STUDY OF MECHANICAL MAINTENACE IN SBM

Submitted
In partial fulfillment of requirements under
Industrial project for the award of

Bachelor in technology
in
Mechanical Engineering
By
D.Venkatesh (Roll No: 23035A0307)

Under the guidance of

Mrs.I.S. Phani sushma

Assistant professor & HOD

Department of mechanical engineering

UNIVERSITY COLLEGE OF ENGINEERING JNTUK NARASARAOPET

(Narasaraopet, Kakani, Andhra Pradesh, 522616)

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 CERTIFICATE

This is to certify that the project work titled “STUDY OF MECHANICAL

MAINTENANCE IN SBM” by

D.VENKATESH (TRAINEE NO: 100031838)

is being submitted in partial fulfillment industrial project for award of bachelor of

technology in mechanical engineering at UNIVERSITY COLLEGE OF ENGINEERING
JNTUK,NARASARAOPET is a record of bonafide work carried out by him under my
guidance and supervision for a duration of 6 weeks from 20th may 2024 to 29th june 2024.

Type your text

K.Sanjay
(Manager)
SBM Department
RINL-Visakhapatnam Steel Plant

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 CERTIFICATE

This is to certify that the project titled “STUDY OF MECHANICAL MAINTENANCE

IN SBM” is a bonafide record of the work done by

D.VENKATESH (Roll no: 23035A0307)

in partial fulfillment of the requirements for the award of the degree of

Bachelor of Technology in Mechanical Engineering

Of the University College of Engineering JNTUK, Narasaraopet during the year 2024

(Head of department)
Mrs.I.S. Phani sushma
(Assistant professor & HOD)
Dept. of Mechanical Engineering.

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 ACKNOWLEDGEMENT

We would like to express our sincere gratitude and thanks to our guide Mrs.I.S. Phani
Sushma, Assistant professor & HOD Dept. of mechanical engineering , university
college of engineering jntuk, narasaraopet, for his timely guidance and time she has
devoted towards us in doing this project.

Our special thanks to, Mrs.I.S. Phani sushma, Head of the department of mechanical
engineering for their whole hearted co-operation. Finally, we thank one and all who
directly as well as indirectly helped us in the completion of this project.

We are very thankful to Mr.G. Chanra Sekhar Rao , General manager, SBM
Department, RINL - VSP, for his constant support & motivation throughtout my project.

I would like to express my gratitude to Mr.k. Sanjay, Manager in SBM Department of

mechanical engineering, during all phases of my training without his enthusiasm and
encouragement this dissertation would not have been completed. His valuable knowledge
and innovative ideas helped me to take the training to the final stage. I am thankful to all
the SBM Employes and other technical & non-technical staff of SBM department for
their cooperation.

I really admire the fond support of our L&DC Team for their co-operation and constant
help. It gives immense pleasure to acknowledge the encouragement and support extended
by them. Last but not least I am extremely thankful to all who have directly or indirectly
helped me for the completion of my project.

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 ABSTRACT

A Hydraulic Cylinder is a mechanical actuator that is used to give a unidirectionally

force through a mechanical stroke. Hydraulic Cylinders get their power from pressurized
hydraulic fluid, Which is incompressible. Hydraulic Cylinders are actuation devices that
use pressurized hydraulic fluid to produce linear motion and force. They are used in a
variety of power transfer applcations and can be single or double-action.
As heavy engineering industries grow so are the implements and the necessity for more
powerful mechanism to actuate the implements. Hydraulic Cylinders force are one such
actuator that generates linear translator motion. Hydraulic cylinder force required for
actuation depends on implementation requirements and in heavier applications where
output forces needed are higher, the internal components of the cylinder need to
withstand these higher loads hence the design of hydraulic cylinder internal components
gains importance.
Hydraulic cylinder piston rod failure can occur due to various reasons, one of the major
cases of hydraulic cylinder piston rod failure is overloading. When the load exceeds the
capacity of the hydraulic cylinder, it puts excessive stress on the piston rod, which can
cause it to bend or break.
Therefore, the main objective of the present work is to mitigate the failure by reducing
the vast tensile stress acting on the piston rod by changing the course of the lifting arm.
Finite element analysis is performed on the piston rod to compare and validate the
deformation, induced strees, and failure rate before and after the modification.

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 RASHTRIYA ISPAT NIGAM Ltd.- An Overview
Rashtriya Ispat Nigam Limited (RINL), also known as Visakhapatnam Steel Plant, is a
premier steel producer in India. Established in 1982, RINL is a Navratna Public Sector
Enterprise under the Ministry of Steel, Government of India. The plant is located in
Visakhapatnam, Andhra Pradesh, along the eastern coast of India, and is often referred
to as "Vizag Steel."

RINL was conceived with the vision of producing high-quality steel and driving
industrial growth in the region. The plant's strategic location near the port of
Visakhapatnam facilitates easy import of raw materials and export of finished
products. The integrated steel plant is known for its state-of-the-art technology and
efficient production processes. It uses the latest technologies for steelmaking, which
include Blast Furnace, Steel Melting Shop, Continuous Casting, and Rolling Mills.

The plant commenced production in 1990 and has since grown to become a significant
player in the steel industry. With an initial capacity of 3 million tons per annum
(MTPA), the plant has undergone several expansions to increase its capacity, this will
be discussed later same section. This growth reflects RINL’s commitment to meeting
the rising demand for steel in both domestic and international markets.

RINL's product portfolio includes a wide range of steel products such as billets, wire
rods, rounds, structural’s, TMT bars, and seamless tubes. These products cater to
various sectors including construction, infrastructure, automotive, engineering, and
power. RINL’s steel is renowned for its quality, and the company has received several
certifications and accolades for its products and processes.

Sustainability and environmental responsibility are integral to RINL's operations. The

company has implemented numerous measures to minimize its environmental
footprint. These include the adoption of cleaner production technologies, efficient
waste management systems, and initiatives for reducing emissions. The plant also has
extensive green cover, with millions of trees planted in and around its premises.

RINL places a strong emphasis on innovation and continuous improvement. The

company invests in research and development to enhance product quality and
operational efficiency. Additionally, RINL has forged collaborations with leading
research institutions and technology providers to stay at the forefront of technological
advancements in the steel industry.

Steel Making Process in RINL

The main departments involved in Steel Making Process are:

1. Raw Material Handling Plant.

2. Coke Ovens.
3. Sinter Plant.
4. Blast Furnace.
5. Steel Melting Shop.
6. Mills.

Raw Material Handling Plant (RMHP)

The Raw Material Handling Plant (RMHP) at Rashtriya Ispat Nigam Limited (RINL),
Visakhapatnam Steel Plant, is a critical component in the steel production process,
ensuring the efficient handling, storage, and transportation of raw materials such as
iron ore, coal, limestone, dolomite, and manganese ore. These materials are essential
for the subsequent stages of steelmaking, including sintering and blast furnace
operations.

Upon arrival, raw materials are unloaded using advanced unloading systems. Railway
wagons are tipped using wagon tipplers, which tilt the wagons to empty their contents
into hoppers. Similarly, materials delivered by trucks are unloaded using truck tipplers
or directly into storage yards. This initial handling stage is crucial for managing the
large volumes of raw materials efficiently.

Storage and stockpiling are the next critical steps. Raw materials are stored in large
stockyards, with stackers creating piles and reclaimers retrieving materials when
needed. Covered storage areas are used for materials that require protection from the
elements, ensuring their quality is maintained. This organized storage system ensures
that the plant has a continuous supply of raw materials ready for processing.

Blending and mixing processes are essential for achieving consistent quality. Different
grades of materials are blended in predefined proportions in blending beds to ensure
homogeneity. Proportioning and mixing stations further refine the mix before
materials are sent to the sinter plant or blast furnaces. This step is vital for maintaining
the chemical composition and physical properties required for efficient steelmaking.

The RMHP also includes crushing and screening operations. Large chunks of raw
materials are crushed into smaller pieces to facilitate handling and processing.
Screening separates fines from larger pieces, with fines used in the sinter plant and
larger pieces directed to the blast furnaces. These processes help in achieving the
desired size and quality of raw materials for efficient downstream processing.
Extensive conveying systems, primarily belt conveyors, transport raw materials
through various stages of handling and processing within the RMHP. Transfer towers
and chutes facilitate the movement between different conveyor belts and processing
units, ensuring a smooth and continuous flow of materials. These systems are
designed to handle large volumes efficiently, reducing downtime and maintaining a
steady supply to the steel production units.

Coke Ovens

The Coke ovens at Rashtriya Ispat Nigam Limited (RINL), Visakhapatnam Steel Plant, are
essential for converting coal into coke, a crucial material for the steelmaking process.
Coke acts as both a fuel and a reducing agent in blast furnaces. The conversion
process, known as carbonization, involves heating coal in the absence of air, which
drives off volatile compounds and leaves behind a solid carbon-rich residue known as
coke.

Initially, coal is received and stored in large stockpiles or silos. Different grades of
coal are blended to achieve the desired properties for coking. The blended coal is then
crushed into smaller particles to ensure uniform heating during the carbonization
process. This preparation stage is crucial for producing high-quality coke.

