ACKNOWLEDGEMENT:

We are very thankful from the core of my heart to honorable Chief Executive Officer, PAKISTAN STEEL, for providing me opportunity for training and whos intelligent, wise and sound leadership has converted manpower into winning combination by this industry into a Gold mine. We wish to express my deep gratefulness to Mr.Hamid Pervez, Director (Personnel & HR) for his consideration and supervision. It was a memorable time in Pakistan Steel due to his kind concern. We are also thankful to Mr. Raza Muhammad tunio (hrd) and Mr. Yousuf Ayub, Deputy Manager/Incharge (In-Plant Training) for his precious advice and for the great encouragement and cooperation, because of which I have successfully completed my internship training at PAKISTAN STEEL where we learned a lot.

Pakistan Steel ,an Introduction

Description:
A steel mill (British English and Australian English steelworks) is an industrial plant for the manufacture of steel. Steel is an alloy of iron and carbon. It is produced in a two-stage process. First, iron ore is reduced or smelted with coke and limestone in a blast furnace, producing molten iron which is either cast into pig iron or carried to the next stage as molten iron. In the second stage, known as steelmaking, impurities such as sulfur, phosphorus, and excess carbon are removed and alloying elements such as manganese, nickel, chromium and vanadium added to produce the exact steel required. In the late 19th Century and early 20th Century the world's largest steel mill was located in Barrow-inFurness, UK. Today, the world's largest steel mill is in Gwangyang, South Korea.[1][2] Steel mills turn molten steel into blooms, ingots, slabs and sheet through casting, hot rolling and cold rolling.

History Of Pakistan Steel:

Pakistan Steel is strategically located 40km south east of Karachi in close vicinity to port Muhammad Bin Qasim. Pakistan Steel is a costal site which lies on the National Highway and is linked to the railway network. Spread over an area of 18,600 acres (29 square miles) with 10,390 acres for the main plant, 8070 acres for the township and 200 acres for the water reservoir Pakistan Steel is Pakistan's largest industrial complex, comprising After independence in 1947, it did not take long for Pakistan to come to the realisation that progressive industrial and economic development would be impossible without the possession of a self-reliant iron and steel making plant. The dependance on imports would cause serious setbacks to the country along with an extortionately high import bill which would be impossible to support. The initial idea for a domestic iron and steel mill was put forward in the first five year plan of Pakistan (1955 - 1960). Debates over the manufacturing process, supply sources of the requisite machinery and raw materials, plant site, domestic ore versus imported ore, ownership pattern, product mix and above all foreign financing credit kept the project on hold for a considerable time.

In 1968 besides other factors, it was considered by the Government of Pakistan that a basic steel industry should be established in the public sector, as public sponsorship of the project would enable integrated development of the steel industry in the country. In light of this, the government decided that the Karachi Steel Project should be sponsored in the public sector for which a separate Corporation under the Companies Act be formed. As a result on the 2nd of July, 1968 Pakistan Steel Mills Corporation was setup as a private limited company in the public sector in accordance to the Companies Act of 1913, with the objective to establish and run steel mills at Karachi and other places in Pakistan. In January, 1969, Pakistan Steel concluded an agreement with V/O Tiajpro export of the then USSR for the preparation of a feasibility report into the establishment of a steel mill at Karachi. Subsequently in January, 1971 Pakistan and the USSR signed an agreement under which the latter agreed to provide techno-financial assistance for the construction of a coastal based intergrated steel mill at Karachi. The foundation stone for this gigantic project was laid on the 30th of December, 1973 by the then prime minister Mr. Zulfiqar Ali Bhutto. The mammoth construction and erection work of the intergrated steel mill, never experienced before in the country, was carried out by a consortium of Pakistani construction companies under the supervision of Soviet experts. ................................................................ Pakistan Steel did not only have to construct the main production units but a host of infrastructure facilities involving unprecendented volumes of work and expertise. Component units of the steel mill numbering over twenty and each a big enough factory in its own right were commisioned as they were completed between April, 1981 to August, 1985 with the Coke Ovens and By Products Plant coming online first and the Galvanising Unit last. Commissioning of Blast Furnace Number 1 on the 14th of August, 1981 marked Pakistan's entry into the elite club of iron and steel producing nations. The project was completed at a capital cost of Rs. 24,700 million. The completion of the steel mill was formally launched by General Zia-UlHaq the then President of Pakistan on the 15th of January 1985. Today Pakistan Steel is the country's largest industrial undertaking having a production capacity of 1.1 million tonnes of steel. The enormous dimensions of the project can be visualised from the construction inputs which involved the use of 1.29 million cubic meters of concrete, 5.70 million cubic meters of earth work (second to Tarbela Dam), 330,000 tonnes of machinery, steel structures and electrical equipment. Its unloading and conveyor system at Port Qasim is the third largest in the world and its industrial water reservior with a capacity of 110 million

