PROJECT REPORT:

ADDRESS: SUBMITTED BY:

BHUSHAN POWER AND STEELS LTD. GAUTAM SHARMA

DERA BASSI, MOHALI, PUNJAB. ROLL NO.-12001170030

ON AMBALA-CHD. HIGHWAY. GOVT. POLY, AMBALA CITY

Company History  

Growing from strength to strength

1970

- Started with very small initial outlay for manufacturing Door Hinges & later on, Rail Track Fasteners.

1973

- Manufacturing facilities set up for Tor Steel and Wire Rod in Chandigarh.

1981

- Rolling Mill Project commissioned at Chandigarh for Round and Narrow Strips.

1985

- Backward Integration Project for Steel Melting facilities.

1986

- Upgrading of Mini Steel Plant with continuous casting and ladle furnace facilities.

1997

- Commissioning of Narrow Width Cold Rolling Project at Chandigarh.

1998

- Commissioning of Precision Pipe Project at Chandigarh.

2001

- Commissioning of Cold Rolling & Galvanizing Complex at Kolkata.

2002

- Addition of narrow width Cold Rolling facilities at Kolkata.

2003

- Expansion of wide width Cold Rolling facilities, ERW Water Pipes & Tubes down stream facilities at Kolkata.

2004

- Further expansion of Cold Rolling facilities at Kolkata.

2005

- Commissioning of Orissa Project Phase-I consisting of 4 DRI Kilns, Steel Making Facilities, Coal Washery and 100 MW Power Plant.

2007

- Commissioning of further expansion of Orissa Project Phase-II consisting of HR Coil Mill, Steel making, Blast Furnance, Sinter plant, Coke oven plant, Oxygen plant and Lime & Calcining Plant.

2009

- Commissioning of 3.5 million tpa Coal Washery, 146 MW Power Plant and 0.3 million tpa Sponge Iron under Phase III of Orissa Project.

2010

- Commissioning of 130 MW Power Plant and Electric Arc Furnace under Phase III of Orissa Project and further expansion of Orissa Project under Phase IV consisting of 6 DRI Kilns, 130 MW Power Plant, Steel Making Facilities,2nd CSP Caster & 6th strand along with

Tunnel Furnace, Oxygen Plant, Lime Calcining with downstream facilities - Cold Rolling, Galvanizing, Galvalume, Colour Coating, Precision Tube & Black Pipe/GI Pipe.

2011

- Commissioning of DRI Kilns, Electric Arc Furnace, 2nd CSP Caster & 6th Strand alongwith Tunnel Furnace, Cold Rolling Mill Complex and Galvanising under Phase-IV of Odisha Project.

2012

- Commissioning of DRI Kilns, Power Plant, Oxygen Plant, Lime Calcining Plant, Galvalume, Color Coating, Precision Tube and Pipe Plant under Odisha Phase-IV Project, and implementation of further expansion of Odisha Project under Phase V, consisting of DRI Kilns, Iron Ore Benefication Plant, Pellet Plant, Cold Rolling, Pickling Line, Precision Tube Mill, Black  Pipe Plant and Bright Bar finishing lines.

2013

- Commissioning of Cold Rolling Mill, Pickling Line, Precision Tube Mill, Black Pipe Plant and Bright Bar Finishing Line Under Odisha Phase -V Project

Profile:“Our mission is to grow our company by providing innovative strong and high performance products and

solutions to meet our global customer needs.”

Bhushan Steel Ltd formerly known as Bhushan Steel & Strips Ltd. is a globally renowned one of the leading

prominent player in Steel Industry. Backed by more than two decades, of experience in Steel making, Bhushan

Steel is now India’s 3rd largest Secondary Steel Producer company with an existing steel production capacity of 2

million tones per annum’s (approx.).

It was the vision of the founder; Brij Bhushan Singal, that the first stake was driven into the soil of Sahibabad

(Uttar Pradesh) in 1987. His vision helped BSL overcome several periods of adversity and strive to improve against

all odds.

The company has three manufacturing units in the state of Uttar Pradesh (Sahibabad Unit), Maharashtra

(Khopoli unit), and Orissa Plant (Meramandali unit) in India and sales network is across many countries.

The company is a source for vivid variety of products such as Cold Rolled Closed Annealed, Galvanized Coil and

Sheet, High Tensile Steel Strapping, Colour Coated Coils , Galume Sheets and Coils, Hardened & Tempered Steel Strips ,

Billets, Sponge Iron, Precision Tubes and HFW/ERW Pipe.

As one of the prime movers of the technological revolutions in Indian Cold Rolled Steel Industry, BSL has emerged

as the country’s largest and the only Cold Rolled Steel Plant with an independent line for manufacturing Cold

Rolled Coil and Sheet up to a width of 1700mm, as well as Galvanized Coil and Sheet up to a width of 1350 mm.

In due course of time, BSL has grown incredibly its turnover and production capacity by successive expansions as

well as improved realizations with these manufacturing units.

The dynamic reason of awesome and unparallel growth of BSL, is rapid integration on the Steel value chain;

conceivably, it would be its unwavering focus on acquiring the latest technology and know how, also the BSL’s

commitment to provide its customers with the best quality products.

Given a vibrant Steel industry dynamics in India, we are on a course to become a fully Integrated Steel & Power

Company with market leading offerings in value added Steel in Automotive and White Good Segment with the

quality  been approved by ISO 9001:2008 & ISO 14001:2004.

Mission & Values Our Mission is to achieve clear identity and leadership globally in Steel production and distribution by integration of complete chain of production starting from captive iron ore to end user Steel products.

Our revolution in Steel production has helped us to carve a niche unique only to a market leader. Every year passes by with new value additions and more accolades from our customers - Locally and Globally. Our rising chart in respect of all-important parameters of production and finance is a testimony to our claim.

In pursuing our mission, we at Bhushan Power & Steel Ltd. are guided by the following values -

Quality - To be the best in quality. We aim and achieve excellence.

Technology - State of the art technology and product enrichment by continuous Research and Development.

Customer Friendly - Our products are world class and more and more clients are appreciating and using our products. We also undertake customized products with values addition and enhancement.

Corporate Governance - We comply with all applicable laws and regulations. We believe in maintaining clean environment and conservation of natural resources. We contribute towards betterment of our staff and provide them with best of facilities.

Environment Protection and Practice - We are adopting and implementing pollution control measures as a matter of policy. Please read our thrust and directions on this subject by Clicking here (All our efforts are in accordance with the laid down norms of Central Pollution Control Board for Industrial and Mixed use areas).

STEEL PIPES:

Steel pipes are long, hollow tubes that are used for a variety of purposes. They are produced by two distinct methods which result in either a welded or seamless pipe. In both methods, raw steel is first cast into a more workable starting form. It is then made into a pipe by stretching the steel out into a seamless tube or forcing the edges together and sealing them with a weld. The first methods for producing steel pipe were introduced in the early 1800s, and they have steadily evolved into the modern processes we use today. Each year, millions of tons of steel pipe are produced. Its versatility makes it the most often used product produced by the steel industry.

