Technical Session – TCDP

Course contents
• CRM OVERALL
• PLTCM
• ECL.
• BAF
• SPM
• CGL
• TECHNICAL SERVICE
• FINISHING AND DESPATCH
• TQM
 CRM OVERALL
1. What is Cold Rolling ?
Process by which hot rolled strip or stock is introduced between
rollers and then squeezed or compressed to the desired
thickness
Amount of strain introduced determines the properties of the
finished product

2. Why is Cold Rolling done ?

 Good Formability.
 Superior Surface Finish

 Reasonable Strength
 Commonly used Grades of Cold Rolled Steel

1. D/DD - Drawing/Deep Drawing: Simple forming/bending

applications
2. EDD - Extra Deep Drawing : Deep Drawn components

3. IF (Interstitial Free) : Critical Draw and Stretch Components

in terms of geometry of the
component, type and depth of draw
and press parameters

4. IFHS (Interstitial Free High Strength): For components

involving draw and
requiring resistance
against dent and
impact
 HR Coils
1. Thickness: 2.0 to 6.5 mm
2. Width: 800 to 1580 mm
3. Coil weight: 28 Ton Maximum
4. Dia of Coil: Inside: 762mm, Outside: 1000 to 2100mm.
5. Specific weight: 18 Kg/ mm
 Thickness and Width range

PLTCM ROLLING CAPABILITY

Thickness Thickness Maximum Width

(From) (To)
.25mm .299mm 1000mm
.30mm .349mm 1100mm
.35mm .399mm 1250m
.40mm .499mm 1325mm
.50mm .599mm 1400mm
.60mm .699mm 1450mm
.70mm 3.2mm 1580mm (max HR
width is 1540mm)
 Customers

• KEY AUTO CUSTOMERS:

Mahindra and Mahindra, Tata Motors,
Hyundai Motors, Toyota Kirloskar,
Maruti Udyog, Bajaj Auto,
Ford, General Motors, Toyota
DRUMS & BARRELS
Balmer & Lawrie
 Branded Products

Advantage Galvano:

•Excellent drawability.
•Absolute Flatness.
Tata Shaktee GC sheet –
•Superior surface texture and finish.
A premium product for
•Potential for paint cost reduction.
the rural sector
•Enhanced corrosion resistance.
•Superior paint adhesion.
 Process flow in CRM

HRC FROM
HOT STRIP MILL COUPLED PICKLING &
TANDEM COLD MILL

ELECTROLYTIC H2 BATCH SKIN PASS

CLEANING LINE ANNEALING MILL

PACKAGING
GALV. LINE RECOILING & LINE
2 INSPECTION LINE

GALV. LINE - 1
DESPATCH
 Questions
• Why we do Cold Rolling?
• What are the usages of Cold Rolled Products? Give Example.
• How many Brand of CR Products we make at CRM, Jamshedpur?
• Make the Block Diagram for Cold Rolling Process.
• What is range of Thickness and Width range for HR coils coming as input to
CRM?
• What is range of Thickness and Width range for CR coils we produce in our
CRM?
• Name ant five customers name for CR products?
• Names ant five TDC for CRCA and Galvanizing Line?
• Name suppliers of these process Lines—PL, TCM, ECL. BAF, SPM, CGL1,
CGL2, RCL1-2, RCL3
 PLTCM
(Pickling Line & Tendom Cold
Mill)
PL ENTRY
 PICKLING
Side Trimmer Tension Leveller

Rinsing
Tanks Pickling
Tanks
Delivery Looper 1
Delivery Looper 2

Entry Looper
 PURPOSE OF PICKLING
1. To eliminate scales from hot rolled strip.

2. Improve cold rolling operatibility.

3. Ensure the appearance of strip

4. Improve the efficiency and quality of processes downstream , the size

of coil increased by welding.

5. A strip is trimmed on both the edges to a specified width.

6. Any portion of strip that are bound to be detrimental to downstream

processes or that to turn defective are eliminated
 Pickling Acid Concentration

There are 4 Acid tanks for Pickle the HR coils.

