REPORT ON

INDUSTRIAL INTERNSHIP (3182101)

Jindal SAW Ltd.

Submitted by

Solanki Dinesh A.
(190133121018)

INTERNSHIP INCHARGE
Prof. S. I. PATEL & Prof. H. H. JADAV
Asst. Prof. (Metallurgy)

In partial fulfilment for the semester 8 of

BACHELOR OF ENGINEERING
In
Metallurgy

Government Engineering College, Sec- 28, Gandhinagar

Gujarat Technological University, Ahmedabad
APRIL, 2022

i
VISION AND MISSION OF INDUSTRY

 Our Vision
 To be the most preferred and reliable provider of value in all our businesses.

 Core Values

 Integrity
 Conduct all business dealings along transparent lines.

 Respect for Individual

 Recognize individual's contribution in the growth and development of the Company.
Treat all Jindalites with respect and dignity.

 Meritocracy
 Foster an environment of excellence in performance.

 Dynamic Thinking
 Demonstrate a winner's attitude with a crystal clear focus to deliver sustained value for all
Stakeholders.

 Creativity & Innovation

 Encourage creative experimentation, embrace new ideas and institutionalize continuous
improvement in all aspects of business and performance.

 Social Responsibility
 Dedicate efforts to the social and environmental issues to enrich the quality of life of the
communities we serve.

ii
NBA VISION AND MISSION OF INSTITUTE

 VISION OF INSTITUTE
 To be a premier engineering institution imparting quality education for innovative
solutions relevant to society and environment.

 MISSION OF INSTITUTE
 To be develop human potential to its fullest extent so that intellectual and innovative
engineers can emerge in a wide range of professions.

 To advance knowledge and educate students in engineering and other areas of scholarship
that will best serve the nation and the world in future.

 To produce quality engineers, entrepreneurs and leader to meet the present and future
needs of society as well as environment.

NBA VISION AND MISSION OF DEPARTMENT

a) VISION OF DEPARTMENT
 Developing excellence in metallography engineering education through research,
development innovation and team work for the benefit of society & environment.

b) MISSION OF DEPARTMENT
 To prepare competent metallurgy engineers who can apply metallurgical fundamental to
control and manage different metallurgical & materials processing operation to produce
quality metal products in industries.

 To deliver information about current trends in the field of metallurgy & material to the
student.

 To encourage students to work on innovative projects related to metallurgy engineering

for managing defects free economic energy efficient products processes or devices to best
serve the nation to fulfill the socioeconomic, techno-commercial & Environmental needs.

iii
ACKNOWLEDGEMENT

First I would like to thank Mr. Vinay Kumar, HR, Head, of Jindal Saw Ltd. Samaghogha,
Mundra, Kutch, (GJ) for giving me the opportunity to do an internship within the
organization.

I also would like to thank all the people that worked along with me in Jindal Saw Ltd. with
their patience and openness they created an enjoyable working environment.

It is indeed with a great sense and pleasure and immense of sense gratitude that I
acknowledge the help of these individuals.

I would like to thank my Head of the Department Dr. I.B. Dave for his constructive criticism
throughout my internship. I would like to thank Dr. Minal Dani, College internship
coordinator Department of Metallurgy for their support and advices to get and complete
internship in above said organization.

I am extremely grateful to my department staff members and friends who helped me in

successful completion of this internship.

I would also very thankful to my guide Mr. Keyur Chaudhary for help and guidance
throughout the internship.

iv
About Summer Internship
Internship are often viewed negatively by recent graduates due to negative stereotyping about
interns- namely the belief that interns don’t do anything except make coffee and photocopies.
While the tasks assigned to an intern may not be the most challenging or interesting,
internships can provide value beyond the actual tasks an intern is assigned.

Because some internship doesn’t provide compensation, many people discount them as an
activity not worth their time. The truth is the value they provide is often worth more than the
pay that you could get from a part-time summer job unrelated to your field of interest. Since
they offer multiple ways to enhance skills in a specific job function, internships are a great
way for graduates to break into a new career. Unlike working in an unrelated job for the
summer, an internship will give you an opportunity to gain real working experience, and
possibly get hired by the company with which you’re interning.

Internships are not limited to college students. Anyone seeking a career change will find that
internships introduce them to a new career, help them to explore different skills, and prepare
them for new experiences.

Objectives of Internship
One of the main objectives of an internship is to expose you to a particular job and a
profession or industry. While you might have an idea about what a job is like, you won’t
know until you actually perform it if it’s what you thought it was, if you have the training and
skills to do it and if it’s something you like.

An internship provides a variety of benefits for young workers who want to broaden their
chances for landing a job and jump-starting their careers. Internships give you a taste of what
a profession is like, help you build your resume and let you meet people who can help you in
your career. Don’t be passive during an internship and miss opportunities to expand your
business background. Take advantage of the many benefits of holding an internship.

v
Role of Metallurgist
As a metallurgist you’ll be concerned with the extraction and processing of various metals
and alloys. You’ll investigate and examine the performance of metals such as iron, steel
aluminium, nickel and copper and use them to produce a range of useful products ad material
with certain properties.

Responsibilities
As a chemical metallurgist, you'll need to:

 Design and control processes to separate metals from ore

 Monitor and test for corrosion
 Develop ways to improve metals by making them stronger or more adaptable
 Test metals to ensure they meet quality and safety standards.

In physical metallurgy, you'll need to:

 Assess the physical structure and behaviour of metals

 Investigate accidents where it is suspected that the cause may be related to metallurgical
failure, such as in air crashes
 Produce reports on research and tests carried out.

As a process metallurgist, you'll need to:

 Control the shaping of metals through casting, rolling, forging and drawing
 Join metals using welding and soldering techniques
 Design metal components and prototypes.