USES:Steel pipes are found in a variety of places. Since they are strong, they are used underground for transporting water and gas throughout cities and towns. They are also employed in construction to protect electrical wires. While steel pipes are strong, they can also be lightweight. This makes them perfect for use in bicycle frame manufacture. Other places they find utility is in automobiles, refrigeration units, heating and plumbing systems, flagpoles, street lamps, and medicine to name a few.

Design There are two types of steel pipe, one is seamless and another has a single welded seam along its length. Both have different uses. Seamless tubes are typically more light weight, and have thinner walls. They are used for bicycles and transporting liquids. Seamed tubes are heavier and more rigid. The have a better consistency and are typically straighter. They are used for things such as gas transportation, electrical conduit and plumbing. Typically, they are used in instances when the pipe is not put under a high degree of stress.

Certain pipe characteristics can be controlled during production. For example, the diameter of the pipe is often modified depending how it will be used. The diameter can range from tiny pipes used to make hypodermic needles, to large pipes used to transport gas throughout a city. The wall thickness of the pipe can also be controlled. Often the type of steel will also have an impact on pipe's the strength and flexibility. Other controllable characteristics include length, coating material, and end finish.

Raw Materials The primary raw material in pipe production is steel. Steel is made up of primarily iron. Other metals that may be present in the alloy include aluminum, manganese, titanium, tungsten, vanadium, and zirconium. Some finishing materials are sometimes used during production.

Seamless pipe is manufactured using a process that heats and molds a solid billet into a cylindrical shape and then rolls it until it is stretched and hollowed. Since the hollowed center is irregularly shaped, a bullet-shaped piercer point is pushed through the middle of the billet as it is being rolled. used if the pipe is coated. Typically, a light amount of oil is applied to steel pipes at the end of the production line. This helps protect the pipe. While it is not actually a part of the finished product, sulfuric acid is used in one manufacturing step to clean the pipe.

The Manufacturing Process Steel pipes are made by two different processes. The overall production method for both processes involves three steps. First, raw steel is converted into a more workable form. Next, the pipe is formed on a continuous or semicontinuous production line. Finally, the pipe is cut and modified to meet the customer's needs.

Pipe making • 8 Both skelp and billets are used to make pipes. Skelp is made into welded pipe. It is first placed on

an unwinding machine. As the spool of steel is unwound, it is heated. The steel is then passed through a series of grooved rollers. As it passes by, the rollers cause the edges of the skelp to curl together. This forms an unwelded pipe.

• 9 The steel next passes by welding electrodes. These devices seal the two ends of the pipe together. The welded seam is then passed through a high pressure roller which helps create a tight weld. The pipe is then cut to a desired length and stacked for further processing. Welded steel pipe is a continuous process and depending on the size of the pipe, it can be made as fast as 1,100 ft (335.3 m) per minute.

• 10 When seamless pipe is needed, square billets are used for production. They are heated and molded to form a cylinder shape, also called a round. The round is then put in a furnace where it is heated white-hot. The heated round is then rolled with great pressure. This high pressure rolling causes the billet to stretch out and a hole to form in the center. Since this hole is irregularly shaped, a bullet shaped piercer point is pushed through the middle of the billet as it is being rolled. After the piercing stage, the pipe may still be of irregular thickness and shape. To correct this it is passed through another series of rolling mills.

Final processing • 11 After either type of pipe is made, they may be put through a straightening machine. They may

also be fitted with joints so two or more pieces of pipe can be connected. The most common type of joint for pipes with smaller diameters is threading—tight grooves that are cut into the end of the pipe. The pipes are also sent through a measuring machine. This information along with other quality control data is automatically stenciled on the pipe. The pipe is then sprayed with a light coating of protective oil. Most pipe is typically treated to prevent it from rusting. This is done by galvanizing it or giving it a coating of zinc. Depending on the use of the pipe, other paints or coatings may be used.

Electric Resistance Welded Pipe: Electric resistance welded (ERW) pipe is manufactured by cold-forming a sheet of steel into a cylindrical shape. Current is then passed between the two edges of the steel to heat the steel to a point at which the edges are forced together to form a bond without the use of welding filler material. Initially this manufacturing process used low frequency A.C. current to heat the edges. This low frequency process was used from the 1920’s until 1970. In 1970, the low frequency process was superseded by a high frequency ERW process which produced a higher quality weld.

Over time, the welds of low frequency ERW pipe was found to be susceptible to selective seam corrosion, hook cracks, and inadequate bonding of the seams, so low frequency ERW is no longer used to manufacture pipe. The high frequency process is still being used to manufacture pipe for use in new pipeline construction.

Seamless Pipe: Seamless pipe has been manufactured since the 1800’s. While the process has evolved, certain elements have remained the same. Seamless pipe is manufactured by piercing a hot round steel billet with a mandrel. The hollowed steel is than rolled and stretched to achieve the desired length and diameter. The main advantage of seamless pipe is the elimination of seam-related defects; however, the cost of manufacture is greater.

Early seamless pipe was susceptible to defects caused by impurities in the steel. As steel-making techniques improved, these defects were reduced, but they have not been totally eliminated. While it seems that seamless pipe would be preferable to formed, seam-welded pipe, the ability to improve characteristics desirable in pipe is limited. For this reason, seamless pipe is currently available in lower grades and wall thicknesses than welded pipe.

Conclusion

Continual advances in materials and welding techniques have resulted in dramatic improvements in the reliability of pipes. As mentioned, however, there is still pipe in use that is susceptible to corrosion and seam-related defects. These defects are identified through integrity assessments and are repaired when found.

Pipe manufactured today is subject to non-destructive tests such as ultrasonic testing and x-ray, as well as pressure-testing. Each individual section of pipe must be pressure-tested by the manufacturer, and new pipelines are also pressure-tested during the actual construction process

WHAT IS A PIPE?A pipe is a tubular section or hollow cylinder, usually but not necessarily of circular cross-section, used mainly to convey substances which can flow — liquids and gases (fluids), slurries, powders, masses of small solids. It can also be used for structural applications; hollow pipe is far stiffer per unit weight than solid members.

In common usage the words pipe and tube are usually interchangeable, but in industry and engineering, the terms are uniquely defined. Depending on the applicable standard to which it is manufactured, pipe is generally specified by a nominal diameter with a constant outside diameter (OD) and a schedule that defines the thickness.

USES :• Plumbing

• Tap water

• Pipelines transporting gas or liquid over long distances

• Scaffolding

• Structural steel

• As components in mechanical systems such as:

• Rollers in conveyor belts

• Compactors (E.g.: steam rollers)

• Bearing casing

• Casing for concrete pilings used in construction projects

• High temperature or pressure manufacturing processes

• The petroleum industry:

• Oil well casing

• Oil refinery equipment

• Delivery of fluids, either gaseous or liquid, in a process plant from one point to another point in the process

• Delivery of bulk solids, in a food or process plant from one point to another point in the process

• The construction of high pressure storage vessels (note that large pressure vessels are constructed from plate, not pipe owing to their wall thickness and size).