gallons per day is the largest in Asia. A 2.5km long sea water channel connects the sea water circulation system to the plant site with a consumption of 216 million gallans of sea water per day. The above figures illustrate the massive civil works, intricate erections, installations of sophisticated electrical and mechanical equipment. With the completion of Pakistan Steel, the local contractors gained the technical ability till then unknown, which they utilised later to undertake million dollar projects both within the country and abroad especially the Middle East.

Pakistan Steel Mission

Pakistan Steel is committed to be a leading steel industry By : 1 Greater response to customer's present & future needs. 2 Focus on productivity and Quality. 3 Facing Challenges of free Market Economy . 4 Ensuring higher rate of return on invested capital . 5 Developing Human resource and motivating employees .through .empowerment and hard consequences. 6 Safe Working and Environment friendly conditions. 7 Minimizing process wastages,rejections and recyling .wastes. 8 Good Governance. 9 Fulfilling Social Obligations. 10 Improving Corporate Image. The leadership at Pakistan Steel insured the contribution of all its workforce in order to establish a vision and mission that clearly articulated Pakistan Steel's aims and embodied the companys aspirations.

Pak Steel Vision

To become a leading steel company in south Asia committed to serving stake holders by offering quality products through an innovative and cost effective manner in accordance to environmentally friendly conditions.

WE AIM TO LEAD AND NOT FOLLOW

We continuously seek to to push are limits and bounds in innovation of our processes and products.

OUR COMMITMENT IS TO OUR CUSTOMERS

We aim to work closely with our customers and suppliers providing them with superior products, services and ideas.

OUR ENVIRONMENT IS OUR RESPONSIBILITY

Our success comes from our people and communities. We aim to create a safe and satisfying working environment. We are entrusted with the care of our environment and support of our communities.

DEPARTMENT TO BE DISCUSSED:

Cold Rolling Mill Thermal Power Plant EDC Steel Making Department

COLD ROLLING MILL (C.R.M):Cold rolling is a metalworking process in which metal is deformed by passing it through rollers at a temperature below its recrystallization temperature. Cold rolling increases the yield strength and hardness of a metal by introducing defects into the metal's crystal structure. These defects prevent further slip and can reduce the grain size of the metal. Cold rolling is a method of cold working a metal. When a metal is cold worked, microscopic defects are nucleated throughout the deformed area. These defects can be either point defects (a vacancy on the crystal lattice) or a line defect (an extra half plane of atoms jammed in a crystal). As defects accumulate through deformation, it becomes increasingly more difficult for slip, or the movement of defects, to occur. This results in a hardening of the metal. If enough grains split apart, a grain may split into two or more grains in order to minimize the strain energy of the system. When large grains split into smaller grains, the alloy hardens as a result of the Hall-Petch relationship. If cold work is continued, the hardened metal may fracture. During cold rolling, metal absorbs a great deal of energy. Some of this energy is used to nucleate and move defects (and subsequently deform the metal). The remainder of the energy is released as heat. While cold rolling increases the hardness and strength of a metal, it also results in a large decrease in ductility. Thus metals strengthened by cold rolling are more sensitive to the presence of cracks and are prone to brittle fracture. In C.R.M. we get input(feeding) from Hot Steel Making (H.S.M) unit. In C.R.M the sheet gets thinned forcefully.

UNITS OF C.R.M:*) C.P.U(CENTRALISED PROCESSING UNIT) *) REVERSIBLE ROLLING MILL *) ANNEALING UNIT *) TEMPER MILL UNIT *) SHEARING UNIT *) SLITTING UNIT *) GALVANIZING UNIT *) COMBINE SHEARING AND SLITTING UNIT *) SECTION FORMING UNIT(PROFILE BENDING UNIT)