Across all of the specialist areas, you'll need to:

 Interpret and understand design drawings and make recommendations

 Make manufacturing time-critical decisions
 Monitor quality standards in manufacturing and finishing
 Take responsibility for health and safety issues of staff and components in manufacturing
 Carry out structural analysis using sophisticated computer software
 Write documents, manuals, metallurgical investigations, and reports in support of
customer liaison
 Discuss different solutions to problems with other technical staff
 Interpret customers' manufacturing design requirements and product application
 Install and commission processing equipment
 Research and develop test or repair technology and new products.

vi
List of Figures
Figure 1. Coke Oven 7
Figure 2. Sinter 8
Figure 3. Mould 26
Figure 4. Core 27
Figure 5. Annealing furnace 28
Figure 6. Annealing furnace pipes feeding 33

List of Table
Table 1. Design Parameter of B/F...........................................................................................6
Table 2. Operational Parameter of B/F..................................................................................6
Table 3. Raw Material for Sinter..........................................................................................10
Table 4. Required Chemistry of B/F.....................................................................................15
Table 5. Use of Materials Addition........................................................................................15
Table 6. Required Chemistry of Induction F/C...................................................................15
Table 7. Required Chemistry of Converter..........................................................................16
Table 8. Required Chemistry of Hopper..............................................................................16
Table 9. Annealing Temperature & Chain Speed................................................................17
Table 10. Various Pressures as per Size & Class.................................................................18
Table 11. Cement Mortar Lining..........................................................................................19
Table 12. Chemical composition of LDERA........................................................................29
Table 13. CCM Parameters of LDERA................................................................................29
Table 14. Annealing furnace zone temperature LDERA...................................................30
Table 15. % Contraction and % growth of LDERA...........................................................30
Table 16. Chemical composition of dimensionally accepted pipe......................................31
Table 17. CCM Parameter of dimensionally accepted pipe...............................................31
Table 18. Annealing furnace zone temperature...................................................................32
Table 19. %contraction and %growth of dimensionally accepted pipe............................32

List of Flow Chart

Flow Chart 1. Blast Furnace [1]..............................................................................................3
Flow Chart 2. Coke Making....................................................................................................7
Flow Chart 3. Sinter Making [3].............................................................................................9
Flow Chart 4. Ductile Iron Plant...........................................................................................13
Flow Chart 5. Pipe Manufacturing Process.........................................................................14
Flow Chart 6. Quality check Parameters.............................................................................21

Contents
VISION AND MISSION OF INDUSTRY................................................................................ii
 Our Vision.......................................................................................................................ii
 Core Values.....................................................................................................................ii
 Integrity...........................................................................................................................ii
vii
  Respect for Individual.....................................................................................................ii
 Meritocracy.....................................................................................................................ii
 Dynamic Thinking...........................................................................................................ii
 Creativity & Innovation..................................................................................................ii
 Social Responsibility.......................................................................................................ii
NBA VISION AND MISSION OF INSTITUTE.....................................................................iii
 VISION OF INSTITUTE...............................................................................................iii
 MISSION OF INSTITUTE............................................................................................iii
NBA VISION AND MISSION OF DEPARTMENT...............................................................iii
a) VISION OF DEPARTMENT........................................................................................iii
b) MISSION OF DEPARTMENT.....................................................................................iii
ACKNOWLEDGEMENT.........................................................................................................iv
About Summer Internship..........................................................................................................v
Objectives of Internship..............................................................................................................v
Role of Metallurgist...................................................................................................................vi
Responsibilities..........................................................................................................................vi
List of Figures..........................................................................................................................vii
List of Table.............................................................................................................................vii
List of Flow Chart....................................................................................................................vii
1. Introduction to Industry..........................................................................................................1
1.1 The Group.........................................................................................................................1
1.2 Jindal SAW Ltd................................................................................................................1
2. Introduction to Departments in Plant.....................................................................................3
2.1 Blast Furnace....................................................................................................................3
2.1.1 Different Sections of Blast Furnace..............................................................................4
a) Cast House.......................................................................................................................4
b) Stoves..............................................................................................................................4
c) Raw material storage & Charging Section......................................................................4
d) Pulverised coal Injection.................................................................................................4
e) Gas cleaning Plant (GCP)................................................................................................4
f) Slag Granulation Plant (SGP) / Slag Dumping Yard.......................................................4
g) Pig Casting Machine (PCM)...........................................................................................4
2.1.2 Blast furnace zones........................................................................................................5

viii
 2.1.3 Reactions in Blast furnace.............................................................................................5
2.1.4 Furnace Design & Operational Parameters...................................................................6
2.2 Coke Plant............................................................................................................................6
2.2.1 Role of Coke in Blast furnace........................................................................................7
2.3 Sintering...............................................................................................................................8
2.3.1 Sintering Process...........................................................................................................9
2.3.2 Quality of Sinter..........................................................................................................10
2.3.3 Advantages of Using Sinter in Blast furnace...............................................................10
2.4 Refractory...........................................................................................................................10
2.4.1 Applications.................................................................................................................10
2.4.2 Classification of refractory..........................................................................................11
2.5 Ductile Iron (DI) Pipe Plant...............................................................................................11
2.5.1 Ductile Iron..................................................................................................................12
2.5.2 History of Ductile Iron Pipe........................................................................................12
2.5.3 Blast Furnace Molten Metal........................................................................................15
2.5.4 Induction Furnace........................................................................................................15
2.5.5 Converter Magnesium (Mg) Treatment.......................................................................16
2.5.6 Hopper.........................................................................................................................16
2.5.7 Centrifugal Casting Machine.......................................................................................17
2.5.8 Annealing Treatment....................................................................................................17
2.5.9 Zinc Coating................................................................................................................18
2.5.10 Grinding and Socket Coating....................................................................................18
2.5.11 Hydrostatic Pressure Testing.....................................................................................18
2.5.12 Cement Mortar Lining...............................................................................................19
2.5.13 External Coating.........................................................................................................19
3. Quality Control.....................................................................................................................19
3.1 Quality checks................................................................................................................19
3.2 Stages of Manufacturing and Quality Checks................................................................20
4 Projects Assigned: Dimensional issues in ductile iron spun pipes in large diameter............23
4.1 Aim and Objectives:.......................................................................................................23
4.2 Introduction....................................................................................................................23
4.3 Factors affecting to dimensional issues..........................................................................23
I. Effect of alloying elements...............................................................................................23