Manufacturing:

Tube drawing There are three processes for metallic pipe manufacture. Centrifugal casting of hot alloyed metal is one of the most prominent process.[further explanation needed] Ductile iron pipes are generally manufactured in such a fashion. Seamless (SMLS) pipe is formed by drawing a solid billet over a piercing rod to create the hollow shell. As the manufacturing process does not include any welding, seamless pipes are perceived to be stronger and more reliable. Historically seamless pipe was regarded as withstanding pressure better than other types, and was often more easily available than welded pipe.

Advances since the 1970s in materials, process control and non-destructive testing allow correctly specified welded pipe to replace seamless in many applications. Welded (also Electric Resistance Welded ("ERW"), and Electric Fusion Welded ("EFW")) pipe is formed by rolling plate and welding the seam. The weld flash can be removed from the outside or inside surfaces using a scarfing blade. The weld zone can also be heat treated to make the seam less visible. Welded pipe often has tighter dimensional tolerances than seamless, and can be cheaper if manufactured in the same quantities.

There are a number of processes that may be used to produce ERW pipes. Each of these processes leads to coalescence or merging of steel components into pipes. Electric current is passed through the surfaces that have to be welded together; as the components being welded together resist the electric current, heat is generated which forms the weld. Pools of molten metal are formed where the two surfaces are being connected as strong electric current is passed through the metal; these pools of molten metal form the weld that binds the two connected components.

ERW pipes are manufactured from the longitudinal welding of steel. The welding process for ERW pipes is continuous as opposed to welding of distinct sections at intervals. ERW process uses steel coil as feedstock.

The High Frequency Induction Technology (HFI) welding process is used for manufacturing ERW pipes. In this process the current to weld the pipe is applied by means of an induction coil around the tube. HFI is generally considered to be technically superior to “ordinary” ERW when manufacturing pipes for critical applications, such as for usage in the energy sector In addition to other uses in line pipe applications, as well as for casing and tubing.

Large-diameter pipe (25 centimetres (10 in) or greater) may be ERW, EFW or Submerged Arc Welded ("SAW") pipe. There are two technologies that can be used to manufacture steel pipes of sizes larger than the steel pipes that can be produced by seamless and ERW processes. The two types of pipes produced through these technologies are Longitudinal submerged arc welded (LSAW) and Spiral submerged arc welded (SSAW) pipes. LSAW are made by bending and welding wide steel plates and most commonly used in oil and gas industry applications. Due to their high cost, LSAW pipes are seldom used in lower value non-energy applications such as water pipelines. SSAW pipes are produced by spiral (helicoidal) welding of steel

coil and have a cost advantage over LSAW pipes as the process uses coils rather than steel plates. As such, in applications where spiral-weld is acceptable, SSAW pipes may be preferred over LSAW pipes. Both LSAW pipes and SSAW pipes compete against ERW pipes and seamless pipes in the diameter ranges of 16”-24”.

Tubing, either metal or plastic, is generally extruded.

Materials:

Pipe is made in many materials including ceramic, fiberglass, many metals, concrete and plastic. In the past, wood and lead (Latin plumbum, from which comes the word 'plumbing') were commonly used.

Typically metallic piping is made of steel or iron, such as unfinished, black (lacquer) steel, carbon steel, stainless steel or galvanized steel, brass, and ductile iron. Iron based piping is subject to corrosion in highly oxygenated water stream.[2] Aluminum pipe or tubing may be utilized where iron is incompatible with the service fluid or where weight is a concern; aluminum is also used for heat transfer tubing such as in refrigerant systems. Copper tubing is popular for domestic water (potable) plumbing systems; copper may be used where heat transfer is desirable (i.e. radiators or heat exchangers). Inconel, chrome moly, and titanium steel alloys are used in high temperature and pressure piping in prcess and power facilities. When specifying alloys for new processes, the known issues of creep and sensitization effect must be taken into account.

Lead piping is still found in old domestic and other water distribution systems, but it is no longer permitted for new potable water piping installations due to its toxicity. Many building codes now require that lead piping in residential or institutional installations be replaced with non-toxic piping or that the tubes' interiors be treated with phosphoric acid. According to a senior researcher and lead expert with the Canadian Environmental Law Association, "...there is no safe level of lead [for human exposure]".[3]

Plastic tubing is widely used for its light weight, chemical resistance, non-corrosive properties, and ease of making connections. Plastic materials include polyvinyl chloride (PVC),[4] chlorinated polyvinyl chloride (CPVC), fibre reinforced plastic (FRP),[5] reinforced polymer mortar (RPMP),[5] polypropylene (PP), polyethylene (PE), cross-linked high-density polyethylene (PEX), polybutylene (PB), and acrylonitrile butadiene styrene (ABS), for example. In many countries, PVC pipes account for most pipe materials used in buried municipal applications for drinking water distribution and wastewater mains.[4] Market researchers are forecasting total global revenues of more than US$80 billion in 2019. [6] In Europe, market value will amount to approx. €12.7 billion in 2020

TUBE MILL PLANT:ERW Pipe Manufacturing Process:

ERW pipe means Electric Resistance Welded Pipes. A plate rolled to become a pipe and welded using Electric Resistance Welding process. Usully for for high diameter. (cheapest process avaiable)

Index:

• Slitting

• Uncoiling, End Shearing And Welding

• Forming

• Welding

• De beading

• Seam Annealing

• Sizing

• Cutting

• End Facing And Bevelling

• Electric resistance welding at a glance

• Galvanizing

Our manufacturing process generally involves the following stages in a step by step procedure.

Slitting:HR Coils are slitted to pre-determined widths for each and every size of pipes

HR COIL SLITTING ROLL FORMING

Uncoiling, End Shearing And Welding:The slitted coil is uncoiled at the entry of ERW mill and the ends are sheared and welded one after another. This results in a single endless strip.

Round forming

Forming:The slitted coils are initially formed into U shape and after that into a cylindrical shape with open edges utilizing a series of forming rolls.

Welding:Welding In this stage, the open edges are heated to the forging temperature through high-frequency, low-voltage, high current and press welded by forge rolls making perfect and strong but weld without filler materials

Debeading: In this stage, the weld flash on top and inside (if required) is trimmed out using the carbide tools. Seam Annealing

Seam Annealing If required, the welding portion and heat affected zone is put to normalizing and then are cooled down in a air cooling bed.

Sizing After water quenching, slight reduction is applied to pipes with sizing rolls. This results in . producing desired accurate outside diameter

Cutting In cutting stage, the pipes are cut to required lengths by flying cut off disc/saw cutter.

End Facing And Bevelling This is usually stage, where the pipes ends are faced and bevelled by the end facer. All these processes are

continuous with automatic arrangements. These plain ended tubes further go for processing as per the

customer requirements such as galvanizing, threading, black varnishing and more

ERW Pipes Manufacturing Process :ERW pipe is formed from hot-rolled coil produced in steel mill. All the incoming coils are verified based on the test certificate received from steel mill for their chemistry and mechanical properties.

The forming stage of ERW pipe begins with a single-width strip. The width of strip is roughly equal to the perimeter of the pipe to be produced. The edges of coil are sheared to pre-specified widths in slitting line.

The process involves uncoiling & leveling of coils and processing the same. The lead end of each coil is squared by shearing operation for threading into the mill. Then this end is joined with coil end of outgoing coil to maintain continuity in production and reduce losses.