The prepared coal is transported to the coke ovens using coal charging cars. These
cars discharge the coal into the ovens through charging holes on the oven roof,
ensuring even distribution. The coal is then subjected to high temperatures, around
1100-1300°C, in an oxygen-free environment. This heating process drives off volatile
compounds such as tar, ammonia, benzene, and gas, which are collected and
processed in the by-products plant.

After about 16-20 hours of heating, the coal is transformed into coke. The hot coke is
then pushed out of the oven using a coke pusher machine and transferred to a
quenching car. The coke is quenched to cool it down and prevent it from igniting.
There are two main methods of quenching: wet quenching, which uses water and
generates wastewater that must be treated, and dry quenching, which uses inert gases
and is more environmentally friendly.

Following quenching, the coke is screened to separate it into different size fractions.
Larger pieces are used in the blast furnaces, while smaller pieces have various other
uses. The sorted coke is stored in designated areas before being transported to the
blast furnaces, where it plays a crucial role in the steelmaking process by providing
the necessary heat and acting as a reducing agent for iron ore.

SINTER PLANT

The Sinter Plant at Rashtriya Ispat Nigam Limited (RINL), Visakhapatnam Steel
Plant, is a crucial facility in the steelmaking process. It is responsible for producing
sinter, a material that is fed into the blast furnaces. Sinter is made by agglomerating
fine particles of iron ore, coke breeze, limestone, dolomite, and other metallurgical
fines into a porous mass, which is then heated until the particles fuse together. This
process enhances the physical and chemical properties of the raw materials, making
them suitable for efficient blast furnace operations.

The process begins with the mixing and preparation of raw materials. Fine iron ore,
coke breeze, limestone, dolomite, and other additives are thoroughly mixed in specific
proportions. This mixture is known as the sinter mix. The precise control of the
composition and homogeneity of the sinter mix is essential to ensure high-quality
sinter production.

Once the sinter mix is prepared, it is loaded onto a sinter strand, a continuously
moving grate. The mix is evenly distributed across the strand to form a bed of
material. This bed is then ignited at the top using gas burners, initiating the sintering
process. The combustion of coke breeze generates the necessary heat for the sinter
mix to partially melt and fuse together.

As the sinter strand moves forward, air is drawn through the bed from below,
facilitating the combustion process and ensuring uniform heating throughout the
material. The heat causes the iron ore fines to fuse into a clinker-like aggregate. This
process also helps in the removal of volatile impurities and enhances the strength and
reducibility of the sinter.

After passing through the sintering zone, the hot sinter is discharged onto a cooler,
where it is cooled by forced air. Cooling is an essential step as it stabilizes the sinter
structure and makes it suitable for handling and transportation. The cooled sinter is
then broken into smaller pieces and screened to obtain the desired size fraction. The
undersized material, known as return fines, is recycled back into the sinter mix.
The final product, sinter, is a strong and porous material that is ideal for use in blast
furnaces. Its high strength allows it to support the burden of other materials in the
furnace, and its porosity facilitates the efficient flow of gases during the iron-making
process. This results in improved furnace efficiency, higher productivity, and better
quality of hot metal.

The Sinter Plant at RINL is designed to optimize energy usage and minimize
environmental impact. Measures are in place to control emissions of dust, sulfur
dioxide, and other pollutants. Waste heat recovery systems are also employed to
harness the heat generated during sintering, improving overall energy efficiency.

In conclusion, the Sinter Plant at RINL plays a vital role in preparing raw materials for
the blast furnaces. Through the sintering process, fine iron ore and other materials are
transformed into a high-quality, efficient feedstock for iron-making. This not only
enhances the productivity of the blast furnaces but also contributes to the overall
efficiency and sustainability of the steel production process.

BLAST FURNACE:

The blast furnaces at Rashtriya Ispat Nigam Limited (RINL), Visakhapatnam Steel
Plant, are the heart of the iron-making process. These massive structures are used to
convert raw materials such as iron ore, coke, and limestone into molten iron, also
known as hot metal. The blast furnace operation is a continuous process, running 24/7
to meet the high demand for iron in steel production.

The process begins with the charging of raw materials into the top of the blast furnace.
Iron ore, sinter, coke, and fluxes (limestone and dolomite) are loaded in alternating
layers. Iron ore and sinter provide the iron content, coke serves as both a fuel and a
reducing agent, and fluxes help in removing impurities. These materials are gradually
fed into the furnace using a skip car or a conveyor belt.

Once inside the furnace, the coke is ignited by a hot blast of air, which is preheated to
temperatures around 1000°C and blown into the furnace through tuyeres at the
bottom. The combustion of coke generates the necessary heat for the chemical
reactions and produces carbon monoxide, which acts as a reducing agent. This carbon
monoxide reacts with the iron ore, reducing it to molten iron.

As the raw materials descend through the furnace, they undergo various physical and
chemical transformations. The heat from the combustion zone melts the iron ore and
fluxes, forming molten iron and slag. The slag, which contains impurities from the ore
and fluxes, floats on top of the denser molten iron. The molten iron collects at the
bottom of the furnace, while the slag is periodically removed through a slag tap.
The hot blast air also plays a crucial role in maintaining the temperature and
facilitating the reduction reactions. The furnace operates at temperatures ranging from
1500°C to 2300°C. This high temperature ensures that the iron ore is completely
reduced and melted, producing high-quality hot metal. The hot gases produced in the
furnace rise to the top, preheating the incoming raw materials and enhancing the
overall efficiency of the process.

Periodically, the molten iron is tapped from the bottom of the furnace through a
taphole. This hot metal is then transported to the steelmaking shop, where it undergoes
further refining and conversion into various steel products. The frequency of tapping
depends on the furnace's productivity and operational requirements.

STEEL MELTING SHOP (SMS):

The Steel Melting Shop (SMS) at Rashtriya Ispat Nigam Limited (RINL),
Visakhapatnam Steel Plant, is where molten iron from the blast furnace is transformed
into high-quality steel. This transformation involves several processes, including
refining, alloying, and casting, each designed to produce steel with specific properties
and characteristics required for various applications.

The process begins with the transfer of molten iron, or hot metal, from the blast
furnace to the SMS. The hot metal is transported in large ladles via torpedo ladle cars
or transfer cars. Upon arrival at the SMS, the hot metal undergoes preliminary
treatment in the desulfurization station, where impurities like sulfur are removed to
improve the quality of the final steel.
Next, the desulfurized hot metal is charged into a Basic Oxygen Furnace (BOF). The
BOF is the primary vessel used for steelmaking at RINL. In the BOF, pure oxygen is
blown at high pressure through the molten iron. The oxygen reacts with carbon and
other impurities, oxidizing them and producing carbon dioxide and other gases that
escape from the furnace. This process significantly reduces the carbon content of the
iron, converting it into steel. The exothermic reactions generate enough heat to melt
scrap steel, which is often added to the BOF to utilize recycled materials and control
the temperature.

Once the desired carbon content is achieved, the molten steel is tapped from the BOF
into a ladle. At this stage, alloying elements such as manganese, chromium, nickel,
and vanadium may be added to produce different grades of steel with specific
properties, such as enhanced strength, toughness, or corrosion resistance. This
alloying process is crucial for tailoring the steel to meet various industrial
requirements.

The molten steel then undergoes secondary refining in a Ladle Furnace (LF) or a
Vacuum Degassing (VD) unit. In the LF, the steel is further refined by adjusting its
temperature and composition. This process ensures the removal of any remaining
impurities and precise control over the chemical composition of the steel. The VD unit
is used to remove dissolved gases like hydrogen and nitrogen, which can cause defects
in the final product. The result is ultra-clean steel with superior mechanical properties.

After refining, the molten steel is cast into semi-finished products using Continuous
Casting Shop (CCS). The molten steel is poured into a water-cooled mold, where it
solidifies as it is gradually withdrawn from the bottom of the mold. This continuous
casting process produces, billets, or blooms, which are then cut to the desired length.
Continuous casting is highly efficient and produces high-quality steel with a uniform
structure.

MILLS:

There are many Mills present in RINL, all having their own contribution in the production for
RINL. The mills present are:

 Light and Medium Merchant Mill: The cast blooms from continuous casting
department are heated and rolled in the two high speed and fully automated rolling
mills namely Light & Medium Merchant Mill (LMMM) and Medium Merchant &
Structural Mill (MMSM). The billets produced in LMMM are further rolled in Bar
Mill / Wire Rod Mill (WRM). The finished products include wire rods & long
products like reinforcement bars, rounds, squares, flats, angles, channels, billets etc.
  Wire Rod Mill:

WRM-1: The Mill is high speed 4 strand No-Twist continuous mill designed to produce
10,50,000 Tons of wire rod coils per year. Rolled billets of 125 mm x 125 mm square
cross section, length ranging from 9.8 m to 10.4 m and weighing approximately 1250
kgs are used. The mill is designed to roll steel stock of 0.9% max. carbon content.

WRM-2: The Mill is designed to produce 6,00,000 tons per year of rounds in coil form.
The Mill is designed to roll low, medium and high carbon steel, case hardening steel,
cold heading quality steel, electrode steel, spring steel, bearing steel and free cutting
steel. The mill shall use continuous cast billets of 150 mm X 150 mm square cross
section, 12 m length and weighing 2100 kg approximately, are used as input material.

