Académique Documents
Professionnel Documents
Culture Documents
2013
AMRELI STEELS
INTERNEES:
1. MUHAMMAD ADEEL
2. SAMIULLAH
INSTITUTE:
NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY
Submitted To:
AMRELI STEEL PVT LTD
DATE: 24-12-2013
ACKNOWLEDGEMENT
First of all, we thank Almighty Allah, most merciful, who bestowed us with the ability to
think, work and deliver what we were assigned to do.
Amreli steel industry is an excellent opportunity for learning and self-development. We
consider ourselves fortunate and honored to have so many wonderful people lead us
through in completion of this project.
Mr. Shabbir Hussain, executive manager, Plant Head of Amreli Steel monitored our progress
and arranged all facilities to make it easier; we choose this moment to acknowledge his
contribution gratefully.
My great thanks to Mr. Innayatullah, Senior Manager Maintenance, and Mr. Jamsheed,
Manager Mechanical Maintenance, who inspite of being too busy with their duties took
time out to hear, guide and keep us on the correct path.
We especially thank to all the engineers and workers who shared their valuable knowledge
during our internship.
Table of Contents
ACKNOWLEDGEMENT ................................................................................................................ 2
1.
AMRELI STEELS.................................................................................................................. 5
INTRODUCTION: .................................................................................................................... 5
HISTORY: ................................................................................................................................ 5
COMPANYS PROFILE:............................................................................................................ 5
CROWNING GLORY: ............................................................................................................... 6
VISION: .................................................................................................................................. 6
MISSION: ............................................................................................................................... 6
AMRELI CERTIFICATIONS & AWARDS .................................................................................... 6
FLOW CHART ......................................................................................................................... 8
STEEL MELT SHOP BILLET COMPOSITIONS............................................................................ 9
BILLET LENGTH REQUIREMENT ............................................................................................. 9
2.
3.
4.
5.
7.
8.
RECOMMENDATION ....................................................................................................... 28
9.
CONCLUSION .................................................................................................................. 29
1.
AMRELI STEELS
INTRODUCTION:
Amreli Steels is one of the largest manufacturers of steel reinforcement bars in Pakistan
industrial hub; its plant uses one of the most modern hot rolling mill technologies in the
industry and is capable of continuously producing straight bars up to 35 tons per hour. This
translates into an annual production capacity of approx. 150,000 metric tons. ASL use stateof-the-art equipment and our high degree of automation enable it to produce a high quality
product that falls well within established international standards.
HISTORY:
Amreli Steels established in 1984, is the power house that drives the steel bar sales in
Pakistan since many decades. Prior to 1984, the Company was operating manual re-rolling
mills to manufacture mild steel bars. These rolling mills were dependent for raw material on
the family-owned ship breaking business.
What started off as a small family owned hand rolling mills business is today a professionally
run corporate entity, a fully automatic state-of-the-art mill that produces quality steel bars
on International Standards that are followed all over the world.
With internationally educated young entrepreneurs, and some very experienced senior
professionals in the family at the helm, the company is being steered into the 21st century
with ideas that are sure to put the industry in awe. A well-educated and professionally
trained staff is putting management ideas and vision into action and making a success story
out of it.
With traditional values like Customer is King and services that are second to none, Amreli
has been consistently delivering good quality and timely deliveries which has given its
customers confidence and have over the years developed a trust that is unrivaled in the
industry today.
With a database of customers spanning every major industry in the country, Amreli has
been an industry leader since the two decades.
COMPANYS PROFILE:
Amreli Steels Limited is one of the largest manufacturers of Steel Reinforcement Bars in
Pakistan. Situated in the industrial hub of Karachi, our plant uses one of the most modern
hot re-rolling mill technologies in the industry and is capable of continuously producing
straight bars up to 35 tons per hour. This translates into an annual production capacity of
150,000
metric
tons.
We use state-of-the-art equipment and our high degree of automation enables us to
produce high quality products that falls well within established international standards.