Tank#1. Acid concentration 2 to 3%.
Tank#2. Acid concentration 4 to 6%.
Tank#3. Acid concentration 7 to 9%.
Tank#2. Acid concentration 10 to 12%.
Temperature 85ºC, Inhibitor 0.3%.
Speed: 180 m/min for Al-killed steel.
120 m / min for IF steel
 Pickling Process Variables :

There are three types of oxides on strip surface as scale.

1) Ferric oxide ---- Fe 2 O3 ------- Haematite.

2) Ferroso ferric oxide ---- Fe 3 O4 ------- Magnetite.

3) Ferrous oxide ---- Fe O ------- Wustite .

Scale is a mixture of Iron oxides, Haematite,Magnatite and

Wustite. The Ferric oxide layer is the outer most layer of
Scale and the ferrous oxide layer is close to the steel matrix .
 TANDEM COLD MILL

The tandem mill derives its name from the tandem rolling pattern of
the same strip which is reduced successively in a number of stands
without reversing.
In CRM we have Tandem Cold Mill of 6 Hi 5 Stand mill.
 TCM – TECHNICAL DATA

• WORK ROLL DIA 385MM – 425MM

• INTER. ROLL DIA 440MM – 490MM
• BACK UP ROLL DIA 1150MM – 1300 MM
• ROLL BARREL LENGTH 1700MM
• DISTANCE BETWEEN MILL STAND 5500MM
• ROLL FORCE 1800 TON
• WORK ROLL BENDING FORCE 36TON/CHOCK (POSITIVE)
• WORK ROLL BENDING FORCE 18TON/CHOCK (NEGATIVE)
• INTER. ROLL BENDING FORCE 46TON/CHOCK (POSITIVE)
• Forged steel Roll used in all the three types of Roll
 Questions
• What are check points to receive any HR coils coming to CRM from Hot Strip Mill?
• What are the steps we should follow to reject any Coils at HR Receiving Yard?
• What are checkpoints mentioned in your Crane Check list?
• How we should handle the Scrap Box in PL Entry?
• How many Acid tanks are there for Pickle the CR Coils?
• Why we do Pickling?
• Which Acid we are using to Pickle the HR Coils?
• Why Hydrochloric Acid is used for our Pickling Section?
• What is use of ARP?
• What is designed capacity of PLTCM?
• What is Concentration range of Acid in each Tank?
• Are we mixing any other Chemical with Acid in Pickling Tanks?
• What precaution we should take while taking the sample of acid from Pickling tanks?
• What the use of tension Leveller in Pickling Section?
• What is use of Buffer/accumulator? Name the types of buffer used in our Cold Rolling Mill?
• How we can check the Pickling performance of HR coils in PL section?
• Which type welder we are using in PLTCM?
• What is Notching and Punching, what the use of these process?
• What is use of Trimmer in PLTCM?
• Which mechanism we are using at trimming station ( CPC/EPC).
• What the types of Rolls we using in PLTCM?
• Name the configuration of our mother Mill?
• The Product comes out from PLTCM are termed as?
• What are defects related to Pickling and Rolling name any three or four defects?
• What is Full form of…. EPC, CPC, CRCA, GA, GP, GC, AGC, ASC, IMR, BUR, EDT, HRPO, HRSPO, FHCR.
• What is role of dryer in picking area?
 ECL
( Electrolytic Cleaning Line)
 WHY CLEANING

To remove:
-Oil
-Grease
-Iron fines
-Mill dirt
-Other undesired materials.
To condition surface for subsequent operation
WHAT IS ELECTROCLEANING ?
Electro cleaning is a process where cleaning is Achieved
by applying electric current between the work piece & counter
Electrode in aqueous bath consisting high conductivity
electrolytes.
 WHY ELECTROCLEANING
• Electro Cleaning is required to remove residual soil that may remain
after primary soak / spray cleaning.
• Electro cleaning helps in :
– Achieving High degree of cleanliness.
– Providing silicate layer if required.
– Reducing contact time.
– Increasing line speed.
– Reducing line length.
Chemical Used: Alkali Tank:- NaOH-1-3%, temp-60-85°C
Chemical Tank- Thio-Urea
Welder: Mesh-Seam Welder supplied by Guild,USA.
Alkali Clean: Silicate Base, Silicon-3-6mg/m²
MAGNETIC CONVEYOR -2

PAY OFF REEL-2

 Questions

• Why we do Electrolytic Cleaning?

