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INSTITUTE OF ENGINEERING
PURWANCHAL CAMPUS

AN INDUSTRIAL ATTACHMENT REPORT AT

AARATI STRIPS (P) LTD

Submitted By:
Suraj Ghimire (PUR076BME093)
Newton Pokharel (PUR076BME056)
Manoj Kumar sah (PUR076BME088)
Rasmita Gautam (PUR076BME074)
Pawan Shah (PUR076BME068)

Submitted To:
Aarati Strips Pvt. Ltd.
Morang, Biratnagar

June, 2023
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ACKNOWLEDGEMENT

We would like to express our heartfelt gratitude to all those who have contributed to the
successful completion of our industrial attachment at Arti Strips Pvt. Ltd. This experience has
been invaluable in enhancing our understanding of mechanical engineering principles and their
practical applications in an industrial setting.

First and foremost, we would like to extend our sincere gratitude to Mr. Sanjay Singh for his
valuable assistance in setting up our contacts with engineers and technicians at various
departments during our industrial attachment at Arti Strips Pvt. Ltd. His efforts in facilitating
these connections have been instrumental in enhancing our learning experience.

We would like to extend our sincere appreciation to Er. Lokesh Singh sir, the Head of the
Mechanical Department at Arti Strips. His guidance, support, and expertise throughout our
attachment period were instrumental in shaping our learning experience. We are grateful for his
willingness to share his knowledge and provide valuable insights into the intricacies of
mechanical engineering.

Special thanks to Er. Dharmendra Yadav sir for his guidance and motivation. His cheerfulness
and willingness to teach us like his friends motivated us to give our hundred percentage in Arti
Strips Pvt. Ltd.

We would like to extend our thanks to Er. Om Prakash Shrivastav and Er. Pappu Chaudhary
from Pickling Line, Er. Ram Prakash Manal and Mr. Shuvam Mandal from Galvalume Line,
Er. Reeky Rajbanshi and Er. Mukesh Shah from Color Coating line, Mr. Ramesh Mandal and
Mr. Bishwajit Das from Tube Mill, Er. Satyendra Singh, Er. Dharmendra Yadav and Er. Amit
Singh from CRM Section, and Er. Rajan Yadav from Utility Department. Their support and
willingness to share their expertise and experiences have greatly enriched our learning during
this attachment. We are grateful for the time they dedicated to answering our questions and
providing practical insights into their respective areas of specialization.

We would also like to express our gratitude to Er. Roshan Ghimire, the Head of the Mechanical
Engineering Department at Purwanchal Campus, for writing the letter of recommendation that
facilitated our attachment at Arti Strips Pvt. Ltd. His encouragement and support have been
pivotal in providing us with this valuable opportunity to gain hands-on experience in the field of
mechanical engineering.

We are also indebted to the entire management and staff at Arti Strips Pvt. Ltd. for their warm
welcome and for creating a conducive learning environment. The cooperation and support we
received from everyone during our attachment have made this experience truly enriching.
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ABSTRACT

This internship at Aarti Strips Pvt. Ltd., Nepal was effectively carried out under the guidance and
supervision of the senior Engineers and Technicians of Aarti Strips Pvt. Ltd.

The objective of the attachment was to gain practical knowledge and experience in the field of
mechanical engineering within a real-world industrial setting. The report focuses on the various
aspects of Aarti Strips Pvt. Ltd. operations, including its manufacturing processes and equipment.

The report begins with an overview of Aarti Strips Pvt. Ltd., highlighting its position as a
prominent player in the manufacturing industry in Nepal. It describes the company's vision,
mission, and core values, along with its production capacity and market presence.

The manufacturing processes employed at Aarti Strips Pvt. Ltd. were examined in detail. We’ve
gained hands-on experience in the production of various metal strips, coils, and sheets,
understanding the principles of raw material selection, processing techniques, and quality
assurance practices. Special attention was given to the use of advanced machinery and
equipment, including rolling mills, slitters, and surface treatment systems.

Throughout the attachment period, we had the opportunity to collaborate with a team of
experienced engineers and technicians. This report presents insights gained from interactions
with these professionals, emphasizing the importance of effective communication, teamwork,
and problem-solving skills in the mechanical engineering field.

Finally, the report concludes with a critical analysis of the attachment experience, discussing the
strengths and limitations of the internship program at Aarti Strips Pvt. Ltd., Recommendations
are provided to further enhance the student's learning experience and suggest areas for
improvement in the company's operations.
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LIST OF FIGURES
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TABLE OF CONTENTS
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ABBREVATIONS
 

ASPL: Aarti Strips Pvt. Ltd.
MTPA: Metric Ton Per Annum
PPGI: Color Coated Galvanizing Iron Sheets
CGL: Continuous Galvanizing Line
CCL: Color Coating Line
CTL: Cut to Length
HR: Hard Roll
MS: Mild Steel
HRCTL: Hard Roll Cut to Length
MSCTL: Mild Steel Cut to Length
MPM: Meters per Minute
CR: Cold Roll
CRFH: Cold Roll Full Hard
ACC: Accumulator
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INTRODUCTION

1. BACKGROUND

Aarti Strips (P) Ltd., situated in Tanki Sinwari, Biratnagar, is a fully integrated steel
manufacturing company associated with state of the art of facilities and NS 141, ISO 9001-
2008 certified company with the current 195000(MTPA) manufacturing capacity. ASPL have
partnered with world-renowned equipment suppliers like Largo of Germany, ABBE Ltd,
ISMS Demand for its technology Plant and machinery in order to produce world-class
products.

Aarti Strips Pvt. Ltd. (ASPL) was established in April 2000, with the installation of a single
galvanizing line at Tanki Sinwari, Ward No. 1 Biratnagar, Morang district, Nepal. Initially,
the company had a galvanizing line capacity of 50,000 (MTPA). ASPL is backed by four
Indian promoter companies - ASL Investment Ltd., Adhunik Investment Ltd., BIC
Investment Ltd., and ESSENN Investment Ltd. - each holding equal shareholding rights.
Since its inception, ASPL has been delivering high-quality products to the Nepalese market,
receiving an overwhelming response. In 2004, ASPL underwent a capacity expansion,
increasing its galvanizing iron sheets production capacity by 100% to 100,000 (MTPA) from
the initial 50,000 metric tons per annum.