ix
 1. Influence of normal base iron composition......................................................................24
2. Residual Magnesium.........................................................................................................24
3. Alloying elements.............................................................................................................25
Microstructural Analysis......................................................................................................25
II. Centrifugal Casting Machine............................................................................................26
a) Mould............................................................................................................................26
b) Core...............................................................................................................................27
c) Effect of mould powder.................................................................................................27
d) Effect of Innoculant.......................................................................................................27
III. HEAT TREATMENT....................................................................................................27
a) Annealing.......................................................................................................................27
b) Chain speed:...................................................................................................................28
c) Annealing furnace zone temperature.............................................................................28
4.4 Experiment procedure.....................................................................................................28
4.5 Result and Discussion......................................................................................................29
5. Recommendations:................................................................................................................33
6. References............................................................................................................................34

x
1. Introduction to Industry

1.1 The Group

The O. P. Jindal Group was founded in 1952 by Sh. O.P. Jindal, a first generation
entrepreneur who began an indigenous single-unit steel plant in Hisar, Haryana. The group
today enjoys global presence with manufacturing facilities across India, USA, Europe,
Middle East & Indonesia and mining concessions in Chile, Australia, Indonesia, South Africa
& Mozambique with marketing offices around the world. The group is a $15 billion
conglomerate with business interest spanning steel, pipes, mining, power, industrial gases,
and cement and seaport facilities. The group has further diversified into petroleum, diamond,
high value metals and mineral exploration.

Jindal SAW Limited was founded in the year 1984 by Mr. P.R. Jindal.

With an enviable track record of stability, trust, growth and performance for over 30 years,
Jindal SAW is now the undisputed leader in the pipe industry with manufacturing facilities in
India, UAE, Europe and USA. Jindal SAW manufactures Long Seam SAW Pipes, Helical
(spiral) Seam SAW Pipes, Anti-corrosion and Concrete Weight Coatings, Hot Induction
Bends, Connector Casings, Ductile Iron Pipes & Fittings, Seamless Tubes & Pipes. Jindal
SAW has further diversified into mining & pellets. Our customers include world's leading oil
& gas companies, government bodies heading irrigation & water resource and engineering &
construction companies which undertake large EPC contracts, transportation, power
generation and other industrial applications.

1.2 Jindal SAW Ltd.

Jindal SAW Ltd. is in a commanding position in India’s tubular market, being the undisputed
leader with a turnover in excess of Rs.7500 Crore.

Jindal SAW Ltd. is a part of the USD $ 18 billion O.P. Jindal Group, one of the country's top-
most industry houses and the foremost indigenous steel producers and exporters. It started
operation in the year 1984, when it became the first company in India to manufacture
Submerged Arc Welded (SAW) Pipes using the internationally acclaimed U-O-E technology.

With integrated facilities at multiple locations and an ever expanding market opportunity,
Jindal SAW Ltd. has diversified from a single product company to a multi-product company,
manufacturing large diameter submerged arc pipes and spiral pipes for the energy
transportation sector; carbon, alloy and stainless steel seamless pipes and tubes manufactured
by conical piercing process used for industrial applications; and Ductile iron (DI) pipes for
water and wastewater transportation. Besides these, the company also provides various value
added products like pipe coatings, bends and connector castings to its clients.

Over the years Jindal SAW has continued to gain the confidence and trust of its stakeholders
from employees, associates, shareholders and people whose lives have benefitted by the
company's endeavours.
1
With its vision of sustainable development firmly in place, Jindal SAW has played a leading
role in developing liveable cities across the world - that in turn has helped transform the lives
of people staying in them.

Ensuring timely transportation of oil, gas and water, Jindal SAW helps residents and
organizations in numerous cities function efficiently. The pipes produced by the company are
energy efficient, reduce dependence on fossil fuels, and help conserve natural resources like
water.

At the very core of Jindal SAW is imprinted the conviction of never being content with the
success attained and it is constantly striving for newer horizons. New boundaries, new
challenges and new opportunities keep the company driven to surge ahead. Venturing
forward into different areas of businesses with Jindal ITF, the infrastructure arm of Jindal
SAW, the company is making rapid progress in urban services sectors with: Water,
Wastewater and Solid Waste Management, Domestic Transport and Logistics, Transportation
Equipment Fabrication.

Having identified the immense potential offered by these sectors for the future, JITF has
diversified into five business verticals in these areas: JITF Eco polis, JITF Aqua source, JITF
Vector, JITF Shipyards, and Jindal Rail Infrastructure.

2
2. Introduction to Departments in Plant

2.1 Blast Furnace

In the Blast Furnaces (BF) liquid iron (Popularly termed as ‘Hot Metal’) is produced by the
process of reduction at high temperature from raw materials like iron ore, base mix, sinter,
coke, fluxes (limestone / quartzite), etc. &also air blast / O2. In blast furnace the process is
also known as “Counter current process” as solid raw material is being charged from the top
and hot air is being blown from bottom. During the process the impurities are removed in the
form of slag and hot metal is produced. Coal is being injected to reduce consumption of main
fuel coke which is a cost reduction measure.

Liquid metal and slag are being separated in the area known as cast house. The liquid Hot
Metal is transported in Hot Metal Ladles / Torpedoes to the Steel Melting Shops (SMS) for
the production of steel by the process of oxidation of the Hot Metal in specially designed
Convertors.

