Industrial Training Report

(Bhushan Steels & Strips Ltd.)

Name
Univ. Roll No.
Academic Session

: AKSHAY KUMAR SINGH

: 110106027
: 2011-2015

SHARDA UNIVERSITY
DEPARTMENT OF MECHANICAL ENGINEERING

JSS MAHAVIDYAPEETHA

JSS ACADEMY OF TECHNICAL EDUCATION

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 equipments 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 its
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
Website

Steel
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 componentsCORE
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. BSLs 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. Fire
b. Explosion
c. Oil Spillage
d. Toxic release (gases & chemicals)
e. Electrocution
f. Structure/building collapse
g. 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. Area / Activity
No
.
1
Storage and
Handling of
High Speed
Diesel (HSD)

Hazard

Hazard Impact
Potentia
l
Pool Fire /
Medium Fire may
Fireball may
propagate and
occur in case of
spread over to
direct contact
other areas
with flame
2
Storage and
Leakage of Gas Major
Chlorine gas may
Handling of
from Chlorine
spread affecting
Chlorine
Cylinder
the people in the
Cylinder
nearby areas
3
Storage and
Leakage of gas Major
CO gas may
handling of BF from the Gas
spread affecting
Gas (CO Gas)
holder Tank
the people in the
nearby areas
4
Storage and
Explosion may Major
Fire may
handling of LPG occur in case of
propagate and
leakage of gas
spread over to
with contact
nearby areas
with fire
5
Electrical Power Fire and
Medium Fire may
supply and
electrocution
propagate to other
distribution in
may occur
areas
Transformer
yard and motor
control center
ACTION PLAN FOR ON-SITE EMERGENCY PLAN

STEP
NO
1.

2.

INITIATOR
The person
noticing the
emergency
Combat team
Leader (CTL)

ACTION TO TAKE

Inform the Security Gate, Combat team leader and the

concerned Shift-in charge immediately.

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.
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.
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.
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.

3.

Site Incident
Controller
(SIC)

4.

Works main
Controller
(WMC)

5.

Rescue Team
(RTL)


6.

Auxiliary
Team (ATL)

7.

Team
members

To inform the auxiliary team Leader for necessary help from

mutual aid Partners.
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.
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 equipments 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.

solution

called pickle

liquor,

which

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

commonly

used

to

various steelmaking processes.

descale

or

clean steel in

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 Ibeams 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 coldrolled 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: fullhard, 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 costeffective 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 m (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 metalswhich must be
cooled slowly to annealcopper, 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 stressfree 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 Ficks 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 metals
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 50C above the
austenic temperature as graph shows) and held for sufficient time to
allow the material to fully austenitize, to form austenite or austenitecementite 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

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 t a 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,
qualifications

such

as

knowledge,

skills,

experience,

and

3. Soft

elements,

such

integrity, confidence, organizational

as

personnel

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,

documentation of findings about these requirements.

and

BSL have fully fledged laboratory with test equipments 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 follows
Cold 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 3040 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 buildings 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 buildings 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 sites 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%), S
outh 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 futureoriented, 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