ASPL is a dynamic, agile, and well-managed company that has earned certifications such as
ISO 9001, BIS, and NS, reflecting its commitment to quality. The company is continuously
enhancing its capabilities to support its impressive growth trajectory. After a successful
decade in the Nepalese market, ASPL expanded its product range in 2012 to include value-
added products, specifically Color Coated Galvanizing Iron Sheets (PPGI). The installed
capacity of the Color Coated Galvanizing Line was approximately 50,000 metric tons per
annum. ASPL made history in Nepal by being the first company to produce 26 colors,
offering a wide range of multi-color sheets. In 2013, ASPL further expanded its operations
and commenced the production of M.S Black Pipe and ERW Precision Tube. The installed
capacity for this production line was 50,000 metric tons per annum.

2. INTERNSHIP OBJECTIVES

a) To gain insight into the mechanical operations within the industry.

b) To develop a comprehensive understanding of various machines, flow patterns,
manufacturing and production processes, material handling, quality management, and
production planning and control (PPC).
c) To apply theoretical knowledge practically by observing and analyzing real-life
scenarios.
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3. ORGANIZATION STRUCTURE

President
V.P.
Prouction Mechanical Electrical Quality Dispatch Account Custom Store

A.G.M A.G.M A.G.M A.G.M A.G.M. V.P. V.P. V.P

Sr. Manager Sr. Manager Sr. Manager Sr. Manager Sr. Manager Sr. Manager Sr. Manager Sr. Manager

Manager Dy. Manager Dy.

Manager Manager Manager Manager Dy. Manager
Manager
Dy. Manager Dy. Manager Dy. Manager Dy. Manager Dy. Manager
Asst.
Asst. Asst. Asst. Asst. Manager
Manager
Sr. Sr. Sr. Supervisor Loading Supervisor

Engineer Engine
Engineer Sr. Billing Department
er
Asst. Asst. Asst. Engineer

GET/DET/Trainee GET/DET/Trainee GET/DET/Trainee Asst.

GET/DET/Trainee

Figure 1: Organization structure of Aarti Strips Pvt. Ltd.

4. PRODUCT MANUFACTURED

1. Galvanized Sheets
2. Color Coated Sheets
3. Tubes
4. Shutter Profile
5. Corrugated sheets
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Frequently Occurring Components and Rolls

1. Uncoiler: An uncoiler is a component used in sheet metal processing to unwind coils of metal
strip or sheet material. It is designed to safely and smoothly release the coil's tension and feed
the material into the subsequent processing stages. The uncoiler typically consists of a mandrel
or spindle on which the coil is mounted, along with mechanisms to control the speed and
tension of the unwinding process.

2. Mandrel: The mandrel is a cylindrical shaft or core around which the coil of sheet metal is
wound. It provides support and stability to the coil during the unwinding process. The mandrel
is often equipped with mechanisms such as expanding or collapsing segments to securely hold
the coil and allow for easy mounting and dismounting.

3. Pinch roll: A pinch roll, also known as entry or feed roll, is a set of rolls positioned
immediately after the uncoiler. Its primary function is to control the tension and ensure a
smooth and consistent feeding of the sheet metal into the subsequent processing equipment. The
pinch roll exerts pressure on the incoming material, preventing slippage and maintaining proper
alignment.

4. Support roll: Support rolls are used in sheet metal processing to provide additional support and
stability to the material being processed. They are strategically positioned along the production
line to minimize deflection and vibrations, ensuring accurate and consistent processing. Support
rolls help maintain the flatness and shape of the sheet metal during various operations such as
leveling, cutting, bending, or forming.

5. Accumulator: An accumulator is a device used to store and control the movement of sheet
metal in continuous production lines. It accommodates variations in the speed of the line or
interruptions in the processing, allowing for a continuous feed of material. The accumulator
helps to prevent disruptions and ensures a smooth and steady flow of sheet metal, thereby
optimizing production efficiency.
There were mainly following types of accumulators in Arti Strips Pvt. Ltd:
a. Pit: Strip can be stored in a deep pit where it will hang in a loop.
If the pit is "filled" so that the strip loop is at position A, the mill can then be started and
operated continuously. If the supply from the coils is added at the same speed at which
the tube mill removes strip, the loop will stay at position A, and the accumulator will
remain full.
If the supply end is stopped because the supply coil has been depleted, and the tube mill
continues its strip removal, the loop will rise to position B as a new supply coil is end-
joined to the trailing end of the depleted coil. This joining can readily be accomplished
because the entering strip is not in motion.
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Fig: Pit Accumulator

b. Festoon: A variation of the pit is the festoon, which combines several vertical strands. It
can extend either upward or downward from ground level.
A festoon has a number of fixed rolls and a moving structure containing a number of
rolls that move together vertically. Strip accumulation occurs as the moving rolls move
away from the fixed rolls in a vertical direction. A large accumulation can be obtained
from a much smaller total vertical movement.

Fig: Festoon Accumulator

c. Horizontal Accumulator: The strip is fed into the accumulator by a set of pinch rolls.
As in all horizontal accumulators, the strip is turned 90 degrees before it enters the pinch
rolls of the machine. The pinch rolls are driven by a direct current (DC) motor at two to
three times line speed. As the strip enters the accumulator, it is supported immediately
by a rotary table. The rotating table is driven by a separate DC motor, and the OD is
synchronized with the pinch roll. Therefore, the entering strip has no resistance, and the
driven support table helps pull and guide the strip into the accumulator. This reduces the
chances of strip cobbling, jam-ups, marking, tension, etc. The inside wrap of the
accumulated coil is pulled to the center takeout arbor by the mill.

The drive has three modes of operation: stopped, line synchronized, and high-speed fill.
Once the accumulator reaches the full condition, the drive automatically goes into the
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synchronized mode, and the accumulator stays full until the supply of strip from the
uncoiler is depleted.

The operator or an automatic end detector senses the end of the coil, and the pinch roll
stops pulling strip in. The tube mill then feeds from the accumulator by pulling the inner
wrap of the outer coil around the takeout arbor and into the mill.

When the end weld is complete, the operator signals the pinch rolls to start filling. The
accumulator then fills at two to three times line speed until it is full. At this time, the
drive is signaled to go into synchronized mode until the new coil is depleted.

Fig: Horizontal Accumulator

6. Bridle roll: A bridle roll, or steering roll, is used to control the tension and alignment of the
sheet metal as it passes through various processing stages. It consists of multiple rolls that are
adjustable to maintain proper tension and guide the material accurately. Bridle rolls are
commonly employed in operations like leveling, coating, slitting, or any process that requires
precise control of tension and alignment. The primary function of a bridle roll is to apply a
controlled amount of pressure to the web, allowing for proper tension control and preventing the
material from sagging or wrinkling. It also helps to guide the web accurately and maintain its
alignment as it moves through the machine.

