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DEPARTMENT OF
(Internship Program Report) PAKISTAN STEEL NO. OF WEEKS :- 4 WEEKS INTERSHIP PROGRAM Date : 14-06-2010 To 09-07-2010 Submitted To:
Incharge (Trg. Wing) HRD
Submitted By:
MOHAMMAD YOUNUS WAZIR AHMED JATOI SUHAIL AHMED PALIJO SAEED AHMED JANDON KAMRAN MEMON (08IN70) (08IN64) (08IN36) (08IN34) (08IN43)
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PREFACE
This report contains the information about those departments which are visited by the internees. Whatever the machinery seen and the processes are observed, attracting the human mind and realizes the men what science has achieved and what kind of mericals has been done by it. Basically Pakistan steel mill is quite attention attracting industry it provides lot of opportunities to see, to observe, to achieve and to get the lot of experience about the industry as well as about the machinery. The technology installed at Pakistan steel mill is the old one but due to the hardworking labor it can compete the latest technology even today. This report may also contains the facts and the real figures of the various departments which are very beneficial for our experience and the also for the practical knowledge. The functions and the details of their working and the process as well as the timing and work break down structure is also mentioned in this report. This is edit by the students of the INDUSTRIAL ENGINEERING AND MANAGEMENT DEPARTMENT of the nominated university of jamshoro named MEHRAN UNIVERSITY OF ENGINEERING AND TECHNOLOGY JAMSHORO SINDH PAKISTAN. The details of the students are as under:SUHAIL AHMED PALIJO (08IN36). MUHAMMAD YOUNUS (08IN70). WAZIR AHMED JATOI (08IN64). SAEED AHMED JANDAN (08IN34). KAMRAN AHMED MEMON (08IN43).
PAKISTAN STEEL MILL KARACHI
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ACKNOWLEDGEMENT
We are very thankful from the core of my heart to honorable CEO, Pakistan Steel, MALIK ISRAR HUSSAIN for providing us opportunity for training and whose intelligent, wise and sound leadership has converted manpower into wining combination by this industry into a gold mine. We wish to express my deep gratefulness to MR. RIZWAN AHMED, Director (Personnel & HRD) for his consideration and supervision. It was a memorable time in Pakistan steel due to his kind concern. We are also thankful to MR. NISAR A. KHOWAJA, Incharge (Training Wing) and MR. YOUSUF AYUB, Dy. Manager/ Incharge ( In- Plant Training) for his precious advice and for he great encouragement and cooperation, because of which We have successfully completed our internship training of PAKISTAN STEEL where we learned a lot.
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CONTENTS
UNITS UNIT NO. 1 DESCRIPTION INTRODUCTION Brief History Location and Sites PRODUCTION PLANING & CONTROL Introduction of Production, Planning and Control. Objective of Production, Planning and Control. Roll of Production Planning and Control in Pak steel. Hot metal section. Steel making section. Rolling section. Budgeting and procurement section. QUALITY CONTROL DEPARTMENT Quality, Quality Control. Quality Control in Pakistan steel. Quality Control section in Pakistan steel. i) RMHD Section. ii) COBP Section. iii) Sintering section. iv) IMD Section. v) SMD section.
PAKISTAN STEEL MILL KARACHI
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PAGE NO. 07 08 09 10 11 12 12 13 16 17 18
UNIT NO. 3 19 20 20 21 21 23 25 26 28
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vi) HSM section vii) REFRACTORY Section. viii) CRM SECTION UNIT NO. 4 MECHANICAL EQUIPMENT AND REPAIR SECTION Maintenance Objectives of Plant maintenance Importance of the maintenance Maintenance section in Pakistan steel. M.E.R.S Maintenance of HSM Maintenance of SINTERING
33 35 40 43 44 44 44 45 45 46 48 50 51 51 51 51 52 52 52
UNITE NO. 5 INDUSTRIAL ENGINEERING DEPARTMENT DEFINITION FUNCTION SALIENT FUNCTIONS OF I.E.D PRESENT EXERCISE. FUTURE PROGRAMME. WORKING OF I.E.D NOW A DAYS. HAZARD ALLOWANCES
INTRODUCTION
PAKISTAN STEEL MILL KARACHI
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Steel is the main metal in the world without steel the life became incomplete because steel is used in many places where no metal or non-metal thing can not be used not only Pakistan there so much demand of in steel in world steel is the bake bone of any country it plays vital role in the development of any country not only in physical sense but also economically. Similarly like other countries Pakistan has decided to install its own steel mill because before steel mill, the steel and the related metals are the imported from other countries. Before steel mill he was dependents of other countries. But now he is capable of producing 1.1milion ton of steel mill by his own which is not sufficient but quit helpful for the country from every aspect foundation of steel mill was kept by the legend Qaid-e-awam ZULIFIQAR ALI BHUTTO in 1976 with the co-operation of Russia who have transferred the latest technology of that time and this project of about billion approximately it was completed in 1981.first time in Pakistan the blast furnace started in 1981 to produce pig iron further it was converted into steel of different grades. Pakistan steel mill is separated over 18000 acres out of which 10000 was fixed for mill and rest of will be for the housing and medical facilities Pakistan steel mill not only provides the medicate facilities but all type of facilities such as education, sports, completion and higher education facilities etc due to Pakistan steel mill thousands of people are employed and living the prosperous life. BRIEF HISTORY