 Medium Merchant Structural Mill

The Medium Merchant and Structural Mill (MMSM) is one of the modern rolling
mills of Visakhapatnam Steel Plant. This is a single strand continuous mill
having production capacity of 10,70,000 tons per year. The important feature of
this mill is that Universal beams (both parallel and wide flange) have been rolled
for the first time in India using Universal stands. Parallel flange beams have an
advantage over conventional beams because, for the same weight, the section is
stronger and stiffer due to greater moment of inertia and higher radius of
gyration.

 Structural Mill

The Mill is designed to produce 0.7MTPA of structural section in straight

length in approximately 3733 rolling hours and 8,50,000 tones per year of
structural sections in straight length in approximately within 4533 rolling
hours.an input of Continuous cast cold bloom of 200 mm x 200 mm x 12 m and
weighing approximately 3760 kgs.

 Special Bar Mill

The Mill is designed to produce 0.75MTPA of plain rounds in straight length
and in coil form by using an input of Continuous cast billets of 150 mm x 150
mm x 12 m and weighing approximately 2050 kg. The mill is designed to roll
medium and high carbon steel, case hardening steel, cold heading quality steel,
electrode steel, spring steel, bearing steel and free cutting steel.

Expansion of RINL
The expansion of Rashtriya Ispat Nigam Limited (RINL) from an initial capacity of 3
million tons per annum (MTPA) to 7.3 MTPA is a significant milestone in the
company's growth and development. This expansion has been driven by the increasing
demand for steel in domestic and international markets, coupled with RINL's
commitment to enhancing its production capabilities and maintaining its competitive
edge in the industry.

Initial Capacity and the Need for Expansion:

When RINL commenced operations in 1990, it had an initial production capacity of 3

MTPA of liquid steel. This capacity was sufficient to meet the early demand for steel
products, but as India's economy grew and infrastructure development accelerated, the
demand for high-quality steel increased significantly. To cater to this growing demand
and to capitalize on new market opportunities, RINL embarked on an ambitious
expansion program.

Phase 1: Modernization and Upgradation

 Blast Furnaces: Upgradation of existing blast furnaces and installation of new

ones to increase hot metal production capacity.
 Steel Melting Shops: Expansion of steel melting shops with additional
converters and ladle furnaces to enhance steelmaking capacity.
 Continuous Casting: Installation of new continuous casting machines to
improve the efficiency and quality of steel billets.

Phase 2: Rolling Mills and Downstream Facilities

 New Rolling Mills: Establishment of new rolling mills to produce a wider

range of steel products, including wire rods, structurals, and TMT bars.
 Seamless Tube Mill: Installation of a seamless tube mill to diversify the
product portfolio and cater to specialized market segments.

Phase 3: Infrastructure and Utilities

 Raw Material Handling: Development of advanced raw material handling

systems to streamline the supply chain and ensure a steady supply of inputs.
 Power and Utilities: Expansion of captive power plants and utility services to
support the increased production capacity.

Throughout the expansion process, RINL has incorporated the latest technological
advancements in steelmaking. This includes the use of automation and control
systems, energy-efficient processes, and environmentally friendly practices. The
adoption of these technologies has not only increased production capacity but also
improved the overall efficiency and sustainability of operations.
The expansion includes building of Raw Material Handling Plant, Sinter Plant-3, Blast
Furnace-3, Steel Melt Shop-2, Wire Rod Mill-2, Oxygen Plant, Turbo Blower-4,
Structural Mills, Special Bar Mill and several auxiliary systems.

Since I was allotted in Special Bar Mill, I had an opportunity to explore more about
this department.
SPECIAL BAR MILL:
This Mill is part of Expansion Project of RINL. This is commissioned on 3rd April
2015. The Mill is designed to produce 0.75 MTPA of plain rounds in straight length
and in coil form by using an input of Continuous cast billets of 150 mm x 150 mm x
12 m and weighing approximately 2050 kgs. The mill is designed to roll medium and
high carbon steel, case hardening steel, cold heading quality steel, electrode steel,
spring steel, bearing steel and free cutting steel.
The Salient Features of SBM are:
 Continuous Mill consisting of 21 stands of housing-less design.
 20 - 45 mm size in straight & coil form (Reduced wastage for end user).
 Free size rolling (Customized sizes with closed tolerances)
 Low temperature rolling for finer grain structure.
 Online automatic measuring gauge for better quality control.
 Automatic bar Bundling & Strapping machines for packaging of finished
products.

The main Machinery present in Special Bar Mill is:

 Transmission Chain: Helps to lift the Billet from Ground Level to +5m level.
 Re-Heating Furnace (Walking Beam Furnace): Reheats the billets for making it
easy for Rolling and shaping.

 Stands: There are a total of 21 Stands in SBM, each billet goes through them
and according to the desired output the Stands are set for sizing the Billets.

 Cooling Bed: After the required size is made from the Billets, they all kept at a
place for them to cool.

 12M Cutter: Each rod should which is sent outside RINL should be of 12M.
This is where the rod go from Cooling bed.
 Straight Rods Packing: This is the place where the Straight Rods are packed
and dispatched from SBM.

 Garret Area: This is the place where the Coils are made after them attaining
their required Diameter from rolling from Stands.
 Cooling Area: The place where the Coils cools for some time before they going
to packing aera.

 Coil Packing Area: This is the place where the Coils are packed.
These all are the main Machineries present in the Special Bar Mill. For them to have
long life and be Consistent in all conditions Maintenance of these machines is very
much required. Let’s discuss about Maintenance and Maintenance Schedules that are
going on here in SBM.

MAINTENANCE
Maintenance refers to the activities carried out to preserve, restore, or improve the
condition of machinery, equipment, and infrastructure. It ensures that these assets
perform their intended functions efficiently and reliably. Maintenance can be
classified into several types, including preventive, predictive, corrective, and
condition-based maintenance.
Why is Maintenance required in Industries?
Proper industrial maintenance can bring many benefits to company,
including increased equipment uptime and availability, reduced breakdowns or
repairs, and improved efficiency and performance, resulting in energy savings and
cost savings.

 Enhances Equipment Lifespan

 Wear and Tear Management: Regular maintenance addresses normal wear

and tear, preventing minor issues from escalating into major failures.
  Component Replacement: Timely replacement of worn-out parts ensures that
the overall machinery remains in good condition for a longer period.

 Ensures Operational Efficiency

 Optimal Performance: Well-maintained equipment operates at peak

efficiency, ensuring that production processes are smooth and uninterrupted.
 Energy Efficiency: Properly maintained machines consume less energy,
reducing operational costs and minimizing the environmental footprint.

 Prevents Unplanned Downtime

 Scheduled Inspections: Routine maintenance allows for the identification and

rectification of potential issues before they cause equipment failures.
 Minimized Interruptions: Preventive maintenance reduces the likelihood of
unexpected breakdowns, ensuring continuous production and meeting delivery
schedules.

 Improves Safety

 Hazard Prevention: Regular maintenance helps identify and fix safety

hazards, such as faulty wiring or worn-out components, reducing the risk of
accidents.
 Compliance with Regulations: Maintenance ensures that equipment meets
safety standards and regulatory requirements, preventing legal issues and fines.

 Maintains Product Quality

 Consistency: Properly functioning equipment produces consistent and high-

quality products, maintaining customer satisfaction and brand reputation.
 Defect Reduction: Maintenance helps in minimizing defects and ensuring that
products meet quality standards.

 Cost Savings

 Reduced Major Repairs: Preventive maintenance helps in identifying issues

early, reducing the need for costly major repairs.
 Lower Replacement Costs: By extending the lifespan of equipment,
maintenance reduces the frequency and cost of replacing machinery.
 Environmental Compliance

 Leak Prevention: Regular maintenance checks prevent leaks of hazardous

substances, ensuring compliance with environmental regulations.
 Efficient Resource Use: Proper maintenance ensures efficient use of resources,
reducing waste and environmental impact.

 Optimizes Resource Utilization

 Maximized Equipment Usage: Maintenance ensures that all machinery and

equipment are available and in good working condition, optimizing production
capacity.
 Labor Efficiency: Well-maintained equipment reduces the need for emergency
repairs, allowing maintenance staff to focus on planned activities.

 Supports Predictive Maintenance Initiatives

 Data Collection: Regular maintenance activities help collect data on

equipment performance, supporting predictive maintenance strategies.
 Early Issue Detection: Predictive maintenance uses data to predict and address
potential issues before they lead to failures.

 Supports Continuous Improvement

 Feedback Loop: Maintenance activities provide valuable feedback on

equipment performance, informing continuous improvement initiatives and
process optimization.
 Innovation and Upgrades: Maintenance routines offer opportunities to
implement upgrades and innovations that enhance efficiency and productivity.

Maintenance in SBM
One of the main kinds of Maintenance that takes place in SBM is Hydraulic
Maintenance. It is broadly classified as Hydraulic and Lubrication Maintenance.

