DURATION: 29/09/2021 – 27/10/2021

SUBMITTED BY:
NAME : ROOPAM KR. RAJ
QUALIFICATION : B.TECH, 4TH YEAR
(ELECTRICAL ENGINEERING)
REG. NO. : 18030450072
ACADEMIC SESSION : 2018-2022

BIT Sindri
BIRSA INSTITUTE OF TECHNOLOGY, SINDRI
DHANBAD, JHARKHAND
 TABLE OF CONTENTS

 ACKNOWLEDGEMENT……………………………………………………… PG.1
 HISTORY OF COMPANY & COMPANY PROFILE………………… PG.2-3
 CORE VALUES…………………………………………………………………… PG.4
 SAFETY EXCELLENCE……………………………………………………….. PG.5-6
 LIST OF PLANTS……………………………………………………………….. PG.7
 SAHIBABAD PLANT AND FACILITIES……………………………….. PG.8
 UTILITIES........................................................................................................ PG.9
 HR (HOT ROLLED) SLITTING………………………………………….... PG.10-11
 PICKLING………………………………………………………………………….. PG.12-13
 COLD ROLLING MILL………………………………………………………… PG.14
 ELECTROLYTIC CLEANING LINE……………………………………..... PG.15
 ANNEALING…………………………………………………………………….... PG.16
 CONTINOUS GALVANIZING LINES (CGL)………………………….. PG.17-22
 COLOR COATING LINE……………………………………………………... PG.23
 H & T LINE, FINISHING SECTION……………………………………... PG.24
 ELECTRICAL MAINTENANCE…………………………………………… PG.25-26
 MECHANICAL MAINTENANCE…………………………………………. PG.27-28
 QUALITY MANAGEMENT SYSTEM…………………………………… PG.29
 ROLE OF INTERN DURING INTERNSHIP………………………….. PG.30
 CONCLUSION………………………………………………………………….... PG.31-32
 ACKNOWLEDGEMENT

This internship opportunity with TATA STEEL BSL LTD. Sahibabad was
a stepping stone for my career and professional development.
Therefore, I consider myself as a very lucky individual as I was provided
with an opportunity to be a part of it. I am also grateful for having a
chance to meet so many wonderful people and professionals who led
me though this internship period.

I express my deepest thanks to Mr. Abhinav Sharma, HEAD HRM for

taking part in useful decision & giving necessary advices and guidance
and arranged all facilities to make life easier. I choose this moment to
acknowledge his/her contribution gratefully.

I express my thanks to my mentor Mr. Siddharth Jain, Divisional

Manager GP-1 Electrical for guiding me throughout my internship and
in making of this project. I would also like to express my deep sense of
gratitude to the entire workers and technicians of various
departments.

I perceive as this opportunity as a big milestone in my career

development. I will strive to use gained skills and knowledge in the best
possible way, and I will continue to work on their improvement, in
order to attain desired career objectives. Hope to continue
cooperation with all of you in the future,
Sincerely,
Roopam Kr. Raj
 HISTORY OF COMPANY
&
COMPANY PROFILE

On May 18, 2018, Tata Steel acquired Tata Steel BSL Limited (formerly
known as Bhushan Steel Limited) through its wholly owned
subsidiary Bamnipal Steel Limited.

Tata Steel BSL Ltd is one of the prominent players in the Indian Steel
industry. Backed with more than 27 years of experience, the company
is now India's 3rd largest Secondary Steel Producing Company with an
existing steel production capacity of 5.6 million ton per annum.

As one of the largest integrated steel players in India, Tata Steel BSL is
a source for vivid variety of products such as Hot Rolled Coil ,CRCA
,CRFH ,Galvanized Coil and Sheet, Galume Coil and Sheet, Color Coated
Coils, Color Coated Tiles, High Tensile Steel Strips, Hardened &
Tempered Steel Strips, Precision Tubes, HFW/ERW Pipe (API
Grade),3LP Coated Pipes, Billets and Sponge Iron.
Being amongst the prime movers of the technological revolution in
Indian Cold Rolled Steel Industry, Tata Steel BSL has emerged as the
country's 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. Along with this we also have a Galvanized Coil and
Sheet line up to a width of 1350 mm.

In addition, strengthening us to grow from pillar to pillar is our robust

network of sales and marketing units across Indian continent and other
countries helping us reach our global customer base.