To maintain continuity of production, it is accumulated in an accumulator/loop pit. It is then gradually and continuously formed into a circular shape by shaped rolls as per the required diameter in forming stands arranged in tandem. In the welding stand, edges of formed strip are pre heated by High Frequency Electrical Induction heating process to the desired temperature, which are mechanically pressed together horizontally to form continuous weld seam. This welding process does not need any filler metal. Instead, the welding pressure causes some of the metal to be squeezed from the joint, forming a bead of metal on inside and outside of the tube. This bead or welding flash is trimmed during the process. The weld seam is examined and adjusted as per the weld parameters, including temperature and outside diameters. The weld area of the string of the pipe so welded is then annealed, as per customer's specification by induction heating process, to get fine grain structure in weld area. It is then cooled in open followed by water quenching. Subsequently pipe string passes through sizing stands to obtain perfect roundness and diameter. The pipes are non-destructively tested by Eddy Current Process to detect any flaw in weld or otherwise as per customers requirement.

During production, online visual inspection is also carried out for surface defects, diameter accuracy, ovality and weld bead shape. Required sample rings as per specification are cut to carry out mechanical testing of weld and body e.g. flattening test, bend test etc. All pipes are then processed in finishing and testing area for pipe end preparation i.e. Facing/Beveling followed by hydrostatic pressure testing as per specification.

Individual pipe is then visually inspected for the parameters specified in the specification before offering to the customer's inspection, if any. Data of all tests is re-verified and submitted to the customers.

BLACK PIPES - On acceptance, all pipes are marked and/or paint stenciled as per the order requirements, packed in bundles before shifting in the storage yard. Pipes are then loaded on trailers or trucks and dispatched to the customer's site. These pipes can also be supplied with black paint/oiling &/or threading.

GALVANISED PIPES - the accepted pipes are washed in solution of caustic soda tank followed by pickling by hydrochloric acid of suitable concentration to remove oxides on pipe surface & is then dipped in fluxing tank. Pipes are then preheated & dipped in molten zinc bath. Pipes are then pulled out from the bath & wiped externally & internally for uniform & smooth zinc coating. Pipes are then cooled in quenching tank followed by passivation. Pipe ends are then threaded as per specification, if any, inspected for coating & threading defects, physical dimensions & condition before stenciling & packing.

Applications of ERW pipes:• Agriculture and Irrigation Water Distribution, Sprinklers, Drill Rods, Bore-well etc.

• Construction Water Distribution, Fire Fighting System, Chilled Water System etc.

• Structural Scaffolding and Props, Space Frames, Fence, Green House etc.

• Industrial General Engineering, Container making, Auto Industry etc.

• Oil Sector Distribution of Gas, Crude, products.

• Electricity Conduits, poles, Transmission tower etc

Packaging:BPSL can provide packaging in Pelletized form, Coils form , Strips form & in Sheet form. All Packaging have an initial layer of transparent plastic wrapping, second layer of thick plastic wrapping & final layer of hessian cloth wrapping. This ensures complete cover from moisture thus preventing any corrosion even at the surface for a long duration of time. Packing using VCI Paper is provided for Exports

  Pickling

At ASPL we have state-of-the-art Push-Pull Pickling line with capability to pickle width up to 1550 mm. Hydrochloric Acid maintained at a certain temperature is used to clean the coils. This process helps remove the rusty layers & scales from the surface and gives a bright surface finish. This processing is necessary since rust is formed on the surface of the coils at room temperature, whereas scales are formed at a high temperature during rolling in the hot strip mill.                                                                                                                                                

    

Slitting

ASPL has Hi-speed slitting facilities with multi-slit cutting up to width as low as 6mm. These lines ensure no slitting burr as well as maintain close camber tolerances. Coils are slit by length and side trims are removed to obtain a uniform width throughout the coil.

   Shearing/Cut-to-Length

ASPL has two shearing lines for precision blanking at high speeds. Shearing converts Coils/Strips into sheets as per customer requirements.

     Job work

ASPL with its state-of-the-art facilities provides job work services to many TS16949 certified companies.

 

Black Steel Pipes and Black Steel Tubes, India.

Sizes: Dia : ½" to 8"

Thickness : 1.00 mm - 5.40 mm

Specifications: Confirming IS: 1239 Equivalent to BS-1387, ASTM A-53,

A120, A513, DIN 2439, 2440, 2441 &   JIS G3444, G3445.

Applications: Water, Gas, Air Steam, Sewage, Water Wells, Mechanical,

General Engineering purpose.   Black Steel Pipes Conforming To IS: 1239 (Part- I) 1990, Equivalent to BS:

1387

Indian Standards International Standards

What is black steel?

Black iron is the uncoated steel and is also called as black steel. When steel pipe is forged, a black

oxide scale forms on its surface to give it the finish which is seen on this type of pipe. Because steel is

subject to rust and corrosion, the factory also coats it with protective oil. Those black steel are used for

manufacturing pipe and tube, which will not rust for a long time and requires very little maintenance. It

is sold in standard 21-foot lengths TBE.

Usages:

Widely applicable for ordinary uses in water, gas, air and steam, black steel tubes and pipes are

utilized for gas distribution inside and outside the house and for hot water circulation in boiler systems.

It is also used for line pipes in oil and petroleum industries, for water wells and for water, gas and

sewage purposes. It is not used for potable water or for drain waste or vent lines.

How it is used:

Black steel pipes and tubes are cut and threaded to fit the job. Fittings for this type of pipe are of

black malleable (soft) cast iron. They connect by screwing onto the threaded pipe, after applying a

small amount of pipe joint compound on the threads. Larger diameter pipe is welded rather than

threaded. Black steel pipe is cut either with a heavy-duty tube cutter or cutoff saw or by hacksaw.

Inspection Facilities:

GI Tubes & Pipes Ltd has a well equipped Quality control laboratory with all modern facilities for Chemical, Physical

and Mechanical Testing properties of basic raw material, Pipe, Socket and Galvanising.

Testing   

Equipments: Chemical Analysis Testing:   

• Carbon, Sulphur Determination (STROHLEIN Apparatus)

• Complete Chemical Laboratory for testing Steel, Zinc and Galvanizing Test   

Metallurgical Testing:   Non Destructive Testing:

• Microscope with Photographic

Attachments  

• On line Eddy current testing units on two mills

• Hydraulic Test for Pipe (From Size NB 15 mm to NB 500 mm)

& Sockets

Mechanical Testing:   Metrological Testing:

• Universal Testing Machine

• Hardness tester

• Pipe Bending Machine

 

• Digital Vernier Calipers, Digital Micrometers, Ultrasonic

Thickness Gauge

• Ring & Plug Gauges

• Load Testing machines for Deflection & Permanent Set test

• Digital Coating measurement gauges

Manufacturing Process:Our Manufacturing Process is carried out in the state of the art mills having size range from 15 NB to 300 NB and also Square and

Rectangular Hollow Sections from 15 x 15mm to 72 x 72 SQ mm and 25 x 50 to 96 x 48 up to maximum thickness offer 8 mm. We

also have galvanized bath with G.I. capacity of 20000 MT per year.

