Industrial training report

On
Manufacturing of M.S.pipes and Shuttering plates

Prepared by: Summited to:

Mohit Dubey Mrs. Neha Bhadauria
B.Tech(M.E) 140294090 Assistant Professor (M.E)

K.I.E.T Group of Institutions K.I.E.T Group of Institutions

 SHANA FABRICATORS
Khasra no.2G, 45 feet road,Hindon Vihar
Ghaziabad
 ACKNOWLEDGEMENTS

I would like to express my utmost gratitude to Mrs.Neha Bhadauria for

providing the Opportunity to me to pursue the engineering training as a
partial fulfilment of the degree of Bachelor of Engineering.

Throughout this training, I was very fortune to be blessed with the

Guidance and encouragement from Mr. Hazi Ali. In addition I would
acknowledge the contribution made by Akib Mohammad and Alok
Bhagel. I would also like to thank whole staff for their guidance, kind
supervision and cooperation with me.
 TABLE OF CONTENT

1) Steel in india
2) Mild steel
3) M.s pipes
4) Most important mild steel properties
5) Manufacturing process of m.s pipes
6) Difference between seamless and ERW pipes
7) Shuttering plates
8) How shuttering plates are made
9) Other products
 INTRODUCTION

As a part of the curriculum, and for the partial fulfilment of the requirements for
completion of the B.Tech degree from APJAKTU,LUCKNOW I underwent an
industrial training at SHANA FABRICATORS GHAZIABAD for 45days during the two
months period of june-july 2017.

Shana fabricator is the one of the big industry in Ghaziabad, with wide variety of
discipline. The primary engineering divisions that this industry possesses is rolling
mill and welding equipment.my training was mostly concerned with rolling mill
and the manufacturing of M.S pipes. These mills have wide application in many
industries like iron and steel industry, sheet metal industry and even in sugar
industries. During my training I touched every concept from engineering point of
view to commercial to environmental point of view. The company also produces
other products such as shuttering plates, clamps, channels acrospan etc.
 Steel in India

India was the worlds third-largest steel producer in 2016. The Indian
steel industry is very modern with state-of-the-art steel mills.
Indias crude steel output grew 10.7 per cent year-on-year to 25.76
million tonnes (MT) during Jan-March 2017.
As of FY16 SAIL was the leader in Indias steel sector with the
company accounting for 13 per cent of countrys finished steel
production and 15.8 per cent of countrys crude steel production.
Tata Steel, another household name in the country, leads private
sector activity in the steel sector. During FY16(1), the firm accounted
for 10.33 per cent of finished steel production and 11.03 per cent of
the countrys crude steel production
Jindal Stainless (Hisar) Limited, Indias largest stainless steel
producer, has entered into the defence sector by signing an
agreement with Defence Research & Development Organisation
(DRDO) to manufacture high nitrogen steel (HNS) for armour
applications
The Union Cabinet, Government of India has approved the National
Steel Policy (NSP) 2017, as it seeks to create a globally competitive
steel industry in India. NSP 2017 targets 300 million tonnes (MT)
steel-making capacity and 160 kgs per capita steel consumption by
2030.
 MILD STEEL
Mild steel is not an alloy steel and therefore does not contain large
amounts of other elements besides iron; you will not find vast amounts of
chromium, molybdenum, or other alloying elements in mild steel. Since its
carbon and alloying element content are relatively low, there are several
properties it has that differentiate it from higher carbon and alloy steel
.Less carbon means that mild steel is typically more ductile, machine able,
and weld able than high carbon and other steels, however, it also means it
is nearly impossible to harden and strengthen through heating and
quenching. The low carbon content also means it has very little carbon and
other alloying elements to block dislocations in its crystal structure,
generally resulting in less tensile strength than high carbon and alloy steels.
Mild steel also has a high amount iron and ferrite, making it magnetic.he
lack of alloying elements such as those found in stainless steels means that
the iron in mild steel is subject to oxidation (rust) if not properly coated.
But the negligible amount of alloying elements also helps mild steel to be
relatively affordable when compared with other steels. It is the
affordability, weld ability, and machine ability that make it such a popular
choice of steel for consumers.

