Industrial Training Report (Bhushan Steels & Strips Ltd.)

Name : AKSHAY KUMAR SINGHUniv. Roll No. : 110106027Academic Session : 2011-2015

SHARDA UNIVERSITY DEPARTMENT OF MECHANICAL ENGINEERING

CONTENTS

1. ACKNOWLEDGEMENT

2. INTRODUCTION

3. HISTORY OF THE COMPANY

4. COMPANY PROFILE

5. VISION OF THE COMPANY

6. POLICIES OF THE COMPANY

7. LIST OF THE DEPARTMENT VISITED DURING TRAINING

• SAFETY

• HRS/PICKLING

• HITACHI – MILLS

• ECL

• ANNEALING

• SKIN PASS MILL

• FINISHING

• QUALITY SYSTEM

• COLOUR COATING LINE

• MECHANICAL MAINTENANCE

• ELECTRICAL MAINTENANCE

• R&D

• UTILITY

8. CONCLUSION

9. BIBLOGRAPY

ACKNOWLEDGEMENT

“Expression of Gratitude is  the least one can do in response to the favors received.” 

I would wish to express my gratitude to my H.O.D Dr. Tripuri Sharma

for providing me the opportunity to explore studies beyond academics. I

am also thankful to BHUSHAN STEELS Ltd for allowing me to

undergo the SUMMER TRAINING PROGRAMME in their

organization. At last but not the least I extend my thanks to all the staff

members for providing valuable information regarding the plant and

processes that formed the core of the training.

INTRODUCTION

This entire report deals with the study of the various operations conducted in NCRM (New Cold Rolling Mill) in order to manufactured the products like cold rolled sheets, galvanized coil etc. during the entire period we deals with the various processes that are involved in the manufacturing of the above mentioned products. We visited departments like HRS, SPM, RGM, GP-1, GP-2 etc. where the various operations are conducted involved in the production of CR coils, Galvanized coil. The machines and equipment’s used are of higher standard and norms which are imported from the JAPAN, GERMANY and other countries in order to maintain the accuracy and precision as well as to produce good quality products. The working environment of the company is excellent, technicians and workers are highly skilled. They work hardly to develop standards products and achieving the goals of the company. Workers are trained by the company to update their knowledge and skills. Finally it’s really a great learning experience for me while working in the BSL, SAHIBABAD. This training helps me to learn the basics of the industrial work and other relevant factors which work as the steppingstone of my professional life. I am thankful to each and every one who is involved in my work and all the officials, technicians and workers which help me to learn a fruitful lesson from the working environment of the BSL, SAHIBABAD.

HISTORY OF THE COMPANY

Year events 1983 - The company was incorporated on 7thJanuary, under the name of Jawahar Metal Industries Private Limited for the manufacture of cold rolled steel strips and steel ingots at Sahibabad Industrial Area, District Ghaziabad. 

1987 - On 14th January, Brij Bhushan Singal and his sons Sanjay Singal and Neeraj Singal and associate companies took over the management of the company by acquiring the entire share capital of the company.

1989 - The company undertook the setting up of a new plant for the manufacture of wide width Cold Rolled Steel Strips with integrated plant facilities.

1992 - The name of the company was changed to the present name of Bhushan Steel & Strips Limited and fresh Certificate of Incorporation was issued on 9th June.

1993 - The company made its maiden Public Issue of 22 lac equity shares of Rs.10 each at a premium of Rs.55 share aggregating Rs. 1430 lacs in September/October.

1994 - The galvanizing plant was commissioned in January. Presently the company has facilities for the manufacture of 1, 20,000 tones per' annum of wide width cold rolled steel strips and 1, 00,000 tones per annum of galvanized sheets. 

1995 - The Cold Rolling Expansion the Company is installing state of the art 1600mm width 6HI combination Universal Crown Mill (UCM) of Hitachi, Japan with sophisticated features for shape control and surface finish to cater to the requirements of the automobile and white

goods sector. 

1996 - The Part B of 68,94,800 14% unsecured fully convertible Debentures aggregating Rs 8375 Lacs have been converted into Equity Shares w.e.f. 1st April.

1998 - With the commissioning of the new plant recently set up at company's existing site at Sahibabad (UP), the company is now exploring further growth possibilities of setting up a modern Cold Rolling cum Galvanizing Unit at West Coast of the Country. 

1999 - During the year, the company has set up a dedicated service Centre for large OEM customers at Sahibabad so as to ensure supplies to them on 'just in time' concept.

2000 - The Delhi-based Bhushan Steel and Strips' to set up a Rs 750 crore cold rolled steel plant is likely to hit a road block.

2002-Strikes an important position in the market for cold rolled steel for automobiles, feeding over 70% of demand for car bodies.

2003-Enters into a strategic alliance with Sumitomo Metal Industries of Japan under which, the latter has further extended process know-how for the manufacture of automotive steel sheets for a period of six years

2004-Bhushan Steel awards Rs 36 cr order for BHEL

2006-Bhushan Steel & Strips Ltd has informed that Sh. Sanjay Singal, has ceased to be a Director of the Company w.e.f. October 18, 2006.

2007-Company name has been changed from Bhushan Steel & Strips Ltd to Bhushan Steel Ltd

2008-Bhushan Steel Ltd has informed that w.e.f. September 23, 2008, Sh. B B Tandon has been appointed as an Additional Director on the

Board of the Company as a Independent Non-Executive Director.

2009-Bhushan Steel buys Aussie exploration firm 

2010- Bhushan Steel Ltd has informed that Life Insurance Corporation of India has appointed Smt. Sunita Sharma, their representative as a Nominee Director on the Board of the Company.

COMPANY PROFILE

Bhushan Steel & Strips Ltd.

Type Private

Founded in 1987

Headquarters India

Key people Brij Bhushan Singhal (Chairman) Neeraj Singhal (Managing Director)

Industry Steel

Website http://www.bhushan-group.org/

VISION OF THE COMPANY

The key to Vision is to use rigorous conceptual framework and to understand how that framework connects to the underlying DNA of enduring great companies.

A well-conceived vision consists of two major components—“CORE IDEOLOGY” and an “ENVISIONED FUTURE”. A good vision builds on the interplay between these two complementary Yin-and-Yang forces; it defines “What we stand for and Why we exist” that does not change the Core Ideology and sets forth “What we aspire to become, to achieve.

It is true to say that most of our vision statements express an element of ambition. BSL’s vision of total integration is a lot closer to realization today. Through seamless backward integration, BSL is consolidating its position on the entire steel value chain from iron ore to specialized is surging ahead.

POLICIES OF THE COMPANY

Integrated Quality, Environment, Occupational Health & Safety Management System Policy.