7. Steering Roll: A steering roll, also known as a guide roll or idler roll, is a roller used to steer
and guide a moving web of material through a processing or converting machine. It is typically
positioned at an angle to the web path and is adjustable to control the lateral position or
alignment of the web. Steering rolls are commonly used in applications where the web needs to
be kept on a specific path or centered within the machine. They are often used in conjunction
with other rolls or guide mechanisms to ensure the proper alignment and tracking of the web.

8. Deflection Roll: A deflection roll is a roller used to change the direction or path of a moving
web of material. It is typically used in situations where the web needs to be redirected or guided
around a specific point or obstacle in a machine or production line. Deflection rolls can be used
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to change the web's direction horizontally, vertically, or both, depending on the application.
They are often used in combination with other rolls, guides, or pulleys to create complex web
paths or to navigate around machine components.

9. Tension Leveler: A tension leveler is a specialized component used to remove residual stress
and correct the flatness of sheet metal. It consists of a series of rolls that apply controlled
tension to the metal strip, stretching it in a controlled manner. The tension leveler is especially
useful in processes where the material undergoes significant deformation, such as rolling,
forming, or coil coating. It helps to eliminate distortions and improve the flatness and quality of
the final product.

10. Shear: A shear is a cutting tool used to make straight cuts in sheet metal. It typically consists of
a fixed upper blade and a moving lower blade, which slide past each other to create the cutting
action.

11. Welding and Stitching Machines: Welding and stitching machines are used to join or fuse
metal components together. Various welding techniques such as arc welding, MIG welding, TIG
welding, or spot welding are employed in sheet metal processing, depending on the specific
application and requirements.

12. Deburring Roll: A deburring roll is a specialized tool used in manufacturing processes to
remove burrs or sharp edges from metal or other materials. Burrs are unwanted rough edges or
protrusions that can occur during various machining or cutting operations, such as milling,
drilling, stitching or stamping.

13. Burr Mashers: Burr mashers, also known as deburring brushes or disc brushes, are rotating
tools with abrasive bristles. They are used to remove burrs from metal or plastic workpieces.
The high-speed rotation of the bristles allows for efficient abrasion, effectively eliminating
burrs from the edges or surfaces of the workpiece. Burr mashers are commonly employed in
handheld power tools, offering precise control for localized deburring tasks.

14. Slip drum: In theory, a slip drum is used in sheet metal rolls to control torque transmission and
prevent damage to the rolls. It consists of two components, the drum and the hub, which engage
with each other. When the torque exceeds a predetermined threshold, the slip drum allows
controlled slippage between the components, protecting the rolls from excessive stress and
extending their lifespan. It acts as an overload protection mechanism in sheet metal rolling
operations.

In application, slip drum is used in thin sheet rolls so that they maintain a circular shape and is
easier to load the sheet into the mandrel. The operators call it “Silu”.
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CHAPTER 2: PICKLING PROCESS

The pickling process is a surface treatment used to remove scales and impurities from hot-rolled
steel. It involves the use of hydrochloric acid (HCl) or a mixture of acids, such as sulfuric acid
(H2SO4) and hydrochloric acid, commonly known as pickling solution. However, HCL is used to
in Aarti Strips for the removal of scales and impurities.

The pickling process typically takes place in an enclosed tank or vessel designed to withstand the
corrosive nature of the pickling solution. The steel coils or sheets are immersed in the pickling
solution, or the solution is sprayed onto the surface of the steel. The acid reacts with the scales and
impurities, dissolving them and leaving behind a clean and smooth surface.

During the hot rolling process, oxide scales can form on the surface of the hot-rolled coil. These
oxide scales consist of different iron oxide compounds, namely:

1. Hematite (Fe2O3)

2. Magnetite (Fe3O4)

3. Wüstite (FeO).

Overall, HCl pickling lines play a vital role in the steel manufacturing process, contributing to the
production of clean, scale-free, and corrosion-resistant steel surfaces for a wide range of
applications. The line diagram of the process is attached below:

Figure 2: Pickling Process Line Diagram

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WORK-FLOW

UNCOILER

TENSON LEVELLER

BURR MASHER

PRE-WASH TANK

ACID TANK-1

ACID TANK-2

ACID TANK-3

WATER TANK-1

WATER TANK-2

WATER TANK-3

WATER TANK-4

WATER TANK-5

HOT AIR DRYER

DEBURR ROLL

RECOILER

Figure 2.1: Pickling Line Work Flow

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UNCOILER

The uncoiler is the initial component of the pickling line responsible for unwinding the HR steel coil
and feeding it into the line for further processing. Only one uncoiler is present in picking process. The
absence of multiple uncoiler restricts the ability to continuously feed the steel coil into the pickling line
without interruption. Instead, the pickling process is carried out on one coil at a time. Once the pickling
of a coil is complete, the uncoiler is stopped, and the processed coil is recoiled. Then, a new coil is
loaded onto the uncoiler for the next pickling cycle.

TENSION LEVELER

The tension leveler ensures that the HR steel coil maintains a consistent tension throughout the
pickling process, which helps prevent any deformation or warping. It prevents slack or excessive
tension, which can lead to strip misalignment, wrinkling, or coil breaks. By maintaining proper
tension, the tension leveler facilitates smooth and stable movement of the strip through the
pickling line.

BURR MASHER

The burr masher is used to remove any burrs or sharp edges that may be present on the steel
surface. This process helps achieve a smoother and more uniform surface finish. The burr masher
utilizes mechanical or abrasive means to eliminate any sharp edges, burrs, or irregularities on the
steel surface. This process enhances the surface quality and facilitates subsequent processing.

PRE-WASH TANK

The pre-wash tank is used to remove loose dirt, oil, and other contaminants from the surface of the
steel before it enters the pickling line. It prepares the steel for effective pickling. The pre-wash
tank is equipped with spray nozzles that deliver high-pressure water to remove loose debris, oils,
and greases from the steel surface. This pre-cleaning step ensures effective pickling by minimizing
potential contamination.

ACID TANK

There are three Acid Tank in Pickling Line: Acid Tank-1, Acid Tank-2, Acid Tank-3: These acid
tanks contain the pickling solution, which is hydrochloric acid (HCl) at different concentrations.
Tank-1 typically contains 6% HCl, Tank-2 contains 12% HCl, and Tank-3 contains 18% HCl. The
steel passes through these tanks, where the acid removes the oxide scales from the surface of the
steel.

The main function of HCl is to dissolve and remove the oxide scales that form on the surface of
the hot-rolled steel during the manufacturing process. These scales, such as wüstite, magnetite, or
hematite, can negatively impact the surface quality and subsequent processing of the steel. HCl
reacts with the scales, breaking them down and allowing them to be easily removed, resulting in a
clean and scale-free surface.
 Page 18

HCl also acts as an acid activator, enhancing the efficiency of the pickling process. It creates an
acidic environment that promotes the chemical reaction between the acid and the oxide scales. The
acid activation helps to accelerate the scale removal process and improves the overall effectiveness
of the pickling solution.