Hydraulic Maintenance:

Hydraulic maintenance refers to the activities involved in keeping hydraulic systems

and components in optimal working condition. Hydraulic systems use fluid power to
perform work, commonly seen in machinery such as excavators, presses, and cranes.
Proper maintenance is crucial to ensure these systems operate efficiently, safely, and
reliably.

Key Aspects of Hydraulic Maintenance

1. Fluid Maintenance
o Checking Fluid Levels: Ensuring hydraulic fluid levels are within the
specified range to maintain system pressure and performance.
o Fluid Quality: Monitoring the quality of hydraulic fluid for
contamination, viscosity, and proper additives. Contaminated fluid can
cause significant damage to hydraulic components.
o Fluid Replacement: Regularly replacing hydraulic fluid based on the
manufacturer's recommendations or when it shows signs of degradation.

2. Filter Maintenance
o Filter Inspection and Replacement: Regularly inspecting and
replacing hydraulic filters to prevent contaminants from entering the
system. Clean filters are essential for maintaining fluid cleanliness and
system performance.
o Monitoring Filter Indicators: Many hydraulic systems have indicators
that show when filters need changing. Keeping an eye on these
indicators helps maintain filter effectiveness.

3. Hose and Fittings Maintenance

o Inspecting Hoses and Fittings: Regularly checking hoses and fittings
for signs of wear, damage, or leaks. Hoses should be flexible without
cracks or bulges, and fittings should be secure.
o Replacing Worn Components: Promptly replacing any damaged or
worn hoses and fittings to prevent leaks and system failures.

4. Seal and Gasket Maintenance

o Checking Seals and Gaskets: Inspecting seals and gaskets for wear,
damage, or leaks. These components are crucial for maintaining system
pressure and preventing fluid leaks.
o Replacing Worn Seals: Replacing any worn or damaged seals and
gaskets to maintain system integrity and performance.

5. Component Inspection
 o Inspecting Hydraulic Pumps and Motors: Regularly inspecting
hydraulic pumps, motors, and cylinders for signs of wear or damage.
Proper functioning of these components is critical for system
performance.
o Monitoring Performance: Keeping track of the performance of
hydraulic components and addressing any signs of inefficiency or
malfunction.

6. System Cleanliness
o Flushing the System: Periodically flushing the hydraulic system to
remove contaminants and old fluid. This helps maintain the cleanliness
and efficiency of the system.
o Cleaning Reservoirs and Tanks: Ensuring that hydraulic reservoirs
and tanks are clean and free from sludge or sediment.

7. Preventive Maintenance Schedule

o Establishing a Maintenance Schedule: Creating and adhering to a
regular maintenance schedule based on manufacturer recommendations
and operational conditions.
o Record Keeping: Maintaining detailed records of all maintenance
activities, inspections, and replacements to track the health and
performance of the hydraulic system.

Benefits of Hydraulic Maintenance

 Enhanced System Reliability: Regular maintenance ensures hydraulic

systems operate reliably, reducing the risk of unexpected breakdowns.
 Prolonged Component Life: Proper care and maintenance extend the lifespan
of hydraulic components, reducing the need for frequent replacements.
 Improved Performance: Well-maintained hydraulic systems perform
efficiently, providing consistent power and responsiveness.
 Safety: Maintaining hydraulic systems reduces the risk of leaks, failures, and
accidents, ensuring a safe working environment.
 Cost Savings: Preventive maintenance reduces the likelihood of costly repairs
and downtime, leading to overall cost savings.

Lubrication Maintenance:

Lubrication maintenance is a critical aspect of maintaining machinery and

equipment, focusing on the application and management of lubricants to ensure
smooth operation and minimize wear and tear. Proper lubrication reduces friction
between moving parts, dissipates heat, prevents corrosion, and helps in maintaining
the efficiency and longevity of mechanical components.

Key Aspects of Lubrication Maintenance

1. Types of Lubricants
o Oils: Fluid lubricants used for high-speed or high-temperature
applications. Commonly used in engines, gearboxes, and hydraulic
systems.
o Greases: Semi-solid lubricants used for components that require long-
lasting lubrication under heavy loads. Ideal for bearings, joints, and
bushings.
o Solid Lubricants: Materials like graphite or molybdenum disulfide used
in extreme conditions where liquid lubricants may not perform well.
o Synthetic Lubricants: Engineered lubricants designed for specific
applications, offering enhanced performance under extreme conditions.

2. Lubrication Methods
o Manual Lubrication: Applying lubricants by hand using tools like
grease guns or oil cans. Suitable for smaller systems or components with
low lubrication needs.
o Automatic Lubrication Systems: Automated systems that deliver
precise amounts of lubricant at specified intervals. Common in large,
complex machinery where manual lubrication is impractical.
o Centralized Lubrication Systems: A single system that distributes
lubricant to multiple points in a machine or system, ensuring consistent
lubrication across all components.
o Drip Feed Lubrication: A method where lubricants are fed drop by
drop to specific points, often used in conveyor belts and other
continuous systems.

3. Lubrication Schedule
o Regular Intervals: Lubrication tasks are scheduled at regular intervals
based on equipment usage, operating conditions, and manufacturer
recommendations.
o Condition-Based: Lubrication is performed based on the actual
condition of the machinery, often determined through monitoring tools
and sensors.

4. Lubrication Management
 o Selection of Lubricants: Choosing the right type and grade of lubricant
based on the specific requirements of the machinery and operating
conditions.
o Storage and Handling: Proper storage of lubricants to prevent
contamination and degradation. This includes keeping containers sealed
and stored in a clean, temperature-controlled environment.
o Application Techniques: Ensuring correct application techniques to
avoid over-lubrication or under-lubrication, both of which can lead to
equipment issues.

Now we know all the Maintenance Practices of Special Bar Mill. Let us now discuss
about the machines on which all these practices are taken place. All these machines
are also classified as 2:

 Hydraulic Systems
 Lubrication Systems

HYDRAULIC SYSTEMS
Hydraulic systems are crucial components in various industrial applications,
employing fluid power to transmit force and control motion. They utilize hydraulic
fluid, typically oil, under pressure to generate, transmit, and control power. These
systems are prized for their high-power density, precise control, and ability to operate
in diverse environments. Industries such as manufacturing, construction, aerospace,
and agriculture rely on hydraulic systems for tasks ranging from heavy lifting and
pressing to precise positioning and control mechanisms. Key components include
pumps, actuators (such as cylinders and motors), valves, and hydraulic fluids, all
working together to deliver efficient and reliable power transmission in industrial
settings.

Let's delve into each advantage of hydraulic systems over traditional mechanical
methods in a broader sense:

1. Power and Efficiency:

o Power Transmission: Hydraulic systems can transmit a large amount of
power efficiently because they utilize hydraulic fluid, which is nearly
incompressible. This means they can generate significant force using
relatively compact components like hydraulic pumps, cylinders, and
valves.
o Size and Weight: Compared to mechanical systems that might require
large gears, levers, and linkages to achieve similar force transmission,
hydraulic systems are often more compact and lighter, which can be
advantageous in applications where space and weight are critical factors.
2. Smooth and Precise Control:
o Control Mechanism: Hydraulic systems provide precise control over
movement and force through the manipulation of hydraulic fluid flow
rates. By adjusting valves, operators can smoothly vary the speed and
force exerted by hydraulic actuators such as cylinders or motors.
o Applications: This precise control is crucial in applications where
smooth, accurate movement is essential, such as in construction
machinery for lifting and positioning heavy loads, or in manufacturing
equipment for precise assembly operations.

3. Safety:
o Built-in Safety Features: Hydraulic systems can incorporate safety
features like pressure relief valves that prevent system overloads and
potential damage. These valves release excess pressure to protect the
system and operators from potential hazards.
o Environmental Safety: Hydraulic systems are preferred in
environments where sparks from electrical systems could ignite
flammable substances or gases, making them suitable for industries like
mining, oil and gas, and chemical processing.

4. Versatility:
o Adaptability: Hydraulic systems are highly adaptable to different
applications across various industries. They can operate effectively in a
wide range of temperatures and environmental conditions, from extreme
cold to high heat, without significant loss of performance.
o Industry Applications: They are commonly used in heavy machinery
like excavators, bulldozers, and cranes, as well as in aerospace for flight
control systems and in automotive braking systems.

5. Durability and Reliability:

o Longevity: Hydraulic components are known for their durability and
longevity when properly maintained. This reduces downtime and
maintenance costs compared to mechanical systems that may require
more frequent lubrication, adjustment, or replacement of wearing parts.
o Industrial Reliability: In industrial settings where reliability is crucial
for continuous operation, hydraulic systems offer robust performance,
contributing to overall productivity and efficiency.
In summary, hydraulic systems excel in power transmission efficiency, precise control
capabilities, safety features, adaptability to diverse environments and applications, and
long-term reliability. These qualities make them a preferred choice over traditional
mechanical methods in many industrial and commercial settings.

Hydraulic Station:

A hydraulic station is a centralized system designed to generate, control, and distribute

hydraulic power for various industrial applications. It typically includes components
such as a hydraulic pump that converts mechanical power into hydraulic energy, a
reservoir for storing hydraulic fluid (usually oil), control valves to regulate fluid flow,
and an accumulator for storing energy under pressure. Filters and cooling systems
maintain fluid cleanliness and temperature, while pressure relief valves ensure system
safety by releasing excess pressure. Hydraulic stations are essential in industries like
manufacturing and construction, providing efficient power transmission to heavy
machinery and equipment that require hydraulic force for their operation. They
streamline hydraulic power management, ensuring reliable performance and safety
across diverse industrial settings.