• What are different sections in ECL?
• Which Chemicals we using in ECL area.
• What is type of Welder used in ECL?
• What are the check-points at ECL Entry for accepting the CR Coils?
• How we communicate about any abnormality observed in process to our next
line through CRM-IS?
 BAF
(Batch Annealing Furnace)
 Annealing
1. Why annealing is done?
• Steel Coils are hard and brittle after Cold Rolling
• Has Elongated grain Structure
• Not suitable for end use
2. Annealing ensures
a) Softening of the cold rolled steel- Relieving the internal stress
developed during cold rolling.
b) Develop desired mechanical properties suitable for
intended applications
c) Bright Surface Finish
 Stages of Annealing
Process of relieving internal stresses induced during cold rolling takes place
in three stages
1. Recovery : Physical and mechanical properties ( Hardness, ductility
elect prop.)which suffered changes as a result of cold working tend to
recover to their original values.
Occurs at the initial phase of annealing at lower temperatures.
2. Recrystallization : Process of nucleation of new strain free crystals
(grains) which replaces all deformed crystals of the cold worked
material. Takes place at a temperature known as Recrystallization
temperature .

3. Grain Growth: Increase in average size of crystals/grains on further

annealing subsequent to the completion of Recrystallization.
Grain size has direct effect on the mechanical properties. Hence it is
controlled to achieve optimum properties
 Why Hydrogen
1. High Conductive value, 6.5 times more than Nitrogen at 790ºC.
2. Low viscosity. 50% of Nitrogen at 790ºC.
3. Low Density, One fourth of Nitrogen.
4. High Reducing potential.
5. High Decarburizing Power.
BAF Filling factor
BAF
SPM (Skin Pass Mill)
 Purpose of Skin pass
1. Improvement of mechanical properties of material.
a. Elimination of yield point Elongation.
b. Improvement of formability by decreasing the yield point.
2. Shape correction.
3. Adjustment of surface properties
- Roughness - Matte Bright
4. Apply Rust Preventive oil (optional)
Fundamentals of Skinpassing
When the As - annealed mild sheet is preformed, surface markings, called stretcher
strains markings, appear on deformed parts. Stretcher strains are also called as
Luder bands.
bands The formation of these markings can be prevented by
Skinpassing up to 1-2 % Extension before performing.
This band is formed with an angle of about 45o - 50o with respect to the tensile axis.
 Questions
• Why we do Annealing? Which type of Annealing we do at our Cold Rolling Mill?
• Which gas we used as Annealing Medium, Atmospheric Gas and Fuel for Heating?
• Why we use the Coke Oven Gas in BAF for fuel?
• What is use of Take over Points in BAF?
• What steps we should follow during entering in Cellars of BAF?
• What max designed Stack Weight can be loaded to a Base supplied by LOI?
• How CO, Nitrogen and Hydrogen gas is harmful for us?
• How we make a Stack in BAF?
• Why we use Hydrogen as Annealing Medium?
• What is use of Convector Plate in BAF?
• How TOP convector used in CCSU is different from BAF intermediate Convector Plate?
• What is use of Waste gas Blower in BAF?
• What is use of Recuperator in Heating Hood?
• What do mean by TPOH?
• What are the different cooling processes we use in BAF annealing Base?
• Why water Quick fit nozzle is provided in Annealing Bases?
• What is use of H2 Coupling in Annealing Process?
 CGL
( Continuous Galvanizing Line )
 What is Galvanizing ?

When two dissimilar metals are joined, a galvanic couple is

set up, such as between zinc and steel substrate. Due to
the galvanic action i.e. electrolytic phenomenon taking place
between such metals, zinc is sacrificed to protect the steel
substrate from corrosion.
Application of zinc in molten condition on steel substrate or
electrolytically is known as galvanizing.
1.Galvanizing: Aluminum-0.13-0.2% and rest Zinc.
2.Galfan : Aluminum 4.5 % and rest Zinc.
3.Galvalume: Aluminum 55% and rest Zinc
 Reasons for corrosion in steel affecting life

• Salt (NaCl – De-icing salt & salt in atmosphere

• Humidity (Specially at coastal areas)

• Number of dry-wet cycles – tropical environment like India

• Temperature variations – exhaust system

• Small pebbles, sand hit, scratches, dents etc

• Acid rain

• Industrial pollution (Sulphur Di-Oxide)

 WHY GALVANIZING

• Protects steel sheets from corrosion attack by

acting as a barrier between steel and the
environment.