Bhushan Steel Ltd. commits to produce cold rolled and galvanized steel sheets of world class quality in a safe, healthy and clean environment by involving employees with continual improvements in system implementation, technological advancement, operational integration, prevention of pollution & hazards maintaining.

Legal compliance and satisfying needs & expectations of Customers.

For environment management system BSL have ISO 14001:2004 certification

For quality system BSL have ISO/TS 16949:2002 certification

For safety management system BSL have OHSAS 18001:2007 certification for quality system BSL have ISO/TS 16949:2002 certification.

LIST OF DEPARTMENT VISITED DURING TRAINING

SAFETY

HRS/PICKLING

HITACHI – MILLS

ECL

ANNEALING

SKIN PASS MILL

FINISHING

QUALITY SYSTEM

COLOUR COATING LINE

MECHANICAL MAINTENANCE

ELECTRICAL MAINTENANCE

R&D

UTILITY

SAFETY

Safety is the state of being "safe", the condition of being protected against physical, social, spiritual, financial, political, emotional, occupational, psychological, educational or other types or consequences of failure, damage, error, accidents, harm or any other event which could be considered non-desirable. Safety can also be defined to be the control of recognized hazards to achieve an acceptable level of risk. This can take the form of being protected from the event or from exposure to something that causes health or economical losses. It can include protection of people or of possessions.

HAZARD- A hazard is a situation that poses a level of threat to life, health, property, or environment. Most hazards are dormant or potential, with only a theoretical risk of harm; however, once a hazard becomes "active", it can create an emergency situation. A hazardous situation that has come to pass is called an incident. Hazard and possibility interact together to create risk.

Types of Hazard

Hazards are generally labeled as one of five types:

Physical  hazards are conditions or situations that can cause the body physical harm or intense stress. Physical hazards can be both natural and human made elements.

Chemical  hazards are substances that can cause harm or damage to the body, property or the environment. Chemical hazards can be both natural and human made origin.

Biological  hazards are biological agents that can cause harm to the human body. These some biological agents can be viruses, parasite, bacteria, food, fungi, and foreign toxin.

Psychological  hazards are created during work related stress or a stressful environment.

Radiation  hazards are those which cause harm or damage to the human body by affecting the cell directly.

EMERGENCY AND DISASTER

Emergency situations: The following are the situations where we can face an emergency and disaster may take place.

a. Fireb. Explosionc. Oil Spillaged. Toxic release (gases & chemicals)e. Electrocutionf. Structure/building collapseg. Flood/cyclone/earth quake/aggression/sabotage etc.

IDENTIFICATION OF HAZARDS

Hazard is in fact the characteristics of a system/plant/storage that presents potential for an accident and risk is the probability of occurrence of hazard. Hence hazard identification is of prime significance for the quantification of risk and for cost-effective control of accidents in any industrial installation. Various techniques of predictive hazard evaluation and quantitative risk analysis suggest that identification of hazard has very important role in estimation of probability of an undesired event and its consequences on the basis of risk quantification in terms of damage to personnel, property and environment.

Hazards are mostly manifested in the form of toxic release. Each anticipated hazard scenario associated in the unit is described along with its assessment of impact on plant and locality in the following table:

ANTICIPATED HAZARDS

Sl. No.

Area / Activity Hazard Hazard Potential

Impact

1 Storage and Handling of High Speed Diesel (HSD)

Pool Fire / Fireball may occur in case of direct contact with flame

Medium Fire may propagate and spread over to other areas

2 Storage and Handling of Chlorine Cylinder

Leakage of Gas from Chlorine Cylinder

Major Chlorine gas may spread affecting the people in the nearby areas

3 Storage and handling of BF Gas (CO Gas)

Leakage of gas from the Gas holder Tank

Major CO gas may spread affecting the people in the nearby areas

4 Storage and handling of LPG

Explosion may occur in case of leakage of gas with contact with fire

Major Fire may propagate and spread over to nearby areas

5 Electrical Power supply and distribution in Transformer yard and motor control center

Fire and electrocution may occur

Medium Fire may propagate to other areas

ACTION PLAN FOR ON-SITE EMERGENCY PLAN

STEP NO

INITIATOR ACTION TO TAKE

1. The person noticing the emergency

Inform the Security Gate, Combat team leader and the concerned Shift-in –charge immediately.

2. Combat team Leader (CTL)

Inform site incident Controller (SIC) and rush to spot and organize his team.

Take charge of the situation, arrange for fire fighting and medical first-aid available at site.

To start combating, shut-down equipments, arrest the leakage of gas/fire.

3. Site Incident Controller

(SIC)

Inform works main controller (WMC) and rush to emergency site.

Discuss with Combat Team Leader (CTL), assesses the situation and call the Rescue Team Leader (RTL) & Auxiliary Team Leader (ATL).

Organize the Rescue Team and Auxiliary Team and send the rescue Team to site.

Arrange to evacuate the unwanted persons and call for additional help.

Pass information to the works main controller (WMC) periodically about the position at site.

4. Works main Controller

(WMC)

Rush to emergency site and observe the ongoing activities. Take stock of the situation in consultation with the SIC. Move to Emergency Control Room. Take decision on declaration of emergency. Advise Auxiliary Team Leader to inform the statutory

authorities and seek help of mutual aid from partners as required.

Decide on declaration of cessation of emergency. Ensure that the emergency operations are recorded

chronologically.5. Rescue Team

(RTL) Consult with Site incident controller (SIC) and organize his

team with amenities to arrest fire fighting and medical treatment.

Rush to Emergency Site through safe route along with the team members.

Arrange to set off the fire by fire fighting equipments and hydrant points to arrest the fire or to evacuate the area.

Shift the injured persons to hospital by ambulance after providing necessary first aid.

To inform the auxiliary team Leader for necessary help from mutual aid Partners.

6. Auxiliary Team (ATL)

On being directed by works main Controller (WMC) inform about the emergency to statutory authorities.

Seek help of Mutual Aid partners and Coordinate with Mutual Aid partners to render their services.

Arrange to inform the relatives of casualties. Take care of visit of the authorities to the Emergency site.

7. Team members

Each of the team members should follow the instruction of concerned team leader to mitigate the emergency.

FACILITIES AVAILABLE TO COMBAT

Fire Fighting Facilities

Fire Station – 5 Fires Officers – Crew Members - 22 nos. in each shift

Fire Tenders- 4 (2- Foam Tender, 2- Water Tender). Portable Pumps – 2 nos. Required fire fighting & Rescue Equipments.