HCl also has cleaning properties that aid in removing contaminants, oils, greases, and other
impurities from the steel surface. This ensures that the surface is thoroughly cleaned before further
processing or coating, improving adhesion and surface quality.

WATER TANK

There are Five water tank in Pickling process: Water Tank-1, Water Tank-2, Water Tank-3, Water
Tank-4, Water Tank-5: These water tanks are used for rinsing the steel after the pickling process.
Water Tank-1 typically contains cold water, which helps remove any residual acid. The remaining
water tanks use hard water for rinsing purposes.

Cold water is typically used in Water Tank-1 for rinsing the steel strip after it passes through the
acid tanks. The cold water helps to wash off any residual acid from the surface of the steel.
Rinsing with cold water is effective in removing the acid while also cooling down the steel strip.

Hard water, which contains minerals such as calcium and magnesium, is often used in the
remaining water tanks for further rinsing. The presence of minerals in hard water can help in
neutralizing any remaining traces of acid on the steel surface. The minerals react with the residual
acid, forming insoluble compounds that can be easily rinsed away.

HOT AIR DRYER

The hot air dryer is used to remove any remaining moisture from the surface of the steel after
rinsing. It helps prevent the formation of water spots or corrosion.

The hot air dryer uses a combination of heat and forced air to evaporate any remaining moisture
from the steel strip. This drying process prevents water spots and corrosion from forming on the
steel surface.

DEBURR ROLL

The deburr roll further removes any remaining burrs or sharp edges from the steel surface,
ensuring a smooth and clean finish. The deburr roll further smoothens the edges and removes any
remaining burrs or imperfections on the steel strip. It enhances the surface quality and prepares the
steel for subsequent processing or surface coating.

RECOILER:

The recoiler is the final component of the pickling line. It rewinds the steel coil after the pickling
and rinsing process, preparing it for further processing or storage. The recoiler rewinds the pickled
and dried steel strip into a new coil, ready for further processing or storage. It ensures proper
tension control and coil formation for efficient handling.
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CHAPTER 4: COLOR COATING LINE

WORK-FLOW

UNCOILER
SHEAR
STICHER
ENTRY ACCUMULATOR
BRUSH TANK
HOT WATER RINSE
COLD WATER RINSE
HOT AIR DRYER
CHEMICAL TANK
AIR DRYER
PRIME COATER
PRIME OVEN
QUENCHING TANK
AIR DRYER
FINISH COAT
FINISH OVEN
QUENCHING TANK
AIR DRYER
EXIT ACCUMULATOR

Figure 4: Color Coating Line Work-Flow.

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UNCOILER

The production of color coated steel coils starts with the utilization of galvanized coils as the
primary raw material. In order to ensure a continuous production process, two uncoilers are
employed. The first uncoiler unravels the galvanized coil to facilitate further processing, while
the second uncoiler, known as uncoiler-2, performs the same function. These uncoilers are
operated alternately to optimize time utilization and avoid delays caused by reloading coils onto
the same uncoiler. To maintain a seamless production flow, the end of one sheet from an uncoiler
can be seamlessly connected to the beginning of a sheet from another uncoiler.

Each uncoiler is composed of a liner and segments, where the liner is movable and the segments
remain fixed. The liner undergoes reciprocating motion, moving back and forth with the
assistance of a hydraulic cylinder. Consequently, the segments within the uncoiler expand and
contract accordingly. During the expansion phase, the coil is placed on the uncoiler, while during
the contraction phase, the coil is removed. This cyclical expansion and contraction of the
segments facilitate the efficient operation of the uncoiler.

STITCHER

The strip joiner/stitcher is utilized to connect the end of the finishing strip with the end of the
starting strip in the color coated steel production process. This joining process is carefully
engineered to achieve optimal strength while minimizing the risk of damage to any rolls
throughout the process line. The strip joiner/stitcher comprises a hydraulic power unit that
includes pumps, a motor, a starter, and a joining die.

To ensure maximum strength, a triple line stitch technique is employed. This involves stitching
the two strip ends together using a specific stitch pattern. In some cases, an additional small strip
may also be stitched along with the two ends to enhance the stitch strength further.

The stitching process involves punching holes in the strips. The lower portion of the strip moves
upward, while the upper portion moves downward, effectively interlocking the two ends. To
reinforce the stitch, a metal strip with high strength properties is inserted between the two ends.

It's important to note that the stitched portion is not subjected to the color coating process. At the
end of the production line, this stitched portion is sheared or cut, separating it from the rest of the
coil.

ENTRY ACCUMULATOR

The accumulator serves as a storage area positioned between static steel coils and the continuous
strip that runs through various sections of the production line. Its main function is to accumulate
the sheet material. When the empty feed coil comes to a halt and is replaced with a new full coil,
both strips are stitched together. Meanwhile, the entry accumulator unwinds to provide a
continuous flow of strips. This unwinding action creates a sufficient amount of time for tasks
such as coil replacement, cutting, welding, and arranging to take place. By enabling
uninterrupted material flow, the accumulator ensures continuous production and improved
profitability.
 Page 21

To facilitate this specific operation, multiple rolls are employed. There are eight upper rolls,
which are vertically movable, allowing them to move up or down as needed. These rolls descend
to provide the necessary time for operations. Additionally, there are seven lower rolls that remain
stationary, without vertical movement. The work progresses through the lower rolls first before
transitioning to the upper rolls and so forth.

Prior to reaching the accumulator, the work passes through a deflector roll, which is strategically
positioned to squeeze the work material with ease and precision. After the deflector roll, the
work then proceeds through the first staring roll, located at the topmost section. Following the
accumulator, the work continues through the second staring roll and another deflector roll.

BRUSH TANK

The brush tank is utilized to enhance the cleaning process of the metal surface by employing
brushes. Applying caustic alone may not be sufficient as it lacks the necessary pressure. The
brush applies additional pressure to the sheet, enabling effective cleaning and degreasing by
reaching more surfaces.

To fulfill this purpose, a brush roll is incorporated, which is driven by a motor. The motor is
connected to the shaft of the brush roll, enabling its rotation. The brush roll rotates in the
opposite direction to the motion of the sheet. This opposing rotation generates increased friction,
leading to efficient cleaning. The desired temperature range within the brush tank typically falls
between 60 to 70 degrees Celsius.

