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Reheating Furnace
A 65 tonne per hour coke oven and mixed gas-fired
continuous reheating furnace supplied by OFAG of
Germany was installed with the Mill. The furnace is
fitted with full automatic controls. The chimney is
provided with a venturi and has an induced draft fan
to control the draft in the chimney. The furnace has
two zones, each fired by nine burners. The heating
zone has one set of controls, whereas the soaking
zone is further divided into mill side and pusher side
zones with separate controls for both zones. There
are two additional burners to heat the front and tail.
Billet Pusher
The pusher consists of six rams, each having a
pushing power of 12 tons. Each ram unit consists of
double acting high-pressure cylinder with piston and
piston rod. All the six cylinders have independent
hydraulic power packs supplied by M/s Vicker Sperry
India Ltd. The pumps are vane type, fixed delivery
rotary pumps. The speeds of the pushers are
synchronised by a flow control valve provided in
each power pack.
Billet Ejector
The hot and soaked billets are pushed out of the
furnace by a billet ejector bar moved by friction rolls
worked by an electric motor through reduction gear
box and splined shafts.
Mills
The Mill is divided into three groups. The first six
stands constitute the roughing mill, where strand
Nos. 1& 2 have 450 mm pitch diameter (PD) ,strand
number 3 to 6 have 420 mm pitch diameter(PD).
The second group of stands (stand Nos. 7 to 10)
constitute the intermediate mill, all 360 mm P.D.
One motor
400 KW
Stands 3 & 4
One motor
500 KW
Stands 5 & 6
One motor
700 KW
Stands 7, 8, 9 & 10
individual
motors each
500 KW
Individual
700 KW
motors each
Stands 17 & 18"
Individual
500 KW
motors each
There are two cold shears each with 360 tons cutting
capacity in the same finishing line with the cut bar
run-out table to take care of the finished materials.
The rake type cooling bed along with the braking and
separating devices and rotary shear No. 2 can be
operated automatically through photocells to cut the
stock length to the cooling bed length.The Suppliers
are Morgan.
Rotary Shear#2
Rotary Shear No. 2 is operated automatically
through a HMD and photocell to cut the delivered
bar to proper length suitable for accommodating
the cut-bar on the cooling bed.
The bars collected on the other side of the cooling
bed are bunched together by shuffle bar
mechanism and are cut to transportable lengths.
The sheared bars are weighed in a tough and
shifted to the stocking bay for shipment.
Manual bundle strapping and unitisation is done
before shipment.The supplier is Morgan, India.
TMT Quenching Unit
Cooling Beds
A fully automatic eccentric rake type cooling bed, 88
m long and 8.5 m wide has been provided.
Tempcore facility has been installed just before the
cooling bed for on-line thermo- mechanical treatment
of rolled ribbed bars. The details of this facility are
available in the write-up on Wire Rod Mill.
Grade
Installation and successful commissioning of Crop and Cobble shear. This led to elimination of
front split end cobbles.
Commissioning of HMI based mill control system in maintaining consistent dimensional control.
Cpk of weight tolerance through Daily management. Cpk improved from 0.89 to 1.33.
Developed threaded Rebar & successful Rolling of Fe600 grade.
Reduction in section change & shutdown time by 2.16 hrs per shutdown through SMED.
Increase in tons/hour in 20mm section reducing the Billet gap time . Tuning of Finishing mill drive
for better loop control and reduce the Mill pacing.
Reduction in cobble rate through modification of guide in roughnig and Intermediate mill .
Use of Critical Chain Project Management (CCPM) during Major Shutdowns (MSDs) to reduce
shutdown duration and hence increase the available hours for rolling.
Design & Development of Half Water Header to increase the cooling efficiency of TMT.
Common roll pass up to intermediate Mill to facilitate minimum Roll charging & Pass changing.
Introduced double stage twisting in roughing and Intermediate mill.
Report
DONTS
Do
Do not go near Electrical panels, Cables, Substations and Control Rooms without the
departmental Guide.
Take
Wear
Use
Before
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Move
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PutIn
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