At Amreli, we have created a strong culture based on values that have been a part of our
long tradition. The hallmark of our success is our reputation as a company that generates
and supports exceptional levels of opportunity, initiative and goodwill.
During the past two decades, Amreli Steels has achieved many milestones that have
contributed to its success today. We believe in using the most sophisticated re-rolling
technologies available in the world and our strategic partnerships with the worlds most
prominent re-rolling mill manufacturers has realized our dream to be truly unique, and the
best in Pakistan.
CROWNING GLORY:
With the recent addition of a state-of-the-art melt shop at Dhabeji, the company
accomplished yet another milestone not only for itself but also for the nation. We are now
producing our own high quality billets in our melt shop that are then transferred to our
rolling mill where we are manufacturing the next generation 500MPA High Strength
Deformed Bars (Xtreme G-500), the backbone of modern construction throughout the
world.
VISION:
We are committed to setup integrated steel manufacturing facilities, value added services
and other diversified businesses with the employment of best human resources and systems
implementation. We aim to achieve a high profitable growth rate, create value for our
shareholders and customers, and to look after the well-being of our employees and their
families.
MISSION:
Amreli Group exists to carry forward its family legacy by maintaining its dominant position
in trade and industry by being socially compliant and contributing to the well being of
shareholders and employees.
ISO 9001-2008:In support of our quality policy, Amreli Steels has established a formal management system
conforming to ISO 9001: 2008. We are an ISO 9001: 2008 certified company.
PSQCA CERTIFICATION:All our products are also approved and certified Pakistan Standards Quality Control
Authority (PSQCA)
Amreli have recently registered their plant under Self-Monitoring and Reporting Program
(SMART), monitored by Pakistan Environmental Protection Agency under the umbrella of
Ministry of Environment, Government of Pakistan.
FLOW CHART
TMT PROCESS
COOLING BED
BILLET STORAGE
MECHANICAL TESTING
BILLET INSPECTION
BILLET SHEARING
BY PASS
(if 6m)
(if 3m)
BILLET CHARGING
REHEATING FURNACE
BILLET DISCHARGE
ROUGHING MILL
INTERMEDIATE MILL
FINISHING ROLLER
IN CASE OF FAILURE
REJECTION
BUNDLING
SCRAP
ASL
Grade
Color
Coding
BS 4449-1
Green
(Cut in 6 m)
BS 4449-2
Blue
(Cut in 3 m)
Bs 4449-3
Yellow
(Cut in 6 m)
Special Grade
Red
(Cutting vary)
Billet
Chemistry
C
P
Si
S
Mn
C
P
Si
S
Mn
C
P
Si
S
Mn
C
P
Si
S
Mn
0.18-0.26%
<0.05%
0.15-0.3%
<0.05%
0.6-0.8%
0.26-0.3%
<0.05%
0.15-0.3%
<0.05%
0.6-0.8%
0.-0.24%
<0.05%
0.15-0.3%
<0.05%
0.55-0.65%
0.22-0.25%
<0.05%
0.-0.3%
<0.05%
1.05-1.15%
Carbon
Equivalent
Size to
be Roll
0.36-0.38
(For Xtreme bars
up to 25 mm)
12-16 mm
0.39-0.44
(For G-60 bars
up to 25 mm)
19-22 mm
Max. 0.35
(Only for 3/8
rolling)
9.5 mm
0.48-0.51
40 mm
NOTE:
o If P% is greater than 0.05 then cutting length should be 3m
o If S% is greater than 0.05 then cutting length should be 3
3 Meter
6 Meter
Minimum
2.8 m
Minimum
5.6 m
Maximum
3.1 m
Maximum
6.2 m
PASSING ROLLERS
AND SHEAR
ROUGHING MILL
BILLET
REHEATING
FURNACE
INTER-MEDIATE
ROLLERS
CONTINUOUS ROLLERS
SHEAR
REPEATOR
THERMO MECHANICAL
TREATMENT
COOLING BED
SHEAR
BAR
S
BUNDLING
TRANSFER TABLE
2.