Fire Hydrant system

Fire hydrant system is provided at different locations inside the plant. Fire hydrant hoses are 63 mm. dia in size. Two motors along with two suitable pumps which can discharge 173 cum. water per hour are provided to main header to maintain a pressure of 7 kg/cm square. In case of temporary power failure, the fire pumps are run through DG. An overhead tank is supplying water to the fire main line.

Fire Extinguishers

Required types of fire extinguishers have been provided at different locations of the plant. Types & number of fire extinguishers provided in different locations.

Siren

Company has siren/hooter arrangement which can be activated manually during fire related/gas leakage emergency.

Communication

Public address system, mobile phones and EPABX telephone is available for effective communication inside the plant. Telephone directory is available in the entire department.

Ambulance

Ambulance with all facility round the clock is available. Medical and paramedical staff is available round the clock.

Safety – Qualified, trained and experienced safety officers are there manned in shifts.

Security – Security officers and ranks are doing duties for 24 hours who will assist in handling emergency.

Transport – Number of different types of vehicles, cranes and equipment’s with operators are available.

Others – Other depts. and sections like mechanical, electrical, civil, utilities (water, air, oil, fuel, DG, etc.), P&A, stores, purchase, accounts, etc. are also available anytime for the emergency.

HRS/PICKLING

HR SLITTING

Roll slitting, also known as log slitting, is a shearing operation that cuts

a large roll of material into narrower rolls. The log slitting terminology

refers back to the olden days of saw mills when they would cut logs into

smaller sections. They would also use these saw mills to cut iron rods

into smaller sections; see slitting mill. The multiple narrower strips of

material are known as mults (short for multiple) by today's definition,

slitting is a process in which a coil of material is cut down into a number

of smaller coils of narrower measure. Potential work pieces are

selectively thin (0.001 to 0.215 in.) and can be machined in sheet or roll

form. Slitting is considered a practical alternative to other methods due

to its high productivity and the versatility of materials it can manage.

Soft materials

Several methods are available for soft materials like plastic films and

paper. Razor blades, straight, or circular blades are being used. Some

blades cut through the material while others crush the material against a

hard roll. Those are similar to knives and cut the material into narrow

strips, which are called coils when being rewound. The cutting blades

can be set to a desired width. Some machines have many blades to

increase the options of cutting widths, others have just a single blade and

can be set to a desired location. The slit material is being rewound on

paper or plastic cores on the exit side of the machine.

Examples of materials that can be cut this way are: adhesive tape, foam,

rubber, paper products, foil, plastics (such as tarps and cling wrap), glass

cloth, fabrics, release liner and film. Hard materials

For harder materials, such as sheet metal, blades cannot be used. Instead

a modified form of shearing is used. Two cylindrical rolls with matching

ribs and grooves are used to cut a large roll into multiple narrower rolls.

This continuous production process is very economical yet precise;

usually more precise than most other cutting processes. However, the

occurrence of rough or irregular edges known as burrs are commonplace

on slit edges.

PICKLING

Pickling is a metal surface treatment used to remove impurities, such as

stains, inorganic contaminants, rust or scale from ferrous metals, copper,

and aluminum alloy. A solution called pickle liquor, which

contains strong acids, is used to remove the surface impurities. It is

commonly used to descale or clean steel in

various steelmaking processes.

Process

Many hot working processes and other processes that occur at high temperatures leave a discolouring oxide layer or scale on the surface. In order to remove the scale the work piece is dipped into a vat of pickle liquor.

The primary acid used is hydrochloric acid, although sulphuric acid was previously more common. Hydrochloric acid is more expensive than sulphuric acid, but it pickles much faster while minimizing base metal loss. The speed is a requirement for integration in automatic steel mills that run production at high speed; speeds as high as 800 ft. /min (~243 metres/min) have been reported.

Carbon steels, with an alloy content less than or equal to 6%, are often pickled in hydrochloric or sulphuric acid. Steels with an alloy content greater than 6% must be pickled in two steps and other acids are used, such as phosphoric, nitric and hydrofluoric. Rust- and acid-resistant chromium-nickel steels are pickled in a bath of hydrochloric and nitric acid. Most copper alloys are pickled in dilute sulphuric acid, but brass is pickled in concentrated sulphuric and nitric acid mixed with sodium chloride and soot.[1]

In jewellery making, pickling is used to remove the oxidation layer from copper surfaces, which occurs after heating. A diluted sulphuric acid pickling bath is used.

Sheet steel that undergoes acid pickling will oxidize (rust) when exposed to atmospheric conditions of moderately high humidity. For this reason, a thin film of oil or similar waterproof coating is applied to create a barrier to moisture in the air. This oil film must later be removed for many fabrication, plating or painting processes.

Disadvantages

Acid cleaning has limitations in that it is difficult to handle because of its corrosiveness, and it is not applicable to all steels. Hydrogen embrittlement becomes a problem for some alloys and high-carbon steels. The hydrogen from the acid reacts with the surface and makes it brittle and causes cracks. Because of its high reactance to treatable steels, acid concentrations and solution temperatures must be kept under control to assure desired pickling rates.

Waste products

Pickling sludge is the waste product from pickling, and includes acidic

rinse waters, metallic salts and waste acid.] Spent pickle liquor is

considered a hazardous waste by EPA . Pickle sludge from steel

processes is usually neutralized with lime and disposed of in a land fill.

After neutralization the EPA no longer deems the waste a hazardous

waste. The lime neutralization process raises the pH of the spent acid

and makes heavy metals in the sludge less likely to leach into the

environment. Since the 1960s, hydrochloric pickling sludge is often

treated in a hydrochloric acid regeneration system, which recovers some

of the hydrochloric acid and ferric oxide. The rest must still be

neutralized and disposed of in landfills. The by-products of nitric acid

pickling are marketable to other industries, such as fertilizer processors.

HITACHI – MILLS

In metalworking, rolling is a metal forming process in which metal stock is passed through a pair of rolls. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is termed as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is termed as cold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process and cold rolling processes the most tonnage out of all cold working processes.

There are many types of rolling processes, including flat rolling, foil rolling, ring rolling, roll bending, roll forming, profile rolling, and controlled rolling.

Hot rolling is a metalworking process that occurs above the recrystallization temperature of the material. After the grains deform during processing, they recrystallize, which maintains an equated microstructure and prevents the metal from work hardening. The starting material is usually large pieces of metal, like semi-finished casting products, such as slabs, blooms, and billets. If these products came from a continuous casting operation the products are usually fed directly into the rolling mills at the proper temperature. In smaller operations the material starts at room temperature and must be heated. This is done in a gas- or oil-fired soaking pit for larger work pieces and for smaller work pieces induction heating is used. As the material is worked the temperature must be monitored to make sure it remains above the recrystallization temperature. To maintain a safety factor a finishing temperature is defined above the recrystallization temperature; this is usually 50 to 100 °C (122 to 212 °F) above the recrystallization temperature. If the temperature does drop below this temperature the material must be re-heated before hotter rolling.