Black ERW Pipes:Our plant employs HF frequency welding process for manufacturing pipes, using the finest virgin steel from renowned steel plants

in India like JSW, ISPAT, ESSAR and SAIL. In HF process pipes are welded with Radio Frequency Induction Tube Welder of 200

KW, which Weld at high speed with superior finish. The process begins with Cold Stamping of Lakshmi Cauvery Seal of quality.

The tubes then progressively form as the strip passes through successive rolls and is followed by high frequency induction welding

at the edges to complete the weld. Subsequently the welded tube under goes further processes to ensure superior finish and

strong weld. Tubes that pass all quality parameters undergo end-facing operations to ensure smooth & clean edges. Final quality

checks and finishing operations are performed before dispatch.

Galvanized ERW Pipes

Galvanizing process starts by dipping the Black ERW Pipe in Hydro Chloric acid to get rid of debris and any foreign substance that

might have gathered on the pipe. The pipes are then cleaned by water and dipped again in a mixture of ammonium chloride and

Zinc Chloride (Flux) to improve the bind between steel and zinc coating.

The pipes are now dipped in high-grade molten zinc and special care is taken that the zinc tank is at an apt temperature to ensure

superior finish and consistent zinc coating on pipes. Pipes are then introduced to pressurized steam to remove any excess zinc that

might have deposited on the surface of the pipe. Pipes are then cleaned and sent for finishing / quality processes.

MANUFACTURING PROCESSES:

» Slitting    HR Coils are slitted to predetermined widths for each size of pipes.

» Uncoiling, End Shearing and Welding   Slitted coil is uncoiled at the entry of ERW mill and the ends are sheared and    welded one after another to make it a single endless strip.

» Forming   Slitted coils are initially formed into U shape and then into a cylindrical shape with    open edges using a series of forming rolls.

» Welding    The open edges are heated to the forging temperature through high frequency low     voltage high current and press welded by forge rolls making perfect and strong but     weld without filler materials.

» Debeading   Weld flash on top and inside (if needed) is trimmed out through carbide tools.

» Seam Annealing   Whenever required, welding portion and heat-affected zone is put to normalizing     and then cooled down in air-cooling bed.

» Sizling   After water quenching, slight reduction is applied to pipes with sizing rolls to give

   them desired accurate outside diameter.

» Cutting   Pipes are cut to required lengths by flying cut off disc/saw cutter.

» End Facing and Bevelling   The pipes ends are faced and bevelled by the end facer. All the processes are    continuous with auto arrangements. These plain-ended tubes go for further    processing as per the customer need like galvanizing, threading, black varnishing    etc.

Black Pipes

When steel pipe is forged, a black oxide scale forms on its surface to give it the finish which is seen on this type of pipe. Because steel is subject to rust and corrosion, the factory also coats it with protective oil. Those black steel are used for manufacturing pipe and tube, which will not rust for a long time and requires very little maintenance. It is sold in standard 21-foot lengths TBE.

Black steel pipes and tubing are cut and threaded to fit the job. Fittings for this type of pipe are of black malleable (soft) cast iron. They connect by screwing onto the threaded pipe, after applying a small amount of pipe joint compound on the threads. Larger diameter pipe is welded rather than threaded. Black steel pipe is cut either with a heavy-duty tube cutter or cutoff saw or by hacksaw.

Black Steel Pipes Conforming To IS: 1239

N.B. and Series

Outside Diameter

Wall Thickness

Black Tubes Sockets

Plain EndScrewed & Socketed

Min.

O.D

Max.Length

mm Max. Min. mm SWG Kg / m M / Ton Kg / m M / Ton mm mm

15LMH

21.421.821.8

21.021.021.0

2.02.63.2

141210

0.9471.2101.440

1056826694

0.9561.221.45

1046819689

27 37

20LMH

26.927.327.3

26.426.5 26.5

2.32.63.2

131210

1.3801.5601.870

724641534

1.391.571.88

719637532

32 39

25LMH

33.834.234.2

33.233.333.3

2.63.24.0

12108

1.9802.4102.930

505415341

2.002.432.95

500411339

39 46

32LMH

42.542.542.9

41.942.042.0

2.63.24.0

12108

2.5403.1003.790

393322264

2.573.133.82

389319261

49 51

40LMH

48.448.848.8

47.847.947.9

2.93.24.0

11108

3.2303.5604.370

309281229

3.273.604.41

306277226

56 51

50LMH

60.260.860.8

59.659.759.7

2.93.64.5

1197

4.0805.0306.190

245199161

4.155.10 6.26

241 196 159

68 60

65LMH

76.076.676.6

75.275.375.3

3.23.64.5

1097

5.7106.4207.930

175155126

171153124

171153124

84 69

80LMH

88.789.589.5

87.988.088.0

3.24.04.8

1086

6.7208.3609.900

149119101

6.898.5310.40

14511796

98 75

100MH

113.9115.0115.0

113.1113.1113.1

3.64.55.4

975

9.75012.20014.500

1028269

10.0012.5014.80

1008067

124 87

125MH

140.8140.8

138.5138.5

4.85.4

65

15.90017.900

6356

16.4018.40

6154

151 96

150MH

166.5166.5

163.9163.9

4.85.4

65

18.90021.300

5347

19.5021.90

5145

178 96

Click here to send business enquiry.    

GALVANISED IRON PLANT:

RINSING: first of all,the pipes are dipped in water tank so as to remove dirt, dust ,scraps and other foreign materials from the surface of the black pipes.

PICKLING: after rinsing the bundle of black pipes are then pickled in acid tank ,having HCL of Concentration about 18-20 % . Scale, rust, oil, paint and other surface contaminants are carefully removed from the steel by suitable preliminary treatment and subsequent acid cleaning or pickling in sulphuric or hydrochloric acids, followed by rinsing.

RINSING: Then the pipes are rinsed again in water tank with the purpose of removing excess acid from outer and inner surfaces of the pipes otherwise the acid may cause corrosion of the pipes.

FLUXING: The acid-cleaned pipes are immersed in a flux solution,(FLUX-725) usually 30% zinc ammonium chloride with wetting agents, maintained above 65°C. The flux solution removes the oxide film which forms on the highly reactive steel surface after acid cleaning, and prevents further oxidation before galvanizing. The work is then dried ready for galvanizing.

DRYING: Now the pipes are dried in a drier bed which accomodates about 40 pipes at a time on its base called fingers.the drier is kept at atemperature of about 80-100 C .The purpose is to remove the moisture content from the surface of pipes.

HOT DIP GALVANISING IN MOLTEN ZINC BATH:

Galvanizing:Prepared items are galvanized by immersion in molten zinc. On immersion in the galvanizing bath the steel surface is completely covered by the molten zinc, which reacts with the steel to form a series of zinc-iron alloy layers, producing a uniform coating. The thickness of these layers is determined principally by the mass of the steel being galvanized.  This is an important advantage of the galvanizing process – a standard minimum coating thickness is applied automatically regardless of the operator. 

To allow formation of the coating the work remains in the bath until its temperature reaches that of the molten zinc, in the range of 445°C to 465°C. The work is then withdrawn at a controlled rate and carries with it an outer layer of molten zinc which solidifies to form the relatively pure outer zinc coating.