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The engineering goods industry is recognized the world over as most critical for the development of self reliant and vibrant economy. This industry, however, depends heavily on basic metals industry, specially the iron & steel industry for the supply of resource inputs. the iron & steel industry, therefore holds the key To the sustained growth of the engineering sector and hence to the development of the economy as whole. As such the steel industry can be termed as mother industry to all modern industries, being the basic source of metal for them. In this perspective the importance of the national assets such as PAKISTAN STEEL, which determined on their strength and ability to sustain the national growth rate, need not be emphasized. Abundant steel, sufficient power and adequate Transport are otherwise also absolute necessities for the rapid industrialization of developing countries today. If one desires to find out what PAKISTAN STEEL has done for the country, one will have to venture back in time, into the early 70s when PAKISTAN STEEL was only a dream on paper. By that time non-existence of an iron & steel making plant of a reasonable size in Pakistan had shown its adverse effects on the industrial and economic development of the country which continued to suffer various set backs because of dependence on import of iron and steel products. A stage had been reached when it had been realized that the import bill to meet all the re3quirements of steel could not be supported indefinitely. In fact the idea of setting up of a steel mill in the country had been cooking over the red hot coals of controversy since the introduction of the first five year plan (1955-60) which laid emphasis on the domestic production of iron and steel. Debates over the manufacturing process, supply sources of the requisite machinery and raw materials, plant site, domestic ore versus imported ore, ownership pattern, productmix and above all, foreign financing g credits, kept the projects simmering over as period of two decades. In 1968 beside other factors, it was considered by the Government that a basic steel industry should be established in the public sector as public sponsorship of the project would enable integrated development of steel industry in the country. in the light of this, 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, in the pursuance of this decision Pakistan Steel Mills Corporation was setup as a private limited company under companies act 1913 in the public sector on 2 nd July, 1968 with the object to establish and run Steel Mills at Karachi and other places in Pakistan. In January, 1969, PAKISTAN STEEL concluded an agreement with V/O Tiajpromexport of the then USSR for preparation of a feasibility report for the establishment of steel Mills 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 integrated Steel Mills at Karachi. The foundation stone of this vital and gigantic project was laid on 30 th December,1973 the then Prime Minister of Pakistan., the mammoth construction and erection work, of an integrated steel mills never experienced before in the country, was carried out by a PAKISTAN STEEL MILL KARACHI
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consortium of Pakistani construction companies under the overall supervision of soviet experts. PAKISTAN STEEL does not only have to construct the main production units but a host of infrastructure facilities involving unprecedented volumes of work and expertise. Component units of the Steel Mills numbering over twenty and each a big enough factory in its own right were commissioned as they were august, 1985 with coke oven and byproduct plant coming on steam the first and the galvanizing unit the last. Commissioning of blast furnace No. 1 on 14th August, 1981 marked Pakistans 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 mills was formally launched by the president of Pakistan on 15th January, 1985. PAKISTAN STEEL today is the countrys largest industrial undertaking having production capacity of 1.1million tones of steel. The enormous dimensions of the project can be visualized from the construction inputs which involved the use of unparalleled 1 29 million cubic meters of concrete, 5.70million cubic meters of earth work (secondly to Tarbela Dam), 330,000 tones of machinery, steel structure and electrical equipment. Its unloading and conveyor system at Port Qasim is the third largest in the world and its industrial water re3soervior with a capacity of 110 million gallons per day is the lar54gest concrete reservoir in Asia. A 2.5 kilometers long sea water channel connects the plant site to feed the sea water circulation system with 216 million gallons per day. The plants 2 km long flyover which connects the steel mills with National Highway was the largest in the country when built. The above figures illustrate the massive civil works, intricate erect ions, installation of sophisticate4d electrical and mechanical and equipment with the completion of PAKISTAN STEEL, the local contractors gained the technical ability till the unknown to them which they utilized later to undertake works worth millions of rupees/dollars both within the country and abroad specially Middle East.
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Production planning and control as its name suggest that it is combination of three departments: 1. PRODUCTION DEPTT: 2. PLANNING DEPTT: 3. CONTROL DEPT:
1-Production:
It is the process or procedure to develop to transform a set of input element like men, material, machine and capital information and energy into ratio specified set of output elements like finished products and services in proper quantity and quantity to achieve the objectives of the enterprise
PLANNING:
1. Planning all aspects of the production, selling etc, are essential in order to minimize intangibles. 2. Planning is the process by which a manager anticipates the future and discovers the alternative courses of actions open to him. 3. Planning is the economic, rational, systematic way of making decisions today which will affect the future e.g what will be done in future, who will do it and where it will be done. 4. Infect every managerial work/act whether it would be physical or mental is inexorably intertwined with planning. 5. Without proper planning the activities of an enterprise became confused. 6. Prior planning is necessary or very essential for utilizing the available facilities (Men, material, machine, etc) to the best of the advantage.
CONTROL :
1. Controlling is the process that measures current performance and guides it towards some pre-determined goals. 2. controlling involves: Monitoring of the activities to make sure that the objectives are being met. The initiation of corrective actions as required overcoming problems, if any hindrance is occurred during the process. Checking and the examination is required on the periodic basis to ensure that the things are preceding as per plan. It is necessary to ensure that the orders are not miss-understood rules are not violated and objectives have not been unknowingly shifted.
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It is the continuous process that measures the progress of the operations (compares) verifies them confirms with the pre-determined plan and takes correctives actions if required.
