STEEL AUTHORITY OF INDIA LIMITED

(A MAHARATHNA COMPANY)

SALEM STEEL PLANT

Summer Internship Report

DEPARTMENT OF MECHANICAL ENGINEERING

Government College of Engineering,

Salem – 636011.

Submitted by,
ANAND M 1851003
ARUNKUMAR S 1851006
RAGUL V 1851076

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 TABLE OF CONTENTS

S. No INDEX Page No.

1 ABSTRACT 3
2 INTRODUCTION 4
3 FEATURES OF SALEM STEEL PLANT 7
4 PROCESS INVOLVED 8
5 STEEL MELTING SHOP 9
Electric Arc Furnace 9
Moulding and Casting 9
6 HOT ROLLING MILL 10
Slab yard 10
Reheating furnace 11
De-scalar 11
Roughing mill 11
Steckel mill 12
Laminar cooling 12
Down coiler 13
Coil yard 13
7 COLD ROLLING MILL 14
Bell Annealing furnace 14
Coil Buildup line 14
Sendzimir mill 14
Annealing 15
Pickling 15
Skin pass mill 16
Shearing and Slitting 16
8 PUMP HOUSE 17
9 COMPRESSOR HOUSE 18
10 BOILER HOUSE 20
11 CONCLUSION 21

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 ABSTRACT

It’s a great honour and privilege to be a part of SAIL (Steel authority of India
limited) a Maharathna company, which holds our nation’s economy rate. Being
a part, is likely to feel, to achieve something new and make our nation proud.
Really grateful for his opportunity and had learnt a lot of things in Salem steel
plant. The Consumer satisfaction also places a vital role. Sail is consistently
making the customer to be happy to the core, by providing the quality products
Hot Rolling Mill (HRM) and Cold Rolling Mill (CRM) are the core process for
iron making. The robust equipment handled here, is periodically verified by
undergoing the preventive and predictive maintenance. In order to study the
process that takes place inside the steel plant industry. We selected to do
internship in Salem Steel Plant (SSP), and we successfully completed our
internship on HRM, CRM, and process taking place inside those mills. The
process that we understood have been submitted as the report. Hereby, we thank
the Human Resources Department (HRD) of SSP who gave this wonderful
opportunity to learn something new, which will be more useful to my future.

ANAND M 1851003
ARUNKUMAR S 1851006
RAGUL V 1851076

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 INTRODUCTION
A state-owned enterprise in India is called a Public Sector Undertaking (PSU)
or a Public Sector Enterprise. These companies are wholly or partly owned by
the Government of India or one of the many state or territorial governments or
both together in parts. The officers working in these entities are gazetted
officers. The company stock is majority-owned by the government in a PSU.
PSUs are classified as central public sector enterprises (CPSUs, CPSEs) which
are wholly or partly owned by Government of India or state level public
enterprises (SLPEs) which are partly owned by state or territorial governments.

There are three types of government companies,

a) Maharatna companies (profit > 25000 crores)

b) Navaratna companies (profit 10000 – 25000 crores)
c) Miniratna companies (profit < 10000 crores)

There are 10 Maharatnas, 14 Navratnas, and 73 Miniratnas. There are nearly

300 CPSEs (central public sector enterprises) in total.

MAHARATHNA COMPANIES

1. Indian Oil Corporation Limited

2. Bharat Petroleum Corporation Limited
3. Hindustan Petroleum Corporation Limited
4. Oil and Natural Gas Corporation Limited
5. Coal India Limited
6. NTPC Limited
7. GAIL (India) Limited
8. Steel Authority India Limited
9. Power Grid Corporation of India Limited
10.Bharat Heavy Electrical Limited

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Steel Authority of India Limited (SAIL) is an Indian government owned steel
manufacturing enterprise based in New Delhi, India. It is owned and operated
by the Ministry of Steel, Government of India with an annual turnover of INR
66,267 Crore for fiscal year 2018 – 19. Incorporated on 24 January 1973, SAIL
has 65,807 employees (as of 01-Mar-2021). With an annual production of 16.30
million metric tons, SAIL is the 20th largest steel producer in the world and the
largest in India. The Hot Metal production capacity of the company will further
increase and is expected to reach a level of 50 million tonnes per annum by
2025. Smt. Soma Mondal is the current Chairman of SAIL.

Steel Authority India Limited operates and owns five integrated steel plants
at Bhilai, Rourkela, Durgapur, Bokaro and Burnpur (Asansol) and three special
steel plants at Salem, Durgapur and Bhadravathi. It also owns a Ferro
Alloy plant at Chandrapur. As a part of its global ambition, the company is
undergoing a massive expansion and modernisation programme involving
upgrading and building new facilities with emphasis on state of the art green
technology. According to a recent survey, SAIL is one of India’s fastest
growing Public Sector Units. Besides, it has R&D centre for Iron & Steel
(RDCIS), centre for Engineering in Ranchi, Jharkhand.