The brush tank plays a crucial role in achieving effective cleaning and degreasing of the metal
surface. The brush roll, driven by a motor, applies pressure and reaches more surfaces, resulting
in efficient cleaning. The presence of headers and a steam coil ensures the desired temperature is
maintained within the brush tank.

HOT RINSE TANK

The hot rinse tank is utilized to wash the workpieces with hot water. After treatment with caustic
soda, it is necessary to clean the workpieces to remove any residue or alkaline solution before
proceeding with further processing. Hot water is used in this stage to ensure effective removal of
the alkaline solution, as the higher temperature aids in the cleaning process. The temperature is
typically maintained between 55 to 70 degrees Celsius.

Similar to other tanks, headers and a steam coil are present in the hot rinse tank to regulate and
maintain the desired temperature. This ensures that the hot water used for rinsing remains at the
appropriate temperature throughout the process. The drive system employed in the hot rinse tank
is similar to the one used in other tanks.

Additionally, a sump pump is employed in the hot rinse tank to remove the dirty water that
accumulates in the base. The sump pump is designed to eliminate water that collects in a water
 Page 22

collecting sump basin. It is installed within the sump pit. Once the water level in the sump
reaches a certain point, typically every 4 to 5 hours, the pump activates and discharges the
accumulated dirty water outside, effectively removing it from the system.

COLD RINSE TANK

After the workpieces have been washed with hot water in the previous stage, they are subjected to
a cold rinse to further remove any remaining residues or impurities. The cold rinse is crucial as it
helps to ensure thorough cleaning and prepares the workpieces for subsequent processing steps.
Cold water is used in this tank, typically at ambient temperature or slightly lower, to provide a
refreshing and thorough rinsing action. The temperature in the cold rinse tank is maintained at a
suitable level to promote effective cleaning and minimize any potential damage to the material.

HOT AIR DRYER

The hot air dryer is a crucial component in the metal processing line, specifically designed to dry
the sheet after chemical treatments. As the sheet is wet following the chemical processing stage, it
is essential to remove the moisture before proceeding with further processing.

The drying process is achieved by blowing hot air through the sheet. Rolls within the drying
section simply move the sheet forward, facilitating the drying action. A blower is employed to
draw in surrounding air and rapidly mix it with hot steam supplied through a steam line. This
combined mixture is then directed onto the sheet to expedite the drying process. The steam and air
mixture, once utilized, is expelled through a duct, directing it to the outside environment.

To ensure effective drying, the temperature within the drying section is typically maintained
within the range of 85 to 100 degrees Celsius. This elevated temperature aids in the quick
evaporation of moisture from the sheet, resulting in efficient and thorough drying.

CHEMICAL TANK

The chemical tank is a crucial component in the continuous color coating process of galvanized
sheets. Once the strip has undergone necessary pre-treatment processes, it enters the chemical tank
where it is coated with specialized chemicals. These chemicals serve the purpose of enhancing the
longevity of the coating and promoting strong bonding with the base metal.

The chemical is dispensed onto a roll within the tank, which ensures complete coverage of the
sheet. The chemicals used in the color coating process are carefully selected to provide the desired
properties and characteristics to the final coated product.

The chemicals used in the coating process are stored in a separate chemical storage tank. A pump
is employed to transfer the chemicals from the storage tank to the chemical tank, ensuring a
continuous and controlled supply of the required chemicals.

By applying the chemicals onto the strip within the chemical tank, the galvanized sheet is prepared
for the subsequent color coating process. The specialized chemicals play a vital role in enhancing
the durability and adhesion of the coating, contributing to the overall quality of the final product.
 Page 23

AIR DRYER

After the strip has been coated with chemicals in the previous stage, it is necessary to remove any
residual moisture or solvents from the surface before proceeding with further processing. The air
dryer accomplishes this by utilizing a stream of hot air directed onto the coated strip.

The hot air is generated by a heating element within the air dryer. It is then blown onto the strip,
effectively evaporating the moisture and drying the coating. The airflow within the dryer is
carefully regulated to ensure even and thorough drying of the coated strip.

PRIME COATER

The prime coater is employed to apply a prime coating onto the strip before the finish coat. The
prime coating serves multiple purposes, including enhancing the adhesion of the paint system to
the substrate, providing additional corrosion resistance properties through the use of corrosion-
resistant pigmentation, and improving the flexibility of the paint system.

Before entering the prime coater, the strip passes through the bridle roll. The bridle roll helps in
maintaining tension and controlling the strip's movement, ensuring smooth and precise processing.

Once the strip is properly guided by the bridle roll, it enters the prime coater, where the prime
coating is applied. The prime coating is carefully formulated to provide the desired properties such
as improved adhesion, corrosion resistance, and flexibility. The coating is evenly distributed and
applied to the strip, ensuring complete coverage and uniformity.

By applying the prime coating, the paint system's performance is enhanced, ensuring a strong bond
between the paint and the substrate. This contributes to the overall durability and longevity of the
finished product.

The prime oven is a critical component in the metal processing line, located after the prime coater.
Its primary function is to dry the prime coating applied to the strip. The prime oven consists of two
zones: zone one and zone two, each responsible for drying the prime coating.

Once the strip has been coated in the prime coater, it progresses towards the prime oven. In the
prime oven, the strip moves through zone one and zone two, where the prime coating is dried. The
drying process is facilitated by the use of RC fans, with each zone equipped with its own fan. In
total, there are two RC fans within the prime oven.

The temperature within the prime oven is carefully controlled to ensure effective drying of the
prime coating. In zone one, the temperature is maintained at approximately 180 degrees Celsius,
while in zone two, the temperature is increased to around 205 degrees Celsius. These temperature
settings are subject to adjustment based on specific requirements and process parameters.

To assist in the drying process, an air dryer is employed to remove any remaining moisture from
the strip. Additionally, a deflector roll is used to guide and redirect the strip towards the finish
coater machine.
 Page 24

The prime oven is equipped with both hot and cold dampers. The cold dampers are utilized to
reduce the oven's temperature when necessary. This is achieved by introducing ambient air into the
oven, effectively lowering the temperature. The exhaust gas generated within the oven is directed
to the primary heat exchanger for further processing.

FINISH COATER

The finish coater is a critical component in the metal processing line, responsible for applying the
final coats onto the strip after the prime coating stage. The finish coats serve multiple purposes,
including achieving the desired physical appearance, enhancing physical properties such as
hardness and flexibility, and providing weathering characteristics like gloss retention.

The main rolls used in the color coating process within the finish coater are the pick-up roll,
applicator roll, and back-up roll. The applicator roll is responsible for applying the color to the
strip, while the pick-up roll transfers the color to the applicator roll. These rolls work together to
ensure even and consistent application of the finish coats onto the strip.