OBJECTIVES CONTROL:
OF
THE
PRODUCTION
PLANNAING
AND
Effectiveness: goods to fulfill customers needs Maximizing output: maximum output with minimum input Quality control: Product/service quality meets planned quality specifications Minimize throughput time: conversion of RM to FG in minimum time Capacity: full utilization of men & machines Minimize cost: minimum cost of production Maintaining inventory: optimal inventory Flexibility: flexibility in production operations Coordination: between men & machines Capacity: plan for current & future needs Reduce bottlenecks: solve production problems early Maximize profit: minimize cost Production schedules: as per plan Routes & schedules: to optimize use of men, material & machinery Maintain performance: maintain standards
ROLE OF PRODUCTION PLANNING AND CONTROL IN STEEL MILL:It is one of the main department of the steel mill basically its main function is to make planning for the over all production either it is daily, weekly, monthly or annually. It plays the role of the backbone in the steel mill. Without ppc steel mill is useless if you really want to make it useful their must be ppc department. If any org. is working without planning it has to bear heavy loss as well as the lot of wastage of the time and other factors such as money, material, machinery. Planning is the single tool which minimizes that effect and maximizes the profit. In steel mill under the quit capable supervision of the production planning and control deptt: almost all production deptt: are working. Due to large numbers of the department ppc has divided them into the three groups. By grouping system it is easy to handle and control. Details of the department are as under There are 4 major groups:1. Hot metal section/department. 2. Steel making department/section. 3. Rolling section. 4. Budgeting and Procurement section. All these sections are further divided into various units or departments. PAKISTAN STEEL MILL KARACHI
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HOT METAL SECTION:It is the main section of the ppc department. It deals with the all type of the hot metal and the raw material. It contains the following departments. 1. 2. 3. 4. RAW MATERIAL AND HANDLIND DEPARTMENT. SINITERING DEPARTMENT. COCK OVEN AND BY PRODUCT DEPARTMENT. IRON MAKING DEPARTMENT.
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Silica sand ITEM IMPORTED:Coking coal Iron ore Manganese ore Ferro-manganese Ferro-silicon Aluminum Zinc Fluorite LOCAL:Limestone Dolomite(sinitert grade) Dolomite(refractory grade) Refractory clay Silica sand
19 Location Australia ,Canada Australia, Canada, Iran, India Canada Canada, Iran, India India, Iran Australia, Canada Iran, India India, Iran Makli Distt: Thatta Jhumpir Jhumpir Balochistan Balochistan
BLENDING YARD:IT is the ground where blends are made by mixings the same material but ratio of the % should be different.
BLEND:It is the mountain of the mixtures of the two materials of different % ratio. Let have an example of the iron ore there are two types of the iron ore one is local and other is imported. Both these materials are mixed to attain the required % of the iron ore because the imported iron ore is the expensive one so that we cannot used the imported iron ore at all.
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SINITERING:This plant has two sintering machines with an effective sintering area of the 75 square meters. After BMR the sintering area has increased to 90 sq.m thereby increasing the annual production capacity from 1.5 million tones to 1.8 million tones of the sinter. These machines provide sinter to the iron making deptt: for production of the hot metal /pig iron sinter is prepared by heating up an amalgam or cake ,dolomite, limestone and iron ore.
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It also produces the gas utilized in thermal power plant for the generation of the electricity. the molten iron produced by the iron making department called the pig iron is not only sufficient for the internal demands of the Pakistan steel mill but numerous foundries demands the pig iron in the country. This pig iron is measures up a/c to the international standards and has been supplied to the various foreign countries such as India, Bangladesh, Saudi Arabia, Indonesia, china, south Korea and Japan
STEEL
MAKING
PLANT/DEPARTMENT:-
In this plant two top-blown basic oxygen furnaces (linz-donawitz) Converter of 130 tones charge weight each is installed which transform molten iron into steel. In order cast molten steel in the shapes of the blooms, slabs, and billets. A bloom caster and the billet caster are added in 1989and the two slab casters are also installed in the plant blooms of 260*260mm size are used for making the billets in the billet mill where as the slabs of the 150to200mm and width size of 700 to1550mm are supplied to the 1700mm or hot strip mill for the manufacturing of the hot rolled sheets. The cast billets of 80*80mm-150*150mm size produced in the billet caster are directly marketed the first converter was commissioned on the 18 th December 1982 and the billet caster on the 22nd December 1982,first slab caster on the 10 th august 1983and the second on the 1st November 1983.
BILLET MILL(800mm):Prime quality rolled billets of the size 50*50mm to 100*100mm are being produced in the billet mill which is most important plant of the Pakistan steel mill. Capability of the manufacturing of the round billets of 56mm diameter has also been attained by the Pakistan steel mill steel billets are utilized for producing, besides construction bars and other products such as wire rods, nuts, bolts, balling hoops, rails, heavy structure rolled sections, seamless pipes, gas cylinders etc. The 800mm billet mill was commissioned on 11th October 1982. CONTINOUS BILLET CASTER:In order to meet the demands of the billets in the market as well as to balance the designed production capacity of the steel mill to cater for the market demand PAKISTAN STEEL has set up a six strands continuous billet caster with production capacity of 400,000 tones per annum, adjacent to steel making department. Billet caster can produce billets in sizes of the 50*50mm,100*100mm,125*125mm,the machinery and equipment were produced from M/s voest-alpine, Austria at the total cost of Rs.167.7 millions .the project was commissioned on the 11 th November 1989,product through the billet caster is more efficient and cost effective than through bloom casting/billet re-rolling route.
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ROLLING SECTION
The rolling section has been further divided into the two sections. 1. Hot strip mill (1700mm). 2. Cold rolling mill. 3.