At Tata Steel BSL, we are living tomorrow today; because the endeavor
to a brighter future starts from today. In superior community building,
in harnessing safety, by nurturing the environment and by adopting
world-class technology for producing outstanding products, Tata's
resilient approach to its impeccable vision makes it a global Integrated
Steel producer.
 CORE VALUES

 Integrity
We will be fair, honest, transparent and ethical in our
conduct; everything we do must stand the test of public
scrutiny.

 Excellence
We will be passionate about achieving the highest
standards of quality, always promoting meritocracy.

 Unity
We will invest in our people and partners, enable
continuous learning, and build caring and collaborative
relationships based on trust and mutual respect.

 Responsibility
We will integrate environmental and social principles in
our businesses, ensuring that what comes from the people
goes back to the people many times over.

 Pioneering
We will be bold and agile, courageously taking on
challenges, using deep customer insight to develop
innovative solutions.
 SAFETY EXCELLENCE

Tata Steel BSL is committed towards a safer and healthier

work environment. Our safety measures include training in:

A dedicated audio-video centre at all our plants.

Every worker is provided with proper first-in-class safety
equipment making it safe for them to undertake different tasks
throughout the day.

Mock drills and seminars that are conducted on a monthly

basis also help in cross-checking the safety knowledge and
awareness amongst the workers, and bridge any
communication gap that might exist between the workers and
our safety department.
Regular health check-ups are done at the plant, with
compulsory participation for all workers to make certain that
their health is not being compromised in anyway.

Our Safety Training Program:

Everyone entering our plant has to go through a safety
training program, in which we teach them all the basic
measures that one needs to follow in case of emergencies
and in general. The task here is to inform, educate and train
employees and visitors in the vicinity of the plant about the
hazards and preventive measures

A specifically shot safety video gives a proper demonstration

of how different safety measures are being undertaken at
Tata Steel BSL. Mock drills are conducted every month with
four mock drills witnessed by the respective district
authorities every year.

With an extensive safety and health policy in place, a

comprehensive system is built around the framework of the
plants to manage safety measures of the highest order. It
involves:
Daily rounds by HODs of every department Appointment of
safety captains.
Officers and internal as well as external safety audits to look
into preventive and safety measures for the plant.
A unique safety rewards and penalty program has been
introduced with regular inspections and checks.

At Odisha plant the company also has a 6-bedded

Occupational Health Centre that stands in service with:
 Two 24-hours in-house doctors
 Adequate medical staff.
 Ambulance
 LIST OF PLANTS

Engaged mostly the in the manufacturing of hot coiled rolls,

alloy billets, galume coils, drawn tubes of OEM grade, cold
rolled steel sheets, colour coated tiles and hardened and
tempered steel strips, the Tata Steel BSL Plant at Khopoli in the
state of Maharashtra is listed as one of the top suppliers of
steel components in India.

The Company’s plants are spread across the four locations of:

Sahibabad

Khopoli

Dhenkanal

Hosur
SAHIBABAD PLANT
AND
FACILITIES
 UTILITIES

Every industry/ plant has some utilities which are

essential for the functioning of the same.
These are the essential utilities at TATA STEEL BSL Ltd,
Sahibabad Plant:
CRANES

PUMP HOUSE

BOILERS

GAS PLANTS

COMPRESSORS
 HR (HOT ROLLED) SLITTING
(SMS– ESMECH)

Slitting serves three purposes:

1. HR coils are available in widths which are wider than the required
for Cold Rolling. The trimming / slitting is done with the HR Slitter.
2. The HR coils available may have width variation of the order of
up to 20 mm, so to get the uniform width these coils are slitted.
3. The edges of HR coils may get damaged during transportation
because of poor packaging and/or improper handling. In order to
remove these damaged edges, the HR coils are trimmed/slitted.

Various process involved are-

 Loading of coil
 Feeding of coil
 Setting of cutters
 Trimming
 Recoiling
 Removal of coil
 Stepping & labelling of output material
 Storage of output material
 PICKLING (SMS-ESMECH
WITH THE TECHNOLOGY
COLLABORATION WITH PRO
ECO, CANADA)

Pickling Line – 01 No
Pickling Line – 02 No's
Pickling is a metal surface treatment used to remove impurities,
such as stains, inorganic contaminants, rust or scale from ferrous
metals, copper, precious metals and aluminium alloys.
 Thickness Range – 1.6 to 6mm
 Width Range – 700 – 1700 mm

WHAT IS STEEL PICKLING?