To ensure safety and handle emergencies, an emergency braking system is incorporated into the
finish coater. This system provides a mechanism to quickly halt the coating process in case of any
unforeseen events or emergencies.

The drive for the rolls within the finish coater is typically provided by a motor that engages the
gears, allowing for smooth and precise rotation of the rolls. The motor and the rolls are connected
by a universal coupling, ensuring efficient power transmission.

Before entering the finish coater, the strip passes through a bridle roll. This roll is employed to
maintain tension in the strip, ensuring proper application of the color and consistent coating
thickness. The bridle roll helps to control the movement of the strip and maintain a stable tension
throughout the coating process.

FINISH OVEN

The finish oven is a crucial component in the metal processing line, following the finish coater
stage. It is responsible for drying the wet strip after the color coating process and achieving the
desired peak metal temperature (PMT). The finish oven consists of two independently
temperature-controlled zones: zone 1 and zone 2.

As the wet strip enters the finish oven, it undergoes the drying process. The temperature within
each zone of the oven is precisely controlled to ensure effective drying. In zone 1, the temperature
is maintained at around 215 degrees Celsius, while in zone 2, it is increased to approximately 290
degrees Celsius. These temperature settings can be adjusted as per specific requirements and
process parameters.

To facilitate the drying process, the finish oven is equipped with RC fans. Each zone of the oven
has its own RC fan, totaling two fans. These fans help in circulating the heated air within the oven,
ensuring uniform drying of the strip.
 Page 25

The RC fans in zone 1 and zone 2 operate at specific speeds to achieve optimal drying conditions.
In zone 1, the fan operates at a speed of 1401 rpm (95%), while in zone 2, the fan operates at a
speed of 1460 rpm (99%). These speeds can be adjusted as needed to meet the desired drying
requirements.

The finish oven incorporates hot and cold dampers to control the temperature inside the oven. Cold
damping is employed when the temperature needs to be reduced. This is achieved by introducing
ambient air into the oven, effectively lowering the temperature.

FINISH QUENCH TANK

The finish quench tank follows the finish oven stage. Its primary purpose is to cool down the
color-coated steel after exiting the oven and prevent undesirable reactions of the newly formed
coating with the surrounding atmosphere. This cooling process is achieved by spraying cold water
onto the steel surface.

The quenching process serves several purposes. Firstly, it reduces the temperature of the color-
coated steel, bringing it closer to room temperature. This rapid cooling helps to maintain the
desired properties of the metal and prevents significant changes in its microstructure caused by the
heat treatment process.

Water is an effective medium for quenching steel, especially when the goal is to achieve maximum
hardness. The cold water is sprayed onto the sheets through specialized nozzles, ensuring uniform
coverage and efficient cooling.

To facilitate the continuous operation of the quenching process, a quench water recirculation pump
is utilized. This pump circulates the water within the quench tank, maintaining a constant flow and
temperature for effective cooling. The recirculation of the water helps to conserve resources and
ensures consistent quenching performance.

HOT AIR DRYER

Following the quenching process, the color-coated steel sheet retains some moisture that needs to
be removed before proceeding with further processing. This drying task is achieved through a hot
air dryer, which effectively eliminates the moisture from the sheet.

The hot air dryer operates by blowing hot air directly onto the surface of the wet sheet. The sheet
is advanced through the dryer using rolls, which facilitate its movement along the processing line.
The dryer incorporates a blower that draws in air from the surrounding environment. This ambient
air is then rapidly mixed with hot steam supplied through a steam line. The mixture of hot air and
steam is directed onto the surface of the sheet, aiding in the drying process. The steam/air
combination, along with the moisture from the sheet, is subsequently expelled through a duct to
the outside environment.
 Page 26

To ensure efficient drying, the temperature within the drying section of the hot air dryer is
maintained at approximately 85-100 degrees Celsius. This temperature range provides optimal
conditions for effectively evaporating the moisture from the sheet, leaving it dry and ready for
subsequent processing stages.

By utilizing the hot air dryer, the color-coated steel sheet undergoes thorough drying, eliminating
any residual moisture resulting from the quenching process. The combination of hot air and steam,
along with the controlled temperature, promotes efficient drying and prepares the sheet for the next
steps in the production line.

EXIT ACCUMULATOR

The exit accumulator plays a vital role in the continuous production of color-coated steel by
providing storage areas between fixed and movable rolls. Once the recoiled color-coated steel is
cut using a shear, the sheet is removed from the recoiler, a new sleeve is placed on the recoiler,
and another sheet is guided through the recoiler for processing. During these operations, the exit
accumulator ensures a seamless flow of production without any interruptions.

The primary function of the exit accumulator is to accumulate the sheets, allowing sufficient time
for the various tasks mentioned above to be completed. This storage area ensures a smooth
transition between the recoiling and further processing stages. The exit accumulator consists of
both upper and lower rolls, with a total of 8 upper rolls and 7 lower rolls. The upper rolls are
movable, while the lower rolls remain stationary.

To guide the sheet effectively, a starting roll is positioned at the top of the accumulator, ensuring
proper alignment and control. Additionally, a deflector roll is strategically placed after the briddle
roll to assist in guiding the sheet smoothly through the accumulator.

By utilizing the exit accumulator, the production line can maintain a continuous flow of color-
coated steel without any stoppages or delays. The accumulation of the sheets provides the
necessary time for essential operations, such as shearing, recoiling, and reloading, to take place
seamlessly.

GUARD FILM

Following the exit accumulator, a guard film is applied to the surface of the color-coated steel
sheet. This protective film serves as a temporary barrier, safeguarding the coated surface during
subsequent handling, transportation, and storage processes.

The application of the guard film involves carefully unrolling a thin, transparent film onto the
sheet's surface. This film is designed to adhere securely to the steel without leaving any residue or
damaging the underlying coating. It acts as a shield, shielding the color-coated surface from
scratches, abrasions, dirt, and other potential sources of damage.
 Page 27

SHEAR

To achieve the desired coil weights and prepare the color-coated steel for recoiling, a shear is
positioned before the recoiler. The shear serves the purpose of cutting the strip at specific points.

When the strip is cut, the first end of the cut strip becomes the ending point of the current coil
being recoiled. Simultaneously, the next end of the cut strip becomes the starting point of the
subsequent coil that will be recoiled. This process ensures that each coil has the desired length and
weight for storage, transportation, and further processing.

The shear is a mechanical device designed to provide precise and clean cuts along the length of the
strip. It enables accurate control over the coil dimensions, allowing manufacturers to meet the
specific requirements of their customers or production processes.