*) C.P.U (CENTRALISED PROCESSING UNIT):A central processing unit (CPU) or processor is an electronic circuit that can execute computer programs. This term has been in use in the computer industry at least since the early 1960s (Weik 1961). The form, design and implementation of CPUs have changed dramatically since the earliest examples, but their fundamental operation has remained much the same. Early CPUs were custom-designed as a part of a larger, sometimes one-of-a-kind, computer. However, this costly method of designing custom CPUs for a particular

application has largely given way to the development of mass-produced processors that are made for one or many purposes. This standardization trend generally began in the era of discrete transistor mainframes and minicomputers and has rapidly accelerated with the popularization of the integrated circuit (IC). The IC has allowed increasingly complex CPUs to be designed and manufactured to tolerances on the order of nanometers. Both the miniaturization and standardization of CPUs have increased the presence of these digital devices in modern life far beyond the limited application of dedicated computing machines. Modern microprocessors appear in everything from automobiles to cell phones and children's toys. Here the sheet gets cleaned and is also cut from sides.

*) REVERSIBLE ROLLING MILL:Reversible cold rolling mill is that one stand of mill is laid out in the line, and strip will pass the mill reciprocally till termination product. This line is characteristic with low cost, small occupation and flexible production. Here sheet gets thinned.

*) ANNEALING UNIT:It is a process of heat treatment by which glass and certain metals and alloys are rendered less brittle and more resistant to fracture. Annealing minimizes internal defects in the atomic structure of the material and leaves it free from internal stresses that might otherwise be present because of prior processing steps. Ferrous metals and glass are annealed by heating them to high temperatures and cooling them slowly; copper and silver, however, are best annealed by heating and cooling quickly, then immersing in water. Large masses of metal or glass are cooled within the heating furnace; sheets are usually annealed in a continuous-process furnace. They are carried on a moving table through a long chamber in which the temperature is carefully graded from initial heat just below the softening point to that of room temperature at the end. Annealing time, especially of glass, varies widely according to the thickness of the individual piece; window glass, for example, requires several hours; plate glass, several days; and glass mirrors for reflecting telescopes, several months. Annealing is required as an intermediate step in metal-forming processes such as wire drawing or brass stamping in order to restore the ductility of the metal lost because of work hardening during the forming operation The output from annealing unit goes into temper mill.

*) TEMPER MILL UNIT:A temper mill is a steel sheet and/or steel plate processing line composed of a horizontal pass cold rolling mill stand, entry and exit conveyor tables and upstream and downstream equipment depending on the design and nature of the processing system. A typical type of temper mill installation includes entry equipment for staging and accepting hot rolled coils of steel which have been hot wound at the end of a hot strip mill or hot rolled plate mill. Also included in a typical temper mill installation are

pinch rolls, a leveler (sometimes two levelers), a shear for cutting the finished product to pre-determined lengths, a stacker for accumulating cut lengths of product into a bundle. Sometimes a temper mill installation includes a re-coil line where the finished product is a coil instead of bundles of cut lengths of product. Maximum product flexibility capability could be attained if the installation was arranged to produce both coils and bundles of cut to length product. The heart of the temper mill is the cold rolling mill stand which produces the temper pass. It will include electric powered drive motors and speed reduction gearing suited to the process desired. The design of the rolling mill can be a 2-high or 4-high (even 6high in some cases). The mill stand can be work roll driven or back up roll driven. The mill can be designed with hydraulic work roll bending and/or back up roll bending. Installations typically have a single rolling mill stand, but may have two. Pinch rolls provide back tension for the pay off reel in the entry section and entry and exit tension for the temper pass. The primary purpose of a temper mill is to improve the surface finish on steel products The process goal is physical property enhancement through cold forming of the steel product in the bite of the work rolls. The physical properties that are enhanced by the temper pass due to elongation of the product include: Dimensional trueness and repeatability Suppression of yield point elongation Improved product surface finish Improve product shape and flatness Decrease coil memory Increase product yield strength Develop proper stiffness or temper Typical elongation produced in the product is 0.5% to 2%. Product dimensions vary. Thicknesses include typical sheet metal gauges up to 3/4" thick plate. Widths vary from 36" to 125". The finish of the rolled product is controlled by using rolls having a variety of surface finishes designed to impart the desired finish to the product. Roll finishes range from ground and polished rolls to impart a bright finish, to shot-blasted or electricdischarged textured rolls that produce a dull, velvety finish on the steel surface. Typical auxiliary equipment includes PLC based controls, overhead traveling cranes, roll changing equipment, roll grinding equipment, hydraulic power unit(s), bundle lifting devices, Coil handling devices, etc. The output from temper unit goes into either sharing unit or slitting unit.