The molten zinc in the galvanizing bath covers corners, seals edges, seams and rivets, and penetrates recesses to give complete protection to areas which are potential corrosion spots with other coating systems. The galvanized coating is slightly thicker at corners and narrow edges, giving greatly increased protection compared to organic coatings which thin out in these critical areas. Complex shapes and open vessels may be galvanized inside and out in one operation.

The period of immersion in the galvanizing bath varies from a few minutes for relatively light articles, or longer for massive structural members.

Upon extraction from the galvanizing bath the item is then quenched to cool.

OUTER DIE: The pipes are then withdrawn from the zinc bath and put in the outer die.The outer die of circular tube type having holes called air knives towards the entering of the pipes.The hot compressed air is blasted on the surface of pipes so as to remove excess zinc layer.

CONVEYOR:the pipe is then forwarded to a inclined conveyor system having rollers on it to support the pipes.

INNER DIE: Inner die is uesd to remove the excess zinc layer from the inner surface of pipes. Inner die is introduced in the pipe and remove extra zinc layer from it.

CYCLONE BLOWER: cyclone blower is used to remove powdered zinc from the pipe when inner die is working.there are two blowers one at each end ,which sucks the zinc particles with air and is collected in a tank.

STEAM BLASTING: SODIUM DICHROMATE SOLUTION:

Sodium dichromate: is the chemical compound with the formula Na2Cr2O7. Usually, however, the salt is handled as its dihydrate Na2Cr2O7·2H2O. Virtually all chromium ore is processed via conversion to sodium dichromate. In this way, many millions of kilograms of sodium dichromate are produced annually.[1] In terms of reactivity and appearance, sodium dichromate and potassium dichromate are very similar. The sodium salt is, however, around twenty times more soluble in water than the potassium salt (49 g/L at 0 °C) and its equivalent weight is also lower, which is often desirable.[2]

ProductionSodium dichromate is generated on a large scale from ores containing chromium(III) oxides. The ore is fused with a base, typically sodium carbonate, at around 1000 °C in the presence of air (source of oxygen):

2 Cr2O3 + 4 Na2CO3 + 3 O2 → 4 Na2CrO4 + 4 CO2

This step solubilizes the chromium and allows it to be extracted into hot water. At this stage, other components of the ore such as aluminium and iron compounds, are poorly soluble. Acidification of the resulting aqueous extract with sulfuric acid or carbon dioxide affords the dichromate, which is isolated at the dihydrate by crystallization. Since chromium(VI) is toxic, especially as the dust, such factories are subject to stringent regulations. For example, effluent from such refineries is treated with reducing agents to return any chromium(VI) to chromium(III), which is less threatening to the environment.[1] A variety of hydrates of this salt are known, ranging from the decahydrate below 19.5 °C (CAS# 13517-17-4 ) as well as hexa-, tetra-, and dihydrates. Above 62 °C, these salts lose water spontaneously to give the anhydrous materi

Reactions:Dichromate and chromate salts are oxidizing agents. For the tanning of leather, sodium dichromate is first reduced with sulfur dioxide.

In the area of organic synthesis,[2] this compound oxidizes benzylic and allylic C-H bonds to carbonyl derivatives. For example, 2,4,6-trinitrotoluene is oxidized to the corresponding carboxylic acid.[3] Similarly, 2,3-dimethylnaphthalene is oxidized by Na2Cr2O7 to 2,3-naphthalenedicarboxylic acid.[4]

Secondary alcohols are oxidized to the corresponding ketone, e.g. menthol to menthone;[5] dihydrocholesterol to cholestanone:[6]

3 R2CHOH + Cr2O72- + 2 H+ → 3 R2C=O + Cr2O3 + 4 H2O

Relative to the potassium salt, the main advantage of sodium dichromate is its greater solubility in water and polar solvents like acetic acid.

When heated strongly, sodium dichromate decomposes to form sodium chromate, chromium(III) oxide and oxygen: 4 Na2Cr2O7 → 4 Na2CrO4 + 2 Cr2O3 + 3 O2 [3][7]

 

 Degreasing:Scale, rust, oil, paint and other surface contaminants are carefully removed from the steel by suitable preliminary treatment and subsequent acid cleaning or pickling in sulphuric or hydrochloric acids, followed by rinsing.

  

HR COIL SLITTING LINE:

SpecificationsCR/HR coil slitting machine 1)Full automatically controlled by PLC, 2)with high speed & high precision

This CR/HR coil slitting machine  can do uncoiling, slitting and recoiling works. slit the steel coil into narrower  coils with any needed widths. The whole line mainly includes coil loading car, uncoiler, coil guide, slitting machine, scrap winder, tension unit, recoiler, coil unloading car, hydraulic system and electrical control system, etc. It is mainly applied for processing cold/hot rolled carbon steel, silicon steel,stainless steel, and all the other kinds of metal materials with surface spreading

White Steel Slitter For Hot Rolled Coils (0.5-3mm)*1250mm Specifications: 

Application: CR/HRC/stainless steel /galvanized and so onthickness of coil plate: 0.5-3mmwidth of coil plate: 1250mmcoil weight: 10MT(max)coil I.D:   ф508coil O.D: ф1600mmthe diameter of slitting blade shaft ф180slitting blade: Φ180Xφ320X20material of slitting blade: 6Crw2Si

the hardness of slitting blade: HRC58°-60°recoiler I.D: φ508power: 380V/50Hz/3Phtolerance of width error: ≤±0.05mm/2Mline speed 0-100m/minarea of the whole machine: 30m(L)x6m(W)Production orientation from left to right

CABLE TAPE PLANT:RAW MATERIAL: the raw material for making cable tapes are CRCA coils….ie (COLD ROLLED CLOSE ANNEALED COILS).

CRCA : means "cold rolled close annealed". This means that after hot rolling and pickling,

the steel is cold rolled to a reduced thickness (which makes it brittle and not too useful), which is then followed by annealing in a closed atmosphere of nitrogen or other non-oxidizing gases (which softens it back up while protecting it from oxidation).

CRCA is steel and therefore highly prone to rusting. Often the rolling mill will apply oil after the annealing, and this will add at least a little short term rust resistance.

But the CRCA must be fabricated into something useful and then pretreated and a surface finish applied in reasonably short order.

APPLICATIONS: cable tapes are used for reinforcement of underground cables and wire etc...

PROCESS PLAN:

OPERATION NO. PROCESS FLOW MACHINERY

PAY OFF REELS 1 PAY OFF M/C

PICKLING &RINSING

2 PICKLING &RINSING TANK

FLUXING 3 FLUXING TANK

DRYING 4 PREHEATER

GALVANIZATION 5 GALVANIZATION TANK

DICHROMATION 6 DICHROMATION TANK

COILING 7 COILER TAKE UP

PACKING 8 MANUAL

DECOILING: the crca coils are decoiled through the P.O.R. Pay off reels, and fed

to the rollers and further processing…as shown in fig.

RINSING in WATER: the coils are then rinsed or cleaned in water to remove

dirt and dust particles from the surface...