Sometimes the Hot Metal is poured in the Pig Casting Machine (PCM) to produce Pig Iron.
Slag produced is granulated by high pressure water jets in the Cast House itself or sent to
Slag Dumping in the Slag Pots. [1]

Flow Chart 1. Blast Furnace [1]

3
2.1.1 Different Sections of Blast Furnace

a) Cast House
 In the Cast House, Hot Metal & slag are tapped from the Furnace tap hole and after
flowing through a system of refractory lined troughs / runners flow into Hot Metal Ladles
/ Torpedoes & Slag Pots, placed on the iron & slag side respectively of the Furnace.

b) Stoves
 Stoves heat the air blast provided by Turbo Blowers to the Blast Furnaces through the
Tuyers.

c) Raw material storage & Charging Section

 In this there are designated bunkers for raw materials transported from mines / Sintering
Plant (SP) / Raw Materials Handling Plant (RMHP) / Coke Ovens (CO) by wagons /
conveyors.

d) Pulverised coal Injection

 In this section coal is pulverized to fine dust in mills and injected in the furnace.

e) Gas cleaning Plant (GCP)

 The blast furnace gas (BFG) generated in the BF is cleaned through a series of steps
before transporting it to the BFG Holder.

f) Slag Granulation Plant (SGP) / Slag Dumping Yard

 During the process of iron making, the impurities are fluxed and removed as slag. The hot
liquid slag is made into slag granules by means of high pressure water jets in the Slag
Granulation Plant in the Cast House itself (sometimes separate SGP is located at a
distance from the furnace proper). If the slag is not granulated in SGP, it is poured in the
Slag Dumping Yard.

g) Pig Casting Machine (PCM)

 Sometimes when there is poor off take of Hot Metal by SMS or if the Hot Metal
chemistry is very adverse, Hot Metal is taken to this section for casting into Pig Iron. [2]

4
2.1.2 Blast furnace zones
 Granular Zone
 Cohesive Zone
 Active coke Zone
 Stagnant coke Zone
 Tuyere Zone
 Hearth Zone

2.1.3 Reactions in Blast furnace

The main chemical reaction producing the molten iron is:

Fe2O3 + 3CO → 2Fe + 3CO2

This reaction might be divided into multiple steps, with the first being that preheated air
blown into the furnace reacts with the carbon in the form of coke to produce carbon
monoxide and heat:

2 C(s) + O2 (g) → 2 CO (g)

The hot carbon monoxide is the reducing agent for the iron ore and reacts with the iron
oxide to produce molten iron and carbon dioxide. Depending on the temperature in the
different parts of the furnace (warmest at the bottom) the iron is reduced in several steps. At
the top, where the temperature usually is in the range between 200 °C and 700 °C, the iron
oxide is partially reduced to iron(II,III) oxide, Fe3O4.

3 Fe2O3(s) + CO (g) → 2 Fe3O4(s) + CO2 (g)

At temperatures around 850 °C, further down in the furnace, the iron is reduced further to
iron oxide:

Fe3O4(s) + CO (g) → 3 FeO(s) + CO2 (g)

Hot carbon dioxide, unreacted carbon monoxide and nitrogen from the air pass up through
the furnace as fresh feed material travels down into the reaction zone. As the material travels
downward, the counter-current gases both preheat the feed charge and decompose the
limestone to calcium oxide and carbon dioxide:

CaCO3(s) → CaO(s) + CO2 (g)

The calcium oxide formed by decomposition reacts with various acidic impurities in the iron
(notably silica), to form a fayalitic slag which is essentially calcium silicate, CaSiO3

SiO2 + CaO → CaSiO3

As the iron oxide moves down to the area with higher temperatures, ranging up to 1200 °C
degrees, it is reduced further to iron metal:

5
FeO(s) + CO (g) → Fe(s) + CO2 (g)

The carbon dioxide formed in this process is re-reduced to carbon monoxide by the coke:

C(s) + CO2 (g) → 2 CO (g)

The temperature-dependent equilibrium controlling the gas atmosphere in the furnace is

called the Boudouard reaction:

2CO ⇌ CO2 + C

2.1.4 Furnace Design & Operational Parameters

Table 1. Design Parameter of B/F

Furnace BF-1 BF-2

Furnace Height(m) 28.70 26.5
Throat nDia(m) 3.6 3.4
Stack Height(m) 11.8 11
Parallel Bosh Dia(m) 5.9 5.3
Bosh Height(m) 2.7 2.7
Hearth Diameter(m) 4.7 4.2
Volume(m3) 350 262

Table 2. Operational Parameter of B/F

Operational Parameter BF-1 BF-2

Hot Blast volume(Nm3/hr) 48000 45000
Hot Blast Pressure(kg/cm2) 1.5 Max 1.5 Max
Hot Blast Temperature(°c) 1050 Max 1050 Max
Top Pressure(kg/cm2) 0.50 Max 0.50 Max
Top Temperature(°c) 100-250 100-250
Tuyers Velocity(m/s) 250 Max 250 Max
RAFT(°c) 2100-2250 2100-2250
Hot metal Production(MT/day) 750 700
Annual capacity (Million ton) 0.5 0.5

2.2 Coke Plant

Coke is manufactured by heating of the suitable coal blends in absence /controlled air inside
the refractory lined oven at temperature of 1150ºC to 1250ºC for about 45 to 50 hours coking
time. During the carbonization process all VM present in the coal burnt and produce heat.
The remnant solid mass after carbonization is called Coke, which is pushed out and quenched
with water, segregated in to various size fractions for end users.