COLD ROLLING MILL:This plant is used for the production of the cold rolled coils which are more beneficial for various types of works such as sheets pf the vehicles, as well as the body of the aero planes and etc. An other assignment is also fulfilled which is of the slitting and shearing these sheared sheets are used for the flouring, as well as ceiling and in various other functions where there hot rolled sheets are not benefited. CRM is the one of the largest and the cleanest department in the whole steel mill .It is the one of the best deptt: which always remain clean, all the products of the steel mill depend on the CRM deptt because each and every product has to pass from that deptt: CRM contains following units or sections: 1. Continuous pickling unit. 2. Reversible unit. 3. Annealing furnace. 4. Tempering mill unit. 5. Combined slitting and shearing units. 6. Galvanizing unit. 7. Profile bending. The most important section of the CRM deptt: is the single strand reversible mill which has the annual production capacity of 200,000 tones .out of this 100,000tonnes can be utilized to manufacture the formed sections and 90,000 tones are salable in the market as the cold rolled sheets /coils. Cold rolled sheets and coils are used in the those industries which are manufacturing the bicycles ,steel containers, drums, barrels, jerry can bodies of the buses and other vehicles and steel furnitures ,machinery parts instruments for oil and gas etc. galvanized sheets are used for the manufacturing of the trucks, buckets ,iron shuttering ceilings air-conditioning, ducts, ribbed sheets deserts, coolers utensils of the daily use, air-conditioners water heaters, and water tanks, etc all the units of the cold PAKISTAN STEEL MILL KARACHI
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rolling mill were commissioned b/w the February to December 1984.the operation of the main cold rolling mill units marked the completion of the phase of producing 1.1 millions tones of steel products.
BUDGTING AND PROCURMENT:Budgeting and procurement are two different phrases each phrase has its own actual meaning as the phrase budgeting from its name it suggest the process of the making budget of the org. Each and every organization must have a separate budgeting section because until and unless an organization .doesnt prepare its budget, obviously it will bear heavy losses not only in case of capital but due to not perfectly defined budget itll also remain at the backside in all fields. Similarly in Pakistan steel mill the budgeting section is performing its duties under the kind control of the production planning and control department. FUNCTION OF THE BUDGETING SECTION:Its first and for most function is to make budget for the whole organization. Sometimes the budget will be out of the situation so in that case first to overcome all types of the waste or extra expenses then the strategy is made. This will prove better for the organization.
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QUALITY
PAKISTAN STEEL MILL KARACHI
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Quality means the degree of perfection of excellence when applied to manufactured produces. It not necessary means the beat. It should imply the best for money that is the product should meet the desired requirement at lowest cost. The word quality is meaning less until and unless the product made up of high quality has specified used means product serve the specified function for which it is made. Quality of product is relative terms and it can only be comparing some standards hence the quality of product may be defined as the conformance to standard and speciation. Quantity also has a considerable effect on quality and hence it becomes more complex to manger to control and to achieve the quantity output.
QUALITY CONTROL
Basically Quality control we mean that those process or operation of testing measuring and manufacturing components with a standard and then determining whether it should be accepted, rejected, adjusted, or reworked. It is off course more sensible to control the process so that the standard are being maintained and that defective parts will not be produced instead of accepting or rejecting a part after it has been manufactured thus the quality control means the systematic control of those variable in a manufacturing process which affect the excessive.
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7) SINTRING SECTION 8) HOT STRIP MILL (HSM) 9) COMBINE SHARING AND SILITING (CSSU) 10) COLD ROLL MILL (CRM) 11) FINAL PRODUCT DISPATCH CONTROL DEPARMTENT (FPDC). Above are the quality control section in every department and performing their job pleasantly. Here we are going to describe each one by one.
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5) LIME STONE 6) SILICA SAND 7) BANTONITE CLAY. PROCEDURE OF RHMD The material that has come internationally is unloaded at JT. There are two types of convare belt that has taken the unloaded material i) 12-1 ii)12-2 There are two sampler is installed on each convere i-e Sample no. 1 on 12-1 and sampler no. 2 on 12-2. Whenever the ore flow over the convere the extreme of that ore is to be cutter and on each sampler there is material box in which the cutter material is inserted until the bucket is full the material is shifted down. After all that the reversing belt is there now if the belt is moved forward there is sieve of -6mm to + 6 mm present. The material less then under the size of 6 30, is to be sieved and drill down as fine and which is not sieved is also taken from the surface and hence by forward moving we get both lump and fine form of ore. On the other hand if the material is moved in reversed direction there is combine crusher to crushes further into the size of -10 to +10 mm. Now all these ore (material) is further crushing & girding the metal is becomes very much powder like sand is shifted to the process so that through various analyses they may get the required %age of Fe content in crushed ore and hence observed the quality. RAW MATERIL QUALITY CONTROL SECTION At RMHD the quality control section is responsible to taken the sample of raw material and make it in proper form by following a particular process and then send it to the process lab so that to analyze the content of material and % age of their presence in the material is also taken.
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COBP FUNCTION
COBP works on to performs the following actions, COCK to convert COAL COBP has major works to produce coal through cock so that it provided facility in the blast furnace and in converter as well as a fuel. When the coal is to be taken from the battery one by one after that quenching of coal is to be done in two different fashion i-e dry or wet quenching. After quenching sieve analysis is to be done if the size of cock is in b/w 25-80 mm the cock is continuously transferred to the blast furnace and more the 80 mm size means +80 mm is to be sell out and -25 mm is lying down and make use of it if required.
BY PRODUCT OF COBP
COAL TAR, COCO ONE GAS, AMMONIA GAS. Ammonia gas after passing through sulfuric acid is to be manufactured as a by product which is used fertilizers. Similarly coco one is also collected and this gas used as a burned in various even it is also used in cock battery. The coco one gas has low colorific value then natural gas but it is the by product so its provide facility as a fuel. Coal tar is major by product it is used as a fuel in various section and also used in refractory bricks.