Hot rolled metals generally have little directionality in their mechanical properties and deformation induced residual stresses. However, in certain instances non-metallic inclusions will impart

some directionality and work pieces less than 20 mm (0.79 in) thick often have some directional properties. Also, non-uniformed cooling will induce a lot of residual stresses, which usually occurs in shapes that have a non-uniform cross-section, such as I-beams and H-beams. While the finished product is of good quality, the surface is covered in mill scale, which is an oxide that forms at high-temperatures. It is usually removed via pickling or the smooth clean surface process, which reveals a smooth surface. Dimensional tolerances are usually 2 to 5% of the overall dimension.Hot rolling is used mainly to produce sheet metal or simple cross sections, such as rail tracks.

Cold rolling

Cold rolling occurs with the metal below its recrystallization temperature (usually at room temperature), which increases the strength via strain hardening up to 20%. It also improves the surface finish and holds tighter tolerances. Commonly cold-rolled products include sheets, strips, bars, and rods; these products are usually smaller than the same products that are hot rolled. Because of the smaller size of the work pieces and their greater strength, as compared to hot rolled stock, four-high or cluster mills are used. Cold rolling cannot reduce the thickness of a work piece as much as hot rolling in a single pass.

Cold-rolled sheets and strips come in various conditions: full-hard, half-hard, quarter-hard, and skin-rolled. Full-hard rolling reduces the thickness by 50%, while the others involve less of a reduction. Quarter-hard is defined by its ability to be bent back onto itself along the grain boundary without breaking. Half-hard can be bent 90°, while full-hard can only be bent 45°, with the bend radius approximately equal to the material thickness. Skin-rolling, also known as a skin-pass, involves the least amount of reduction: 0.5-1%. It is used to produce a smooth surface, a uniform thickness, and reduce the yield-point phenomenon (by preventing Luder bands from forming in later processing). It is also used to break up the spangles in galvanized steel. Skin-rolled stock is usually used in subsequent cold-working processes where good ductility is required.Other shapes can be cold-rolled if the cross-section is relatively uniform and the transverse dimension is relatively small;

approximately less than 50 mm (2.0 in). This may be a cost-effective alternative to extruding or machining the profile if the volume is in the several tons or more. Cold rolling shapes requires a series of shaping operations, usually along the lines of: sizing, breakdown, roughing, semi-roughing, semi-finishing, and finishing.

Flat rolling

Flat rolling is the most basic form of rolling with the starting and ending material having a rectangular cross-section. The material is fed in between two rollers, called working rolls that rotate in opposite directions. The gap between the two rolls is less than the thickness of the starting material, which causes it to deform. The decrease in material thickness causes the material to elongate. The friction at the interface between the material and the rolls causes the material to be pushed through. The amount of deformation possible in a single pass is limited by the friction between the rolls; if the change in thickness is too great the rolls just slip over the material and do not draw it in. The final product is either sheet or plate, with the former being less than 6 mm (0.24 in) thick and the latter greater than; however, heavy plates tend to be formed using a press, which is termed forming, rather than rolling.

Oftentimes the rolls are heated to assist in the workability of the metal. Lubrication is often used to keep the work piece from sticking to the rolls. To fine tune the process the speed of the rolls and the temperature of the rollers are adjusted.

Foil rolling

Foil rolling is a specialized type of flat rolling, specifically used to produce foil, which is sheet metal with a thickness less than 200 µm (0.0079 in) the rolling is done in a cluster mill because the small thickness requires a small diameter rolls. To reduce the need for small rolls pack rolling is used, which rolls multiple sheets together to increase the effective starting thickness. As the foil sheets come through the rollers, they are trimmed and silted with circular or razor-like knives. Trimming refers to the edges of the foil, while slitting involves cutting it into several sheets Aluminium foil is the most commonly produced product via pack rolling. This is evident from the two different surface finishes; the

shiny side is on the roll side and the dull side is against the other sheet of foil.

ECL (ELECTROLYTIC CLEANING LINE)

Utilizing a performance enhanced, low temperature, high volume, updraft re-circulating hot air design, the Electrolytic cleaning line is ideal for refreshing steel products and other metallic mater. The Electrolytic cleaning lines are the ideal wet cleaning complement for advanced Electrolytic components.

Electrolytic Cleaning is required in case material rolled with high percentage of oil while reduction in mills goes for annealing in furnace. Oil free base material is essential for the production of bright and corrosion resistant steel. Sodium Orthosilicate is used as cleaning agent in ECL. Tension is given according to thickness, width based on customer requirement the installed production capacity of the line is 86102 MT/Annum

SPECIFICATION

ANNEALING

Annealing, in metallurgy and materials science, is a heat

treatment wherein a material is altered, causing changes in its properties

such as strength and hardness. It is a process that produces conditions by

heating to above the recrystallization temperature, maintaining a suitable

temperature, and then cooling. Annealing is used to induce ductility,

soften material, relieve internal stresses, refine the structure by making it

homogeneous, and improve cold working properties.

In the cases of copper, steel, silver, and brass, this process is performed

by substantially heating the material (generally until glowing) for a

while and allowing it to cool. Unlike ferrous metals—which must be

cooled slowly to anneal—copper, silver and brass can be cooled slowly

in air or quickly by quenching in water. In this fashion the metal is

softened and prepared for further work such as shaping, stamping, or

forming.

Thermodynamics

Annealing occurs by the diffusion of atoms within a solid material, so

that the material progresses towards its equilibrium state. Heat is needed

to increase the rate of diffusion by providing the energy needed to break

bonds. The movement of atoms has the effect of redistributing and

destroying the dislocations in metals and (to a lesser extent) in ceramics.

This alteration in dislocations allows metals to deform more easily, so

increases their ductility.

The amount of process-initiating Gibbs free energy in a deformed metal

is also reduced by the annealing process. In practice and industry, this

reduction of Gibbs free energy is termed "stress relief"..

The relief of internal stresses is a thermodynamically spontaneous

process; however, at room temperatures, it is a very slow process. The

high temperatures at which the annealing process occurs serve to

accelerate this process.

The reaction facilitating the return of the cold-worked metal to its stress-

free state has many reaction pathways, mostly involving the elimination

of lattice vacancy gradients within the body of the metal. The creation of

lattice vacancies is governed by the Arrhenius equation, and the

migration/diffusion of lattice vacancies are governed by Fick’s laws of

diffusion.