RECOILER

The coil after passing through the exit accumulator passes through the deflector roll, briddle roll,
pinch roll, shear and finally to re-coiler where the sheet is recoiled again as a finished product.
The sheet is cut through the shear and the coil is taken out along with the sleeve. Another sleeve is
again placed to the re-coiler and the sheet is guided onto it.

Re-coiler consists of liner and segments. The liner is movable, whereas, the segments are fixed.
Liner has the reciprocating motion. It moves back and front with the help of the hydraulic cylinder.
During this, the expansion and contraction takes place in the un-coiler. When it expands, the coil is
placed on it with sleeve at that time and when the coil is removed, it contracts.

QUALITY CONTROL DEPARTMENT

The Quality Control Department is responsible for ensuring the optimum quality of the finished
goods produced. Throughout the production process, various stages of quality testing are
performed to evaluate the product's adherence to defined standards. These tests encompass both
chemical and physical evaluations to assess the product's performance and characteristics.

Some of the fundamental tests conducted by the Quality Control Department include:

1. Scratch Test - An Automatic Scratch Tester is utilized to assess the product's resistance to
scratches. This test helps determine the durability and protective coating integrity of the
color-coated steel.

2. Shade Variation - A Spectro Guide is employed to measure and analyze the color
consistency and uniformity of the coated steel. This test ensures that the desired color
shade is achieved consistently across the product.
 Page 28

3. Impact Test - This test assesses the product's ability to withstand impact or sudden force. It
helps evaluate the strength and resilience of the color coating, ensuring it meets the
required standards for impact resistance.

4. Minimum Color Coating - The Elcometer device is used to measure the thickness of the
color coating. This test verifies that the applied coating meets the specified minimum
thickness, ensuring sufficient protection and aesthetic appearance.

CHAPTER 5: TUBE MILL

WORK-FLOW
 Page 29

SLITTER MACHINE

PAY OFF REEL

SHEAR AND BUTT WELDING

HORIZONTAL SPIRAL ACCUMULATOR

FORMING ROLL

FIN PASS

ERT WELDING

COOLANT TANK

SIZING ROLLS

TURKS HEADS

ENCODER

COC

RUN OUT TABLE

Figure 5: Tube Mill Work-Flow.

SLITTER MACHINE

The raw material for the production of the steel tubes is HR coil. The HR coil is cut into coil of
different widths with the help of slitting line. It consists of series of operations. Slitting line issued
to cut an entry mother coil of a certain width into several narrower and lighter daughter coils. It
includes: un-coiler, leveler, feeder, edge trimmer, shears, slitter, tensioning machine and re-coiler.
 Page 30

The slitting line has very stiff and well-designed slitter heads with zero axial gaps, absolute
parallelism of shafts on rotation combined with right tensioning device that is able to provide high
tension to the slits without marks on the material surface or edges. High quality of slit edges is
enabled by high precision slitter heads.

Fig: Slitting Mechanism

Fig: Slitting Line

PAY OFF REEL

The Pay Off Reel, also known as the Un-coiler, is a vital component used in tube mills for storing,
loading, holding, and supplying strip coils. Its primary function is to securely hold the coil and
provide a continuous feed of material during tube production. Equipped with an expanding
mandrel, the Un-coiler ensures the coil remains tightly wound and prevents it from becoming
loose. It is motor-driven through a gear reducer box, with the main shaft featuring a brake device
to prevent loose winding and maintain controlled tension. The Un-coiler is typically of the double
cone rotary type, where one cone unwinds the coil while the other is loaded with a new coil,
enhancing work efficiency. It accommodates various strip widths required for tube production and
 Page 31

can accept coils on both sides. Coils, often made from HR steel and previously slitted into
different widths, are loaded onto the Un-coiler using a pillar crane or similar lifting equipment.
The Pay Off Reel's versatility and efficient design contribute to uninterrupted material feed and
increased productivity in the tube manufacturing process.

SHEAR AND BUT WELDING

The Shear and Butt welding process is an important step in tube manufacturing that involves
manual operations performed by an operator. The welding process takes place near the un-coiler.
The operation begins by positioning the tail end for shearing. The tail end is carefully guided,
adjusted, clamped, and then sheared. Similarly, the lead end of the new coil is fed into position,
guided along the edges, clamped, and sheared. It is crucial to ensure that the ends are cut
perpendicular to the strip side to prevent joint breakage when the strip is formed into a tube. Any
sheared scrap is manually removed, often using a hydraulic cutter. Once the ends are sheared, they
are brought together in preparation for welding. Butt welding is performed manually with the
assistance of an electrode. Care is taken during the welding process to prevent any holes in the
strip and to ensure that the ends are securely joined together. Proper execution of shearing and butt
welding is essential to maintain the integrity and quality of the welded tube.

HORIZONTAL SPIRAL ACCUMULATOR

The Horizontal Spiral Accumulator is an essential component for ensuring continuous production
in tube manufacturing processes. Its main function is to provide the operator with sufficient time to
cut and weld the ends of two coils together seamlessly. The strip is guided to an inclined position
using control rolls and then directed towards the accumulator with the help of a pinch roll, which
also holds the strip securely and guides it into the accumulator. This process eliminates the need to
place a long length of strip on the floor during coil changeover, minimizing the risk of damage or
contamination that could lead to holes in the tube.

The Horizontal Spiral Accumulator offers numerous advantages, including improved speed,
greater thickness and width range, reduced maintenance requirements, and enhanced flexibility.
By allowing for the continuous feeding of strip to the tube mill from non-continuous coil supplies,
thismachine optimizes production efficiency. Installed between the welder and forming rolls, the
accumulator stores a significant amount of strip in a compact space, ensuring that there is ample
time for the shear and end welder to cut and join the ends of two successive coils without
interrupting the tube mill operation.

The principle of operation is straightforward. The strip enters the accumulator through a set of
pinch rolls, which are preceded by control rolls that twist the strip 90 degrees. Inside the
accumulator, a series of specially designed rollers support and convey the strip, minimizing
resistance and reducing the chances of strip cobbling, tension issues, and markings. The guide rolls
ahead of the accumulator pull the inside wrap of the accumulated coil through the center. The
number of strip wraps can be adjusted based on the material's thickness and width, contributing to
the prolonged life of the forming rolls.

FORMING ROLLS

The forming rolls play a crucial role in shaping the strip into the desired pipe form during the tube
manufacturing process. Typically, forming rolls comprise four horizontal rolls and four vertical
rolls. To maintain optimal operating conditions, cutting oil is continuously sprayed onto the rolls
 Page 32

to cool them down.

