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This plant is developed as backward integration for ISMT Steel Plants to cater with
the quality & cost effective Steel with the desired grades. This plant serves with
60% of its capacity to ISMT Ltd. & with another 40% to outside customers.
Process Flow :-
Scrap/ Metallics
Primary Melting
Secondary Refining
& Ferro alloy
addition
Vacuum Degassing
Continuous Casting
of 160/200/225mm
rounds for Carbon &
alloy steels
Inspection of blooms
As cast products
Rolling
Finishing operations
& inspection
Heat Treatment
Despatch
Raw Material
Metal Scrap is used as input material for EAF (Electric Arc Furnace), which is
primary melting.
Types of scraps:
1) Heavy Melting scrap (includes Mill returns) C : 0.15-0.40%
2) Pig Iron C: 4-4.5%
3) Pig Iron Skull (cheapest)
4) DRI (Direct Reduced Iron) C: 1.25-1.75%
5) Shredded Iron (high volume low mass contents)
FLUXES USED :
EAF (Electric Arc Furnace): Primary melting is carried out in the EAF which
is of eccentric tapping type.
4-5 MT is retained in the ladle to enable easy melting of the new charge.
EAF charging is done in two steps,
Liquid metal
(Scrap/Liquid metal Yield is approximately 90 %)
Process Parameters
While 90 % of refining takes place in the Primary melting phase, the fine tuning of
steel chemistry takes place in the secondary melting phase in the LRF. Samples
are taken 4-5 times during ferro-alloy addition. Cycle time for secondary
refining = 50 mins. Argon purging is continuously done to maintain temperature
and homogeneity.
Vacuum Degassing:
Laddle
Straightener (Three no. of Rolls apply a pressure of 20bars (each) to pull the
Bloom and straighten it)
Auto Gas Cutter (To cut the required length Billets. Front end discard = 1m, Rear
end discard = 1.5m)
Hot stamping (Heat No. stamping is the first step used for tracking of material)
Casting Parameters:
Casting Size mm
160
180 (As specific requirement of customer)
200
225
Walking Hearth Furnace, WHF : (WHF has a capacity of 25T/hr for cold charge
and 40 T/hr for hot charge)
It consists of three heating zones & two soaking zone with 10 no's burners. Two
burners in each Zone
1) Heating Zone I : temp upto 1150 `C
2) Heating Zone II : temp upto 1200`C
3) Heating Zone III : temp upto 1220`C
4) Soaking Zone IV : temp upto 1220`C
5) Soaking Zone V : temp upto 1220`C
De scaler ; 180Kg/cm2 water jet is used to de scale or peel the outer surface of
the bloom. The purpose of the same is to remove the bad conductors that adhere to
the OD.
Rolling Mill:
Spheriodised Graphite Iron Rolls are employed in USRM and DSRM.
Down Stream Rolling Mill, DSRM (Maximum of 20% reduction can be done)
Typical sizes rolled here are as follows:
Despatch (12-15,00Mt/month)
Quality Assurance:
Finish shop Quality Inspection consists of four types for crack detection
The erstwhile Kalyani Seamless Tubes Ltd., 1995 was taken over by ISMT in April
2000 and is referred to as the ISMT Tube Plant B.
Installed Capacity = 150,000 MT/annum
Permanent Employees = 670
Contract Employees = 100 ( 350 additional manpower for PQF Mill)
Despatch = 10,000MT/month
Input to Structo is to the tune of 4000MT/month from this plant.
Manufacturing Process:
Raw Material
Billet
inspection &
Cutting
RHF
Piercing Mill
Assel Mill
Sizing Mill
CD CP
EFS
Billet Cutting:
Billets are gas cut into the required lengths for furnace.
Size :- OD: 137mm – 225mm & Length : 1.8m to 3.6m.
The existing RHF has the installed capacity of 35MT. In addition to this,
installation of new RHF of 75 MT capacity is going on which will cater the PQF
requirement. The billets are heated upto 12000C. Soaking time depends on Billet
Diameter. Fuel used is Furnace oil & LDO.
Piercing Mill:
Piercing is a hot forming process of billets to hollows. The Billets are fed/pushed in
a linear as well as rotary motion (spiral motion) with the help of feeding rollers
placed at 150 inclination. Centering is not required due to the large diameter of the
Billet. Piercing is effected as the hot steel envelopes over the piercing point.