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In the quality section of COBP the strength of the coal is also checked through the used of the drum tester. At this stage the sampler of 25 mm to 80 mm is to be filled into the drum and revolve it about 10 revolution now we have 2 types of sieves namely the 40 M and 10 M sieve there fore the drum cock is to be spread over 40 M sieve. Hence in sieving of the cock taken from the drum so to be pass most of particle down the 40 M sieve to 10 M sieve and further from 10 M to -10 M so the strength of the coal is to be called is poor strength but on the other hand if the drum of cock present more of it past over the 40 M sieve and some of the 10 M sieve so in this case it is called good strength coal.
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SINTERING
INTRODUCTION Sintering is one of the most important plant in pak steel sintering with its material provide basis to B.F so that it may produce the molten iron. The raw material either comes locally or it may internationally in fine or lump form so sintering basically make use of fine form of raw material. PROCESS OF SINTEIRND Q.C.D SECTION First of all through convers raw material comes and it put into the mixture. When the mixture is to be filled by burners the quality observer has to observe how to operate the mixture and this mixture is also called the ball because it converts the fine forms of raw material into the balling drum which revolves, the quality observer observed the mixture or sinter is properly mixed or not and if he issue so that mixture to is send to the sintering machine now this mixture is to be burned by applying heat from up side after wards these mixture cake is fully burned and continuously cooling when of away from the hot blast and then this cake is diminish by jaw crusher and tend the sinter to the blast furnace now remember quality of sinter has major importance and hence it produce wonderful type of raw iron. SINTER COMPOSTION As we know that nowadays the Pakistan steel facing a lot of problem due to the lankness of raw material and many of its so now a day the composition of sintering which is send to the B.F is as follow, Chemistry Fe MnO MgO CaO FeO Al2O3 SiO2 % age of material involved 55.85 - 57.85 0.90 1.10 1.85 2.05 1.19 1.39 11.0 13.00 1.65 1.85 6.50 6.70 PAKISTAN STEEL MILL KARACHI
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High pressure in employed through tuyers and all charge inside reaction and hence as a result it is to be converted into two things i-e molten iron or slage. The iron has the high density and hence it is to be shifted down the blast furnace where as the slag has low density is placed above the molted iron. Now through taping whole first the iron is to be taking and filled it in the bowl and after that the slag is also taken and it is also taken into the bowl.
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PROCEDURE OF SMD
STEEL MAKING PROCESS THROUGH CONVERTER Hot metal is transported from the twp blast furnace by rail cars in 140 tones open transfer ladles and charged into the mixer by crane. The mixer acts as a buffer storage vessel to accommodate variation b/w iron production and the steel making operation. To maintain the temperature in the mixer natural gas burners heat the surface of the hot metal. Hot metal is poured from the mixer into a charging ladle mounted on the self propelled rail car. During pouring the ladle car is positioned on a weighbridge. The hot, metal is charged into the converter by crane. After charging, the converter is rotated to a vertical position and one of the two watercooled oxygen lances nozzle relative to the liquid metal surface is important in order to create the optimum reaction conditions. To attain the desired carbon content in the refined and to oxidize other impurities a calculated volume of oxygen is blow into the converter at a controlled flown rate. During blowing process a pre- determined quantity of calcinated lime is added to the vessel to produce a slag which aids the refining process. Fluoride is added for slag fluidity control. Iron ore is sometimes added for temperature control. Coke can be added for carbon control. If the desired steel temperature and carbon contents are not attained then a re blow is undertaken. When the end-point conditions are achieved, the converter is tilted is poured into a 130 tones steel ladle through a tap hole. Alloying materials are added to the ladle during tapping. Ladle additives, namely for ferromanganese and ferrosilicon, are weighed out of storage bins and loaded into boxes which are transported by a fork lifter truck to the steel ladle side of the converter. Two boxes can be positioned together on a discharging device and the contents added to the ladle. Aluminum bars by bags of cokes breeze are added to the ladle by hand. For certain steel speciation calcium silicates is also added to the ladle.