FURNACE DEPARTMENT
2a. SPECIFICATION:
FURNACE DETAILS:
FURNACE ZONES:
RECUPERATOR ZONE:
No burner
Billets are warm up by hot incoming air.
Temperature 400-500 oC
TOP HEATING ZONE:
8 burners
Max temperature 1280 OC
705000 kcal/hr
Combustion Air flow 869 m3/hr (preheat-530 oC)
Natural gas flow 85 m3/hr
8 burners
Max temperature 1280 oC
Natural gas flow 95 m3/hr
760000 kcal/hr
Combustion Air flow 937 m3/hr (preheat-530 oC)
SOAKING ZONE:
3 burners
Max temperature 1240 oC
430000 kcal/hr
Combustion Air flow 530 m3/hr (preheat-530 oC)
Natural gas flow 55 m3/hr
COMBUSTION BLOWER:
WORKING:
As the rotor rotates; the air entrapped between the rotor blades is radially and
circumferentially accelerated and pushed in to the side cavity. Here it is pressurized and
pushed back to the rotor blades where it is again radially and circumferentially
accelerated. It will then push along a special path through the Impeller and side channel till
it is discharged into the discharge port. Thus leaving the blade tip, the air flow around the
housing contours back down to the root of the succeeding the blade where the flow pattern
is repeated. The Impeller rotates with absolutely no contact between it and the casing. This
means that no lubrication is required; guaranteeing 100% oil free operation. Since there is
only one moving part it has got maximum operating reliability and totally maintenance free.
WORKING:
Induced Draft (ID) fans are used to create a vacuum or negative air pressure in a system or
stack. Our centrifugal blowers are used to maintain elevated ventilation, resulting in
increased system efficiency. In the boiler industry ID Fans are often used in conjunction with
FD fans to maintain system pressure which is slightly lower than ambient.
PUSHERS/EJECTORS DETAIL:
Hydraulic Cylinders = 2
Push Force = 100 tons -150 tons
Working pressure: 31.5MPa
Oil = Hydrol VG 32
CHARGING GRIT:
It is use to transfer stock billets to recuperative chamber of furnace. Working principle
involves the movement of counter weights, counter weight moves by the force of 2
hydraulic cylinders. Magnetic crane charge billets from stock pile to charging grit
Pumps:
Details:
No of pumps = 3
Motor rpm of compressor : 1490 rpm
Flow rate : 313 lit/sec
No of compressor = 2
Type : Screw type
Model : GA110W
Nominal working pressure: 8 bar
Maximum pressure : 8.5 bar
Parameters
1. Furnace Capacity
2. Rate
Quantity or Values
3. Burners
4. Thermocouples
5.
6.
7.
8.
Numbers of skids
Outlet Temperature
Air-Fuel Ratio
Pusher Capacity
9. Charging Grid
160 Billets
31 metric tons/hour
62 billets per hour
19 burners (8 upper zone, 8
lower zone, soaking zone)
4 Automatic and 15 manual
8 Thermocouples
K type (Metal)
R type (Ceramic)
4 skids with water supply
Range 1100-1200 C
10:1 ratio
10 tons
Hydraulic system
2 cylinders
Counter weight balance
3.
MILLING ZONE
INTRODUCTION:
Milling zone consists of rollers that define the size of the bars. In Amreli steel, there are total
18 rollers in milling zone.
Roughing area
Intermediate area
Finishing area
Thermo Mechanical Treatment Area
ROUGHING AREA:
INTERMEDIATE AREA:
It is designated by I-1, I-2 and I-3.
Each of these contains two rollers which reduce the area of billet and increases the
length.
After I-3, the billet`s both ends are cut by shearing machine.
FINISHING AREA:
It is designated as C-1, C-2.C-10.