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Native name Hindustan Steel Limited

Type Government of India Enterprise

Industry Steel

Founded 19 January 1954; 67 years ago

Headquarters New Delhi, India

Key people Soma Mondal, (Chairman)

Products Steel, flat steel products, long steel products, wire

products, Wheel & axle for Indian railways, plates

Revenue ₹62,569 crore (2020)

Operating income ₹6,594 crore (2020)

Net income ₹1,926 crore (2020)

Total assets ₹126,927 crore (2020)

Owner Government of India (64.9%)

Parent Ministry of Steel , Government of India

Subsidiaries NSPCL

Website www.sail.co.in

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 FEATURES OF SALEM STEEL PLANT
Salem Steel Plant (SSP), a unit of Steel Authority of India Limited (SAIL), is
a steel plant involved in the production of stainless steel. It is located along the
Salem — Bangalore NH 44 in the foothills of Kanjamalai in Salem
district, Tamil Nadu, India. The plant has an installed capacity of 70,000 tonnes
per annum in its cold rolling mill and 3,64,000 tonnes per annum in the hot
rolling mill. It also has the country’s first stainless steel blanking facility.

SSP supplies steel to BHEL-Trichy, HMT, Bharat Electronics Limited-

Bangalore and Indian Telephone Industries. Stainless steel is also exported to
over more than 37 countries including Spain, UK, Japan, Germany and
Switzerland. Between 1994–95, around 41,500 tonnes to as many as 27
countries

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 PROCESS INVOLVED

The major facilities at the plant include,

• Steel Melting Shop

• Cold Rolling Mill Complex
• Hot Rolling Mill Complex
• Stainless Steel Blanking Line

Salem Steel Plant specializes in the production of cold rolled stainless

steel in the form of coils and sheets. The raw materials are imported and also
supplied by Alloy Steel Plant in Durgapur. The steel melting shop’s annual
capacity is 1,80,000 tonnes of slabs per annum. The hot-rolling mill and cold-
rolling mill have capacities of 3,64,000 and 66,600 tonnes per annum
respectively.

Type Public Sector Undertakings in India

Industry Steel

Founded 13 September 1981; 39 years ago

Headquarters Salem, Tamil Nadu, India

• Hot-rolled stainless steel

Products
• Cold-rolled stainless steel
Owner SAIL

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 STEEL MELTING SHOP
It is the place where the metal from the scrap yard is intended to pass through
the furnace, maintained at high temperature of range (1680°C-1800°C), once it
liquified, later on moulding and casting are involved. The primary raw material
for the SMS is stainless steel, were bought from many sources. Initially the
metal from scrap yard is loaded to a truck by EOT (Electric overhead travelling
crane). The carbon steel slabs are bought from sail Billai and Rourkella.

Electric arc furnace is used, having working temperature about (1680 -1800°C).
On basis of the required grade, metal is melted at the ranging temperature. Once
it is liquified, it is poured in the mould cavity (cuboid shaped cavity is used in
Salem steel plant) for moulding, latter on casting.

It is allowed to the air cooling (72 hours) for the toughness to be attained, for
the further process.

ELECTRIC ARC FURNACE

An electric arc furnace (EAF) is a furnace that heats charged material by means
of an electric arc.

Industrial arc furnaces range in size from small units of approximately one ton
capacity (used in foundries for producing cast iron products) up to about 400ton
units used for secondary steelmaking. Arc furnaces used in research laboratories
and by dentists may have a capacity of only a few dozen grams. Industrial
electric arc furnace temperatures can reach 1,800 °C (3,300 °F), while
laboratory units can exceed 3,000 °C (5,400 °F).

MOULDING AND CASTING

Moulding: Moulding is the act of creating mould cavity.

Casting: Casting is the process of pouring the liquid metal into the cavity.

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 HOT ROLLING MILL
Hot rolling is a metalworking process in which metal is heated above the
recrystallization temperature to plastically deform it in the working or rolling
operation. This process is used to create shapes with the desired geometrical
dimensions and material properties while maintaining the same volume of
metal.