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On completion of tapping, the steel ladle is moved by a self- propelled rail car into the ladle bay of casting area. The converter is tilted in the opposite direction and the slag is discharge into the slag pot, which is taken by a self- propelled a rail car to the slag bay. STEEL CONVERTER SPECFICATION The various specification of steel converters used in SMD shop is as follows, No. of converters Type Capacity Working volume Specific volume M/T Ration H/L Mouth Dia Inner Dia Inner Height Total thickness of wall brick work No. of bottoms 2 No.s Top blown oxygen converter 130 tons capacity 93 M 0.68 1.68 2430 mm 4240 mm 7125 mm 920 mm 3 No.s for two converters
Total thickness of the safety lining Chrome magnesite bottom brick work Working lining Ten bonded dolomite Lining life Rate of oxygen blowing Oxygen blowing time Oxygen consumption Tap to Tap blowing time 400 heats 450 M/min 18 minute (average) 58 Cu.M/Ton. 40 60 Max / Heat Min/Heat
MIXER The mixer used has the following specifications No. of Mixer Capacity One 1300 tones
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SLAB CASTER
No. of Machines No. of Strands Size : thickness Size : width Type of machine Machine radius Casting speed Capacity 2 No.s Two strands each 150- 200 mm 700-1550mm Radial Curvilinear 10 meter 0.6-0.9 m/minutes 825,000 T/year meter
Machine length Mould top to last roller 22 Mould top to cutter 36.5 meter Metal flow control in mould Mono- block tundish stopper
BLOOM CASTER
No. of Machines No. of Strands Size : 200 x 200 mm Type of machine Machine radius Cating speed Capacity 1 No 04 No.s each 260 x 260 mm Radial 12 meter 1.1-1.2 m/minutes 400,000 T/year
Machine length Mould top to last roller 20 meter Mould top to cutter 30 meter Metal flow control in mould Hydraulically operated mono-block tundish stopper
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When the molted iron through ladle insert into the converter the quality observer has to take the sample of hot metal for analysis as it poured and the temperature of the charge in the ladle is measured using an expandable immersion thermocouple. After blowing the converter is tilled and the temperature of the steel is measured using an expandable immersion thermo couple. A sample is to be taken for analysis at he express spectrographic laboratory with in the SMD building. The prepared steel in casting section to cast the blooms, slabs the quality observer taken the temperature of steel and also see the tendish of mould is properly positioned or not, the cooling system is also ok or not and afterwards the ladle tap is open steel is casted in various blooms, slabs. When the casted slabs, blooms getting cooled the quality observer received various defects of casting because of cooling system these defects are as o Longitude straight crack o Longitudinal corner crack o Auxiliary crack o Technical o Mixing o Ballet etc the quality observer mark the error and sent the casted slabs to yard section. At the yard section the length and thickness (which is verifying) and also the scarfing process is to be done through gas welding to determine the stability of the crack slab after wards the verifying slab is going to HRM or hot rolling section. SUGGESTION Whatever we observe in SMD section through whole analysis we found the following those are needed to be change in order to increase the production. The must be computerized application those gives the perfect composition of manufactured steel when the air in blowing through lance because to observe the compositions specially the %age of carbon (C) and volume or air blowing to get the required grade of steel through the observation of flame produce during blowing is totally logical and requires too much experience on the other hand if the blowing system is computerized which gives the minute to minute to change in composition. Latest technology should be installed in order to prepare various type of steel instead to produced steel of various grade.
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INTRODUCTION
It is one of the most important department of pak steel. It is situated nearly to the SMD section. It works to produce the coils of various grad, quality, variety of the sheets / plates. The coils produced at this section is either dispatch to sell or it may send to the CRM for further processing. The manufactured coil can also be send to the CSSU section if the shearing or silitted bundle is required. The coils produced through HSM which is dispatch into the market varies in thickness and some time more thick coil can also be dispatch if the required demand is receive.
PROCEDURE
It is basically a forging process as a name suggest hot rolled mean the red hoted slab of various grade is rolled by high pressure and shape it into the coil by passing through various pressing stand under a heavy pressure. It can be started when the verified slabs is to be taken through yard section hence ensure slabs going over the rolling section. First one by one slab are put it down on the rollers now these slabs are measured and then put it into the furnace, the furnace has a capacity to carry 32 slabs at a time and to heated them at a temperature more then 1500 degree centigrade therefore rolled the quality observed obtain the temperature of slab so that it may sustain the rollers action and hence through control room it is allowed to perform job. Now at rolling action there are various stage over which the red- hoted coil has passes through the following,
VERTICAL STAND
Its function first to remove all the scrap PAKISTAN STEEL MILL KARACHI
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from the slab and 2nd the compressed the slab b/w two rollers, the vertical also controls the width of the slabs because when the slabs is to be compressed through passes the width of it needed to be maintain. After the water from a huge pressure 130 kg is to be applied on the compressed slab and hence to avoid the compressed to stick each other.
UNIVERSAL STAND
It is one of the basic and it has the capacity to produce 35mm, 30mm, 25mm of thickness of coil (sheet) from 200mm. It also the width as well which is necessary because when the sheet is to be compressed the width controlling is necessary. Universal stand contain two type roller i-e back or press roller and working roller. The coil obtain from universal stand is quit thick but it also has demanded in market and many times pak steel has provided 35mm thickness of coil to shipping cocorporation mostly , shipping corporation requires thick coil in making the body of ship which is need to be to thick. It is to be remembering that after universal stand the continuous supply of water is necessary in order to avoid the sheets in the coil to stick each other.
FINISHING STAND
There are 7-finishing stand in this shop which produced the coil of thickness 2, 3 mm from 30-35mm on final stand. Each stand has two rollers i-e working rollers and back roller The quality inspector at this is responsible to watch either posses is successfully done or not the water which is supplied in proper manner or not and hence watch through all this can we achieve the required thickness with tolerance or not.
REFRACTORIES SHOP
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INTRODUCTION
The main purpose of the department is to produce Calcined lime for SMD and others. Tar bonded dolomite bricks for SMD. Fire clay bricks for different uses all-over the Pakistan steel mil. o The department also deals with repair and installation of refractory bricks lining all over the plant. It has also a limited capacity to undertake thermal insulation wherever necessary. o
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b. DOLOMITE SHOP
Installed capacity No. of production lines MAIN EQUIPMENTS No. of hydraulic presses No. of Tube mills No. of roll crusher No. of rotary Kiln = = = = 02, 01, 01, 01, Pressing force = 1600 T capacity = 2 T/hr capacity = 2.5 T/hr charging rate = 2.3 2.5 T/hr = = 7,600 M.tons 02.