ACID PICKLING: the coils are then pickled in acid tank ,having HCL of Concentration about 18-20 %. Scale, rust, oil, paint and other surface contaminants are carefully removed from the steel by suitable preliminary treatment and subsequent acid cleaning or pickling in sulphuric or hydrochloric acids, followed by rinsing.

WATER TANK CLEANING: Then the coils are rinsed again in water tank with the purpose of removing excess acid from surfaces of the coils otherwise the acid may cause corrosion of the coil.

ZINC AMMONIUM CHLORIDE FLUXING: The acid-cleaned coils are immersed in a flux solution,(FLUX-725) usually 30% zinc ammonium chloride with wetting agents, maintained above 65°C. The flux solution removes the oxide film which forms on the highly reactive steel surface after acid cleaning, and prevents further oxidation before galvanizing. The work is then dried ready for galvanizing .

PREHEATING OR DRYING: Now these are dried in a drier bed time on its base.the drier is kept at a temperature of about 80-100 C .The purpose is to remove the

moisture content from the surface of coils. So that they may not splash when dipped in molten zinc.

HOT DIP GALVANIZING BATH: Galvanizing:

Prepared items are galvanized by immersion in molten zinc. On immersion in the galvanizing bath the steel surface is completely covered by the molten zinc, which reacts with the steel to form a series of zinc-iron alloy layers, producing a uniform coating. The thickness of these layers is determined principally by the mass of the steel being galvanized.  This is an important advantage of the galvanizing process – a standard minimum coating thickness is applied automatically regardless of the operator. 

To allow formation of the coating the work remains in the bath until its temperature reaches that of the molten zinc, in the range of 445°C to 465°C. The work is then withdrawn at a controlled rate and carries with it an outer layer of molten zinc which solidifies to form the relatively pure outer zinc coating.

The molten zinc in the galvanizing bath covers corners, seals edges, seams and rivets, and penetrates recesses to give complete protection to areas which are potential corrosion spots with other coating systems. The galvanized coating is slightly thicker at corners and narrow edges, giving greatly increased protection compared to organic coatings which thin out in these critical areas. Complex shapes and open vessels may be galvanized inside and out in one operation.

DICHROMATION SOLUTION TANK: Sodium dichromate:

is the chemical compound with the formula Na2Cr2O7. Usually, however, the salt is handled as its dihydrate Na2Cr2O7·2H2O. Virtually all chromium ore is processed via conversion to sodium dichromate. In this way, many millions of kilograms of sodium dichromate are produced annually.[1] In terms of reactivity and appearance, sodium dichromate and potassium dichromate are very similar. The sodium salt is, however, around twenty times more soluble in water than the potassium salt (49 g/L at 0 °C) and its equivalent weight is also lower, which is often desirable.[2]

REWINDING or RECOILING: now the cable tapes are recoiled through the

T.O.R. take off reels.. by a set of 16 recoilers. As shown in fig.

PACKING AND DISPATCH: in the packing is done manually through

woodwn mallets by workers….they align the roll properlyand seal them at the corners.cable tapes are now lifted by the overhead cranes for dispatch….

TESTING (QUALITY ASSURANCE):When new product is made ,its first sample is tested to insure the quality of the finished product ,cable tapes. There is a standard given by ISO: 9001:2008,that the zinc coating weight should not be less than 210gm/m2. on each side.for this purpose following test is performed

STEP1: A strip of cable tape is taken and its exact weight(W1) is calculated and noted down.

STEP 2: now the strip is dipped in HCL of conc. 30.33% .the acid will vanish the zinc coating from the surface of the strip.

STEP3: Again the weight of strip(W2) is taken and noted down.

FORMULA USED: (w1 - w2)/w2 x1000 kg/ton

SCRAP BALING MACHINE:

Salient Features

* Highly Automated but very simple in operation through two nos. Direction Control Values, one for Three side Pressing Automatically and other to delock and to eject the pressed bale.* Single compact unit mounted over solid gridders(I - Beam).* No Civil Foundation is required except one pit for Ejector Cylinder.* The above data are indicative and not binding.

Optional Features (Against Charges)

* Replaceable wear-resistance plates can be provided for long life of the feeding chamber.* Shearing blades on the Edges of the Chamber and Top Lid to shear the excess and over size scrap.* Heat Exchanger to keep the oil cool.

WORKSHOP AND MAINTAINCE PLANT:

MACHINES AND EQUIPMENTS USED:

SR NAME OF MODEL /MAKE QTY.1  CENTRE LATHES    9 NO.2 SHAPER MACHINE NKH 2 NO.3 SURFACE GRINDERS NKH 2 NO.4 POWER HACKSAW VIRDI 3 NO.5 TEETH PROFILING MACHINE VIRDI 3 NO.6 OXY-ACETYLENE WELDING MASSEY 1 NO.7 DRILLING M/C  AMETEEP 3 NO.8 ARC WELDING SET MANKOO MAKE  1 NO.9 TOOL GRINDERS 2NO.

Applications of BPSL Products :S.No. Segment Product & Application

1. Automobiles Inner Critical Components

Outer skin Panels

Reinforcement & Outer Body Components.

2. Appliances Home Appliances

Refrigerator Doors

Side Panels

Washing Machine Panels

3. Electrical Panels Computer Cabinets

Electronic Equipment Cabinets

Switch Gears

4. Engineering Air-Conditioners & Ducting

Boiler Panel Strips

Finning Strips for Heat Exchanger

Motors

Pollution Control Equipment

Tubes

Transformers

Ventilation

5. Packing Barrels & Containers

Drums

6. Furniture Chairs & Office Furniture Components etc.

7. HRGC Strips Heat Exchangers

Taper Roll Bearing Cages

Expansion projects:Bhushan Steel Ltd announced that its board of directors in a meeting held on 22 January 2007 approved the following projects –

(1) Setting up of an integrated steel plant in West Bengal with facilities including slab plant, coke ovens and captive power plant.

(2) Setting up of a 6 million tonne per annum integrated steel plant as an expansion of its existing plant being set up at Meramandali (Distt Dhenkanal) in Odisha.

(3) Its biggest expansion is in Odisha – it has signed an agreement with the Government of Odisha for setting up of a three million tonnes capacity steel plant at Meramandali in Dhenkanal district, and as part of its total integration of the steel value chain.

(4) Bhushan Steel is in the process of setting up a power plant and an advanced hot rolling plant on 3,200 acres (13 km2) at Meramandali in Dhenkanal district near Angul, at a cost of 52 billion and its subsequent backward integration and expansion to 4 million tonnes.

(5) In West Bengal, Bhushan Steel has signed an agreement with the Government of West Bengal and West Bengal Industrial Development Corporation Ltd. to set up a two million tones steel plant at Salanpur in Bardhaman district.

(6) The cold rolling and galvanizing unit will be set up in North 24 Parganas district.(7) It has also zeroed in on Kharagpur for another power and 2 million tones steel plant and is in talks

with the state government for allocation of about 4,000 acres (16 km2) of land. (8) In Karnataka, Bhushan Steel will be setting up a 6 million tonne per annum integrated steel

manufacturing facility at Bellary, at an investment of 279.28 billion. (9) In Maharashtra, Bhushan Steel has signed an agreement with the Maharashtra Industrial

Development Corporation (MIDC) to invest Rs13.50 billion at Butibori.