Mechanical properties, such as hardness and ductility, change as

dislocations are eliminated and the metal's crystal lattice is altered. On

heating at specific temperature and cooling it is possible to bring the

atom at the right lattice site and new grain growth can improve the

mechanical properties.

Stages

There are three stages in the annealing process, with the first being

the recovery phase, which results in softening of the metal through

removal of crystal defects (the primary type of which is the linear defect

called a dislocation) and the internal stresses which they cause.

Recovery phase covers all annealing phenomena that occur before the

appearance of new strain-free grains. The second phase

is recrystallization, where new strain-free grains nucleate and grow to

replace those deformed by internal stresses. If annealing is allowed to

continue once recrystallization has been completed, grain growth will

occur, in which the microstructure starts to coarsen and may cause the

metal to have less than satisfactory mechanical properties.

Controlled atmospheres

The high temperature of annealing may result in oxidation of the metal’s

surface, resulting in scale. If scale is to be avoided, annealing is carried

out in a special atmosphere, such as with endothermic gas (a mixture of

carbon monoxide, hydrogen gas, and nitrogen gas).

The magnetic properties of mu-metal (Espey cores) are introduced by

annealing the alloy in a hydrogen atmosphere.

Setup and equipment

Typically, large ovens are used for the annealing process. The inside of

the oven is large enough to place the work piece in a position to receive

maximum exposure to the circulating heated air. For high volume

process annealing, gas fired conveyor furnaces are often used. For large

workpieces or high quantity parts Car-bottom furnaces will be used in

order to move the parts in and out with ease. Once the annealing process

has been successfully completed, the work pieces are sometimes left in

the oven in order for the parts to have a controlled cooling process.

While some workpieces are left in the oven to cool in a controlled

fashion, other materials and alloys are removed from the oven. After

being removed from the oven, the workpieces are often quickly cooled

off in a process known as quench hardening. Some typical methods of

quench hardening materials involve the use of media such as air, water,

oil, or salt.

Diffusion annealing of semiconductors

In the semiconductor industry, silicon wafers are annealed, so

that dopant atoms, usually boron, phosphorus or arsenic, can diffuse into

substitutional positions in the crystal lattice, resulting in drastic changes

in the electrical properties of the semiconducting material.

Normalization

Normalization is an annealing process in which a metal is cooled in air

after heating in order to relieve stress.

It can also be referred to as: Heating a ferrous alloy to a suitable

temperature above the transformation temperature range and cooling in

air to a temperature substantially below the transformation range.

This process is typically confined to hardenable steel. It is used to refine

grains which have been deformed through cold work, and can improve

ductility and toughness of the steel. It involves heating the steel to just

above its upper critical point. It is soaked for a short period then allowed

to cool in air. Small grains are formed which give a much harder and

tougher metal with normal tensile strength and not the maximum

ductility achieved by annealing. It eliminates columnar grains and

dendritic segregation that sometimes occurs during casting. Normalizing

improves machinability of a component and provides dimensional

stability if subjected to further heat treatment processes. Process

annealing

Process annealing, also called "intermediate annealing", "subcritical

annealing", or "in-process annealing", is a heat treatment cycle that

restores some of the ductility to a work piece allowing it be worked

further without breaking. Ductility is important in shaping and creating a

more refined piece of work through processes such

as rolling, drawing, forging, spinning, extruding and heading. The piece

is heated to a temperature typically below the austenizing temperature,

and held there long enough to relieve stresses in the metal. The piece is

finally cooled slowly to room temperature. It is then ready again for

additional cold working. This can also be used to ensure there is reduced

risk of distortion of the work piece during machining, welding, or further

heat treatment cycles.

The temperature range for process annealing ranges from 260 °C(500

°F) to 760 °C(1400 °F), depending on the alloy in question.

Full anneal

A full anneal typically results in the second most ductile state a metal can assume for metal alloy. It creates an entirely new homogeneous and uniform structure with good dynamic properties. To perform a full anneal, a metal is heated to its annealing point (about 50°C above the austenic temperature as graph shows) and held for sufficient time to allow the material to fully austenitize, to form austenite or austenite-cementite grain structure. The material is then allowed to cool slowly so that the equilibrium microstructure is obtained. In some cases this means the material is allowed to air cool. In other cases the material is allowed to furnace cool. The details of the process depend on the type of metal and the precise alloy involved. In any case the result is a more ductile material that has greater stretch ratio and reduction of area properties but a lower yield strength and a lower tensile strength. This process is also called LP annealing for lamellar pearlite in the steel industry as opposed to a process anneal which does not specify a microstructure and only has the goal of softening the material. Often material that is to be

machined, will be annealed, then be followed by further heat treatment to obtain the final desired properties.

Short cycle anneal

Short cycle annealing is used for turning normal ferrite into malleable ferrite. It consists of heating, cooling, and then heating again from 4 to 8 hours.

Resistive heating

Resistive heating can be used to efficiently anneal copper wire; the

heating system employs a controlled electrical short circuit. It can be

advantageous because it does not require a temperature-

regulated furnace like other methods of annealing.

The process consists of two conductive pulleys (step pulleys) which the

wire passes across after it is drawn. The two pulleys have an electrical

potential across them, which causes the wire to form a short circuit.

The Joule effect causes the temperature of the wire to rise to

approximately 400 °C. This temperature is affected by the rotational

speed of the pulleys, the ambient temperature, and the voltage applied.

Where t is the temperature of the wire, K is a constant, V is the voltage

applied, r is the number of rotations of the pulleys per minute, and ta is

the ambient temperature:

The constant K depends on the diameter of the pulleys and the resistivity

of the copper.

Purely in terms of the temperature of the copper wire, an increase in the

speed with which the wire passes through the pulley system has the

same effect as an increase in resistance. Therefore, the speed with which

the wire can be drawn through varies quadratic ally as the voltage

applied.

SKIN PASS MILL

Skin Pass Mill These skin pass mills are specifically designed for manufacturing sheet / strip of medium hardness or to provide finish pass. The Rolls are made of alloy steel & have high hardness, which is generally up to 65 HRC or more. For increasing demands with respect to strip flatness, elongation and roughness, especially for hard material grades, skin-pass mill is an ideal solution due to higher rolling forces and torques that can be achieved in this case.

