INTERNSHIP REPORT

SUBMITTED BY :

PRASHANT RANJAN

11EEO15
INTERNSHIP
AT
BHUSHAN STEEL LTD.

LINGAYAS UNIVERSITY,FARIDABAD
SESSION 2011-2015

ACKNOWLEDGEMENT
Every Work big or small is successful largely due to the effort of a number
of wonderful people who have always given their valuable advice or lent a
helping hand. I sincerely appreciate the inspiration; support and guidance
of all those people who have been instrumental in making this internship a
success.
I, PRASHANT RANJAN, the student of LINGAYAS UNIVERSITY(EEE),
am extremely grateful to BHUSHAN STEEL for the confidence
bestowed in me and entrusting my six month internship.
At this juncture I feel deeply honored in expressing my sincere thanks to
MR. ANCHIT TIWARI at the company for making good information about
the process under going in the company and providing valuable insights
leading to the successful completion of my six month internship.
I express my gratitude to College Director for arranging the summer
training in good schedule. I also extend my gratitude to my mentor
Guide MR. RAKESH CHOUDHARY , who assisted me in compiling the
internhip.
I would also like to thank all the faculty members of LINGAYAS
UNIVERSITY for their critical advice and guidance without which this
internship would not have been possible.
Last but not the least I place a deep sense of gratitude to my family
members and my friends who have been constant source of inspiration
during the internship.

ABSTRACT
In todays world, Bhushan group has a commendable presence in India among
the leading industrial houses. Since 1987, Bhushan steel ltd. has epitomized itself
as a pioneer in product innovation and technological upgradation.

The company now commands an enviable positions of having Indias one of the
best steel manufacturing plants, production of steel sheet up to a width of
1700mm, as well as Galvanized Coil and Sheet up to a width of 1350 mm.

Bhushan group is constantly on the lookout for advanced technology assimilation

for product development and innovation. Product process optimization and
benchmark itself with world class quality products and customer service have
made the group highly competitive, reliable and efficient.

CONTENT
Acknowledgement
Abstract
Content
1. CHAPTER 1 : INTRODUCTION
1.1 ABOUT BHUSHAN STEEL LTD.

2.CHAPTER 2 : THEORETICAL PROCESS

2.1 SAFETY
2.2 PICKLING/HRS
2.3 HITACHI MILL
2.4 ECL (ELECTROLYTIC CLEANING LINE)

CHAPTER 1

INTRODUCTION

CHAPTER 1.1
BHUSHAN STEEL.
Bhushan Steel Ltd formerly known as Bhushan Steel & Strips Ltd. is a globally
renowned one of the leading prominent player in Steel Industry. Backed by more
than two decades, of experience in Steel making, Bhushan Steel is now Indias 3rd
largest Secondary Steel Producer company with an existing steel production
capacity of 2 million tones per annums (approx.).
It was the vision of the founder; Brij Bhushan Singal , that the first stake was
driven into the soil of Sahibabad (Uttar Pradesh) in 1987. His vision helped BSL
overcome several periods of adversity and strive to improve against all odds.
The company has three manufacturing units in the state of Uttar Pradesh
(Sahibabad Unit), Maharashtra (Khopoli unit), and Orissa Plant (Meramandali
unit) in India and sales network is across many countries.

The company is a source for vivid variety of products such as Cold Rolled Closed
Annealed , Galvanized Coil and Sheet, High Tensile Steel Strapping , Colour Coated
Coils , Galume Sheets and Coils, Hardened & Tempered Steel Strips , Billets,
Sponge Iron, Precision Tubes and HFW/ERW Pipe.
As one of the prime movers of the technological revolutions in Indian Cold Rolled
Steel Industry, BSL has emerged as the countrys largest and the only Cold Rolled
Steel Plant with an independent line for manufacturing Cold Rolled Coil and Sheet
up to a width of 1700mm, as well as Galvanized Coil and Sheet up to a width of
1350 mm.
In due course of time, BSL has grown incredibly its turnover and production
capacity by successive expansions as well as improved realizations with these
manufacturing units.
The dynamic reason of awesome and unparallel growth of BSL, is rapid
integration on the Steel value chain; conceivably, it would be its unwavering focus
on acquiring the latest technology and know how, also the BSLs commitment to
provide its customers with the best quality products.
Given a vibrant Steel industry dynamics in India, we are on a course to become a
fully Integrated Steel & Power Company with market leading offerings in value
added Steel in Automotive and White Good Segment with the quality been
approved by ISO 9001:2008 & ISO 14001:2004.

CHAPTER 2.1

SAFETY
NO JOB OR TASK IS MORE IMPORTANT THAN WORKER SAFETY.

SAFETY COMMITTEE
The primary purpose of the Safety Committee is to promote safety awareness and
reduce the potential for injury/loss throughout the Company.