C) LIME SHOP
Installed capacity No. of production lines MAIN EQUIPMENTS No. of rotary Kilns Length Dia No. of heat recovery boilers No. of shaft coolers = 02, capacity = 20 T/hr = 75 m = 3.6 m = 02, capacity = 16-18 T/Hr each = 02, = steam generation = = 87500 M.tons 02
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The raw material used for production of fire- clay bricks, Tar bonded Dolomite Bricks and Lime should meet the following requirement. FIRE CLAY BRICKS Semi flint Clay Al2O3 Al203+ Ti02 content Fe203 content SiO2 content Alkali L.O.I (lost of ignition) Refractoriness Fraction size if in coming material Source 48.0 % (Min) 51.0 % (Min) 2.0 % (Max) 30.0 % (Max) 0.005 % (Max) 15.0 % (Max) 1790C 0.300 mm KUNDIAN (Mianwali) Plastic Clay 36.0 (Min) 39.0 (Min) 35.0 (Max) 50-55 % 0.05 % (Max) 14.0 % (Max) 1710C 0-300 mm KUNDIAN (Mianwali)
RAW DOLOMITE
RAW DOLOMITE MgO CaO content SiO2 content Al2O3 + Fe203 + Ti02+ Mn3O4 L.O.I (lost of ignition) Fraction size if coiming material Source in 19.0 % (Min) 33.0 % (Max) 1.0 % (Max) 2.0 % (Max) 45-47 % (Max) 3-80mm PAIKHEL (Mianwali)
LIME STONE
LIME STONE PAKISTAN STEEL MILL KARACHI
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CaO content MgO content SiO2 + Al2O3 content Fe203 content L.O.I (lost of ignition) P contents Fraction size if in coiming material Ti02 content S content Source
53.5 % (Min) 1.2 % (max) 1.2 % (max) 0.8 % (max) 43-45 % 0.060 % (max) 20-50mm 0.25 % (max) 0.025 % (max) MAKLI
DOLOMITE BRICKS
The chemical composition of calcined dolomite PAKISTAN STEEL MILL KARACHI
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Properties of Tar bonded dolomite bricks / blocks are Density Mechanical strength Size variation 2.9 g/Cm (min) 250 Kg/Cm (average) Length = +3 to -3 mm Width = +2 to -2 mm Height = +1 to -1 mm
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cold rolled coils which are more beneficial for various types of works such as sheets pf the vehicles, as well as the body of the aero planes and etc. an other assignment is also fulfilled which is of the siliting and shearing these sheared sheets are used for the flouring, as well as celling and in various other functions where there hot rolled sheets are not beneficial. CRM is the one of the largest and the cleanest department in the whole steel mill. It is the one of the best department which always remain clean, all the products of the steel mill depend on the CRM department because each and every product has to pass from that department CRM contains following units or sections, i) Continuous pickling unit. ii) Reversible unit. iii) Annealing furnace. iv) Tempering mill unit. v) Combined slitting and shearing units. vi) Galvanizing unit. vii) Profile bending. Any type of raw material or coil come to CRM department it has to pass all above mentioned units then that product can be said that it is the completely finished product. The coil at time of entering in the CRM department is of about 14 tons but at the time of discharging is of 5 tons sometime for special purpose its weight is increased from 5 tons to 10 tons and the thickness of the coil is below 4 mm ,at CRM it is further reduced to 1.4 - 1.6mm.
DISCRIPTION OF THE VARIOUS SECTIONS AND THE QUALITY CONTROL CONTINOUS PICKLING UNIT.
It is the unit where the coil came from the hot strip mill (1700mm) by the underground conveyer belt which directly connects the HSM and the CRM. when the coil reach at the pickling section there is lifter fixed in the machine whose work is to lift the coil and wear it on the uncoiler which uncoils the coil and stretch it to the length of about 5-6m through the coils after that these coils are dipped into the acid bath where all types of scales has been removed and then goes to the an other stand where its width is maintained by trimming the rough edges, it is set as follows: 1250 1220 PAKISTAN STEEL MILL KARACHI
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1030 1000 950 900. After that it passes through gracing stand where it is grecced / oil is applied to coil as it can be kept prevented from the corrosion and the natural effects.
FUNCTION OF THE PICKLING UNIT:The most important function is defined as hot rolled coils are pickled in order to remove the scales and layers of the FeOiron oxide by the emersion of the sheet into the hydrochloric acid (HCL).
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ANNELING FURNACE:It is the furnace which is used to improve the internal structure of the coil or to increase the strength of the material. MAIN PARTS OF THE ANNELING FURNACE Main stand . Tower Furnace (moveable). Stove In annealing furnace at a time there are 4 coils of width 950mm and 3 coils of the width 1220mm can kept. Duration of the furnace is minimum 18-44 hours depending on the grade of the coil. Internal atmosphere of the furnace is of nitrogen gas and the heating process takes places in absence of the oxygen/air. After discharging from the furnace these coils are cooled
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MAINTENANCE
Today, in modern industry, equipment and a machinery are a very important part of the total productive effort than was the case years ago. Moreover, with the developments of special purpose and sophistical machines, equipment and machinery cost a lot more money and there fore their and does time becomes much more expensive. For this reason, it is vitally important that the plant machinery should be properly maintained. PAKISTAN STEEL MILL KARACHI
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iv)
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and various other section those involve in providing the facilities to the production side for their smooth production run. Maintenance can be done in the following fashion in any production side, Prevantory maintenance Break down / emergency maintenance Capital maintenance Modernize maintenance Preventary Maintenance It is one in which we check the plant before starting production either is it ok or it is not before as we know that the production giving section those were interlink to each other and hence any type of damage in one part causes to stop the continuality of production and hence the productivity. Capital maintenance The designer of plant section observing the actual life of plant and it can be done when plant fully maintain, such type of maintenance can be done in year, a month, a day, its upon the nature of the plant whose maintenance is to be done. Modernize maintenance It is one in which the modernize method require to handled the situation hence provide the flexibility in the plant in order to increase the productivity.
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Once the schedule is made and according to that schedule the maintenance team has to work over the concerned section. Now we discussing the department in which we went with MERS maintenance team one by one.