Hot rolling mill is a process of decreasing the slab thickness of range (140mm –
220mm) to minimum thickness of about (1.6 – 2mm). The two metals handled
here is stainless steel and carbon steel. HRM in Salem steel plant is inaugurated
in the year 1995. The process involved in HRM is,

• Reheating furnace
• De-scalar
• Roughing mill
• Steckel mill
• Laminar cooling
• Down coiler

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SLAB YARD
The slab from the sheet melting shop is allowed to slow cooling (air cooling) for
around 72 hours. Here both stainless steel and carbon steel slab are handled,

Capacity 25000Tonnes

Cranes used EOT (Electric overhead travelling crane) – 55 Ton

Semi - cantry crane – 25 Tonnes

REHEATING FURNACE
The slab from the slab yard is preheated in the induction furnace at the
recrystallization to change the microstructure for around 1 hour

Type LPG fired walking beam (Induction furnace)

Make Italimpianti

Capacity 55Tonnes/hr (Stainless steel)

70Tonnes/hr (Carbon steel)

Fuel LPG (37 Kg/Ton)

DE - SCALAR
This process is mainly carried out to remove the scales present in the surface of
the slab.

Medium Industrial water

Pressure 200 Bar pressure (204 kg/cm2)

Nozzle angle 15°

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ROUGHING MILL
The roughing mill is made up of six independent rolling mill stands, the last
four of which incorporate small vertical rolling mills called edger. Slabs heated
in the furnace until they glow bright orange-yellow are rolled through one stand
at a time to produce so-called transfer bars suitable for finish rolling.

Depending on the gauge, width, and grade of the product to be rolled, the
average temperature of the bar as it exits the last roughing mill normally ranges
from 1900 to 2100° Fahrenheit.

At constant volume and width, the roughing mill is used to decrease the
thickness from 220mm to 25mm with 4 Hi reversing rolling, the roller of having
diameter 1060mm is used. The slab is continuously fed into roller 4 times to
change its thickness.

Output 25mm thickness (Automation)

Mechanism Screw Down Mechanism

STECKEL MILL
A Steckel mill is similar to a reversing rolling mill except two coilers are used
to feed the material through the mill. One coiler is on the entrance side and the
other on the exit side. The coilers pull the material through the mill; therefore,
the process is more similar to drawing than rolling. The material is fed back and
forth through the mill until the desired thickness is reached, much like a
reversing rolling mill.

Hot rolling Steckel mill, mother unit for hot rolling mill.

The bar from the roughing mill passes to Steckel mill where the thickness is
reduced from 25mm tol.20mm. The entry and exit coiler furnace are to maintain
the temperature of coils.

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Hi reversing

Product: 2 -10mm (Automation) – Stainless Steel

1.6 -12mm (Automation) – Carbon Steel

LAMINAR COOLING
To reduce the size then it will be taken to speed the cooling process by water.
To obtain the optimal mechanical properties have inspection plates, such as
physical size, smooth Skin etc. Cooling the steels depends upon the type of the
steel, whereas Stainless steel means low amount of water is used compare to
Carbon steel.

Banks 24

Medium Industrial water

DOWNCOILER
After being blown dry strip is then passed into the coil winding machine (Down
coiler). Marking the weight, thickness, and roll with band and will have finished
rolling. Ready to send to clients.

Coil winding Hot coiling winding

COIL YARD
Finished winded coil is accumulated later on, if the metal is carbon steel, then
packed to consumers, if stainless steel then carried to CRM

Capacity 15000Tonnes

Crane Goliath Gantry crane – 2 Nos.

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 COLD ROLLING MILL

HOT ROLLING COIL

Hot rolling coil from the hot rolling mill is the raw material for the CRM
process, where only stainless-steel coil is handled

COIL BUILDUP LINE

It is the process of adding a small portion of metal in both head and tail end by
using TIG welding, to avoid metal loss in its both ends.

BELL ANNEALING FURNACE

The annealing process uses the application of heat in an annealing furnace or
oven to change a material’s strength and hardness, relieve internal stresses, and
provide increased ductility. Annealing improves the machinability and
mechanical or electrical properties of the treated material.

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ANNEALING
Annealing is a heat treatment process used mostly to increase the ductility and
reduce the hardness of a material. This change in hardness and ductility is a
result of the reduction of dislocations in the crystal structure of the material
being annealed

SHOT BLASTING
Manufactured metal parts aren’t ready for use right out of the mould. They often
need a coat of paint, powder coating, or welding work. But before this can
happen, the surface of the metal part must be clean.

Shot blasting prepares metal parts for further processing like painting or powder
coating. This step is necessary to ensure the coat adheres properly to the part.
Shot blasting can clean off contaminants like dirt or oil, remove metal oxides
like rust or mill scale, or deburr the surface to make it smooth.

PICKLING
Pickling is a metal surface treatment used to remove impurities, such as stains,
inorganic contaminants, rust or scale from ferrous metals, copper, precious
metals and aluminium alloys. Metal surfaces can contain impurities that may
affect usage of the product or further processing like plating with metal or
painting. Various chemical solutions are usually used to clean these impurities.
Strong acids, such as hydrochloric acid and sulfuric acid are common, but
different applications use various other acids.