6
 Flow Chart 2. Coke Making

Coal Blending Crushing Cake Preparation

Coke Quenching Hot Coke Coking

WHRB &
EXHAUST

Figure 1. Coke Oven

2.2.1 Role of Coke in Blast furnace

 To generate heat.
 To generate reducing gas.
 To support the ferrous burden

7
2.3 Sintering
Sinter plants agglomerate iron ore fines (dust) with other fine materials at high temperature,to
create a product that can be used in a blast furnace. The final product, a sinter, is a small,
irregular nodule of iron mixed with small amounts of other minerals. The process, called
sintering, causes the constituent materials to fuse to make a single porous mass with little
change in the chemical properties of the ingredients. The purposes of sinter are to be used
converting iron into steel.

Figure 2. Sinter

Material is put on a sinter machine in two layers. The bottom layer may vary in thickness
from 30 to 75 millimetres. The second, covering layer consists of mixed materials, making for
a total bed height of 350 to 660 millimetres. The mixed materials are applied with drum
feeders and roll feeders, which distributes the nodules in certain depth throughout the
sintering machine..

The material, also known as a charge, enters the ignition furnace into rows of multi-slit
burners. Air is sucked from the bottom of the bed of mixed material throughout the sintering
machine. Fire penetrates the mixed material gradually, until it reaches the hearth layer. This
end point of burning is called burn through point (BTP).

The hearth layer, which is nothing but sinter in smaller size, restricts sticking of hot sinter
with pallets. BTP is achieved in a certain zone of sinter machine, to optimize the process, by
means of several temperatures measuring instrument placed throughout the sinter machine.
After completion of burning, the mix converts into sinter, which then breaks into smaller size
by sinter breaker. After breaking into small sizes, it cools down in cooler (linear or circular)
by means of forced air.

8
At discharge of sinter cooler, temperature of sinter is maintained as low, so that the hot sinter
can be transported by a conveyor belt made of rubber. Necessary precautions are taken to
trace any existence of fire in the belt and necessary extinguishing is done by spraying water.
Then the complete mixture is being passed through two screens. Smallest sinter fines (< 5
mm) are stored in proportioning bins and reused for preparing sinter again through mixing
and nodulizing drum and fed to sinter machine for burning. A part of the smaller one (5 - 20
mm) is used for hearth layer in sinter machine and the rest is taken to the blast furnace along
with the biggest sized sinters. [3]

Flow Chart 3. Sinter Making [3]

2.3.1 Sintering Process

 During mining operation, crushing of ores to the optimum size will produce fairly large
portion assembly possibly 30 to 40% of 10mm mines which cannot be directly
chargedinto blast furnace.
 To utilize the plant waste
 Environment problem
 Space problem

9
 Table 3. Raw Material for Sinter

Iron Ore 0.6 to 0.8 Size (700 Kg)

BF Return Less than 5mm (135 Kg)
Mill Scale Fe 50 to 60% (0-3mm, 40 Kg)
Flue Dust 12 Kg
Coke Fines 3mm Size
Lime Stone +10mm Size (195 Kg)
Dolomite Mine 0 to 10mm (65 Kg)
Coke Breeze 84 Kg

2.3.2 Quality of Sinter

 Optimum grain distribution: 5-60mm with a mean size of around 18mm
 Higher sinter strength: More than 75%
 High reducibility index > 65%
 Reduction degradation index < 27%
 Constant FeO content range: 7 to 9%

2.3.3 Advantages of Using Sinter in Blast furnace

 Increased productivity In B/F
 Extra addition of fluxes is eliminated
 Reduced fuel rate in B/F

2.4 Refractory
 It is a Material that resistant to decomposition by heat, pressure or chemical attack and
retains strength and form at high temperature.
 These are polycrystalline, inorganic, non-metallic, porous and heterogeneous.
 They are typically composed of oxides or carbides of Si, Al, Mg and Ca & Zn.
 It must be chemically & physically stable at high temperature.

2.4.1 Applications
 Serving as a thermal barrier between a hot medium and the wall of a containing vessel.
 With standing physical erosion of vessel walls due to the hot medium.
 Protecting against corrosion
 Providing thermal insulation

10
2.4.2 Classification of refractory
 Acidic Refractory: Silica, Zirconia & Alumina silicate
 Basic Refractory: Magnesite, Dolomite, Magnesia-chrome
 Neutral Refractory: Carbon refractory, High Alumina

2.5 Ductile Iron (DI) Pipe Plant

Ductile Iron (DI) pipes' good mechanical properties, in addition to high durability and
strength, make them ideal for high-pressure applications. Ductile Iron pipes are used
extensively in systems transporting potable water, industrial water and irrigation water and
pressure sewerage. Metallic pipes, primarily Cast Iron had been used over two centuries for
water and wastewater transportation. Ductile Iron pipes which belong to the family of Cast
Iron have been developed by treating the molten low-sulphur base iron with magnesium
under closely controlled conditions. The startling change in the metal is characterized by the
free graphite in Ductile Iron being deposited in the spheroidal or nodular form, leading to
maximum continuity of metal matrix thereby forming a stronger and tougher ductile material
with high ductility and impact strength.

With protective linings and coatings like cement mortar, Bitumen, Epoxy and Polyurethane,
Ductile Iron pipes provide an exceptionally long life to serve the water and sanitation
networks.

The flexible and leak tight jointing systems in Ductile Iron pipes, which can be easily push
fitted (or mechanically joined) provides ease in transportation of pipes as well as laying
works. The pipeline and jointing system can withstand the vagaries of nature, thereby
ensuring sustainable and quality piping solutions to the customers.

Jindal SAW had commissioned its first Integrated Greenfield Project for Ductile Iron pipe
and Pig Iron unit at Samaghogha, Mundra, Gujarat, India in the year 2005, close to Mundra
and Kandla ports. This port based facility includes:

 Coke oven battery plant (installed capacity: 380,000 MT per annum)

 Blast furnace (installed capacity: 500,000 MT per annum)
 DI pipe manufacturing facility (installed capacity: 500,000 MT per annum)
Quality is the key mantra at Jindal SAW. Quality checks are carried out at every stage of the
manufacturing process to meet the requirements as per international standards.