When steel is cooling, after hot-rolling, the oxygen in the atmosphere
chemically reacts with the hot surface iron on the steel and forms a
compound normally referred to as SCALE.

Chemically speaking, this scale can be made up of one or any or all of

these separate compounds:
Iron Oxide - scale (black, scaly)
Ferrous Oxide - rust (brown, powdery)
Ferric Oxide - magnetite (blue black, magnetic)

This scale, no matter what proportion of the three above

compounds it contains, is generally a very hard, brittle coating, from
between paper thick to 1/32" thick, adhering to the surface of the
steel.

No 'foreign' material can be present when the steel is further

processed such as in sizing by cold rolling or drawing or forming by
stamping etc. This means that the scale must be removed prior to
this processing.

The activities involved in pickling are:

 Loading of Coil.
 Acid treatment of the I/P Material.
 Hot Water Rinsing.
 Drying.
 Oiling.
 Re-Coiling.
 Removing of Coil.
 Strapping & Labelling.
 Transfer of O/P Material.
COLD ROLLING MILL (HITACHI,
JAPAN / CMI, INDIA)

 6 Hi Mill – 3 No's
 2 Hi Mill – 2 No's
 Width Range – 650 – 1700 mm
The primary function of Cold Rolling is to reduce the thickness of
Hot Rolled Pickled strip at room temperature. During the
operation overall max reduction of up to 90 % in thickness of the
HR Coil can be achieved. Cold rolling occurs with the metal below
its recrystallization temperature (usually at room temperature),
which increases the strength via strain hardening up to 20%. It
also improves the surface finish and holds tighter tolerances.

Rotating Rolls perform two main functions:

 Pull the work piece into the gap between them by friction
between work piece and rolls.
 Simultaneously squeeze the work piece to reduce its cross-
section
 ELECTROLYTIC CLEANING
LINE (CMI-FPI, INDIA)

 Thickness – Upto 3 mm
 Width – Upto 1700 mm
Electrolytic Cleaning Line is responsible for the electrolyte
cleaning of the rolled sheet surface in order to have its surface
contaminations and greases removed in two dipping tanks
containing alkaline solution and electrolyte cleaning.

The Process Being Carried Out at ECL Involves Following

Steps:
 Loading of Coil.
 Feeding & Welding of Strip.
 Primary Cleaning of Strip,
 Electrolytic Cleaning of Strip.
 Hot Water Rinsing of Strip.
 Drying Of Strip.
 Inspection.
 Filter Paper Test.
 Pickle lag test.
 Recoiling of Strip,
 Unloading of Coil.
 Storage & Transfer of Processed Coil.
 ANNEALING

ANNEALING FURNACE (EBNER)

Total No. of Bases – 49
Annealing Furnaces are H2 furnaces with higher convection are from
EBNER, AUSTRIA & ALLIED, and MUMBAI. Complete automation in the
line ensures Clean & flawless surfaces. Annealing is a process in which
metals, glass and other materials are treated to render them less
brittle and more workable. In the steel industry, the steel is heated and
profile controlled, with times and temperatures set according to the
properties desired to reach an increased ductility and relieve strains
that lead to failures in service.

KATHABAR (IMTECH DRYGENIC, USA)

Total No. of Bases – 42
BSL is having KATHABAR cooling
system from IMTECH DRYGENIC, USA.
By this system we can supply
dehumidify air to annealed coil for
cooling of coils for best result. In this
system the liquid desiccant can
remove contaminants in the air like
oil & grease & filter them out.
 CONTINOUS GALVANIZING
LINES (CGL)/
GALVANIZING PLANTS(GP)

The purpose of the Continuous Galvanizing line is to apply a coat of

zinc onto the surface of steel sheets in an effort to increase their
corrosion resistance. There is a wide range of control of zinc coat
thickness, and the galvanised steel sheets are used for a board range
of purposes, including construction materials, automobiles and
electrical appliances. The COLD ROLLED (CR) Coils are
galvanized/galvalumed.
GALUME is the trade name for a sheet steel product with a highly
corrosion resistant coating containing nominally 55% aluminium and
43% zinc by weight, the balance primarily silicon is used to effect
excellent adhesion to the steel substrate. This metallic coating which
is applied using a continuous hot-dip coating process combines the
galvanic corrosion protection of zinc with the barrier protection of
aluminium. GALUME coils are produced only in GP-4