HYDRALIC SYSTEMS IN SBM

Hydraulic systems will be provided for the actuation of hydraulic

cylinders/motors/actuators of the various equipment of the SBM, including Furnaces.
The hydraulic systems will be complete with all equipment, electrics, pipework,
instrumentation and controls, as required and as specified in this specification as well
as in VSP's General Specification for Hydraulic Power Systems. Hydraulic system for
reheating furnace will also be provided.

Centralised hydraulic systems is being provided for the equipment of SBM. The
hydraulic systems with all equipment including electrics, pipework, instrumentation
and controls are as per VSP's General Specification for Hydraulic Power Systems.
Mineral oil of ISO VG46 grade are used in the hydraulic systems.

The filling of fresh hydraulic oil in the tank of each hydraulic system are from the
Central Oil Storage of SBM. Separate filling line with duplex filters are provided in
the tank. The spent hydraulic oil from the tanks is dumped into the spent oil tank
inside Central Oil Storage for SBM. The circulation pumps are used for unloading the
spent oil from the system tank. Necessary branch connection is provided on the
downstream side of circulation pumps.

The pipework is included with the piping within the hydraulic tank-pump stations as
well as complete interconnecting piping between hydraulic power packs and actuators
via valve stands and accumulator stands. As far as practicable, use of lengthy
hydraulic pipework is avoided. Pickling and flushing of interconnecting piping for all
hydraulic systems are carried out.
The piping of the hydraulic systems is designed such that the fluid velocity meets the
General Specification for Hydraulic Power Systems. All pipes for hydraulic systems
are seamless pipes as per the DIN standard. For non-servo systems, the
interconnecting piping is carbon steel, and for servo systems, the interconnecting
piping is stainless steel. All interconnecting piping in wet areas is stainless steel. The
interconnecting piping for hydraulic systems conforms to VSP's General Specification
for Pipework.

The hydraulic systems are started from MCCs/local control panels inside the hydraulic
cellars/ rooms. Remote controls are provided in the control pulpits or desks. The
hydraulic directional control valves and other electrical valves are operated from
control pulpits/control desks.

There are many Hydraulic Stations present in Special Bar Mill, each having its own
importance. They are:

 UH01: Hydraulic Unit for Charging Area.

 UH02: Hydraulic Unit for Charging Area.
 UHF/C: Hydraulic Unit for Furnace Area.
 UH4: Hydraulic Unit for Pendulum Shear.
 UH1: Hydraulic Unit for Rolling Mills Stands (1-18)
 UH2: Hydraulic Unit for Rolling Mills Stands (19-21)
 UH3: Hydraulic Unit for Rolling Mills Stands (19-21) (Stand-By Unit)
 UH40: Hydraulic Unit for Cooling Bed and Cold Shear Area.
 UH60: Hydraulic Unit for Bar Bundling Area.
 UH25: Hydraulic Unit for Garret Coiler Area.
 UH28: Hydraulic Unit for Coil Dispatching.
 UHC1
 UHC2
 UHC3

UH01 & UH02:

These are the Hydraulic Systems used for Billet Charging. There are three Billet
charging grids operation one at a time at a rate of 200t/h.

The billet charging grid is a crucial component inSBM, used to transport billets (semi-
finished metal products) from ground level to the +5M for it to enter the Furnace.
Here is a step-by-step description of the process:
 Billet Placement

 Initial Positioning: Billets are initially positioned on the charging grid at

ground level (0 meters). This is done through automated conveyor systems.

 Alignment and Securing

 Alignment: Billets are aligned properly on the grid to ensure balanced lifting.
Misalignment can lead to uneven lifting and potential damage.
 Securing: Depending on the system design, billets may be secured with
clamps, grippers, or other holding mechanisms to prevent movement during
lifting.

 Activation of the Lifting Mechanism

 Control System Activation: The lifting process is initiated by the control

system, which activates the hydraulic, mechanical, lifting mechanisms.
 Hydraulic Cylinders: In hydraulic systems, cylinders extend to start lifting the
billet.

 Final Positioning at +5m

 Deceleration: As the billet approaches the target height of +5 meters, the

lifting mechanism decelerates to ensure precise positioning.
 Alignment and Stability Check: The system ensures that the billet is correctly
positioned and stable at +5 meters before completing the lift.

 Billet Transfer

 Release Mechanism: The securing mechanism (clamps, grippers) is released

once the billet is safely positioned at +5 meters.

UHF/C:
Hydraulic System used in Reheating Furnace. The type of furnace used here is
Walking beam Furnace. There are 5 Standing Beams and 4 moving beams present
inside the Furnace. Now we will understand the working of this Furnace in a better
way.

 Charging

 Loading the Material: Slabs, billets, or blooms are loaded onto the charging
table at the entrance of the furnace. This can be done manually or using
automated systems such as roller tables or conveyor belts.
 Positioning: The material is aligned properly to ensure it can be moved
smoothly through the furnace.
 Initial Heating Zone

 Preheating: As the material enters the furnace, it first passes through the initial
heating zone, where it is preheated by the hot gases exiting the furnace. This
stage helps to gradually raise the temperature of the material, minimizing
thermal shock.
 Temperature Monitoring: Sensors continuously monitor the temperature of
the material to ensure it is heated evenly.

 Walking Beam Mechanism

 Walking Beam Action: The walking beam furnace uses a series of beams that
lift and move the material in a walking motion through the furnace. This
mechanism alternates between lifting the material off the stationary beams and
advancing it forward in a stepwise manner.
 Beam Movement: The walking beams are moved by hydraulic or mechanical
actuators. The motion is carefully controlled to ensure smooth and consistent
movement of the material.

 Heating Zones

 Uniform Heating: The furnace is divided into several heating zones, each with
independently controlled burners. This allows for precise control of the
temperature profile along the length of the furnace.
 Radiant and Convective Heating: Both radiant and convective heating
methods are used to ensure uniform heating of the material. Radiant heat from
the furnace walls and burners, combined with convective heat from the hot
gases, ensures thorough and even heating.

 Soaking Zone

 Temperature Equalization: In the soaking zone, the material is held at a

uniform temperature to allow the heat to penetrate evenly throughout its cross-
section. This step ensures that the entire material reaches the desired
temperature, which is critical for the quality of the final product.
 Soaking Time: The soaking time is controlled based on the type and size of the
material and the desired final temperature.

 Discharge

 Final Heating: Before exiting the furnace, the material passes through the final
heating zone, where it may receive additional heating to ensure it is at the
optimal temperature for the next processing stage.
 Discharge Table: The heated material is then moved onto the discharge table,
where it is ready to be transferred to the rolling mill or forging press.
 Automated handling systems can transfer the material quickly and efficiently to
minimize heat loss.

 Exiting the Furnace

 Transfer to Next Process: The material is transferred to the next stage of the
production process, such as rolling or forging. This transfer is usually done
quickly to maintain the material at the desired temperature.
 Temperature Maintenance: During the transfer, measures are taken to
minimize heat loss, such as covering the material or using insulated transfer
systems.

Let us now understand the Hydraulic Aspect in Walking Beam Furnace:

Hydraulic system plays a crucial role in the operation of a walking beam furnace.
They are responsible for the controlled movement of the walking beams, which lift
and transport the material (such as slabs, billets, or blooms) through the furnace.
Here's a detailed explanation of their use and function:

Function of Hydraulic System

1. Lifting and Lowering Beams

o Vertical Movement: Hydraulic cylinders are used to lift and lower the
walking beams. When the cylinders extend, they lift the beams and the
material off the stationary beams. When they retract, they lower the
beams back down.
o Precise Control: The hydraulic system allows for precise control over
the lifting and lowering process, ensuring smooth and consistent
movement without causing damage to the material
2. Advancing the Material
o Horizontal Movement: In addition to vertical movement, hydraulic
cylinders also facilitate the horizontal advancement of the material.
After lifting the material, the walking beams are moved forward by
hydraulic cylinders.
o Stepwise Motion: The combination of lifting and advancing creates a
stepwise walking motion that moves the material through the furnace in
controlled increments.

UH4:
Hydraulic Unit used for Pendulum Shear. Pendulum shears, also known as swinging
shears or oscillating shears, are critical components in rolling mills used to cut hot or
cold rolled metal products, such as slabs, billets, blooms, and strips, to specific
lengths. These shears offer precise, high-speed cutting and are particularly useful in
continuous rolling processes. Here’s a detailed explanation of their use and function:
Functions of Pendulum Shear

1. Cutting to Length
o Precise Cutting: Pendulum shears are designed to cut metal products to
precise lengths as they exit the rolling mill. This is essential for meeting
product specifications and ensuring uniformity.
o Adjustable Lengths: The shear can be adjusted to cut materials to
various lengths as required by different production processes or
customer requirements.