'Nurture with Nature' is the guiding principle for Jindal SAW. To ensure eco-friendly and
sustainable growth, all the plants of Jindal SAW are equipped with advanced pollution
control units and ecology conservation systems. Ductile Iron pipes manufactured by the
company conform to both Indian and International Standards like IS8329, ISO: 2531, ISO
7186, BSEN 545 and BSEN 598.

11
2.5.1 Ductile Iron
DI is defined as a high carbon containing iron based alloy in which the graphite is present in
spherical shapes rather than the shape of flakes (Gary cast iron), sometimes it is also referred
as spheroidal cast iron (SG Iron) due to its Graphite shape.

Rounded nodules provide good ductility by inhibiting the stress concentration points around
the nodule graphite’s. But whereas grey cast iron shows lesser ductility than the SG iron due
to its flaky graphite.

Nodule form of the graphite particles are achieved by adding nodularizing element (Common
nodularizing element i.e. Magnesium).

2.5.2 History of Ductile Iron Pipe

Ductile iron pipe is a major improvement over the cast iron pipe. In the U.S., 19% of its total
water mains consist of ductile iron pipe. The first ductile iron pipe was produced
experimentally in 1948. Minor but significant changes in chemistries and processing resulted
in physical differences at the micro-structure level that resulted in a vastly improved fracture
toughness and ductility making ductile iron piping products substantially more resistant to
damage from impact or concentrated stresses. [4]

The manufacturing process used for ductile iron pipe is the “De-Lavaud” process which is
similar to the manufacturing of centrifugal cast grey iron pipe. Ductile iron pipe is a product
of advanced metallurgy which offers unique properties for conveying water under pressure
and other piping uses. It combines the physical strength of mild steel with the long life of
grey cast iron. Ductile iron pipe has a greater margin of safety against service failures due to
ground 14 movement and beam stresses. It provides increased resistance to breakage caused
by rough handling in shipping and installation. The corrosion resistance of ductile iron pipe
has been proven in a wide variety of accelerated tests to be at least the equal of cast iron pipe.

Ductile iron pipe is produced by adding a closely controlled amount of magnesium alloy to a
molten iron of low phosphorous and low sulphur content. Adding the magnesium alloy
results in a remarkable change in the microstructure by causing the carbon in the iron to
assume a spheroidal or nodular shape which is different than the flake form of graphite
observed in cast iron pipe. A finer grained iron matrix in the surrounding ferrite structure is
produced. As a result of this remarkable change in the properties, a stronger, tougher and
ductile material is obtained. [5]

Ductile iron pipe is stronger than cast iron pipe and is more resistant to corrosion. Ductile
iron pipe is not susceptible to “graphitic” corrosion unlike cast iron pipe, which is an
electrochemical reaction between the cathodic graphite component (flakes) and the anodic
iron matrix resulting in metal loss. It also has approximately twice the strength of cast iron
pipe. Its impact strength and elongation are also many times greater than cast iron pipe. [6]

12
 Flow Chart 4. Ductile Iron Plant

COKE OVEN 1 COKE OVEN 2 SINTER 1&2 RAW MATARIL

YARD

WHRPP 1 WHRPP 1
15MW (2×7.5MW) 15MW (1×15MW)

BLAST FURNACE SLAG GRINDING

DUCTILE IRON

LARGER DIA (DISP) SMALLER DIA (SDP-1) SMALLER DIA (SDP-2)

(DN 250-1200) (DN 80-300) (DN 80-300)

13
Flow Chart 5. Pipe Manufacturing Process

14
2.5.3 Blast Furnace Molten Metal
 Liquid molten metal is carried through MBF ladle by metro car.
 It possesses the following chemical composition.
 Liquid molten metal from Blast furnace contains high percentage of carbon.
Table 4. Required Chemistry of B/F

Element Specification
Carbon >3.8
Silicon 1.0-2.0
Manganese <0.8
Sulphur <0.02
Phosphorus <0.2
Chromium <0.1
Copper <0.2

2.5.4 Induction Furnace

 Chemistry of Blast furnace molten metal is corrected in Induction furnace using the
following raw materials.

Table 5. Use of Materials Addition

Raw material used Use of addition

MS Scrap To reduce the carbon content of molten metal
Ferro silicon lumps Granules To increase the silicon content of molten metal
Ferro Manganese To increase the Manganese content of molten metal
Calcined Petroleum Coke (CPC) To increase the carbon content of molten metal

 The raw material addition will be based on which element to be corrected as per internal
specification.
Table 6. Required Chemistry of Induction F/C

Element Specification
Carbon 3.7- 4.0
Silicon 1.7-2.3
Manganese <0.8
Sulphur <0.05
Phosphorus <0.14
Chromium <0.1
Copper <0.2
Lead <0.002
Antimony <0.006
Bismuth <0.015

15
2.5.5 Converter Magnesium (Mg) Treatment
 Liquid metal from induction furnace processed for Mg treatment.
 Mg ingot is added into the converter chamber.
 Converter is tilted to react with Mg ingot and liquid metal.
 In order to maintain residual Mg content, the following parameters will be considered
before adding Mg ingot.
 % S present in the liquid metal
 Temperature of the liquid metal
 After Magnesium treatment, Sample to be collected to ensure the residual Mg.
 The acceptance limit for % residual Mg will be in the range of 0.035-0.055%.