• Zinc and Zinc alloys have the ability to react at

scratches and other damages through an
electrochemical (galvanic) action between steel and
zinc.

• In the galvanic process zinc sacrifices itself to

protect structural integrity of the steel.
 Benefits of Galvanizing

Economical
Galvanized steel is the most economical metal roofing and siding
material
Today, steel is a high tech, engineered material
The life cycle costs of steel Roofing and Siding are very attractive
Steel companies are competitive worldwide in regards to quality
and cost .
Steel is strong
Can be used in either Structural or Architectural Roofing and
Siding
 Benefits of Galvanizing

Durable
Steel lasts
Barrier and sacrificial protection against corrosion
Steel resists damage from wind, hail and snow
Recycled Content
Steel is the most highly recycled material on the face of the earth!
Nearly 64% of all steel scrap in North America is recycled
annually
o 60.7% of all steel packaging is recycled
o 81% of all steel appliances is recycled
o 97.6% of all steel automobiles is recycled
When steel Roofing and Siding have completed their useful life they
can be easily recycled and not land filled
•CONTINUOUS GALVANISING LINE #1 - FLAT PRODUCTS,
INDIA ( CGL#1)
- 0.1 MT CAPACITY, CONSTRUCTION PRODUCTS
• CONTINUOUS GALVANISING LINE #2 - CMI, BELGIUM
( CGL#2)
- 0.3 MT CAPACITY
- SPANGLE AND ZERO SPANGLE CAPABILITY
- IN-LINE ECL, GALVANNEALING, SPM, TL, POST-TREATMENMT
- PRODUCTS FOR AUTO, WHITE GOODS, ENGG., CONSTR.
 Product Characteristics:

Dimensions: Thickness : 0.33 – 2 mm

Width : 800 – 1580 mm
I/D : 508 / 610 mm
O/D : 1900 mm max
Weight : 28 tons max

Grades: CQ, DQ, DDQ, EDDQ, Super EDDQ,

Coating Type: Galvanizing ( Zn with Lead / Antimony); spangled
Galvanizing ( Only Zn, no Pb/Sb); Zero-spangled
Galvannealed (Zn-Fe Alloy)
Coating Weight: Galvanizing – 60-600 g/m2 total both sides
Galvanizing – differential up to 400 g/m2 total both sides with a max ratio of 1 to 2
Galvannealed –60-200 g/m2 total both sides with alloy content from 9~12%
Surface Condition: Regular Spangle
Zero spangle through lead and antimony free bath
Extra smooth (Skin Passed) / desired roughness
Flatness control with Tension Leveller.
Chemical Treatment: Chromating
Electrostatic oiling
 LINE DIAGRAM OF CGL#2
Furnace
Exhaust Gases

48380mm

Atmospheric Air for

cooling plenums


42

Atmospheric Air for
cooling plenums
41 43
Alkali
Fumes 
40 44

39


45

     Chromate
fumes
38
 26

 
23 
24 25 46

 
20 37 57

 
54 55 56


12 13 14 15 16 17 18 19   28



   
3 4

     
36

 
 49
   
50


7
  
 47  


  
29 52 58



  


 8
9
11
27  35     53 59
 48
1 2 5 6
 51 
34 

  Scrap Bin

 
 33

  
 32

Zero Level Zero Level Zero Level

      

10 21
22 30 31
Scrap Bins   

N Description No Description No Description No Description No Description No Description

o
1 Pay off reel #1 11 Upper entry acumulator 21 BR#2 31 Sink Roll 41 Cooling plenum #3 51 Chromating Section