Chemical Composition
Element Content
Carbon, C 0.14 - 0.20 %
Iron, Fe 98.81 - 99.26 % (as remainder)
Manganese, Mn 0.60 - 0.90 %
Phosphorous, P 0.040 %
Sulphur, S 0.050 %
The use of mild steel is huge and a person who is into
manufacturing or production business need to know a lot about
the important characteristics of mildsteel.
The study of mild steel becomes more significant for a student
of mechanical engineering or metallurgical engineering. Steel is
an alloy. And alloy is a product made by mixing metals and non
metals. Sometimes a pure metal cannot fulfill all the properties
needed for manufacturing product. So additives are included in
the pure metal to obtain some specific properties necessary for
the production. Mild steel is made by adding carbon and other
elements in the iron. These elements improve the hardness,
ductility and tensile strength of the metal.

Specific manufacturing controls are used for surface

preparation, chemical composition, rolling and heating
processes. All these processes develop a supreme quality
product that are suited to fabrication processes such as
welding, forging, drilling, machining, cold drawing and heat
treating
 M.S.PIPES
Mild steel (M.S) pipes are manufactured using low carbon steel.
Due to low carbon content the pipes do not harden and are easy
to use. As MS pipes are made from mild steel they can easily be
welded and formed in various shapes and sizes for pipelining and
tubing purpose. These are generally used for drinking water
supply i.e. plumbing, firefighting,HVAC but can also be used in
various other industrial and engineering applications. These pipes
are usually coated with other metals/paints/varnish etc to
prevent it from rusting but extra care should be given to prevent
it from extreme conditions.

What are the major features of mild steel pipes?

Some important features of Mild steel pipes have been given:

These pipes comply with ASTM (American Society for Testing

and Materials) specification
MS pipes are extremely stronger
Low percentage of carbon
They can be easily welded
Easy to fabricate and available readily
Not too costly in comparison to other metals
Long life of 100 years or more

The above-listed features and applications areas reflect that MS

pipes emerge as highly useful forms of pipes used in a variety of
industries. They are being manufactured across the country, but
Chennai acts as a leading manufacturer of such pipes. MS pipes
distributors and structural steel dealers in Chennai are available at
a large level. So, it will beneficial to get such pipes from the
trusted dealers, who deal in structural steel business
 Typically carbon steels are stiff and strong. They also exhibit
ferromagnetism (i.e. they are magnetic). This means they are
extensively used in motors and electrical appliances. Welding
carbon steels with a carbon content greater than 0.3 % requires
that special precautions be taken. However, welding carbon steel
presents far fewer problems than welding stainless steels. The
corrosion resistance of carbon steels is poor (i.e. they rust) and so
they should not be used in a corrosive environment unless some
form of protective coating is used.