Table 7. Required Chemistry of Converter

Element Specification
Carbon 3.7-4.0
Silicon 1.7-2.3
Manganese <0.8
Sulphur <0.02
Phosphorus <0.14
Magnesium 0.035-0.055

2.5.6 Hopper
 Liquid metal from converter transferred to hopper through ladle.
 Every ladle will undergo de-slagging process.
 As boiling point of magnesium is 1901°C and the liquid metal temperature after Mg
treatment is in the range of 1370-1450 °C.
 Hence treated liquid metal poured into hopper as quick as possible to avoid Mg fading.
 Sample taken from last hopper to ensure residual %Magnesium.
 The acceptance limit for %residual Mg in last hopper not below 0.02%.
 The liquid metal temperature in the range of 1250-1380°C when pipe making process.

Table 8. Required Chemistry of Hopper

Element Specification
Carbon 3.7-4.0
Silicon 1.7-2.3
Manganese <0.8
Sulphur <0.02
Phosphorus <0.14
Magnesium >0.025

16
2.5.7 Centrifugal Casting Machine
 Pipes are produced of different diameters from respective mold size by using centrifugal
casting machine
 Based on size and class defined parameter as are maintained in centrifugal casting
machine like mold rpm.
 Mold powder used inside the mold before the pipe making to prevent thermal crack,
oxidation and improve the life of the mold.
 Innoculant powder added on stream of liquid metal during pipe making process to
improve the nodularity, promotes the ferrite structure, to stabilize the rare earth elements
and acts as a de-oxidizer.
 Innoculant will helps to achieve the nodule count by act as a nucleating site for graphite
particles.
 Mold outer surface in CCM surrounded by water, during pipe formation solidification
rate is high promotes more carbides and pearlite.
 After pipe formed inside the mold then the pipe is extracted from it and pipe will be feed
into the annealing furnace.

2.5.8 Annealing Treatment

Annealing is a heat treatment where in a material composition is altered, causing changes in
its properties such as strength and hardness. Annealing is used to induce ductility, soften
material, relieve internal stresses, refine the structure by making it homogeneous and
improve cold working properties. Annealing furnace is a horizontal chain style furnace made
up of heating section, heat holding section, slow cooling section and fast cooling section. The
Ductile Iron pipe, after entering the furnace, is pushed rolling forward by claws on chains
driven by a speed regulating motor.

Annealing furnace consists of 5 zones

1. Preheating zone
2. Heating zone
3. Soaking zone
4. Rapid cooling
5. Slow cooling zone
Table 9. Annealing Temperature & Chain Speed

Temperature
Zone Name
Minimum Nominal Maximum
Preheating zone-1 710 834 961
Heating zone-1 850 958 999
Heating zone-2 848 953 998
Soaking zone-1 845 943 988
Soaking zone-2 840 936 982
Cooling zone-1 620 731 769
Cooling zone-2 538 660 705

17
 Chain speed Minimum Nominal Maximum
(mm/minute) 752 950 1045

Annealing carried out to achieve the desired microstructure and mechanical properties

Microstructure

1. Nodularity ≥75%
2. Nodule count ≥150 no’s/mm2
3. Ferrite ≥75%
4. Pearlite ≤25%
5. Carbides ≤10%

2.5.9 Zinc Coating

 Zinc coating is carried out for good corrosion resistance.
 Zn coating is carried out by metallization process.
 The purity of the zinc wire is ≥ 99.99%
 To calculate the mass deposition of zinc on the pipe to be carried out by using Mylar
sheet (500mm × 50mm).
 Pipes will be coated to have average mass of zinc coating shall be not less than 130 g/m2
with a local minimum of 110 g/m2.

2.5.10 Grinding and Socket Coating

 Socket and barrel grinding will be done by three stages on the pipe.
 Lip grinding socket Go and NoGo gauges checked.
 Groove grinding.
 Barrel grinding.
 After grinding socket surface will be coated with zinc wire for corrosion resistance.

2.5.11 Hydrostatic Pressure Testing

 All pipes will be hydrostatically pressure tested to find the leakage of pipe.
 Test pressure shall be applied based on the diameter and class of the pipe.
 Testing pressure for various pipe diameters and classes as per IS 8329:2000, ISO
2531:1998, BSEN 545:2006
Table 10. Various Pressures as per Size & Class

Minimum Test Pressure(bar)

DN Class K7 Class K9 Class K9,K10,K12
80 to 300 32 40 50
350 to 600 25 32 40
700 to 1000 18 25 32
1000 to 1200 12 18 25

18
19
2.5.12 Cement Mortar Lining
 Pipe will be internally coated with cement mortar in the ratio of 1:1.6:0.5 (cement: sand:
water).
 4 major type of cement used for cement mortar linings.
1. OPC
2. SRC
3. HAC
4. BF slag cement
 Cement mortar lining thickness will be provided based on diameter of the pipe as per
IS8329.

Table 11. Cement Mortar Lining

Cement mortar lining thickness (mm)

DN
Nominal value Tolerance
80 to 300 3 -1.5
350 to 600 5 -2
700 to 1200 6 -2.5

 After lining the wet CML thickness will be verified.

 Cement lined pipes are feed in to cultivation furnace for curing.
 After curing dry CML thickness checked with the help of digital coat meter.

2.5.13 External Coating

 Pipes are externally coated with bitumen or epoxy paint to protect external surface.
 One number per size in each size at the starting of the shift for coating thickness.
 The thickness is checked indirectly on a token (at least 500×50mm) which is to be
attached on the pipe and is used after coating to measure the dry film thickness by digital
coating thickness gauge.

3. Quality Control
Quality Control (QC) is a collection of methods and techniques for ensuring that a product is
conforming to standards and is produced & delivered according to given requirements.

Quality is measured by the degree of conformance to pre-determined specifications and

standards and deviations from these standards can lead to poor quality and low reliability.
Efforts for quality improvement are aimed for elimination defects, reduction of rejection
and hence overall reductions in production costs.

3.1 Quality checks

Thorough Check of All Raw Materials for Compliance with Respective National and
International Standard Specifications.