2 Pay off reel #2 12 Pre degreasing 22 Dancer Roll 32 Front Stab Roll 42 Top Rolls 52 Exit Accumulator

3 Flattener #1 13 Degreasing & Brushing 23 Preheating 33 Back Stab Roll 43 Cooling plenum #4 53 Inspection Area

4 Shear way 1 14 Electrolytic Cleaning 24 Heating 34 Air Knives 44 Cooling plenum #5 54 Total Thickness Guage

5 Flattener #2 15 Rinsing & Brushing #1 25 Soaking 35 Guide Rolls 45 Cooling plenum #6 55 OILER

6 Shear way 2 16 Rinsing & Brushing #2 26 Jet Cooling 36 Galvanneal Furnace 46 Quench Tank 56 Exit pinch roll

7 Common Pinch Roll 17 Rinsing & Brushing #3 27 Equalizing tunnel 37 Movable Soaking 47 Top Coating Guage 57 Exit Shear

8 WELDER 18 Rinsing & Brushing #4 28 Hot Bridle 38 Fixed Soaking 48 Bottom Coating Guage 58 Sample Tray

9 BR#1 19 Dryer 29 Snout 39 Cooling plenum #1 49 Mill 59 Tension reel

10 Lower entry acumulator 20 Alkali fume exhauster 30 Zinc 40 Cooling plenum #2 50 Tension Leveller
 PROCESS FLOW & EQUIPMENT DESCRIPTION

3. WELDER
In continuous lines, the tail end of the outgoing coil is joined to the head end of
the incoming coil. For this we have a Press Lap welder with entry and exit
clamps, centering and looping devices. The supplier of the machine is
MISTUBISHI ELECTRICS, Japan. The welds have over thickness of less
than 10% of the thickness of strip and are as resistant as the strip itself. The
welder has an independent PLC which communicates with L2 system
independently.
4. ACCUMULATOR

Horizontal type with 8 strands, actuated by a torque motor. Max capacity is 400
m but working capacity is somewhere around 300 m, giving 120 seconds to
weld at maximum line speed. It isolates entry section and Process section and
reduces dependence between the two. It is basically a buffer. There are 5
steering units in it to maintain strip centre with the mill centre.
 PROCESS FLOW & EQUIPMENT DESCRIPTION

5. Cleaning Section
Cleaning agent, Alkali based
It is one of the extremely efficient and very well designed system. Contains 8
units, all complimentary to each other. Pre-degreasing  Degreasing &
Brushing  Electrolytic Cleaning  Four rinsing and brushing  Dryer.
Adequate recycling is done to conserve Alkali. Conductivity meters and
magnetic separators etc are provided to ensure proper cleaning all the times.
ECL section has intermittent polarity reversal feature for better operational
advantage. Dryer takes care that when the strip enters the furnace, it is perfectly
clean and doesn’t vitiates the furnace atmosphere.

6. Dancer Roll
Absorbs tension fluctuations in the furnace and maintains furnace tension
constant which is very important because of the fact that the strip is at higher
temperatures.
 PROCESS FLOW & EQUIPMENT DESCRIPTION

7. FURNACE
Annealing furnace is a full radiant tube vertical, CO gas fired furnace. It has been
supplied by DREVER International , Belgium. The Furnace has a total of 127 W-
Type, pull type, recuperating, radiant tube burners.
Preheat section recovers heat from the exhaust gases to preheat the strip and also
helps in surface O2 removal prior to annealing section.
Heating and soaking heats the strip to annealing temperature and hold the
temperature to achieve the necessary re-crystallization of steel.
Jet cooling section cools the strip at a very fast rate to coating temperatures of about
460oC.
Snout provides an inert passage for the strip into Zinc bath without coming into
contact with the oxidizing atmosphere.
Furnace atmosphere is maintained reducing by injection of H2 and N2. A very low
dew point is maintained in the furnace so that there is practically no free O2
available.
 PROCESS FLOW & EQUIPMENT DESCRIPTION

8. Zinc Pot & Coating

Working pot is ceramic refractory lined. Two auxiliary iron pots are also provided.
All the pots are fixed but we have a future provision of one more ceramic lined pots
and then they become movable. This configuration helps in quick change of the Zinc
bath chemistry to go from GI Spangle to GI non spangle. Main pot is induction heated
where as the auxiliary pots are electric resistance heated. The pot equipments have
been supplied by AJAX.
9. Zinc Wiping
Zn wiping is achieved by throwing high pressure air onto the strip by air knives.
The wiping can be done using N2 also. The wiping equipment is in close loop with
the coating measuring gauge so automatic correction takes place when ever either
the speed is increased or coating increases. The wiping equipment has been
supplied by KOHLER. We also have Baffle plates to minimize edge over coatings.
The air knives are dual type having two different profiles at 180o. They can be
rotated online.
Coating control
Air Knife

Coating control parameters

• Line speed (m/min)
•Air pressure (mbar)
•Knife lip to strip distance (mm)
•Air knife angle (degree)
•Height of air knife from zinc
level (mm)
•Zinc bath temperature (0C)
 What is Galvannealing ?