Bhushan Steel:Bhushan Steel is the largest manufacturer of auto-grade steel in India[1] and is spending Rs. 260 billion to expand its capacity to 12 million tonnes annually,[2][3] from the present installed capacity of around one million tonnes.[4]

Financials and management:

Gross sales of Bhushan Steel grew from Rs.5 billion in 2001 to Rs.40 billion in 2007. It earned net profits of Rs.3.13 billion in 2007 and exported goods worth Rs.12.57 billion. Its exports include steel for both the automotive and white goods industry and the list of countries it is exporting to includes several developed countries.

Rakesh Verma (UK) is chairman of board of directors of Bhushan Steel. Brahma Nand Chaturvedi[also known as Chopa King(or)Chopa baba] is the Vice Chairman and Managing Director.[4]

The Khopoli plant in Maharashtra was commissioned in 2004 and has been producing colour coated sheets, high tensile steel strappings, hardened and (aluminium and zinc coated sheet) for the first time in India.

At its Sahibabad plant in Ghaziabad, Uttar Pradesh, it has a 1700 mm mill, which produces the widest sheets in India for the automotive industry. It has highly automated systems.

At its Meramandali, Dhenkanal plant in Orissa, Bhusan Steel produces hot rolled coils and has mills for hot rolling. Construction of the first phase is being carried out.[4]

Bhushan Power and Steel Limited has seven plants at four locations – Chandigarh, Derabassi in Punjab, Bangihatti, near Dankuni in West Bengal, and Thelkoloi in Odisha.

How to write a structured Project Report The Project Report

The project report is an extremely important aspect of the project. It should be properly structured and also necessary and appropriate information regarding the project. No data fields are to be exposed in the project field. 

 

The aim of the project is to produce a good product and a good report and that software, hardware, theory etc. that you developed during the project are merely a means to this end.

Design document has to be progressively converted to a project report as and when the various stages of project are completed. Ideally you should produce the bulk of the report as you go along and use the last week or two to bring it together into a coherent document.

How to write a Project Report

A tidy, well laid out and consistently formatted document makes for easier reading and is suggestive of a careful and professional attitude towards its preparation. Remember that quantity does not automatically guarantee quality. A 150 page report is not twice as good as a 75-page one, nor a 10,000 line implementation twice as good as a 5,000 line one. Conciseness, clarity and elegance are invaluable qualities in report writing, just as they are in programming, and will be rewarded appropriately. Try to ensure that your report contains the following elements (the exact structure, chapter titles etc. is up to you):

Title page

This should include the project title and the name of the author of the report. You can also list the name of your supervisor if you wish. IMPORTANT: Before submission you should assemble a project directory which contains all your software, READMEs etc. and your project report (source files and pdf or postscript).

Abstract

The abstract is a very brief summary of the report's contents. It should be about half a page long. Somebody unfamiliar with your project should have a good idea of what it's about having read the abstract alone and will know whether it will be of interest to them.

Acknowledgements

It is usual to thank those individuals who have provided particularly useful assistance, technical or otherwise, during your project. Your supervisor will obviously be pleased to be acknowledged as he or she will have invested quite a lot of time overseeing your progress.

Contents page

This should list the main chapters and (sub)sections of your report. Choose self-explanatory chapter and section titles and use double spacing for clarity. If possible you should include page numbers indicating where each chapter/section begins. Try to avoid too many levels of subheading - three is sufficient.

Introduction

This is one of the most important components of the report. It should begin with a clear statement of what the project is about so that the nature and scope of the project can be understood by a lay reader. It should summarise everything you set out to achieve, provide a clear summary of the project's background, relevance and main contributions. The introduction should set the context for the project and should provide the reader with a summary of the key things to look out for in the remainder of the report. When detailing the contributions it is helpful to provide pointers to the section(s) of the report that provide the relevant technical details. The introduction itself should be largely non-technical. It is useful to state the main objectives of the project as part of the introduction. However, avoid the temptation to list low-level objectives one after another in the introduction and then later, in the evaluation section (see below), say reference to like "All the objectives of the project have been met...".

Background

The background section of the report should set the project into context and give the proposed layout for achieving the project goals. The background section can be included as part of the introduction but is usually better as a separate chapter, especially if the project involved

significant amount of ground work. When referring to other pieces of work, cite the sources where they are referred to or used, rather than just listing them at the end.

Body of report

The central part of the report usually consists of three or four chapters detailing the technical work undertaken during the project. The structure of these chapters is highly project dependent. They can reflect the chronological development of the project, e.g. design, implementation, experimentation, optimisation, evaluation etc. If you have built a new piece of software you should describe and justify the design of your program at some high level, possibly using an approved graphical formalism such as UML. It should also document any interesting problems with, or features of, your implementation. Integration and testing are also important to discuss in some cases. You need to discuss the content of these sections thoroughly with your supervisor.

Evaluation

Be warned that many projects fall down through poor evaluation. Simply building a system and documenting its design and functionality is not enough to gain top marks. It is extremely important that you evaluate what you have done both in absolute terms and in comparison with existing techniques, software, hardware etc. This might involve quantitative evaluation and qualitative evaluation such as expressibility, functionality, ease-of-use etc. At some point you should also evaluate the strengths and weaknesses of what you have done. Avoid statements like "The project has been a complete success and we have solved all the problems asssociated with ...! It is important to understand that there is no such thing as a perfect project. Even the very best pieces of work have their limitations and you are expected to provide a proper critical appraisal of what you have done.

Conclusions and Future Work

The project's conclusions should list the things which have been learnt as a result of the work you have done. For example, "The use of overloading in C++ provides a very elegant mechanism for transparent parallelisation of sequential programs". Avoid tedious personal reflections like "I learned a lot about C++ programming..." It is common to finish the report by listing ways in which the project can be taken further. This might, for example, be a plan for doing the project better if you had a chance to do it again, turning the project deliverables into a more polished end product.

Bibliography

This consists of a list of all the books, articles, manuals etc. used in the project and referred to in the report. You should provide enough information to allow the reader to find the source. In the case of a text book you should quote the name of the publisher as well as the author(s). A weakness of many reports is inadequate citation of a source of information. It's easy to get this right so there are no excuses. Each entry in the bibliography should list the author(s) and title of the piece of work and should give full details of where it can be found.

Appendix

The appendices contain information which is peripheral to the main body of the report. Information typically included are things like parts of the code, tables, test cases or any other material which would break up the theme of the text if it appeared in situ. You should try to bind all your material in a single volume and create the black book. 

Program Listings

Complete program listings should NOT be part of the report except in specific cases at the request of your supervisor.

You are strongly advised to spend some time looking at the reports of previous project students to get a feel for what's good and bad. All reports from the last few years are available in hard copy

form in the CCCF and as soft copy in the student Projects Section. These documents are accessible only from TIFR IP domain.

ABSTRACT: Bhushan power and steel ltd. at dera bassi produces

Black pipe through ERW (Electrical Resistence Welding).In which hr sheets are formed in tube shape in a tube mill , G.I. pipe ,section tubes, cable tapes etc.