SENDZIMIR MILL
A Z-Mill (Sendzimir) Mill is a machine for rolling steel. Unlike a traditional
rolling mill this 20-high cluster mill configuration utilizes cascaded supporting
rolls to apply force on the small work rolls in the centre. This allows the

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application of a higher roll pressure without bending the work rolls, would
result in poor metal quality. Thus, very hard and elastic materials can be rolled.

SKIN PASS MILL

Skin-pass rolling (or temper rolling) is usually the final forming step in the
production of cold-rolled steel sheets, following the annealing process. In this
process, mechanical properties, strip flatness, the surface roughness profile and
other product properties are determined so as to satisfy customer requirements
by rolling with small reduction.

The conditions in skin-pass rolling are unique as a sheet rolling process due to
the small reduction (approximately 1%), large contact length relative to the
change in sheet thickness, large roll radius relative to the contact length and
high friction.

SHEARING LINE
Shearing, also known as die cutting, is a process which cuts stock without the
formation of chips or the use of burning or melting. Strictly speaking, if the
cutting blades are straight the process is called shearing; if the cutting blades are
curved then they are shearing-type operations.

SLITING LINE
Before metal is cut to a specific weight or width, it comes in the form of a
massive coil weighing thousands and sometimes even tens of thousands of
pounds. These coils are then processed by a machine known as a slitting line.
The function of the slitting line is to break down these coils into smaller pieces
based on the customers’ needs. Once the coils are uncoiled, they are then cut to
the specifications need; they are then recoiled and shipped off to be used by the
client.

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 RECYCLE PUMP HOUSE
This is the heart of the steel plant; water is circulated to every process where it
is needed. For instance, primary de-scalar, laminar cooling in HRM requires
industrial water for the scale removal, and Annealing pickling line in CRM,
water is mandatory.

SPECIFICATION

Liquid handled Industrial water

Inlet 9 kg/m2

Outlet 12 kg/m2

COOLING WATER SYSTEM

The industrial water from the HRM and CRM are finally fed into the cooling
tower, to be cooled.

SPECIFICATION

Cooling Tower FORCED DRAFT

No. of Blades in Fan 8 BLADES

PIPELINES:
Oxygen (O), Nitrogen (N), Argon (Ar) => Diameter Ratio – 3:2:1

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 COMPRESSOR HOUSE
The compressor house in SAIL has both the types of compressor i.e.

• Reciprocating compressor
• Centrifugal compressor

RECIPROCATING COMPRESSOR
PRINCIPLE

Boyle’s Law (Pressure is inversely proportional to the volume)

WORKING

The air is sucked from the ambient, then it compresses the air to the
pressure of about 7kg/cm2

SPECIFICATION

“2HA 4 TR”

SAIL using KG.Khosla make compressor,2 stage double acting balanced

opposed reciprocating air compressor

HA - series

Stage 2

Cylinder 4

Piston stroke 150RPM

Speed 750 RPM

Flow rate 33.43 m3/min

Flywheel speed 750 RPM

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Piston stroke 150 RPM

Motor speed 1440 RPM

CENTRIFUGAL COMPRESSOR
As we know that, for the diverging medium pressure increases by
lowering the velocity. The same principle is used in this case also.

Make Kirloskar Pneumatic

Capacity 3500 Nm3/hr

Working pressure 8 kg/m3

No of stages 3

Lubricating oil Servo press 100

Coolant Industrial water

Coolant pressure 3.5-5 kg/cm2

Coolant flow 40 m3/hr

Coolant temperature at outlet 10°C - 12°C

MAINTANENCE

• Preventive maintenance
• Predictive maintenance
• Breakdown maintenance
• Predictive replacement maintenance

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 BOILER HOUSE
SAIL use water tube boiler as their primary one

SPECIFICATION

Medium Soft Water

Fuel Husk

Flow rate of saturated steam is 12 Tonnes/hr

Heating furnace is about 942 m2.

Soft water is used in the boiler as it doesn’t contain calcium and magnesium
(calcium and magnesium main reason for scale formation), has a pH value of 8.

1 TON FUEL = 4 TONNES OF STEAM

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 CONCLUSION

For an Engineering student a learning combination of theory and practice is a

valuable asset which helps in understanding the core principles of business by
the way of first-hand experience. This internship training in Salem Steel Plant
has given me such a great experience about all the managerial functions, which
is going on in the company. It also helped me to understand the exact
mechanism of working of the various departments.

After completing this internship, I could be able to understand much more about
the Salem Steel Plant the MNC which is the most reputed name in the corporate
world. Salem Steel Plant known for its quality products.

This knowledge will help me well to establish myself in the corporate World.

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