The GA process consists in an immersion in a liquid zinc bath

containing 0.135 % aluminium followed by heat treatment in an
annealing furnace

SEM
image
of
surface

The resulting GA coating is

naturally porous, exhibiting
an high surface area
 Why Galvannealing ?

•Improved weldability, particularly spot welding.

•Excellent paint adhesion due to surface structure
•Has found extensive use in the automotive markets
•Reduces under paint film delamination
Role of Aluminium - 0.13%

Increases fluidity of the molten zinc

Inhibits the reaction between the strip and the bath
Improves the adhesion of the coating
Improves the formability of the coating
Aids top dross formation
Improves the brightness of the coating
 PROCESS FLOW & EQUIPMENT DESCRIPTION

10. Galvannealing

The Galvannealing furnace is a high frequency Induction heated (450 OC to 550

O
C)furnace which is mounted on a movable platform. When GA campaign is not
going on we take the furnace out of line to home position. This furnace is a supply
of INDUCTOTHERM, Belgium. This furnace is followed by a movable and a
fixed soaking sections. These electric resistance heated, sections are important
because they provide the necessary time for alloy formation

11. Cooling Tower

The cooling tower has six cooling plenums. They suck atmospheric air from
outside and throw it on to the strip to achieve fast cooling of the hot Zn coated
onto the strip. After this cooling by the plenums, strip enters Quench tank. In
quench tank the strip temperature comes to about 50-60oC. After the quench tank,
the strip is dried by hot air dryers.
 12 Coating Measurement
The coating thickness is measured by the M310 , X-ray fluorescence type coating
gauge supplied by RADIIOMETRIE. It is a non contact type measurement,
independent for both top and bottom. It provides high speed non-contact
measurement of metallic coatings applied to steel strips. It has got different
scanning modes which can be used depending upon the customer requirements of
the strip. Along with the coating weight, it also measures the Fe contents in the
coatings , suitable for GA.
13 Skin Passing and Tension Leveling
SPM and TL has been supplied by Danieli Wean, Italy.We have a 4 high wet type
skin passing mill. The main purpose is to give desired surface texture / roughness
to the strip. It suppresses the yield point elongation. The mill can work in two
modes viz Force mode and Elongation mode.
The 6 high, tension leveler is very important for the line as it makes the strip
perfectly flat removing all residual stresses, coil set and cross bow. The leveler
applies flexion and tension alternated strength with elongation controlled on to
strip. The combination of the flexing rolls and tension imposes a deformation to
homogenize the lengths of different fibers of the strip.
 14 Chromating
Both the faces of the strip are applied with a passivation agent to prevent the
formation of white rust during storage and transportation. This passivation agent
is nothing but Chromic acid. After the wiping the chromatic acid is dried by hot
air dryer.
15 Accumulator
It is another buffer the exit side of the process providing reduced dependence of
process operation and exit operation. It is vertical type with 20 strands or 10 loops.
It permits the accumulation and storage of sufficient strip in order to assure a
constant strip speed through the process section during the different stops of the exit
section. Storage capacity is 309 m or 123 seconds at maximum process speed.