Galvanising Line – 3 No's:

 Galvanizing Plant-1

 Galvanizing Plant-3

 Galvanizing Plant-4 (Galvalume Line)

 CGL Entry Specifications:

Process CR Thickness : 0.25 mm – 2 mm

Process CR Width : 750 mm – 1270 mm
Pay of Reel Tension : 57 KG – 570 KG
Accumulator Tension : 150 KG – 1000 KG
Entry Speed : 12 MPM – 150 MPM
Process Speed : 12 MPM – 120 MPM
Exit Speed : 12 MPM – 150 MPM

CGL Components:

Pay of Reel (POR): Feeds steel sheets through the

production line. It unwinds a coil into the downstream
line. Also called decoiler or unwinder.

Entry Shear: Used to remove scrap from the CR coils

after unwinding.

Seam Welder.
Steering Unit: Used to steer the coils or keep the coils
rolling on the center of the rolls.

 Entry Accumulator: Accumulates the steel coil/ sheet

so that the whole line doesn’t needs to be turned off in
case of particular section freezing for a very short while.

 Line Briddles: Used to provide tension to the sheet as it

tends to get loose while being on the galvanizing line.

 Furnaces: Before getting coated with Zinc/Aluminium,

coils are heated in the furnace so that the coating can
stick properly. Different types of furnaces are used.

GP uses:
 Pre-Heating Furnace (PHF)
 Radial Tube Furnace (RTF)
 Soaking Furnace (SF)
 Jet Cooling Furnace (JCF)

Zinc Pot: Big pot where molten zinc is present, sheet

passes through it and gets coating with use of sink and
stab rolls.
Cooling Towers: After going through zinc pot, sheet
goes through cooling towers where it is cooled using
blowers.

Quenching Towers: Sheet is further cooled using water

in quenching tanks.

 SKIN PASS MILL (SPM):

4 HI (Horizontal Inserted) SKIN PASS MILL, sometimes
when coils of thickness greater than normal processing
thickness comes (upto 4mm), then it is used to reduce
the thickness as per requirement on galvanizing line.
(Also used after annealing as per requirement).
Tension Leveller (TLL): While going through several
processes the sheet surface may become uneven, so
tension leveller is used to keep the whole sheet surface
even i.e., on same level.

Coater Section: Used to coat the galvanized/ galvalume

coil with chromate so as to prevent surface oxidation
and make the sheet long lasting.

Hot Air Dryer: After chromate coating, sheet is sent to

hot air dryer so that the sheet dries up after coating.

Exit Accumulator

Exit Shear

Recoiler: The steel sheet gets recoiled here.

COLOR COATING LINE (SMS-
ESMECH WITH THE
TECHNOLOGY
COLLABORATION WITH EMG,
COMENCO & GFG)

BSL is having Color coating line with hot laminator supplied by

SMS-ESMECH with the technology collaboration with EMG,
COMENCO & GFG. Embossing (NAWOO, KOREA), Profiling (AL-
KONG, KOREA) & Tension Leveller (SMS, ESMECH) are also
installed. we used RMP, SMP & PVDF type of paint which makes
us unique for appliances & high-end products.
 H & T LINE: (SECO WARWICK
ALLIED LTD.)

 Thickness – Up to 3.5 mmWidth – Up to 550 mm

The strip grinding & polishing line is to achieve the desired
surface finish are from BREUER, Germany. Narrow Steel
strips for saw mills, saw are made using lead quenching
which makes the product more durable. The strips here
are hard and have springy action.

FINISHING SECTION

 Corrugation Machine – 13 No's. (ESMECH & REGAL IRON)

 Cut to Length (CTL) Line - 26 No's. (IDH, FIMMI, DAEHWA,
GEORGE)
 Cold Roll Slitting (CRS) Line – 14 No's. (IDH, FIMMI,
DAEHWA)
 Slitting Line for cold rolled steel strip coils cut in
longitudinally direction to get the strip in required width
as per customer requirement.
 ELECTRICAL MAINTENANCE

Electrical maintenance means the care and checklist of

electrical equipments to avoid any breakdown or fault. To
tighten all electrical connections, to upgrade the power rating
of safety switches is also a part of Electrical maintenance.