The strip, guided by rolls, is fed from the accumulator into the forming rolls. As the strip passes
through the forming rolls, it undergoes gradual bending and shaping, transforming into an open-
seam tube. The forming section of the tube mill is a continuous process, involving a series of
driven and non-driven roll stands.

The design of the forming rolls is carefully calibrated to ensure precise shaping of the final tube
dimensions. To dissipate heat and prevent corrosion, a mixture of cutting oil and water is
continuously fed onto the rolls. This coolant serves the dual purpose of cooling the rolls and
protecting them from corrosion.

Driving the rolls is a gearbox equipped with spur gears, which in turn is powered by a motor. The
universal couplings are used to transmit the rotational motion from the motor to the gearbox and
ultimately to the forming rolls.

FINN PASS

The fin pass section of the tube mill includes both horizontal and vertical rolls. It consists of three
vertical rolls, often referred to as cluster rolls, and three horizontal rolls, also known as stand rolls.

Similar to the forming rolls, the fin pass rolls are designed to shape and refine the tube further.
They contribute to achieving the desired dimensions and surface quality of the tube.

To maintain optimal operating conditions, the fin pass rolls are continuously cooled using a
mixture of water and cutting oil. This cooling process helps dissipate heat generated during the
rolling operation and ensures the rolls remain at an appropriate temperature.

By utilizing the fin pass rolls, the tube is further shaped and prepared for subsequent processing
steps in the tube mill. The precise arrangement and design of the rolls play a crucial role in
achieving the desired characteristics of the finished tube.

ELECTRIC RESISTANCE WELDING (ERW)

ER High frequency welding is a commonly used method in the tube mill for the tube welding
process. It involves the application of high frequency induction welding principles.

The process begins with an induction coil connected to a high frequency power supply, which
surrounds the formed tube profile. The induction coil induces a high frequency current in the pipe
profile. The high frequency current concentrates on the bonding surface of the tube profile fringe,
taking advantage of the skin effect and proximity effect.

The resistance of the metal itself generates heat, quickly raising the temperature of the profile
fringe to the welding temperature. The heated fringes are then pressed together and welded using
squeezing rolls.
 Page 33

The equipment used for high frequency welding is equipped with complete automation control,
which improves welding efficiency and reduces technical adjustment time. This automation
ensures precise control over the welding process and minimizes scrap produced during welding.

ER High frequency welding offers several advantages, including fast heating of the bonding
surface, efficient welding, and the ability to achieve high-quality welds. It is widely used in tube
manufacturing due to its effectiveness and reliability.

COOLANT TANK

The coolant tank is equipped with multiple spray nozzles that evenly distribute a coolant fluid onto
the surface of the recently welded tube. This serves two purposes: reducing the temperature of the
welded surface and the tube itself. The coolant used in the tank is a combination of water and
cutting oil, creating an effective cooling mixture.

SIZING AND STRAIGHTEN

Sizing rolls play a vital role in the production of the final end product, as they perform multiple
functions. Firstly, they are responsible for accurately sizing the tube to the desired dimensions.
Additionally, they contribute to relieving stress within the material, thereby normalizing its
properties throughout the body. The sizing section is meticulously designed and set up to ensure
even and uniform finishing, sizing, and straightening of the tube.

To facilitate these operations, a mixture of cutting oil and water is used in the mill, serving two
purposes. Firstly, it provides cooling to all the mill rollers, ensuring their optimal functioning.
Secondly, it aids in the cleaning of the weld seam by rinsing. The sizing rolls are designed to be
reliable and versatile, capable of accommodating various grades and sizes of materials. This
adaptability allows for seamless adjustments as needed.

Operating and maintaining the sizing rolls is straightforward and hassle-free. They are driven by a
motor through a spur gear mechanism, ensuring smooth and efficient operation throughout the
production process.

TURKS HEAD

The Turks Head equipment consists of four units, with two positioned horizontally and two
vertically. These units collectively provide comprehensive support to the tube, exerting pressure to
shape it accordingly. To achieve this, two motors are employed. One motor control the vertical
movement, securing the tube in an up-and-down motion, while the other motor controls the
horizontal movement, ensuring the tube is held firmly from side to side.

The rolls within the Turks Head system are driven by a worm gear mechanism, which is in turn
powered by a motor. This arrangement allows for precise control over the positioning and
movement of the rolls, facilitating the shaping process. The Turks Heads, or squaring stands, are
 Page 34

typically located after the sizing mill. They serve multiple purposes, including final sizing of round
tubes and straightening as necessary.

Utilizing Turks Heads is considered a highly cost-effective method for manufacturing square and
rectangular tubes. The equipment provides efficient support and shaping capabilities, leading to
the desired end product at a reduced production cost.

ENCODER

Before the cutter carriage in the tube mill, an encoder is installed. The purpose of the encoder is to
track the number of revolutions the wheel makes during the tube forming process. This data is
electronically compared to the elapsed time, allowing for the calculation of the mill's speed in feet
per minute.

The speed information obtained from the encoder is crucial at the end of the welded tube mill. It is
used to generate signals for the cutoff process, determining the precise length at which the tube
should be cut. By accurately measuring the speed and correlating it with time, the encoder enables
the generation of cut-to-length signals for the cutoff operation. This ensures the tubes are cut to the
desired lengths based on the mill's speed and timing information provided by the encoder.

CARRIAGE OF CUTTER (COC)

The Carriage of Cutter (COC) is a machine specifically designed for cutting operations in the tube
mill. Once the encoder identifies the designated point on the tube for cutting, the (COC) moves
towards the encoder and securely holds the tube at that precise location. The cutting operation is
then executed with the assistance of a cutting tool that moves downward, powered by a pneumatic
cylinder.

Simultaneously with the cutting process, the carriage of cutter also moves towards the runout
table, facilitating the smooth transition of the cut tube. This coordinated movement ensures the
efficient handling of the cut pieces. The entire operation of the (COC) is programmable, allowing
for precise control and repeatability in the cutting process.

RUN OUT TABLE (ROT)

The Run Out Table (ROT) is an essential component of the tube mill setup. It comprises a series of
rollers that are driven to move the tube away from the cutoff area. These rollers are equipped with
a mechanism that ensures proper alignment and positioning of the tube.
 Page 35

The run out table operates through the motor-driven rotation of one of the rolls. The remaining
rolls are driven through belt arrangements connected to the driven roll, ensuring synchronized
movement. As the tube or pipe exits the cutoff process, it is subjected to inspection to determine
whether it meets the required quality standards. Based on this assessment, the tube is directed to
the appropriate location, either as a qualified and acceptable part or as a reject.

The run out table plays a critical role in efficiently transporting the cut tubes, ensuring they are
positioned correctly and ready for further processing or packaging based on their quality
designation.