2. Trimming
o Edge Trimming: Pendulum shears can be used to trim the edges of
metal strips or sheets, removing any irregularities or excess material.
This ensures that the final product has smooth, straight edges.
o End Trimming: In some cases, the shear trims the ends of the rolled
product to remove any defects or to prepare the material for further
processing.

3. Emergency Cutting
o Safety Cut: In case of emergencies, pendulum shears can quickly cut
the rolling stock to prevent damage to the equipment or to handle
process interruptions. This is crucial for maintaining the safety and
efficiency of the rolling mill operations.

4. Division of Rolling Stock

o Splitting Long Products: When rolling long products, such as strips or
rods, pendulum shears can divide them into shorter sections for easier
handling, storage, and transport.
o Batch Production: For products that need to be produced in batches,
pendulum shears facilitate dividing the continuous rolling stock into
manageable lengths.

 Hydraulic/Mechanical Actuators

 Power Source: The actuators provide the necessary force to move the shear
blades in the oscillating motion. Hydraulic systems are commonly used for
their precision and power.
 Control System: Actuators are controlled by a sophisticated control system
that ensures synchronized and accurate operation with the rolling mill.
UH1, UH2 & UH3
Hydraulic Unit used for Rolling Stands in SBM. UH1 is used for Mills 1-18, UH2 is
used for 19-21 and UH3 is used as a Stand-By unit.

Stands, also known as rolling stands or mill stands, are crucial components in rolling
mills. They house the rolls and provide the necessary pressure and support for the
rolling process, where metal stock (billets) is passed through pairs of rolls to reduce
thickness, increase length, and improve mechanical properties. Here’s a detailed
explanation of their use and function:

Functions of Stands in Rolling Mills

1. Housing the Rolls

o Roll Support: Stands securely hold the working rolls, backup rolls, and
other roll components in place, ensuring they are properly aligned and
supported during the rolling process.
o Roll Adjustment: They allow for the adjustment of roll gap (the
distance between the rolls), which determines the final thickness of the
rolled product.

2. Applying Rolling Force

o Pressure Application: Stands provide the necessary pressure to deform
the metal as it passes through the rolls. This pressure is applied through
hydraulic or mechanical means.
o Force Distribution: They ensure the even distribution of rolling force
across the entire width of the material, preventing uneven deformation.

3. Ensuring Stability
o Structural Support: Stands provide structural support and stability to
the rolling mill, ensuring that the rolls remain in the correct position and
orientation during operation.
o Vibration Reduction: By maintaining stability, stands help reduce
vibrations and deflections that could negatively impact the quality of the
rolled product.

4. Guiding the Material

o Entry and Exit Guides: Stands often include guides at the entry and
exit points to ensure the material is fed smoothly into and out of the roll
gap, preventing misalignment and ensuring consistent rolling.
o Direction Control: They help control the direction and flow of the
material as it moves through the rolling mill.
Hydraulic systems play a crucial role in rolling mill stands, providing the necessary
force, precision, and control to perform various operations efficiently. Here’s a
detailed explanation of the use of hydraulics in rolling mill stands:

Functions of Hydraulics in Rolling Mill Stands

1. Roll Gap Adjustment

1. Precise Control: Hydraulics allow for precise control over the roll gap,
which is the distance between the working rolls. This adjustment is
crucial for achieving the desired thickness of the rolled product.
2. Automated Adjustment: Hydraulic systems can automate the
adjustment of the roll gap, ensuring consistent product dimensions and
reducing manual intervention.

2. Roll Force Application

1. High Pressure: Hydraulic systems can generate high pressure,
providing the necessary force to deform the metal as it passes through
the rolls.
2. Uniform Force Distribution: Hydraulics ensure uniform distribution of
the rolling force across the entire width of the material, preventing
uneven deformation and ensuring product quality.

3. Roll Positioning

 Precise Alignment: Hydraulic systems help in the precise positioning and

alignment of the rolls within the stand, ensuring they remain in the correct
orientation during operation.
 Dynamic Adjustments: Hydraulics allow for dynamic adjustments to roll
position during rolling, accommodating changes in rolling conditions and
material properties.

UH40:
Hydraulic Unit for Cooling Bed and Cold Shear Area. In rolling mills, the cooling bed
and cold shear area are critical components of the finishing process for metal products,
especially in hot rolling operations. Here’s a detailed explanation of each area and
their processes:

The cooling bed and cold shear is a crucial part of the rolling mill where hot-rolled
products are cooled and stabilized to achieve their final properties and the final size
(12M) before further processing or shipment. It serves several important functions:

 Releasing Heat: Hot-rolled products, such as coils, plates, or sections, exit the
rolling mill at temperatures typically ranging from 800°C to 1000°C. The cooling bed
allows these products to cool gradually to a temperature suitable for handling and
further processing.

 Reduction of Residual Stress: As metal products cool on the bed, internal stresses
induced during rolling are gradually reduced. This process, known as stress relieving,
helps improve the mechanical properties and dimensional stability of the final product.

 Uniform Cooling: The cooling bed ensures that the entire surface area of the hot-
rolled product cools uniformly. This uniform cooling helps prevent thermal gradients
and potential distortion, ensuring the product maintains its shape and flatness.

 Length Measurement and Cutting: Products are often cut to specific lengths on
the cooling bed, using equipment such as cold shears, to meet customer specifications.
This ensures uniformity and facilitates downstream processing.

UH60:
Hydraulic Unit for Bar Bundling Area. The bar bundling process is a crucial step in
the handling and packaging of long steel products, such as bars, rods, and structural
sections, typically produced in SBM. The main purpose of bar bundling is to
efficiently group and secure multiple individual bars into a single bundle for easier
handling, transportation, and storage. This process helps streamline logistics and
ensures that the bars remain organized and protected during transit from the
manufacturing facility to the customer or to further processing facilities.

Steps Involved in Bar Bundling

1. Collection and Alignment

o Conveyor System: After the bars are cut to the desired lengths
(typically on a cooling bed or directly from the rolling mill), they are
transported via conveyor systems to the bundling area.
o Alignment: Bars are aligned and oriented in a specific direction to
facilitate bundling. This ensures that all bars in the bundle are uniform
and organized.

2. Bundling and Strapping

o Grouping: Bars are grouped together according to customer
specifications or standard bundle sizes.
o Strapping: Steel straps or wires are used to securely bind the bars
together into a tight bundle. The strapping materials are strong enough
to withstand handling and transportation stresses.
 3. Weighing and Labelling
o Weight Measurement: Each bundle is weighed to ensure it meets the
specified weight range as per customer requirements or industry
standards.
o Labelling: Bundles are labelled with essential information such as
product specifications, heat numbers, batch codes, and destination
details for traceability and identification.

In the bar bundling process, hydraulic systems play a crucial role in several key
aspects, primarily focused on providing the necessary force, control, and automation
to efficiently bundle and handle the bars. Here’s how hydraulics are utilized in the
hydraulic aspect of bar bundling:

Hydraulic Aspects in Bar Bundling

1. Bundling Machines
o Hydraulic Cylinders: Hydraulic cylinders are integral components of
bundling machines. They provide the force required to compress and
hold the bars together during the bundling process.
 Compression Force: Hydraulic cylinders apply controlled and
adjustable compression force to ensure that the bars are tightly
bundled together.
 Uniform Pressure: Hydraulic systems maintain uniform pressure
across the bundle, ensuring consistent bundling quality and
preventing slippage or misalignment of bars.

2. Strapping Systems
o Tensioning Mechanisms: Hydraulic systems are used in strapping
machines to apply tension to steel straps or wires that secure the bundled
bars.
 Tension Control: Hydraulic actuators control the tension applied
to the strapping material, ensuring it is sufficiently tight to secure
the bundle without damaging the bars.
 Automatic Tension Adjustment: Some advanced systems
feature automatic tension adjustment based on bundle size and
material type, optimizing efficiency and consistency.

UH25:
Hydraulic Unit for Garret Coiler Area. The Garret coiler area in a rolling mill is a
critical section where hot-rolled products, such as rods or wires, undergo coiling into
compact coils immediately after exiting the rolling process. Here's a detailed
explanation of what typically happens in the Garret coiler area:
Process in the Garret Coiler Area

1. Feeding from the Rolling Mill:

o Hot-rolled products, which are typically long and at high temperatures
(ranging from 800°C to 1000°C), are fed into the Garret coiler area
directly from the rolling mill.

2. Coiling Mechanism:
o The Garret coiler consists of rotating mandrels or drums around which
the hot-rolled product is coiled.
o Mandrels: These are cylindrical or tapered spindles onto which the
product is wound. They rotate and move horizontally to ensure even and
uniform coiling of the product.
o Coiling Process: Hydraulic or mechanical actuators control the
movement and tension during the coiling process. This ensures that the
product is wound tightly and evenly around the mandrel, preventing
slippage and ensuring compact coil formation.

3. Cooling and Stabilization:

o As the hot-rolled product is coiled around the mandrel, it begins to cool
down. This controlled cooling process is essential to stabilize the
metallurgical properties of the steel.
o Cooling Zones: The Garret coiler area may include designated cooling
zones where the coiled product passes through to facilitate gradual heat
dissipation. This helps to prevent internal stresses and improve the
overall quality of the coil.