Electrical maintenance engineer look after AC motors, DC

motors, Transformer, Electrical switch gears (Air Circuit
breakers, relays etc); Electronics (PLC, drives);
Line instruments (Proximity switch, level switch, RTD)
Preventive maintenance: A preventive maintenance is
a schedule of regularly planned maintenance testing and
actions with the intent of preventing breakdowns and
failures, Finding and replacing worn components before
they can actually fail is the goal of preventive service, as
well as predicting useful life of existing equipment,

Some of the preventive maintenances are:

 To change the carbon brush of DC motors.

 Tightness of Electrical connections.
 To clean the dust is AC so as to prevent from heat.

Predictive maintenance: Predictive maintenance

techniques are designed to determine the condition of
in-service equipment in order to predict when
maintenance should be performed. The main promise of
predictive maintenance is to prevent unexpected
equipment failures. The key is -right information in the
right time.

Breakdown maintenance: Breakdown maintenance is

maintenance performed on equipment that has broken
down and is unstable, Better the preventive
maintenance, lesser
chance of breakdown.
 MECHANICAL MAINTENANCE

Mechanical maintenance means the steps taken to prevent

any mechanical equipments and machines from any kind of
damages.

Mechanical Maintenance engineers carry out planned or

unplanned maintenance and repair activities on a wide
range of equipment e.g., pumps, engines, compressors,
turbines etc.

Types of mechanical maintenance:

 Preventive maintenance.

 Predictive maintenance.

 Breakdown maintenance.

Preventive maintenance: It is a daily maintenance (cleaning,

inspection, oiling, and re-tightening), design to retain healthy
condition of equipment,
Some of the preventive maintenances are:

 To check the alignment.

 To tight the nut and bolt.
 Proper lubrication.

Predictive maintenance: This is a method in which the

service life of important part is predicted based on inspection,
observation or diagnosis, prediction and observation of
temperature, vibrations, level of oil, pressure etc,

Breakdown maintenance: Breakdown maintenance is a

maintenance performed on equipment that has broken down
or damaged, Better the preventive maintenance lessen the
chances of breakdown,
 QUALITY MANAGEMENT
SYSTEM

A Quality Management System, often called a QMS, is a set of

intimal rules that are defined by a collection of policies,
processes, documented procedures and records. This system
defines how a company will achieve the creation and deli
very' of the product or service they provide to their
customers. For simplicity, QMS=QC+QA

Where, QMS: Quality Management System,

QC: Quality Control that focuses on product characteristics

through a reactive approach by line function to identify
defects using operational activities such as testing /
measurements.

QA: Quality Assurance focuses on processes through a

proactive (preventive) approach by staff function to
prevent defects using systematic activities such as
assessments / audits,
 Role of Intern during the
Internship period

“I learned how to adjust myself in the work

environment, how to deal with people at work -
from the boss to the janitor. It was a good and
quality experience; The necessary kind of
experience as it helps you realize what you want in
future. "Also got the opportunity to evaluate
myself under these stressful conditions".
 CONCLUSION

 In TATA STEEL BSL Ltd. Sahibabad plant, steel

undergoes different processes like HR slitting,
pickling, cold rolling, ECL, annealing, galvanizing
then finishing.

 Pickling is a process of removing the oxide scale

from hot rolled steel.

 Rolling is a process of reducing the thickness of

HRS coil (from pickling) with the help of 6H1
HITACHI MILL.

 Electrolytic cleaning line is used to remove the

oil film from the surface of cold rolled steel coils.

 Annealing is a heat treatment and cooling

process used to reduce hardness the steel.
 Skin pass mill is used to give the proper grain
structure to steel coils (from annealing) and also to
remove the yield point.

 Galvanizing is done to provide protective layer

to coils.

 Finishing carries two section lines, first one is

Cold Rolled Slitter where Cold Rolled steel coils are
slitted according to the customers’ needs. And,
second one is Cut-to-length where steels coils are
cut into sheet form having some length based upon
customer requirement.