FOREIGN TRAINING REPORT

The up-gradation of Roughing mill of HSM/SAIL/BSL is planned in year 2014-15.

The successful up-gradation and stabilization of operation required trained manpower. It
is very prestigious project for the HSM and Bokaro Steel Plant. The future and growth of
Bokaro Steel Plant depend upon the successful up-gradation of the roughing mill. For
successful implementation of the project, a group of 40 (forty) executive from BSL &
CET in two batches given theoretical and on-site training at Daineli Training Centre in
Udine, Italy and site visit at Guefong Iron and Steel Company, Tansang, China.
The two batches compromise of the executive from HSM, ETL, DNW, PROJECT and
CET.
The training schedule split in two parts. In first parts, we were given theoretical input
about upcoming project and visit to Daneili Work Shop at Udine.
The major point of learning and observation at Daneili Training Centre, UDINE are:
1. Daneili documentation system for easy understanding of the equipments
drawings.
2. In detailed input were given about upcoming hydraulic system, their maintenance
and safety aspect about hydraulic system.
3. The drawing of different hydraulic system like RR2 HAGC, RR2 Entry Guide and
RR2 edger were discussed in details.
4. The drawing different mechanical equipments like RR2 Edger, RR2 Spindle and
HAGC were discussed in details.
5. The different aspect of roll cooling, descaling and lubrication were discussed.
6. Besides technical input we were also given managerial aspect of new project,
maintenance and safety.
7. We also visited the Daneili mechanical work shop at Udine. The visit to work
shop was very-very useful, as it is one of the best work shops that we have ever
seen. The work shop has advance machining tools and testing facilities. In work
shop we have seen the machining of mill housing and machining, assembling
and testing of the HAGC cylinder.
In second part of the training we were visited the Guefong Iron and Steel Company,
Tansang, China. It is one of best steel plant, we have ever seen. The plant layout and
housekeeping was beyond our imagination. It has two Hot Strip Mill with a capacity of
3.0MT and 3.5MT. The first Hot STRIP Mill was set up by Daneili. The single stand
reversible roughing mill is similar to the proposed RR2 at HSM/BSL. The plant layout is
such that the slab from continuous casting is directly charged to the furnace at the
temperature of 7000C through roller table, saving a lot of energy and heating time.
There we have seen the operation and maintenance of the RR2. There we visited the
different hydraulic room, oil cellars, pump houses and roll grinding shop. The detailed
input given to us will be discussed in next pages:

UP-GRADED FLOW DIAGRAM OF HSM

SCOPE OF UPGRADE
The scope of work will generally consider the following:
1. Installation of new 2Hi Roughing Mill with heavy edger at location of R#2 / E#2.
2. Upgrade / revamp the existing Stand Roughing Stands R#3, R#4 & R#5 with
introduction of hydraulic work roll change system.
3. New short stroke hydraulic AGC in R#5.
4. Modification & strengthening of attached edgers E#3, E#4 & E#5 with provision
of long stroke hydraulic Automatic Width Control to improve width tolerances of
transfer bar.
5. Installation of new passive heat shield on Delay Table with up-gradation of
QWRC system of Finishing Stands.
6. Installation of new width gauges.
7. Roller table modernization with conversion to AC drives from DC drive.
8. Provision of new hydraulic & lubrication systems
9. Introduction of new automation systems.
10. Air-conditioning & ventilation systems.
11. Machining & other modification jobs as may be necessary.
12. Interfacing / integration of modified systems with existing electrics / automation.

ORGANIZATION OF PROJECT NUMBERING

Job Number
Contract Items
Equipment Code
JET
Bill of Material
Parts from Marketing
Spare Parts
Sub Supplier Documentation
Assembly Drawing 8.NNNNNN.L
Assembly Drawing 6.NNNNNN.L
Detail Drawing 4.NNNNNN.L

JOB NUMBER

DP0ACB01
JET NUMBER

DP0ACB010960 = JET Number 09.60

DANIELIS NUMBERING DRAWINGS AND OTHER

DOCUMENTS NOT CLASSIFIED AS SHOWN PREVIOUSLY

MAINTENANCE TASKS

1.
2.
3.

4.