4. Tension Control:
o Tension control devices are employed to ensure that the coiling process
maintains the appropriate tension throughout. This prevents
overstretching or loosening of the coil, maintaining its integrity.

5. Coil Formation:
o The coiled product forms into compact coils of specified dimensions as
it is wound around the mandrel. The coils are tightly wound to ensure
they retain their shape and are easier to handle during subsequent
processing and transportation.
UH28:
Hydraulic Unit for Coil Dispatching. In a Coil Dispatching Area within a rolling mill
or steel processing facility, the primary focus is on securely packaging finished coils
of steel products for storage, transportation, and eventual delivery to customers.
Here’s a detailed overview of what typically happens in a coil packing area:

Process in the Coil Packing Area

The coil packing process typically involves the following steps:

1. Coil Positioning and Orientation:

o Coils are positioned on pallets or skids according to specified stacking
patterns.
o Proper orientation ensures stability and facilitates safe handling during loading
and unloading.

2. Packaging Materials Application:

o Coils are wrapped or strapped using various materials such as plastic film,
stretch wrap, or steel bands (strapping).
o These materials secure the coils, prevent movement, and protect them from
physical damage and environmental factors.

3. Labelling and Documentation:

o Each wrapped coil is labelled with essential information such as coil
identification number, dimensions, weight, material grade, and customer
details.
o Documentation includes packing lists and shipping documents to accompany
the coils during transportation.

4. Quality Control Checks:

o Random or systematic checks ensure that each coil is properly packed,
labelled, and meets quality standards before leaving the packing area.
o Visual inspections verify the integrity of packaging materials and the overall
condition of the coils.

Now we have discussed about all the hydraulic equipment in SBM. Now let us discuss about
Lubrication, Different types of Lubrication and Lubrication Machinaries.

LUBRICATION SYSTEM
The Lubrication system is considered to give a flow to the clean oil at the accurate
temperature, with a appropriate pressure to each part of the engine. The oil is sucked out into
the pump from the sump, as a heart of the system, than forced between the oil filter and
pressure is fed to the main bearings and also to the oil pressure gauge. The oil passes through
the main bearings feed- holes into the drilled passages which is in the crankshaft and on to
the bearings of the connecting rod. The bearings of the piston-pin and cylinder walls get
lubricated oil which dispersed by the rotating crankshaft. By the lower ring in the piston the
excess being scraped. Each camshaft bearing is fed by the main supply passage from a branch
or tributary. And there is another branch which supplies the gears or timing chain on the drive
of camshaft. The oil which is excesses then drains back to the sump, where the heat is being
transferred to the surrounding air.

LUBRICATION SYSTEMS IN SBM

Oil and grease lubrication systems as required for the equipment for SBM including furnaces
covered under this specification, will be provided. Each oil lubrication and grease lubrication
system will be complete with all equipment, electrics, pipework, instrumentation and controls
as required and as specified in this specification as well as in VSP's General Specification for
Lubrication Systems. The quantity and quality requirements of each type of lubricant
indicated. The lubrication systems provided will ensure that all components such as bearings,
gears, moving parts etc served by the systems, will operate safely below their maximum
allowable operating temperatures and without excessive wear.
There are three type of Lubrications Systems in Special Bar mill, Namely
 Oil Lubrication System.
 Grease Lubrication System.
 Air Oil Lubrication System.

OIL LUBRICATION SYSTEM

Oil lubrication is a method of reducing friction and wear between moving parts by
applying a continuous film of oil. This lubricant forms a barrier between surfaces,
reducing heat generation and preventing metal-to-metal contact, thereby extending the
lifespan and improving the efficiency of machinery and equipment in various industrial
applications.

Oil lubrication in mills, particularly in the context of size reduction, beneficiation, and
mineral processing (SBM) applications, is essential for ensuring the smooth and
efficient operation of heavy machinery. This machinery includes crushers, mills, and
conveyors, which are subjected to intense pressures and high loads during the
grinding, crushing, and milling of raw materials. Oil lubrication plays a crucial role in
reducing friction between moving parts, which minimizes wear and tear on
components. By creating a thin film between metal surfaces, oil helps to maintain
smooth operation, reducing the risk of mechanical failures and extending the lifespan
of the equipment.

Another significant benefit of oil lubrication in SBM applications is its effectiveness

in dissipating heat generated from friction and heavy loads. As machinery operates
under high-stress conditions, significant amounts of heat are produced. Oil, with its
excellent thermal conductivity, helps to absorb and transfer this heat away from
critical components, preventing overheating and thermal damage. This temperature
regulation is vital for maintaining optimal performance and ensuring the longevity of
the equipment.

Oil lubrication also excels in the removal of contaminants, such as metal particles and
debris, which can accumulate during the milling process. The flow of oil through the
machinery carries these contaminants away from critical components, helping to keep
the equipment clean and reducing the risk of damage. Additionally, oil can reach tight
spaces and intricate components, ensuring comprehensive lubrication coverage. This
is particularly beneficial in complex machinery with numerous moving parts, where
ensuring adequate lubrication can be challenging.

Various types of oil are used in SBM applications, each selected based on specific
operational requirements. Mineral oils are commonly used due to their cost-
effectiveness and good lubrication properties. They are suitable for a wide range of
temperatures and conditions. Synthetic oils, on the other hand, offer superior
performance, particularly in extreme temperatures and high-load conditions. They
provide better oxidation stability, longer service life, and improved protection against
wear. Specialty oils, such as high-viscosity oils, gear oils, and hydraulic oils, are
formulated to meet specific needs and provide enhanced protection and performance
in particular machinery and operating conditions.

Oil lubrication systems will include tank with clean-out doors, inspection doors,
sloping bottom, baffle plates, tank strainer with magnets, air breathers with silica gel,
pouring strainer, level gauge, level switches (high-level, low-level, low-low-level),
drain valve in each compartment, thermometers, thermostats, floating suction,
sampling cocks, tank heaters, triple screw pumps (including standby pumps), duplex
filters (one working, one standby) with magnets, plate type heat exchangers, pressure
tank for supplying oil to the gear box/bearing during emergency, necessary valves and
instruments within the system as well as near the gear boxes/bearings, interconnecting
piping within the oil lubrication system units as well as interconnecting piping
between oil lubrication systems and lubrication points (gear boxes/bearings), electric
motors and control panel. The level gauge and level switches will be of non-contact
type.
All oil lubrication systems will be started from MCCs/local control panel of the
respective oil lubrication system. Remote control will also be provided in the control
pulpits/desks.
SBM consists of many Oil Lubrication Machines. Some of them are:

 UL 1
 UL 2
 UL 25
 UL 26
  UL 27
 UL 50

GREASE LUBRICATION SYSTEM

Grease lubrication in mills is a crucial aspect of maintaining the operational efficiency

and longevity of heavy machinery used in industries such as mining, metalworking,
and cement production. The primary function of grease lubrication is to reduce
friction between moving parts, which minimizes wear and tear on components. This is
especially important in mills, where machinery operates under heavy loads and high
pressures. By reducing friction, grease helps in maintaining smooth operation, which
is essential for the productivity and reliability of the mill.

In addition to reducing friction, grease lubrication plays a vital role in heat dissipation.
The constant movement of machinery parts generates significant amounts of heat,
which, if not properly managed, can lead to overheating and potential failure of
components. Grease helps to absorb and dissipate this heat, thereby maintaining an
optimal operating temperature for the machinery. This is critical in preventing damage
and ensuring continuous operation without unexpected breakdowns.

Grease lubrication offers several advantages over oil lubrication, particularly in

industrial applications like those found in mills. Here are some of the key advantages:

1. Longer Lubrication Intervals

Grease tends to stay in place longer than oil, providing a more sustained lubrication
effect. This means less frequent application is required, which can reduce maintenance
downtime and labor costs.

2. Enhanced Seal Protection

Grease has a thicker consistency compared to oil, which allows it to form a better seal
around components. This helps keep out contaminants such as dirt, dust, and water,
which can cause wear and corrosion. This is particularly beneficial in harsh
environments where mills often operate.

3. Better Adhesion

Grease adheres better to surfaces than oil, especially in vertical or inclined positions,
and is less likely to drip or leak away from the lubrication points. This ensures
consistent lubrication over time, even in conditions where oil might flow away due to
gravity or centrifugal force.

4. Reduced Leakage
Due to its semi-solid state, grease is less prone to leaking compared to oil. This can be
especially important in applications where leakage could contaminate the product
being processed or pose environmental hazards.

5. Shock Load Absorption

Grease can cushion and absorb shock loads better than oil, providing an additional
layer of protection for machinery operating under high stress or sudden impacts. This
helps in reducing the wear and tear on bearings and other critical components.

6. Simplified Maintenance

Using grease simplifies maintenance procedures. It is easier to apply in many

situations, especially where centralized lubrication systems are used. Additionally, the
need for complex sealing systems to prevent oil leaks is reduced.

7. Enhanced Stability

Grease tends to be more stable than oil under a wide range of temperatures and
conditions. It is less likely to evaporate, degrade, or oxidize, making it suitable for use
in high-temperature or high-pressure environments common in industrial mills.

8. Noise Reduction

Grease can provide better noise-dampening properties than oil, which can be
particularly beneficial in applications where noise reduction is desired. The thicker
consistency of grease helps to dampen vibrations and reduce the noise generated by
moving parts.