Temper rolling (skin pass rolling)

Final cold rolling operation with low thickness reduction conducted in order to impart to the steel required levels of hardness, evenness and surface finish. Four-high rolling mill is used for tempering. Most of annealed low carbon steel strips are tempered since they are too soft (HV<110) in annealed condition. Bending and deep drawing operations of soft annealed steel may cause formation of kinks (cross breaks) and stretcher strains, which are the result of localized stretching of the strip at low cold deformation beyond the yield point. Light tempering of annealed strip (non-kinking temper, pinch pass) produces strip surface conditions, which do not cause formation of cross break sand stretcher strains. Hardness of pinch passed steel is about 115 HV. Other temper conditions of steel strip are: eighth hard (105<HV<125), quarter hard (115<HV<130), half hard (130<HV<160), three quarter hard (150<HV<185).

FINISHING

COLD ROLL SLITTING / CUT TO LENGTH

Some customers require a steel to be of a particular thickness other than the general increment sizes rolled in the hot mill or thinner than the minimum thickness rolled in the mills. These steels are processed in the cold roll reduction mill. These mills are capable of rolling steel to the precise thickness that the customer orders and are a major part of the steel strip production process. The reduction mill in the plant I worked had four rolls in the mill that were stacked upon each other. This arrangement is known as a two high mill. There are two working rolls between which the strip is passed and two large back-up rolls, one on top of the working rolls and one on the bottom. The back-up rolls apply the tremendous pressures required to cold roll (reduce) the strip between the working rolls. The working rolls are usually about two to three feet in diameter while the back-up rolls are about seven to eight feet in diameter. The rolls are made of high alloy steel so they can withstand the tremendous pressure they are under while rolling without deforming. Because of this the rolls are ground in a large lathe using a very large grinding wheel on a movable carriage. Depending on the surface finish required of the strip the working rolls will either have a highly polished (mirror like) finish or a dull finish on them. All working rolls are ground on the lathe in the mill to a highly polished surface periodically. The

rolls that have a dull finish on them are shot blasted after grinding to produce the desired surface.

After grinding to a polished surface the rolls that need a dull finish are placed on a large carriage which has a set of rubber rolls on it. The carriage then travels on a small rail track into a large enclosure and the door is closed down. On top of this enclosure is a large hopper filled with fine steel balls called shot. This shot is very small in diameter (about half the size of a BB or smaller) and is very hard. It is fed down a chute and using either compressed air or a impeller type system it is accelerated to high speed (in excess of a hundred miles per hour) and blasted against the surface of the roll. The rubber rolls on the carriage rotate causing the steel roll to rotate so all its surface is exposed to the shot blast. The shot comes in a variety of sizes and hardness grades and different types are used depending on the type of surface finish required on the rolls. After a predetermined cycle time the roll is removed from the Wheelabrator, as it is called and is ready to be used in the mill.

A saddle type conveyor runs along the side of the reduction mill. Steel coils are place on this conveyor by overhead cranes using the same ‘C’ hook as at the entry and exit ends of the pickle lines. This saddle conveyor moves the coils along to the reduction mill where they are lowered onto a frame at the entry side of the mill. A transfer saddle operated by the mill operator moves out to the frame and picks up the coil and moves it back into the feed mandrel on the entry side. The operator cuts the strap, freeing up the loose end of the coil. He opens a space between the work rolls and feeds the end of the exit side. On the exit side is another expandable mandrel the same as the catcher mandrels of the hot mills and pickle line. The entry operator feed the strip until the exit operator can catch the end in the open segment of his mandrel, expanding it and trapping the end of the strip. The entry operator then closes the gap in the working rolls down on the strip. Pressure (thousands of tons) is applied by the back-up rolls by means of hydraulically operated screws, to the working rolls and the reduction rolling process begins. If the thickness of the steel needs to be greatly reduced, the strip will be passed back and forth between the rolls a number of times with the rolls adjusted for each pass. Due to the great amount of pressure exerted in the reduction process the steel strip becomes very hot. In order to prevent the steel from becoming too hot and sticking to the work rolls, the rolls are flooded with a coolant consisting of 95% water and the other 5% water soluble oil. The end of the strip that is in the exit mandrel is not released in the multiple pass process nor is it completely unwound from the entry mandrel. In the

final pass through the reduction mill, the portion that was not reduced from the entry end is trimmed off in a set shears just before they enter the work rolls to the exit side. A transfer saddle on the exit side then moves the coil back onto the conveyor that runs beside the mill.

QUALITY CONTROL

Quality control is a process by which entities review the quality of all

factors involved in production. This approach places an emphasis on

three aspect

1. Elements such as controls, job management, defined and well

managed processes, performance and integrity criteria, and

identification of records

2. Competence, such as knowledge, skills, experience, and

qualifications

3. Soft elements, such as personnel

integrity, confidence, organizational culture, motivation, team

spirit, and quality relationships.

The quality of the outputs is at risk if any of these three aspects is

deficient in any way.

Quality control emphasizes testing of products to uncover defects, and

reporting to management who make the decision to allow or deny the

release, whereas quality assurance attempts to improve and stabilize

production, and associated processes, to avoid, or at least minimize,

issues that led to the defects in the first pun For contract work,

particularly work awarded by government agencies, quality control

issues are among the top reasons for not renewing a contract.

"Total quality control", also called total quality management, is an

approach that extends beyond ordinary statistical quality control

techniques and quality improvement methods. It implies a complete

overview and re-evaluation of the specification of a product, rather than

just considering a more limited set of changeable features within an

existing product. If the original specification does not reflect the correct

quality requirements, quality cannot be inspected or manufactured into

the product. For instance, the design of a pressure vessel should include

not only the material and dimensions, but also operating,

environmental, safety, reliability and maintainability requirements, and

documentation of findings about these requirements.

BSL have fully fledged laboratory with test equipment’s such as

Emission spectroscope for the chemical analysis, computerized

Universal testing machine with stress-strain graph for tension tests,

surface finish tester, Hardness testers using both Vickers and Rockwell

scales, LFQ testing machine, Cupping tester, on line Radiometric and off

line chemical lab for coating mass, salt spray tester for corrosion

resistance, and Humidity chamber.

 

For Environmental Management System BSL have

ISO14001:2004 Certification.

For Quality System BSL have

ISO/TS 16949:2002Certification

 

For Safety Management System BSL have

OHSAS18001:2007 Certification

COLOUR COATING LINE

Steel and allied flat materials are prone to rusting, which not only reduce the life but also the outlook of the material. Painting is not only reducing the decoration of the product but also gives aesthetic value to it.

It is easiest to coat the flat product than odd shape objects. Hence coil coating phenomenon used for pre painting of the metallic coils. And these repainted coils are used in various applications.

Colour coated sheets in the form of plain, profiled and corrugated are generally used in building applications like roofing, cladding, sandwich panel making and in industrial sectors for appliances like washing machines, refrigerators, for bus body interiors etc.