SAFETY GOALS
The following goals have been established for Bhushan steel Company:
(1) Provide workers with a safe work environment.

(2) Conduct routine/regular workplace inspections.

(3) Provide Personal Protective Equipment.

(4) Develop and implement safe work procedures and rules.

(5) Provide on-going safety training.

(6) Enforce safety rules and appropriate discipline.

(7) Provide on-going property conservation practices.

SAFETY RULES
All safety rules must be obeyed. Failure to do so will result in strict
disciplinary action.
All injuries must be reported as soon as possible.
No horseplay, alcohol, or drugs allowed on premises.
No alcohol usage allowed during lunch break.
PPE must be worn as prescribed by management.
All tools/equipment must be maintained in good condition

Only appropriate tools shall be used for specific jobs.

All guards must be kept in place.
No spliced electrical cords/wiring allowed.
Only authorized personnel can operate forklift vehicles.

Smoking allowed only in lunchroom.

Industrial safety items

CHAPTER 2.2

PICKLING/HRS

Pickling is a metal surface treatment used to remove impurities, such as

stains, inorganic contaminants, rust or scale from steel metal.

A solution called pickle liquor, which contains strong acids, is used to

remove the surface impurities.

SPECIFICATION OF PICKLING
MATERIAL SPECIFICATION : HOT ROLLED STEEL COIL.
DIMENSION SPECIFICATION :
WIDTH

: 1700 MAX.

THICKNESS

: 60 MM MAX.

WEIGHT OF COIL

: 30 MT MAX.

LINE SPECIFICATON

MAX. SPEED

: 120 MPM

STEPS INVOLVE IN PICKLING

1. Loading of coil.
2. Acid treatment of the input material.
3. Hot water rinsing.
4. Drying.
5. Oiling.
6. Recoiling of the coil.
7. Strapping & labeling.
8. Transfer of output material.

LAYOUT OF PICKLING PROCESS

CHAPTER 2.3

HITACHI MILL
The purpose of 6 hi HITACHI ROLLING MILL is to reduce the thickness as per
customer requirement.
This mill provides the high quality, improved productivity, energy savings, and
other characteristics that are demanded in cold rolling, as well as superior shape
control and stable operation.
By reducing the diameter of the work rolls, this mill achieves both high reduction
rolling and lower rolling energy consumption.
The rolling mill adds roll coolant control to the 3 existing types of control
(intermediate roll bender, intermediate roll shift, work roll bender) to deliver
superior shape control capability.

Hitachi mill consists of 6 rolls thats why it is known as 6 HI HITACHI MILL.

These 6 rolls are

1. Backup roll (Number of backup roll 2) .

2. Intermediate roll (Number of intermediate roll 2).
3. Work roll (Number of work roll 2).

The pictorial internal diagram of 6 hi Hitachi

Machine.

GRADE
Grading is the standards of steel material according to their hardness.
Grading provides the information about the Require steps to reduce the thickness
as a desire value.

Grading of steel according to increasing hardness

1. IF
2. EDD
3. DD
4. D
5. 340H
6. 390H
7. 400H
8. MC-11
9. MC-12

CHAPTER 2.4

ECL (Electrolytic cleaning line)

Cold rolled coils processed in cold rolling mills have a thin film of residual rolling oil on
the surface after rolling.

The alkaline cleaning of cold rolled coils by the use of high current density (HCD)
ensures totally clean surface of the strip before annealing.

This electro-chemical cleaning process is called Electrolytic Cleaning and the

processing line the Electrolytic Cleaning Line.

An ECL line cleans the strip surface of oil and dirt by chemical action, using an alkaline
solution.

The strip passes between electrodes which are immersed in tanks containing the
electrolyte.

This technique is more effective in cleaning cold rolled steel than conventional cleaning
processes used on high speed electro tinning and alkaline-cleaning lines.

ECL SPECIFICATON
MAX. SPEED

300 MPM

MAX. STRIP WIDTH

1700 MM

MAX. COIL WEIGHT

30MT

STEPS INVOLVE IN ECL

1. Loading of coil.
2. Feeding of coil.
3. Welding of coil ends.
4. Primary cleaning.
5. Electrolytic cleaning.
6. Hot water rinsing.
7. Drying.
8. Inspection
9. Recoiling
10. Strapping.
11. Storage and transfer to next process.

LAYOUT OF ECL PROCESS

FUTURE LAYOUT
Internships can be a career deciding factor in a students
professional life.
Internships are extremely important as they provide students
with confidence and experience in working in the real world.
In upcoming next 4 months we are going to work under the
department such as:
1. Annealing
2. Skin pass
3. Finishing
4. Quality
5. Color coating lines
6. Mechanical maintenance
7. Electrical maintenance
8. R & D
9. Utility
THANK U.