Thankfully with the advent of development and technology,

various processes came into existence for the manufacturing of
stainless tubes and pipes in India. Now-a-days, stainless steel
pipes and tubes are manufactured with continuous tube mill using
multitorch tungsten Inert gas. The filler metal or forge welding
process is not used in this technique.
Most Important Mild Steel Properties
o A small amount of carbon makes mild steel to change it properties.
Different amount of carbon produces different types of steels. There
are small spaces between the iron lattice. Carbon atoms get attached
to this spaces and makes it stronger and harder. The harder the steel
the lesser the ductility.
o The modulus of elasticity calculated for the industry grade mild steel is
210,000 Mpa. It has a average density of about 7860 kg/m3.
o Mild steel is a great conductor of electricity. So it can be used easily in
the welding process.
o Because of its malleability, mild steel can be used for constructing
pipelines and other construction materials. Even domestic cookwares
are made of mild steel. It is ductileand not brittle but hard.
o Mild steel can be easily magnetized because of its ferromagnetic
properties. So electrical devices can be made of mild steel.
o Mild steel is very much suitable as structural steel.
Different automobile manufacturers also use mild steel for making the
body and parts of the vehicle.
o Mild steel can be easily machined in the lathe, shaper, drillling or
milling machine. Its hardness can be increased by the application of
carbon.
o Mild steel is very much prone to rust because it has high amount of
carbon. When rust free products are needed people prefer stainless
steel over mild steel.
 Manufacturing Process
Rolling and welding
Firstly, the stainless steel strips are made to gone through various quality checks
and are trimmed at edges. They are then fed to the tubes mill by stainless steel
pipe manufacturers in India. The strips pass through the number of rollers as per
the required size. In the tubes-mill, the strip is gradually converted into the
tubular shape. The fitted welding machine is then used to weld trim edges of the
strip using TIG welding process. The scraps and inside weld bead are removed
instantaneously by the Tibo machine. In this way, rolled pipes and tubes are
formed.

The cleaning and heating phase

The rolled stainless steel pipes thus manufactured are cut to the required lengths
depending upon the industrial demand. These stainless pipes and tubes are then
subjected to cleaning to remove the dirt. Further, a heat treatment is given to
these rolled pipes and tubes to remove the stresses that may occur due to
welding and formation processes. Heat treatment is given on the continuously
rolling hearth furnace. The furnace is fitted with temperature recorders and
controllers. After the heat treatment process, the SS tubes and pipes are
straightened and subjected to pickling for removing scales from the surface.

Cold- drawing process

In some cases, the required size may not be obtained from the mill directly. Then,
the cold operation process can be used to obtain the desired size. In cold drawing
process, the tubes or pipes are coated with oxalic and soap solution. This solution
acts as a lubricant to reduce friction while cold drawing operation. In the cold
drawing process, the tube or pipe is drawn over the bench using Die plugs.
 Finishing process
The drawn-out tube or ss pipe is then subjected to cleaning, heat treatment,
pickling and straightening. The computerized ink jet marking machine is used to
do the marking on the finished pipes or tubes. The pipe or tube is marked with
grade of material, size, heat number and the stamp of third party inspection
before passing on to stainless steel pipe exporters. The stainless tubes or pipes
thus produced will undergo certain testing and quality checks. This process is
followed by proper packing and dispatch. There are numerous numbers
of stainless steel pipe applications, these pipes and tubes are used thereafter for.
Mild Steel Pipes, MS Tubes Dimensions Confirming to IS: 1239
(Part I) 2004, Equivalent to BS 1387 / 1985
Light (A-Class) Medium (B-Class) Heavy (C-Class)
Nominal Bore Outside Diameter
Thickness Weight Thickness Weight Thickness Weight