*) SHEARING UNIT:-

Shearing is a process for cutting sheet metal to size out of a larger stock such as roll stock. Shears are used as the preliminary step in preparing stock for stamping processes, or smaller blanks for CNC presses. Material thickness ranges from 0.125 mm to 6.35 mm (0.005 to 0.250 in). The dimensional tolerance ranges from 0.125 mm to 1.5 mm (0.005 to 0.060 in). The shearing process produces a shear edge burr, which can be minimized to less than 10% of the material thickness. The burr is a function of clearance between the punch and the die (which is nominally designed to be the material thickness), and the sharpness of the punch and the die. Material selected for shearing should be standard stock sizes to minimize the extra costs associated with special slitting. Burrs and hold down marks which are inevitable, should be considered in the design of the end product. Burrs should be kept away from handling areas, preferably folded away, or in some obscure area. The same can be done with hold down marks too.

*) SLITTING UNIT:The slitting mill was a watermill for slitting bars of iron into rods. The rods then were passed to nailers who made the rods into nails, by giving them a point and head. The slitting mill was probably invented near Lige in what is now Belgium. The first slitting mill in England was built at Dartford, Kent in 1590. This was followed by one on Cannock Chase by about 1611, and then Hyde Mill in Kinver in 1627. Others followed in various parts of the England where iron was made. However there was a particular concentration of them on the River Stour between Stourbridge and Stourport, where they were conveniently placed to slit iron that was brought up (or down) the River Severn before it reached nailers in the Black Country. The slitting mill consisted of two pairs of rolls turned by water wheels. Mill bars were flat bars of iron about three inches wide and half an inch thick. A piece was cut off the end of the bar with shears powered by one of the water wheels and heated in a furnace. This was then passed between flat rolls which made it into a thick plate. it was then passed through the second rolls (known as cutters), which slit it into rods. The cutters had intersecting grooves, which sheared the iron lengthways.

*) GALVANIZING UNIT:In this unit iron is painted with a suspension of zinc particles in an organic solvent, so that a zinc coating remains following evaporation of the solvent. The principal method of making steel resist corrosion is by alloying it with another metal, zinc. When steel is submerged in melted zinc, the chemical reaction permanently bonds the zinc to the steel through galvanizing. Therefore, the zinc isn't exactly a sealer, like paint, because it doesn't just coat the steel; it actually permanently becomes a part of it. The zinc goes through a reaction with the iron molecules within the steel to form galvanized steel. The most external layer is all zinc, but successive layers are a mixture of zinc and iron, with an interior of pure steel. These multiple layers are responsible for the amazing property of the metal to withstand corrosion-inducing circumstances, such as saltwater or moisture. Zinc also protects the steel by acting as a "sacrificial layer." If, for some reason, rust does take hold on the surface of galvanized steel, the zinc will get corroded first. This allows the zinc that is spread over the breach or scratch to prevent rust from reaching the steel. The degree of galvanizing is usually represented as the zinc's weight per surface area rather than the thickness of the zinc, because this gives a better representation of how much metal has been applied. Steel often gets galvanized after individual parts have been formed, such as braces, nails, screws, beams, or studs. However, raw galvanized steel in sheets will withstand some bending and forming without flaking. Galvanized steel can be found almost everywhere. You might be living in a steel frame house. You are no doubt surrounded by steel parts in your car that allow it to emerge from rainstorms unscathed. Many people work in an office with metal roofing made of galvanized steel. Besides being inexpensive and effective, this metal is popular because it can be recycled and reused multiple times.

*) COMBINE SHEARING AND SLITTING UNIT:Input from Hot Steel Making(H.S.M) also goes into this unit.

*) SECTION FORMING UNIT(PROFILE BENDING UNIT):Rolling is a fabricating process in which the metal, plastic, paper, glass, etc. is passed through a pair (or pairs) of rolls. There are two types of rolling process, flat and profile rolling. In flat rolling the final shape of the product is either classed as sheet (typically thickness less than 3 mm, also called "strip") or plate (typically thickness more than 3 mm). In profile rolling the final product may be a round rod or other shaped bar, such as a structural section (beam, channel, joist etc). Rolling is also classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is termed as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is termed as cold rolling. Another process also termed as 'hot bending' is induction bending, whereby the section is heated in small sections and dragged into a required radius. Heavy plates tend to be formed using a press process, which is termed forming, rather than rolling. Output from Combine Sharing and Slitting Unit go