16 Ink Jet Printing

Every coil going out of the line is marked constantly with the galvanized coil
dimensions and coil id for better identification and traceability, at any point, at the
customer end. But this feature is again optional depending upon the customer
willingness.
 17 Inspection Stations
It’s an horizontal and vertical stand inspection station. Vertical inspection station is
used to inspect the surface quality of both top and bottom side of the strip.
Inspection is done visually at close distances and is assisted by stroboscopic lights.
Horizontal inspection station is used to check the stirp flatness. We have logging of
the defects in L2 system which then goes onto L3. So every coil carry the exact
location and severity of the defect.
18 Electrostatic Oiler
It is a supply of FARA. It is a very precise machine which applies oil
simultaneously on both surfaces through blade applicators. Metering pumps are
controlled by servo motors linked to strip speed via a line speed reference signal.
Film weight : minimum 500 mg/m2 per side.
Maximum 3000 mg/m2 per side
19 Recoiling
It supports the coil and provides the required back tension for recoiling. We have an
option of square winding or stagger winding. Similarily, ID of the coil can be either
508mm or 610mm depending upon the customer requirement. For that we use a
rubber sleeve and we have an automatic sleeve removal system.
CRM - Galvanized product
ROLL FORMING LINE
 Corrugated sheet

810MM
•Pitch : 75.5 +/-2mm
•Depth : 17.5 +/-1.25mm
•Width : 807 - 812mm

840MM
•Pitch : 78 +/-2mm
•Depth : 14 +/-1.25mm
•Width : 835 - 845mm
Branded Products
 MAJOR DEFECTS

UNCOATED SPOTS/ PATCHES

 MAJOR DEFECTS

STRETCHER STRAIN
 MAJOR DEFECTS

POT ROLL MARKS

 MAJOR DEFECTS

NOZZLE STREAK
White Rust
 White Rust - Prevention & Cure

1. White rust is a bulky, white, powdery deposit that forms rapidly on the surface of
the galvanized coating under certain specific conditions.

2. White rust can cause considerable damage to the coating .

3. The surface of galvanized coatings is almost 100% zinc.

4. It is the durability of the zinc that provides the outstanding anti-corrosion
performance for steel, yet zinc is a relatively ‘reactive’ metal.
5. It is a stable oxides that form on the zinc's surface that determine its durability,
and these oxides are formed progressively as the zinc is exposed to the atmosphere.
6. Carbon dioxide in particular is a contributor to the formation of these stable oxides.
7. Industrial Galvanizers uses a chromate passivation in conjunction with its
galvanizing operations to provide protection to the galvanized coating during the
‘youth’ period of the coating. This passivation coating provides
short term protection to the zinc to give the stable oxides on the surface
 Questions
• Why we make coated material?
• What is Width and Thickness range for CGL1 and CGL2?
• How the welders on CGL#1 and CGL#2 are different?
• What is role of SNOUT in Galvanising?
• How many POR is in CGL#1?
• What is use of Air Knife in Galvanising?
• What is meaning 120 GSM?
• Name five defects related to Galvanizing?
• Name the instrument used for checking the online coating in CGL#1?
• Which chemical we use for Passivation?
• Which type of Looper we have in CGL#1 Exit?
• How we print the TATA SHAKTEE logo on the Sheets?
• What is DROSS? How many types of DROSS we collect?
• Tension Leveller is installed in which CGL?
• Roll Coater is new installed facility in which line of CRM?
Finishing & Despatch
1. RCL ( 3 Nos.)
2. PARTING LINE ( 1 No.)
3. CPL
4. RAIL DESPATCH
5. ROAD DESPATCH
RCL
RCL-3
 OEM/EPA
1. OEM: Original Equipment Manufacturer. Coils directly sent to
Customer like Maruti, Tata motors, Toyota, Hyundai, Ford.
2. EPA: External Processing Agency. Coils sent to EPA from CRM. They
process it into cut to length as per required size given by the Customer
and then dispatch . Some EPA’s are:
a. TSPDL( Tata Steel Processing and Distribution Limited)
a. Jamshedpur.
b. Faridabad.
c. Pune.
b. BMW( Bonshal Mechanical Works):
a. Jamshedpur.
b. Kolkata
c. Posh metal.-Mumbai
d. Posh Hyundai: -Chennai
e. Allied Metal: - Faridabad
Identification Of Skin Panel Coils in CTTS
 CPL ( Continuous Packaging Line)