FURNANCE
The furnace used in HSM is one which converts the slab into red hoted form so that the slabs easily further to roll and hence in last the coil is produce. The furnace have its own importance and any lacks in furnace may causes to stop the smooth production therefore in order to achieve maximum productivity in maintenance of furnace is necessary. The maintenance section involves major to remove the defects in furnace like to change the bricks i-e refractory inside the furnace and it is very to look after the active life of the refractory.
VERTICAL STAND
Vertical stand is one of the most important it is the first which causes to compress 200mm thick red hoted slab into the 35mm thickness means it provided basis to other stand for the further reduce in thick, the key feature of the vertical is that with reducing the thickness it also control the width of the coil. PAKISTAN STEEL MILL KARACHI
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The importance of vertical is also to the great extent and properly handled it necessary which requires a lot of effort by department as well as the maintenance section. The defects occur in vertical stand are mostly as follows the rollers used are some times replaced and some times sanded for the polish the surface of the roller, sometimes defects occur and hence some guiding provided by welding and some time the punk plates has to change and many other defects that can occur and hence the maintenance section is responsible to over all this defects in order to increase the life of the vertical stand and hence to increase the productivity.
UNIVERSAL STAND
After vertical the sheet is further rolled in universal stand therefore maintenance section is also to look after the universal stand and replaced the necessary parts if required and hence to remove the defects that can be occur during processing. The one of the most major defect is that the roller is to replaced when their life to be end when they are not in a position for further grinding and many other parts and things are there depends upon the nature of the defects.
FINISHING STAND
Once the sheet is obtain from the universal stand the next step is to finishing stand to further reduce the thick ness and 3mm approximately hence the finishing stand has its own importance hence the maintenance of the finishing is necessary mostly the maintenance teams work to change the damp working role and also change the taper rolling heating inside the cup etc there is many other parts thats has been replaced or may be welded if required. In HSM there is various other part which requires maintenance but here we are not concerned with all that.
SINTERING
It is also the one of the most important section is uses the fine form of ore and convert it into the sinter from by passing through various process and hence this sinter is PAKISTAN STEEL MILL KARACHI
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used in blast furnace in order to obtain the molted raw iron. To avoid complete break down because of the maintenance in sintering plant machine -1 is allowed to running and machine -2 is lying down steadly for maintenance purpose similarly other concerned part to machine-2 are also lying down for maintenance purpose where as the machine-1 performing for the continuity of the work. On maintenance day the maintenance has come from various of its section is responsible to perform the various some of them that we have seen in sintering shop which are as follows.
BALLING DRUM
It is used to mixed the sinter and also make the fine into the ball form, now these balling has to be done by removing flaws and replacing various tools and also fastening various parts, some of the few important consideration in balling are as follows, Ring belt is checked and replaced if possible Gear (driven) and pinion (driver) which rotates the drum is also check and make certain operation in order to improve their workability. To adjust the alignment up and down, left and right to support the wheel.
CHRGING DRUM
The material come from conveyer is to be charge over the charging drum so its maintenance is also much necessary, some necessary action which is to be taken are as follows To check the bearing , map Electric arc welding is used to insert flaws Scraper is used to clean the cut and check the charge Charge gate has to check and to set it.
PILOT CAR
It is also important part for the continuously of sintering process and hence requires maintenance as few achieve those have been taken To check slide plate bars wheel, bearing, and proper lubrication. PAKISTAN STEEL MILL KARACHI
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CRUSHER
When cake is prepared and is totally burned now the cakes is crushed through jaw crusher and insert it into the conveyer bucket and now the sinter which crushed sent to the B.F. The maintenance section is responsible to take the following necessary action. To check all the jaws and hence to repair the jaws as well.
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FUNCTION:Industrial engineering department encompasses activities, which are concerned with the organized and effective utilization of the manpower with the aim of increasing the productivity of the organization.
SALIENT FUNCTIONS OF I.ED:1. To analyze the requirement of the temporary manpower demaned on the regular basis by the different departments and to curtail wherever possible. 2. To prepare the directorate-wise daily attendance of the Pakistan steel mill for a bird eye view of the competent authority. 3. To collect the monthly manpower returns from all departments of the Pakistan steel for the various studies of the cases and analytical comparisons of the man power. 4. To asses requirement of the temporary workers demanded for the different projects/specific works. 5. To monitor and allocation of the hazards allowance. 6. Analysis and recommendation for the various types of the contract manpower including through heeded trust. 7. Monthly recommendation for the allocation of the department-wise overtime limits. 8. Time-to time preparation of the analytical comparison of the rationalized, regular, temporary and other holding manpower on the department /directorate basses directed. 9. Category-wise revision of the wages of the daily wagers and salaries of the contract employees, whenever desired.
PRESENT EXERCISE:IED is conducting an exercise for the requirement of daily wages workers to complete each project/assignment on the basis of the nature of the job, its inevitability and number of the persons/duration required for.
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FUTURE PROGRAMME:Conduction of the exercise to find out the shortcomings in the area where their deployment is not in accordance to their suitability and induction of the qualified engineers with respect to required disciplines.
WORKING OF THE I.E.D NOW A DAY:Now a days it is working on the following things;1. Attendance. 2. Hazards allowances. 3. Control on the distribution of the uniforms among the employees. 4. Controlling the man power. 5. Keeping the records of the temporary and daily wages employees.
HAZARDS ALLOWNCES;There are four categories:1. A-ONE(Most hazardous place) 2. A(less than A-one) 3. B(less than A). 4. C(less than B). There is lot of difference in allowances rates between these categories. These type of incentives are introduced first time in the Pakistan steel mill in 1984.the committee is formed whose is responsible for the hazard allowances.
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