRIBUTION OF ELECTRICAL STEEL IN THE IMPROVEMENT OF
ELECTRICAL SYSTEMS
Turbogenerator; Transformer 20 kVA; Transmition and Refrigerator;
Power Weight distrib. of el. energy; monthly use of energy
Loss per 100 l volume
anno 1901; 0,3 MVA anno 1935; 267 kg anno 1951; 25 % anno 1976; 49 kWh
today; 1700 MVA today; 40 kg today; 3-9 % today; 14 kWh
Source: STEEL TODAY & TOMORROW, No. 158

In efforts to control Global Warming, electrical systems with better efficiency and
performance are one of the frontline options.

Thank you for your
attention.
Any questions?


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Quality Assurance

Kapil Kapoor - Nashik

Developing the future.

• Quality Assurance Functions

• Test Equipment and Details & Lab Accreditation

• Overview of Production process for Electrical Steel

• Electrical steel – Applications and contribution

Theme Quality Assurance Department

Quality in business or manufacturing is a pragmatic interpretation of

Theme Quality Assurance Department

Theme Quality Assurance Department

• Understanding Quality Assurance

• Quality Assurance Functions

• Test Equipment and Details & Lab Accreditation

• Overview of Production process for Electrical Steel

• Electrical steel – Applications and contribution

Theme Quality Assurance Department

• Process Parameters & Defining of Rules / • Strength

• Product Development • Insulation Resistivity

Theme Quality Assurance Department

• Understanding Quality Assurance

• Quality Assurance Functions

• Test Equipment and Details & Lab Accreditation

• Overview of Production process for Electrical Steel

• Electrical steel – Applications and contribution

Theme Quality Assurance Department

Theme Quality Assurance Department

• Thermal Effect on coating

• Resistance to Solvents & Oils

Theme Quality Assurance Department

Hardness • Vickers Hardness - VPN

Spectrometer • Purity of Copper Wire

Theme Quality Assurance Department

• Understanding Quality Assurance

• Quality Assurance Functions

• Test Equipment and Details & Lab Accreditation

• Overview of Production process for Electrical Steel

• Electrical steel – Applications and contribution

Theme Quality Assurance Department

Continuous slab casting (CSC) Thin slab casting (CSP)

250 2-6 mm 60 mm 2-6 mm

Theme Quality Assurance Department

Theme Quality Assurance Department

Max. Core Loss Insulation Coatings Widths (mm)

Theme Quality Assurance Department

Conventional grades C5/C2

1.2 0.23* 0.27 0.30*

1.3 0.27 0.30*

1.4 0.27 0.30*

High permeability grades

0.95 0.23* 0.27

1.00 0.23* 0.27

1.10 0.27 0.30*

Theme Quality Assurance Department

Theme Quality Assurance Department

• Quality Assurance Functions

• Test Equipment and Details & Lab Accreditation

• Overview of Production process for Electrical Steel

• Electrical steel – Applications and contribution

Theme Quality Assurance Department

Theme Quality Assurance Department

Special motors Small-

Theme Quality Assurance Department

Theme Quality Assurance Department