Pre painted material coated in coil coatings are high closely monitored products with uniform appealing finish. By use of these products it gives not only quality but reduces a painting operation at the end users and hence the cost of installation and time. Also the environment hazards are reduced because coil coating is closely monitored process.

Coil coating process:

Normally the method used for coil coating process is roller coating. The various steps in coil coating are as followsCold rolled steel coils/Galvanized coils are first pretreated by cleaning and chemical coating for better adhesion of paint and corrosion resistance of the product.

First primer coat of 5-7 micron is applied and baked. Finish coat is applied over it 18-22 micron on top exposure side and 5-12 micron on backside. These paints are special paints called coil coating paints and baking takes place at about 210-242 °C in 30-40 sec.

Types of paint used are:Primers and back coats - Epoxy, polyester, polyurethane etc. Top coats -Regular modified polyester, silicon modified polyester, PVDF, acrylics, PVC, polyurethane etc.

After every baking material is brought to room temperature by water quenching. Finally the material is recoiled.

Final product is supplied in the form of coils or in different forms like slit coils, cut length sheets, profiled sheets or corrugated sheets with or without protective film.

End use:

1. Building applications: Roofing and cladding sheets; cold storage rooms, sandwich panel making, false roofing etc.

2. Appliances manufacture like Refrigerators, washing machines, coolers; electronic goods etc.

3. Auto body interiors, electrical panels; number plates etc.

MECHANICAL MAINTENANCE

Maintenance, repair and operations (MRO) or maintenance, repair, and overhaul involves fixing any sort of mechanical, plumbing or electrical device should it become out of order or broken (known as repair, unscheduled, or casualty maintenance). It also includes performing routine actions which keep the device in working order (known as scheduled maintenance) or prevent trouble from arising (preventive maintenance). MRO may be defined as, "All actions which have the objective of retaining or restoring an item in or to a state in which it can perform its required function. The actions include the combination of all technical and corresponding administrative, managerial, and supervision actions."

MRO operations can be categorised by whether the product remains the property of the customer, i.e. a service is being offered, or whether the product is bought by the reprocessing organization and sold to any customer wishing to make the purchase (Guadette, 2002). In the former case it may be a backshop operation within a larger organization or smaller operation.

The former of these represents a closed loop supply chain and usually has the scope of maintenance, repair or overhaul of the product. The latter of the categorizations is an open loop supply chain and is typified by refurbishment and remanufacture. The main characteristic of the closed loop system is that the demand for a product is matched with the supply of a used product. Neglecting asset write-offs and exceptional activities the total population of the product between the customer and the service provider remains constant.

Generally speaking, there are three types of maintenance in use:

Preventive maintenance, where equipment is maintained before break down occurs. This type of maintenance has many different variations and is subject of various researches to determine best and most efficient way to maintain equipment. Recent studies have shown that Preventive maintenance is effective in preventing age related failures of the equipment. For random failure patterns which amount to 80% of the failure patterns, condition monitoring proves to be effective.

Operational maintenance, where equipment is maintained in using.

Corrective maintenance, where equipment is maintained after break down. This maintenance is often most expensive because worn equipment can damage other parts and cause multiple damages.

ELECTRICAL MAINTENANCE

Electrical maintenance is the upkeep and preservation of equipment and systems that supply electricity to a residential, industrial or commercial building. It may be performed by the owner or manager of the site or by an outside contractor. The work is commonly performed on a schedule based on the age of the building, the complexity of the electrical system or on an as-needed basis.

The main areas of general electrical maintenance commonly include the power outlets and surge protectors, generators and lighting systems. These supply sources are checked for structural integrity as well as internal stability. The maintenance plan normally includes the regular replacement of burned out fluorescent and incandescent lights. Many building managers in recent years have refitted their lighting systems with energy saving bulbs and elements.

Preventive maintenance is also generally part of a building’s upkeep. This plan ordinarily includes the scheduled inspection of large systems and equipment by a professional electrician. The purpose of these periodic assessments is to fix small problems before they escalate into large ones. This is particularly important at plants, hospitals and factories that heavily rely on these systems for daily operations.

Electrical generators, switches and circuit breakers are regularly checked for solid connections and intact wiring. If flaws are discovered, electricians normally make repairs. Depending on the condition of the wiring, the repairs are typically made by splicing wires together. In some situations, they are encased in metal tubing called conduit to protect them from wear. Keeping the wiring in good shape ensures a consistent flow of power to heating, ventilation and air conditioning systems.

To guarantee the steady, uninterrupted flow of electricity to buildings, electrical maintenance is ordinarily performed by licensed industry professionals. These maintenance electricians normally have building specifications, wiring and equipment diagrams, and blueprints at their disposal to make sure they inspect all areas. They typically use a variety of hand tools, including hand drills, pliers, wire cutters, screwdrivers, knives and conduit benders. Voltage, amps and ohm meters are commonly used in the maintenance operations.

If there are specific areas of concern in a building’s electrical system, the maintenance crew may use specialized testing methods and equipment to isolate the problem. Power transformers are commonly analyzed as well as substation components and the construction of the site’s transformers. The testing procedures generally require a good understanding of switchgears and system design to comprehend how all of the electrical system elements interrelate.

R&D

The phrase research and development (also R and D or, more often, R&D), according to the Organization for Economic Co-operation and Development, refers to "creative work undertaken on a systematic basis in order to increase the stock of knowledge, including knowledge of man, culture and society, and the use of this stock of knowledge to devise new applications".

Research and development is often scientific or towards developing particular technologies and is frequently carried out as corporate or governmental activity.

New product design and development is more often than not a crucial factor in the survival of a company. In an industry that is changing fast, firms must continually revise their design and range of products. This is necessary due to continuous technology change and development as well as other competitors and the changing preference of customers. Without

an R&D program, the firm must rely on strategic alliances, acquisitions, and networks to tap into the innovations of others.

A system driven by marketing is one that puts the customer needs first, and only produces goods that are known to sell. Market research is carried out, which establishes what is needed. If the development is technology driven then it is a matter of selling what it is possible to make. The product range is developed so that production processes are as efficient as possible and the products are technically superior, hence possessing a natural advantage in the market place.

R&D has a special economic significance apart from its conventional association with scientific and technological development. R&D investment generally reflects a government's or organization's willingness to forgo current operations or profit to improve future performance or returns, and its abilities to conduct research and development.