Number of rollers can be adjusted according to the size of resulting bar.
The both ends of the bar are cut down after C-4 roller.
FURNACE
RM-28
PINCH
ROLL 1
I-1
I-2
I-3
PINCH
ROLL 2
SHEAR 1
C-1
C-2
LOPPER-1
C-3
C-4
NEGATIVE
REPEATER
PINCH
ROLL 3
SHEAR
2
C-5
C-6
LOPPER
2
C-7
C-8
LOPPER 3
C-9
C-10
APRON
CHANNEL
COOLING
BED
COLD
SHEAR
TMT
TRANSFER
CHAIN
PINCH
ROLL 4
BUNDLING
SHEAR 3
LOADING
DEVIATOR
WARE
HOUSE
4.
In TMT chamber, the hot deformed billet introduced through roller guide. It has five lines for
passing of billet. The selection of lines depends on the final size of the product.
4a. MECHANISM:
Five nozzles continuously supply water to get the martensitic structure on the case by
quenching process, While the inner core remain soft because of the formation of pearlitic
structure by self-tempering phenomenon. 3 nozzles are supplying water in counter flow to
remove water from the bar at the end. Time of the travel of the bar should be fast to avoid
the formation of martensite to large depth.
Water used in quenching is recycled and transferred back to cooling tower; some amount of
water is evaporated during quenching which is fed using overhead tank to maintain the
desired level of water.
4b. ADVANTAGES:
Major purpose of thermomechanical treatment of steel
Higher yield strength
Improved toughness
Improved weldability
Higher resistance to brittle cleavage
Higher resistance to low-energy ductile fractures
Good cold forming, particularly by bending
Lower costs which are possible by using hot-rolled rather than heat treated sections.
Achieving desired properties with fewer amounts of alloying elements thereby reducing the
production cost.
5.
UTILITY DEPARTMENT:
The function of this department is to supply water for the cooling of machines (e.g. furnace,
rollers, TMT etc.) This department consists of the following main parts:
a) Compressor and drying system
b) Water system
SPECIFICATION:
COOLING TOWER
FURNACE COOLING
TOWER
COLD WELL
COLD WELL
COLD WELL
COLD WELL
CENTRIFUGAL PUMP
CENTRIFUGAL PUMP
CENTRIFUGAL PUMP
CENTRIFUGAL PUMP
MILL COMPLEX
Compress
or
Heat
exchanger
QUINCHING BOX
FURNACE SKITS
HOT WELL
HOT WELL
ROUGHING STAND
INTERMEDIATE ROLLING
FINISHING ROLLERS
HOT WELL
5d. SPECIFICATION:
CLEAR WATER SYSTEM
COLD WELL
VOLUME:
CENTRIFUGAL PUMP
QUANTITY:
IN OPERATION:
FLOW RATE:
HEAD:
POWER:
103m3
2
1 at a time
190m3 /hr
40m
40hp
103m3
CENTRIFUGAL PUMP
QUANTITY:
IN OPERATION:
FLOW RATE:
HEAD:
POWER:
3
2 at a time
225 m3 /hr
140 m
160 KW
HOT WELL
VOLUME:
103m3
QUENCHING BOX
Five lines are present in quenching box
It is used for thermo mechanical treatment
VERTICAL TURBINE PUMP
QUANTITY:
4
IN OPERATION:
2 at a time
FLOW RATE:
230 m3 /hr
HEAD:
20 m
POWER:
40 hp
103m3
CENTRIFUGAL PUMP
QUANTITY:
IN OPERATION:
FLOW RATE:
HEAD:
POWER:
3
2 at a time
170 m3 /hr
40 m
40 hp
HOT WELL
VOLUME:
103m3
FURNACE
TYPE:
CAPACITY:
ZONES:
BURNERS:
SKITS:
WATER SKITS:
Reheating furnace
31 tons/hr
4
19
10
7
214m3
CENTRIFUGAL PUMP
QUANTITY:
IN OPERATION:
FLOW RATE:
HEAD:
POWER:
3
2 at a time
170 m3 /hr
40 m
40 hp
MILL COMPLEX
It consists of following units:
Roughing stand
Intermediate rollers
Finishing rollers
VERTICAL TURBINE PUMP
QUANTITY:
3
IN OPERATION:
2 at a time
FLOW RATE:
190 m3 /hr
HEAD:
40 m
POWER:
40 hp
QUALITY
CONTROL
Visual
Inspection
Billet length
Measurements
Billet Weight
Measurement
Mechanical
Inspection
Tensile Test of
Sample of
final product
Bend Test of
Sample of
final product
Chemical
Inspection
Etching of
Sample of
final product
PRODUCT SPECIFICATION:
Yield Strength: 500 MPA (min)
Ultimate Tensile Strength: 575 MPA (min)
Rm/Re= T.S/Y.S: 1.15-1.35
Elongation [%]: 14% (min)
Amreli Xtreme Bars (ends cut) manufactured to BS 4449-2005
XTREME G-500W
Bar Size, mm
Area, mm2
Kg/m
9.5
12
16
19
22
25
28
32
70.91
113.41
201.4
0.56
0.89
1.58
2.23
2.99
3.86
4.84
6.32
283.64
380.29
491.07
616
804.57
Kg/ft
0.17
0.271
0.482
0.679
0.91
1.176
1.475
1.926
PRODUCT SPECIFICATION:
Yield Strength: 420 MPA (min)
Ultimate Tensile Strength: 620 MPA (min)
Rm/Re= T.S/Y.S: 1.46-1.57
Elongation [%]: 9% (min)
Amreli Deformed Bars (ends cut) manufactured to ASTM A615M
Area, mm2
Kg/m
10
12
16
20
22
25
28
32
36
40
78.57
113.14
201.14
0.62
0.89
1.58
2.47
2.99
3.86
4.84
6.32
8
9.87
314.29
380.29
491.07
616
804.57
1018.29
1257.14
Kg/ft
0.188
0.271
0.482
0.752
0.91
1.176
1.475
1.926
2.438
3.009
Cleaning
1.Table
2.Jaws/Grips
3.Force Measuring
Unit
4.Exterior
Oil Level
Check
Oil Leakage
Check
Bolt/Screw
Tightening
1.Jaws/Grips
2.Jaws Holder
3.Bend Pin
4.Bend support
Daily
MAINTAINANC
E FREQUENCY
Level of
Load Frame
Monthly
Annually
Oiling/
Greasing
Complete
Oil
Change
Oil Tank
Cleaning
Oil Tank
7. OIL SYSTEM
a. HYDRAULIC SYSTEM
POWER PACK
Power pack uses axial piston pumps to increase the pressure of oil. There are 3
nitrogen cylinders to store pressure that can be used if the requirement
increases. There is an ELM machine that cleans oil and separates iron from oil
by working on the principle of electrostatic induction. Pressure generated by
power pack is used in following sections:
Push rods
Ejector
Bar turn (rough mill)
Chain conveyer
b. Lubrication system
Lubrication system is used to provide lubrication to moving parts especially
gear boxes.
The lubrication system involves:
Pumps
Heat exchangers
Filters etc
8. RECOMMENDATION
Safety procedures are not good. Mill should ensure labor / employment protection.
Safety precautions were lacking in the plant. It should be made compulsory for the
workers to at least wear the glasses, gloves and helmet, cap where applicable, as:
Quality makes no sense without YOU & ME
9. CONCLUSION
Training at Amreli Steel Ltd. is really a true learning experience. It has not only taught
the utilization of bookish knowledge into practical field but also the ethics of
professional life. This internship would remain the part of magnificence memories for
the reason of ASLs hospitability. It is expected that this technical guidance &
professional knowledge would be helpful in my future studies