9. Versatility in Application

Grease can be used in a wide variety of applications and machinery, from bearings and
gears to chains and couplings. Its versatility makes it a convenient and practical choice
for many different lubrication needs within industrial settings.

10. Lower Risk of Contamination

With grease, there is a lower risk of contaminating the product or process being
carried out in the mill, which is particularly important in food processing and
pharmaceutical industries. Oil, being more fluid, has a higher risk of contaminating
the end product.

How are Grease Lubrication Systems used in SBM?

Centralised grease lubrication systems are provided for the lubrication of equipment
of SBM. The grease lubrication systems with all equipment, including electrics,
pipework, instrumentation and controls are as per VSP's General Specification for
Lubrication Systems. Separate grease lubrication systems are included for the
lubrication points in hot zone and cold zone.

The grease lubrication systems are dual-line automatic systems. Each system includes
electrical motor-driven pumps with standby pumps, grease reservoirs with a capacity
of 100 kg, check valves, relief valves, pressure gauges, and pressure switches on the
downstream side of each pump. Line filters rated at 250 microns, line changeover
valves, isolation valves with limit switches on the discharge line and tank return line
between each pump and line changeover valve for positive pump selection, dual-line
metering feeders, end-of-line pressure switches with pressure gauges, and an electrical
control cabinet are also provided.

Additionally, the systems feature a pneumatically operated grease filling pump. They
are equipped with necessary line filters (250 microns) and solenoid-operated valves on
the filling lines from the grease filling pump to the reservoirs of the main pumps. End-
of-line pressure switches and pressure gauges are strategically located for easy access
during maintenance activities without disrupting production. Metering feeders on mill
equipment are positioned at safe and accessible locations.

Each grease reservoir of the pumps includes a follower plate, tell-tale rod, limit
switches for high-level alarm and grease filling pump cut-off, as well as low-level
alarm and low-low-level alarm with main pump cut-off. The grease filling pumps
come complete with drum covers, pressure gauges, relief valves, and low-level limit
switches.

All interconnecting piping between the grease pumping station and lubrication points
via metering feeders, interconnecting piping between the grease filling pump and the
main grease pumping station, and interconnecting piping for dry air from TOP to the
grease filling pump comply with VSP's General Specification for Pipework.

The Grease Oil Lubrication Units present in SBM are:

 UG1
 UGF/C
 UG2
 UG3
 UG4
 UG5
 UG6
 UG7

AIR OIL LUBRICATION SYSTEM

Air-oil lubrication, also known as minimal quantity lubrication (MQL) or micro-

lubrication, is a method used to deliver lubricant to various types of machinery and
mechanical systems, especially in high-speed applications. This technique combines a
small quantity of oil with a stream of compressed air, creating an oil-air mist that
ensures precise and efficient lubrication. The primary goal is to minimize the amount
of lubricant used while maximizing its effectiveness, leading to several operational
and environmental benefits.

Principles of Air-Oil Lubrication

In air-oil lubrication systems, a controlled amount of oil is introduced into a

continuous stream of compressed air. The air acts as a carrier, transporting the oil to
the lubrication point. This mixture of air and oil is usually directed through specially
designed nozzles or injectors, ensuring a fine dispersion of oil particles. The oil film
formed on the moving parts reduces friction and wear, providing a cooling effect and
removing contaminants from the contact surfaces.

Advantages of Air-Oil Lubrication Over Grease and Oil Lubrication

Reduced Lubricant Consumption:

One of the most significant advantages of air-oil lubrication is its ability to use
minimal quantities of lubricant. Traditional oil lubrication often requires a continuous
supply of oil, leading to higher consumption and more frequent maintenance. Grease
lubrication, while requiring less frequent reapplication, can still result in over-
lubrication and wastage. Air-oil systems precisely control the amount of oil delivered,
significantly reducing lubricant consumption and associated costs. This efficiency not
only saves money but also minimizes the environmental impact of excess lubricant
disposal.

Enhanced Cooling Capability:

Air-oil lubrication provides superior cooling compared to grease and traditional oil
lubrication. The stream of compressed air used in air-oil systems helps dissipate heat
generated by high-speed or heavily loaded components. This cooling effect is
particularly beneficial in high-speed applications such as spindles, bearings, and
turbines, where excessive heat can lead to premature failure. Grease, due to its higher
viscosity, tends to trap heat, while conventional oil lubrication lacks the air flow
needed for effective cooling.

Cleaner Operation and Reduced Contamination:

Air-oil lubrication systems contribute to cleaner operating environments. Grease can

easily attract dust and debris, leading to contamination and potential damage to
machinery. Excess oil from traditional lubrication methods can drip and spread,
creating messy work areas and increasing the risk of slipping hazards. In contrast, air-
oil systems deliver lubricant precisely where it is needed, minimizing overspray and
contamination. The fine oil mist adheres to the target surfaces without creating excess
buildup, resulting in cleaner machinery and workspaces.

Improved Lubrication Precision:

The precision offered by air-oil lubrication systems is unmatched by grease and

traditional oil lubrication. The ability to control the amount and location of lubricant
ensures that only the necessary areas receive lubrication. This targeted approach
reduces waste and ensures that all critical components are adequately lubricated.
Grease, on the other hand, can be difficult to apply evenly, leading to areas of over-
lubrication and under-lubrication. Traditional oil systems often struggle with
precision, especially in complex machinery with multiple lubrication points.

Reduced Friction and Wear:

Air-oil lubrication provides a continuous supply of fresh oil to the lubrication points,
ensuring a consistent and thin film that reduces friction and wear. Grease, due to its
thicker consistency, can sometimes fail to penetrate tight clearances, leading to
inadequate lubrication. Traditional oil systems can suffer from oil starvation in certain
areas, especially during startup or high-speed operations. The constant renewal of the
oil film in air-oil systems maintains optimal lubrication conditions, extending the life
of bearings, gears, and other components.

Enhanced Machinery Performance:

Machinery lubricated with air-oil systems often exhibits improved performance and
reliability. The combination of reduced friction, effective cooling, and precise
lubrication contributes to smoother operation and higher efficiency. Grease-lubricated
systems can experience increased resistance and slower operation due to the thicker
consistency of the lubricant. Traditional oil-lubricated systems may face issues with
oil degradation and contamination over time, leading to decreased performance. Air-
oil lubrication helps maintain peak operating conditions, enhancing overall machinery
performance.

Air-oil lubrication system will be provided with tank with accessories like air
breathers with silica gel, pouring strainer, level gauge, level switches (high level, low
level and low-low level), thermometers (two Nos.), drain valve in each compartment,
pumps (including stand-by pump), duplex oil filters with electrical switch for filter
clogging indication, progressive oil distributors, progressive oil- air distributors, air
line connection with isolation valve, filter, regulator with pressure gauge, solenoid
valve, pressure gauge & pressure switch on oil & air lines, junction box,
interconnecting stainless steel piping between each air-oil system & lubrication points
and control panel. Necessary flow switches (thermal dispersion type) will be provided
for each equipment for low flow alarm. The level gauge and level switches will be of
non-contact type. Each air-oil lubrication system will be provided with a filling pump
for transferring oil from barrels to the tank of the respective air-oil system.
Some of the Air Oil Lubrication Units present in SBM are:

 CL1
 CL2
Learnings and Conclusions:
After completing an internship focused on studying hydraulics and lubrication in the
SBM (Special Bar Mill) department at RINL steel plant, several valuable learnings
and conclusions have emerged. The internship provided a practical application of
theoretical knowledge gained from academic studies, offering insights into how
hydraulic principles and lubrication techniques are implemented in real-world
industrial settings, particularly within the complex processes of steel production. This
experience bridged the gap between classroom learning and hands-on application,
showcasing the importance of understanding hydraulic systems' components,
functions, and their critical role in operational efficiency.

One of the key takeaways was the opportunity to engage directly with intricate
hydraulic systems and lubrication methodologies used in SBM operations. Through
practical training and exposure, I gained a deeper understanding of maintenance
practices, troubleshooting techniques, and the importance of preventive measures to
ensure the smooth functioning of these critical systems. This hands-on experience not
only enhanced technical skills but also underscored the significance of adherence to
safety protocols and operational standards in an industrial environment like RINL.

Furthermore, the internship highlighted the collaborative nature of industrial work,

emphasizing teamwork among engineers, technicians, and other professionals to
address challenges such as system failures, leaks, and performance optimization. It
provided insights into industry-specific standards, regulations, and best practices
governing hydraulic and lubrication systems in steel manufacturing. This exposure not
only fostered professional development but also illuminated potential career pathways
in mechanical engineering or specialized fields within industrial maintenance and
lubrication engineering.

In conclusion, the internship at RINL's SBM department was instrumental in

expanding my knowledge base, refining practical skills, and understanding the broader
implications of hydraulic and lubrication systems in industrial settings. It offered
valuable insights into operational dynamics, safety considerations, and the critical role
of efficient maintenance practices. Moving forward, these experiences will
undoubtedly inform my career aspirations and contribute to my ongoing pursuit of
excellence in mechanical engineering and industrial applications.