Lubrication
1) lubrication table for components
2) lubrication standard
Condition Monitoring
1) vibration analysis
2) temperature monitoring
Preventive maintenance
1) inspections
2) alignment
3) preventive maintenance time-table
4) repair components
5) tools required
Extraordinary maintenance
1) replace faulty components
2) replace damaged components

NEW DESCALER DESCRIPTION

The descaler removes scale from the transfer bar using high
pressure water.
The main components of the descaler are as follows:
Top metal cover to contain the high pressure water and scale
Top and bottom headers with multiple nozzles across the length
of the headers

Descaler Maintenance Notes

The following are some notes related to Mechanical Maintenance activities:
1. Regular testing must be done on the descaler system to ensure it is working
properly
2. Test the nozzle spray pattern
3. Test individual pumps
4. Test combination of pumps
5. Test individual headers
6. Test combination of descaler headers

Entry Side guide Description

The Entry Side guides at the Vertical Edger E2 are used to guide
the bar into the Edger and Roughing Stand RR2 and keep it
centered.
Design Features:
1. The entry side guides consist of two (2) sections of movable
side guides (one trailing).
2. The leading entry section of the side guides is connected to
a fixed point on both sides near the exit side of the approach
table using pivot pins.
3. The free end of each side guide is connected to a second
set of side guides mounted on each side of the table to the
two (2) ram arms by pivot pins.
4. Operator and drive side guides are mechanically
synchronised through rack and pinions.
5. The sideguides are made of welded steel, each guard
supported on two (2) rams [total four (4) rams].

RR2 EDGER DESCRIPTION

The Vertical Edger E2 is used to keep the bar width within the set
tolerance values and to improve the edge quality.
Design Features:
1) Top driven type - rolls driven through a gear drive coupled with vertical
motors.
2) Edger housings designed to withstand both the separating forces of rolls
combined with the push and pull forces between Edger and reversing
mill. Steel structures connection between edger housing and mill
housings.
3) Roll opening adjustment by hydraulic cylinders with position transducers.
4) Pull back cylinders included for clearance take-up between roll housing
and cylinders.
5) Edging rolls vertically mounted in roll housings provided with tapered roll
face.
6) Edging rolls cooling by means of external headers.
7) Feed rollers mounted on entry and delivery side of edger, rollers
externally water cooled.

RR2 MAIN STAND DESCRIPTION

The 2-Hi Reversing Finishing Mill is used for the rolling of hot steel slabs in
three reversible passes.

Design Features:
1) Two High Reversing Roughing Mill.
2) Mill work rolls individually direct motor driven by means of cardan
shaft type spindles.
3) Top mounted long stroke hydraulic cylinders for HAGC.
4) Hydraulic work roll clamping system.
5) Feed rolls on entry and delivery sides of mill.
6) Pass line adjustable by shims at the bottom of WR.

DESCRIPTION OF TOP WORK ROLL BALANCE OF RR2

The function of this unit is to provide top work roll balancing and assure
proper contact force between the WR chocks and the HAGC Cylinders.

Design Features:
1. The top work roll chocks are suspended by a yoke hanger bar.
2. The top work roll assembly is hydraulically balanced by one (1)
cylinder located in the housing separator.
3. The balancing cylinder is hydraulically locked during Work Roll
changing.
4. The locking pins must be inserted every time work will be done on
this unit or in the area under it inside the mill stand .

DESCRIPTION OF HAGC OF RR2

The HAGC system is used to control the roll gap so as to ensure the proper
bar thickness.

Design Features:
1. The high pressure roll force cylinders are controlled by servo
valves, which are connected to the cylinders by manifold blocks.
2. Two position transducers are used to measure the cylinder
position.
3. The pressure transducers installed on the manifold blocks
measures the cylinder pressure in order to determine indirectly
the rolling load.
4.

DESCRIPTION OF RR2 SPINDLE SUPPORT

The Spindle Support supports the weight of the spindles.

Design Features:
1. Independent supports for top and bottom spindles.
2. Vertical balance unit
a. Spindles riding in split, anti-friction spherical roller bearings
b. Bearings housed in spindle support cartridge
c. Independent balancing system for top and bottom spindle is provided.
d. Top and Bottom spindle cartridges hydraulically positioned through link and pin
arrangement.