By introducing a piercing mandrel arranged in the roller gap, solid round material
could be pierced to produce a hollow shell in the rolling heat by the cross rollers.
Assel Mill:
Wall thickness control is achieved in this Mill. A mandrel bar is in contact with the
hot tube where the inclined rolls of the mill pull the tube. Concentricity is achieved.
The assel mill is ideal for producing low volume customized tubes with high
dimensional accuracy & excellent concentricity. As a result, these tubes are ideal
for manufacturing the items like a bearing rings, cages for velocity joints &
automobile patrs etc.
The assel features a three tapered roller arranged symmetrically at an offset of
120 degrees each.
OD control & finishing is done with the help of multiple tool cassettes mounted in
this mill.
This serves excellent operation for concentricity.
HFS
STP
Notes:
Quality Management:
Following tests are carried out in QA -
YS test, UTS, Impact test, Bend test, Hardness testing & NDT.
ECT : For Non-Bearing steel to identify OD cracks only for sizes from 19mm to
140mm. Standard specimens are prepared with 0.2x50mm sized notch. Tubes are
tested by comparing with the standard specimen. Longitudinal cracks/defects upto
0.3mm can be detected.
Testing Parameters:
a/c input of frequency 60KHz is applied. There are 4 probes which revolve at a
speed of 1440rpm around the tube. A crack is detected by change in magnetic field
since there is change in impedence.
Spiral Testing:
Combination of ECT and UST is done by passing the tubes spirally under the
testing probes. ID & OD i.e. Cross section defects are detected.
1) Tube Plant
2) PTD (Precision Tube Division)
3) CRR & T (Cold Ring Rolling & Tooling)
Mill I Mill II
Centering Induction
Machine Heating Coils
Piercing Mill
Assel mill
Stripper Chain
Hot Finishing
Stand
Cooling Chain
HFS : PROCESS ROUTE
Straightening GKW
Tally Sheet
Tube Plant:
Tube plant has two mills.
Mill I:
Furnaces
A Walking Hearth Furnace is used as the preheating furnace. Here the
temperature up to 800° C – 900° C is achieved and further send to induction
heating coils to achieve the required temperature
• Centering Machine
As Billet diameters are small it requires proper piercing point for accurate
piercing. So centering is done.
• Piercing Mill
The assel mill features three tapered rolls arranged symmetrically at an offset
of 120 degrees. This method is characterized by excellent concentricity &
employed in the production of turned components ( shaft,axles) & also medium
alloy steel roller bearing. The main features of the roller pass is the so-called
shoulder or hump, the height of which determines the degree of wall thickness
reduction.
SR No OD Tolerances
1) 55 mm to 80 mm +/- 0.79 mm
2) 80.1 mm to 120 mm +/- 1.0 mm
3) 120.1mm to 160 mm +/- 1.2 mm
• Stripper chain
• Hot Inspection Table
To avoid the last stage wastage, inspection is done at hot stage only. Here wall
thickness and tube diameter are measured.
SR No OD Tolerances
1) 54 mm to 80 mm +/- 0.60 mm
2) 80.1mm to 120mm +/- 0.79mm
3) 120.1mm to 160mm +/- 1.0mm
Straightening Machine:
1st Installation:
2nd Installation:
Cold Pilgering:- The hollow shell is pushed over a lubricated cylindrical mandrel,
the diameter of which roughly corresponds to the desired inside diameter of the
finished tube. The shell -and-mandrel assembly is then fed into the pilger rolls by a
feeder. As hallow shell is “bitten” by the tapered inlet of the work pass, a small
wave of material is pressed away from its external surface & then forged to the
desired wall thickness by the smoothing portion of the work pass acting on the
mandrel.
The tube elongation is achieved by reduction of the outer diameter as well as the
wall thickness of the ingoing tubes. The cold pilger is characterized by very small
dimensional variations i.e close tolerances can be achieved, the surface finish is
good & because of cold working the hardness level & machineabilites are
excellent.
60-65% OD reduction is possible & Hardness is increased from 180-200 BHN to
225-270 BHN.
Sphereodizing
Cold sizing
Straightening
End Finishing ,
Inspec tion, Pac king &
Despatc h
PTD Division:
Draw Bench:
There are three draw benches of following drawing capacities
DB 1 = 40 MT
DB 2 = 15 MT
DB 3 = 5 MT
STP
Push Pointing
Cold Drawing
Heat Treatment
Process
Straightening
Cutting
ECT
Final Inspection
& Despatch
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