Inch mm Inch mm mm kg/mtr mm kg/mtr mm kg/mtr

1/8 3 mm 0.406 10.32 1.80 0.361 2.00 2.65 0.493

1/4 6 mm 0.532 13.49 1.80 0.517 2.35 0.407 2.90 0.769

3/8 10 mm 0.872 17.10 1.80 0.674 2.35 0.852 2.90 1.02

1/2 15 mm 0.844 21.43 2.00 0.952 2.65 1.122 3.25 1.45

3/4 20 mm 1.094 27.20 2.35 1.410 2.65 1.580 3.25 1.90

1 25 mm 1.312 33.80 2.65 2.010 3.25 2.440 4.05 2.97

1.1/4 32 mm 1.656 42.90 2.65 2.580 3.25 3.140 4.05 3.84

1.1/2 40 mm 1.906 48.40 2.90 3.250 3.25 3.610 4.05 4.43

2 50 mm 2.375 60.30 2.90 4.110 3.65 5.100 4.47 6.17

2.1/2 65 mm 3.004 76.20 3.25 5.840 3.65 6.610 4.47 7.90

3 80 mm 3.500 88.90 3.25 6.810 4.05 8.470 4.85 10.1

4 100 mm 4.500 114.30 3.65 9.890 4.50 12.10 5.40 14.4

5 125 mm 5.500 139.70 4.85 16.20 5.40 17.8

6 150 mm 6.500 165.10 4.85 19.20 5.40 21.2

What is the Difference Between Seamless and
ERW Steel Pipes?
Electric Resistance Welding (ERW) pipe is manufactured by
rolling metal and then welding it longitudinally across its length.
Seamless pipe is manufactured by extruding the metal to the
desired length; therefore ERW pipe have a welded joint in its
cross-section, while seamless pipe does not have any joint in its
cross-section through-out its length.
In Seamless pipe, there are no welding or joints and is
manufactured from solid round billets. The seamless pipe is
finished to dimensional and wall thickness specifications in sizes
from 1/8 inch to 26 inch OD. Applicable in for High-pressure
applications such as Hydrocarbon Industries & Refineries, Oil &
Gas Exploration & Drilling, Oil & Gas Transportation and Air and
Hydraulic cylinders, Bearings, Boilers, Automobiles
etc.
ERW (Electric Resistance Welded) pipes are welded
longitudinally, manufactured from Strip / Coil and can be
manufactured upto 24 OD. ERW pipe cold formed from a
ribbon of steel pulled through a series of rollers and formed
into a tube which is fused through a electric charge. It is mainly
used for low/ medium pressure applications such as
transportation of water / oil. Pearlites steel is one of the
leading ERW Stainless Steel Pipes Manufacturer and exporter
from India. Contact us for product details.
Common sizes for ERW Steel Pipe range from 2 3/8 inch OD to
24 inch OD in a variety of lengths to over 100 feet.
 Welded pipe manufacturing

Seamless pipes manufacturing

 Shuttering plates
Formwork is a sort of mould used for pouring fresh or plastic
concrete. It is closed from all sides and can carry the
hydrostatic load of fluid concrete, additional load due to
vibration, and load of men and machinery. Formwork should be
such that it can be easily removed after hardening of concrete.

Shuttering is a temporary plateform constructed with the help

of wooden planks, wooden logs, steel rods or bamboos over
which formwork is supported and ultimately pouring of
concrete is done.

Shuttering plates / Centering plates are basically used for

supporting items for building construction slab, canopy,
Beam, Lintel for R.C.C construction work.
Shuttering plates are fabricated from 3.00/2.5 mm thick
MS Sheet and 25/30/35 x 4/5 mm thick MS Angle.
There are two types of shuttering plates

1. Welded shuttering plates.

2. Riveted shuttering plates
 How shuttering plates are manufactured?

Manufacturing of shuttering plate is very simple process.it can be made

fully automatic. The manufacturing of mild steel shuttering plates
include basically three steps

1. Raw material
2. Cleaning and shearing
3. Welding
Mild steel consists of iron alloyed with less than 0.3% caron, mpst
cmmonly between 0.1 to 0.25%. The structural industry
frequently uses mild steel in construction because of its ductility
and malleability coupled with anti rust property.

The advent of shuttering has made the constuction of skyscraper

possible.
 Other products
Cuplocks
Shuttering clamp
Acrospan
Channels
H-frames
 Conclusion

India one of the countries that have the advanced technology besides
diligent and good attitude of people in doing work. By training a lot of
knowledge and experience can be gained and built. Moreover, this type
of is suitable for undergraduate students who will work soon or further
their study in research field. From this industrial training, student can
improve their industry skills and also can increase the science
knowledge.

Besides, I also can train myself to be good in attitude while doing my

work. In addition, the knowledge and research skills can be improved as
when I was doing project of analysis food content. This is important
things for our chemist or science student that working on laboratory.