The top eight spenders in terms of percentage of GDP were Israel (4.53%), Sweden (3.73%), Finland (3.45%) Japan (3.39%), South Korea (3.23%), Switzerland (2.9%), Iceland (2.78%) and United States (2.62%).[2] The Commitment to Development Index ranks these countries, rewarding them for research and development that support the creation and dissemination of innovations of value to developing countries.In general, R&D activities are conducted by specialized units or centers belonging to companies, universities and state agencies. In the context of commerce, "research and development" normally refers to future-oriented, longer-term activities inscience or technology, using similar techniques to scientific research without predetermined outcomes and with broad forecasts of commercial yield.

Statistics on organizations devoted to "R&D" may express the state of an industry, the degree of competition or the lure of progress. Some common measures include: budgets, numbers of patents or on rates of peer-reviewed publications. Bank ratios are one of the best measures, because they are continuously maintained, public and reflect risk.

In the U.S., a typical ratio of research and development for an industrial company is about 3.5% of revenues. A high technology company such as a computer manufacturer might spend 7%. Although Allergan (a biotech company) tops the spending table with 43.4% investment, anything over 15% is remarkable and usually gains a

reputation for being a high technology company. Companies in this category include pharmaceutical companies such as Merck & Co. (14.1%) or Novartis (15.1%), and engineering companies like Ericsson (24.9%).[3] Such companies are often seen as poor credit risks because their spending ratios are so unusual.

Generally such firms prosper only in markets whose customers have extreme needs, such as medicine, scientific instruments, safety-critical mechanisms (aircraft) or high technology military armaments. The extreme needs justify the high risk of failure and consequently high gross margins from 60% to 90% of revenues. That is, gross profits will be as much as 90% of the sales cost, with manufacturing costing only 10% of the product price, because so many individual projects yield no exploitable product. Most industrial companies get only 40% revenues.On a technical level, high tech organizations explore ways to re-purpose and repackage advanced technologies as a way of amortizing the high overhead. They often reuse advanced manufacturing processes, expensive safety certifications, specialized embedded software, computer-aided design software, electronic designs and mechanical subsystems.

UTILITY

Utility department of BSL consist of boilers, A.C plant, condenser, RO plant.

BOILER

A boiler is a closed vessel in which water or other fluid is heated. The fluid does not necessarily boil. The heated or vaporized fluid exits the boiler for use in various processes or heating applications, including central heating, boiler-based power generation, cooking, and sanitation.Central air conditioning plants are used for applications like big hotels, large buildings having multiple floors, hospitals, etc, where very high cooling loads are required. The article describes various possible arrangements of central air conditioning plants.

A.C PLANT

The central air conditioning plants or the systems are used when large buildings, hotels, theaters, airports, shopping malls etc are to be air conditioned completely. The window and split air conditioners are used for single rooms or small office spaces. If the whole building is to be cooled it is not economically viable to put window or split air conditioner in each and every room. Further, these small units cannot satisfactorily cool the large halls, auditoriums, receptions areas etc.

In the central air conditioning systems there is a plant room where large compressor, condenser, thermostatic expansion valve and the evaporator are kept in the large plant room. They perform all the functions as usual similar to a typical refrigeration system. However, all these parts are larger in size and have higher capacities. The compressor is of open reciprocating type with multiple cylinders and is cooled by the water just like the automobile engine. The compressor and the condenser are of shell and tube type. While in the small air conditioning system capillary is used as the expansion valve, in the central air conditioning systems thermostatic expansion valve is used.

The chilled is passed via the ducts to all the rooms, halls and other spaces that are to be air conditioned. Thus in all the rooms there is only the duct passing the chilled air and there are no individual cooling coils, and other parts of the refrigeration system in the rooms. What is we get in each room is the completely silent and highly effective air conditions system in the room. Further, the amount of chilled air that is needed in the room can be controlled by the openings depending on the total heat load inside the room.

The central air conditioning systems are highly sophisticated applications of the air conditioning systems and many a times they tend to be complicated. It is due to this reason that there are very few companies in the world that specialize in these systems. In the modern era of computerization a number of additional electronic utilities have been added to the central conditioning systems.

There are two types of central air conditioning plants or systems:

1) Direct expansion or DX central air conditioning plant: In this system the huge compressor, and the condenser are housed in the plant room,

while the expansion valve and the evaporator or the cooling coil and the air handling unit are housed in separate room. The cooling coil is fixed in the air handling unit, which also has large blower housed in it. The blower sucks the hot return air from the room via ducts and blows it over the cooling coil. The cooled air is then supplied through various ducts and into the spaces which are to be cooled. This type of system is useful for small buildings.

2) Chilled water central air conditioning plant: This type of system is more useful for large buildings comprising of a number of floors. It has the plant room where all the important units like the compressor, condenser, throttling valve and the evaporator are housed. The evaporator is a shell and tube. On the tube side the Freon fluid passes at extremely low temperature, while on the shell side the brine solution is passed. After passing through the evaporator, the brine solution gets chilled and is pumped to the various air handling units installed at different floors of the building. The air handling units comprise the cooling coil through which the chilled brine flows, and the blower. The blower sucks hot return air from the room via ducts and blows it over the cooling coil. The cool air is then supplied to the space to be cooled through the ducts. The brine solution which has absorbed the room heat comes back to the evaporator, gets chilled and is again pumped back to the air handling unit.

COMPRESSOR

A gas compressor is a mechanical device that increases the pressure of a gas by reducing its volume. An air compressor is a specific type of gas compressor.

Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through a pipe. As gases are compressible, the compressor also reduces the volume of a gas. Liquids are relatively incompressible; while some can be compressed, the main action of a pump is to pressurize and transport liquids.

R.O PLANT

A reverse osmosis plant is a manufacturing plant where the process of reverse osmosis takes place. An average modern reverse osmosis plant needs six kilowatt-hours of electricity to desalinate one cubic meter of water. The process also results in an amount of salty briny waste. The challenge for these plants is to find ways to reduce energy consumption, use sustainable energy sources, and improve the process of desalination and to innovate in the area of waste management to deal with the waste. Self-contained water treatment plants using reverse osmosis, called reverse osmosis water purification units, are normally used in a military context.

CONCLUSION

IT GIVES ME IMMENSE PLEASURE TO SAY THAT I HAVE SUCESSFULLY UNDERGONE 45 DAYS OF INDUSTRIAL TRANING IN BHUSHAN STEEL LTD. IT WAS A LIFETIME EXPERIENCE. I LEARNED A LOT OF NEW THINGS, AND LOT OF NEW WAYS OF SOLVING A PROBLEM. I WANT TO CONCLUDE MY REPORT ON A POSITIVE NOTE AND I HOPE THAT THE EXPERIENCE WHICH I GOT WILL ALSO BE FRUITFUL IN MY CAREER AHEAD.

BIBLOGRAPY

1.www.bhushan-group.com

2. Wikipedia.com