BARE COIL Stretch Film Wrapping

VCI HDPE
WRAPPING

METAL JACKET , OD & CIRCUMFERENTIAL EYE STRAPS

ID EDGE PROTECTER STRAPS
 Questions
• If line is not running due to “No PDI” then what do you mean?
• How we identify the Skin Panel Coils in CTTS?
• Why we do forced Lay down in CTTS supported Cranes?
• What is Mutation in CTTS System?
• MN Bay Yard stocks which type of product of CRM?
• BC Bay Yard stocks which type of product of CRM?
• DE Bay Yard stocks which type of product of CRM?
• RS, RR and ST Bay Yard stocks which type of product of CRM?
• What functions we do at RCLs?
• What are the ways to dispatch material to OEM/EPA?
• What is TC?
• What is difference between parting and Slitting?
• In CRM-IS what is first alphabets are used for RCLs and Parting Line also for CGL#1
and CGL#2?
Technical service
 TESTS IN LAB
1. PHYSICAL TEST IN LAB
• Hardness
• Yield Strength
• Ultimate Tensile Strength
• % Elongation
• Plastic Strain Ratio ( R-BAR)
• Surface raughness.
2. Chemical Test in CRM Lab.
 Zinc bath.
 Alkali concentration.
 Pickling acid concentration.
 pH value
 Zinc coating value
 PHYSICAL TEST
1. Yield Strength (YS):
Stress required to produce a small
specified amount of plastic/permanent
deformation.
Indicative of ease of forming
operation.
2. Ultimate Tensile Strength (UTS):
Maximum load which the steel can
withstand before fracture/ breaking.
3. Elongation:

Measure of the strain before fracture.

Indicative of the extent to

which metal can be deformed without
fracture
 Physical Test
4. n- Value : Modulus of Work hardening or strain hardening exponent
Indicates better stretch formability
Calculated from the formula = Kn where  is the true stress,  is true strain and K is the material constant.
For good stretchability n value should be >=0.22
5. r & r bar - Value
Quantitative index of the anisotropic property- Directionality
Ratio of strain along width to strain along thickness
Measured along the rolling direction, transverse to the rolling
direction and at 45degrees to the rolling direction indicated as
r0, r90 and r45.
Measured in tensile testing machine or in an instrument module r
r bar value is calculated as r0 + r90 + 2 r45
----------------- 4
 Measurement of I unit ( Flatness)

Flatness of cold rolled strip is measured in terms of

height of wave and wavelength and denoted in I units
as I = (Π/2 x h/L)2 x 105

where h is the wave height and L is the

length of the wave
Flatness
Tata Steel Capability
Flatness achievable
at PLTCM - is 10 I units
at Skin Pass Mill - is 8 I units
 Surface Roughness
Ra value : Average/mean height
of surface peaks and troughs over a
reference length.
Indicates an overall profile of the sheet
surface, dullness or brightness.
Rmax ( Ry): Distance between
the highest of profile peak and bottom most
of profile valley line over a reference length

Rz Value : Sum of the average

value of the peak heights and deepest
valley measured over 5 peaks and 5
crests along the reference length.
 Questions

• How many types of sample we cut from the Lines?

• What physical tests we do at our LAB for CR material?
• What Chemical tests we do at our LAB for CR material?
• What is roughness?
• What is I Unit?
• If any Coils having status like “%D”, what do you mean?
• What do mean by Z-Coil?
 CRCA DEFECTS

Pinch mark UNDER PICKLING

SCUM Sticker
 CRCA DEFECTS

Rubbing mark
Temper agent Patch

MN Patch CC Patch
 TQM
(Total Quality management)
 Daily Management
• Daily Management is defined as all the activities that must be
carried out to efficiently achieve the business objectives of
each department is responsible for.
• Whereas activities that maintain the status quo form the foundation,
daily management also includes activities that improve the status quo
to a more desirable condition.
•Hourly Job
“Daily Management” include • Daily Job
• Weekly Job
Management for • Monthly Job
• Seasonal Job
• Yearly Job & etc
•Jobs in front line Operation.
• Supervisors job
• Section Managers Job
• Department to Top Managers Job & etc.
“Daily Management” : Management for routine Jobs at all levels.
 Questions

• What is daily Management?

• What is role of SGA, QC and TPM?
• As per TQM guidelines how we can define a “Active SGA Circle”?
• What is SOP Culture?
• What is SIP?
• What is a suggestion? How many suggestions we should put into the
system every year?
• What is DAP, DGP, TS16949, EHS, OHSAS18000 and SA 8000?
Thank you..