1. Chemical Analysis

20
 Composition of molten metal Chemical analysis

2. Mechanical Test
 Tensile strength
 Elongation
 Hardness
 Microstructure

3. Dimensions
 Sample checking for socket dimensions
 Checking on external diameter
 Checking internal diameter
 Pipe thickness
 Length of pipes
 Ovality
 Straightness of pipes, chamfering of spigot end

4. Surface Defect Checks

 Pin holes
 Pitting
 Cut marks
 Surface netting/imperfection
 Excess mold powdering/undissolved mold powder

5. Casting Defects Checks

 Cold shots
 Lapping of metal surface

6. External Coating - Online Quality Checks

 Measurement of Zinc/Zinc Aluminum mass deposit on pipe surface
 Measurement of finishing layer (Bitumen/resin) thickness on pipe surface

7. Internal Lining - Online Quality Checks

 Checking of type of cement being used
 Checking of water cement and sand ratio
 Checking of cement-sand ratio
 Checking of wet CML thickness
 Checking for uniform holiday free seal coating over cement mortar lining (if seal coat
provided

3.2 Stages of Manufacturing and Quality Checks

Ductile Iron Pipes All the tests mentioned earlier are carried out at different stages of
production as shown in the following flow chart:

21
 Flow Chart 6. Quality check Parameters

Stages of Manufacturing Quality Checks

Raw Material Receipt/ Storage Analysis of Raw Material According to

Specification for Every Consignment

Mini Blast Furnace Operation Operational Parameters, Chemical

Analysis, Temperature
Liquid Metal Furnace
Chemical Analysis

Chemistry Adjustment and Super Heating in Induction Furnace

Temperature
and Chemical
Magnesium Treatment in Converter

Pipe Casting
Spinning Parameter; Temperature,
Core for Socket, Mold for Pipe,
Inoculation Powder/ Mold Powder
Magnesium

Heat Treatment (Annealing)

Physical Test, Microstructure
Addition by Weight

Zinc Coating

Zinc
Finishingand Continuity
Mass Deposit

Socket
Grove; Visual; Gauging; Spigot
Hydrostatic Pressure Testing 22 Pressure Rating, Body Leak and Sweat
Cement
Mortar Lining
Cement/ Sand/Water Ratio,
Thickness.

23
Steam Curing
Temperature, Humidity, Visual and
Gauging

Bitumen Coating
Thickness and Continuity

Marking As Per Specification and Client

Requirement

24
4 Projects Assigned: Dimensional issues in ductile iron spun pipes
in large diameter

4.1 Aim and Objectives:

 To increase profit by minimizing rejection % by optimum composition for targeted
properties.
 To satisfy the end user of the product by getting whatever properties required.
 To set the optimal composition for the standard grade.

4.2 Introduction
Spheroidal graphite iron is also known as nodular iron or ductile iron. This is obtained by
making small ladle additions of a modifier such as magnesium or cerium to liquid metal.
Unlike flaky graphite in grey cast iron, Spheroidal graphite does not weaken the matrix
considerably. For this reason, the mechanical properties of SG iron are superior to grey iron.
[7] Ductile iron has very good damping characteristics and impact strength. Because of its
mechanical characteristics ductile iron is widely used in various industries’ equipment.
Required characteristics can be impart in ductile iron using various heat treatments i.e.
austempering, tempering annealing and normalizing. Various Heat treatments are carried out
to impart required matrix/phase in the specimen. Different matrix has different mechanical
properties. Presence of phases is confirmed by microstructures observed in metallurgical
optical microscope. Austempered and hardened ductile iron has better required mechanical
properties than conventional ductile iron. Due to the vast area of application, characterisation
of ADI got importance. Fractographic analysis is one of the methods of characterisation of
material.

Annealing treatment increases the ductility at the expense of strength and hardness by
transforming the parent matrix into fully ferritic, whereas high strength and hardness can be
obtained by quenching the specimen into a salt bath (austempering) from the austenitizing
temperature resulting in formation of upper or lower bainitic structure depending on the
cooling rate. Mechanical properties of ductile cast iron, like UTS and hardness increases with
the increase in pearlite content and on the other hand ferritic matrix leads to increase in
ductility and impact strength [8-9].

4.3 Factors affecting to dimensional issues

I. Effects of alloying elements

II. Centrifugal Casting Machine

III. Heat Treatment

I. Effect of alloying elements

The effect of composition may be sub-divided as shown below:

25
1. Influence of the normal base iron composition.

2. Desired residual magnesium content.

3. Influence of alloying elements.

1. Influence of normal base iron composition

(a) Carbon: Carbon percentage normally varies between 3.85 to 4.0 percent. Though the
most practiced carbon percentage varies between 3.85 and 4.0 percent. Castability, which is
improved by improving fluidity, is the one of main parameters which gets influenced by a
change in carbon percentage. Interdendritic shrinkage is caused during the final stage of
solidification. The Interdendritic shrinkage can be sort out up to great extent by increasing
carbon percentage.

(b) Silicon: It is used as graphitizer and it increases the spheroids present in the matrix of the
ductile iron. It increases the ferrite area fraction by reducing primary carbides and pearlite.
Mechanical properties of ductile iron are greatly influenced by the silicon content. Silicon
content and temperature, controls the impact resistance. Increase in silicon or decrease
temperature will reduce the impact value.. Silicon above the normal range promotes excellent
heat resistant qualities. Silicon acts as a inoculants in the production of ductile iron. To
ensure minimum carbides in as-cast specimen 0.6 to 0.8% silicon, as a result of inoculation
with Ferro-silicon, plays as very important role.

(c) Manganese: It acts as an alloy, refines pearlite and stabilizes, thus it decreases ferrite in
as-cast specimen. It stabilises carbide and prevent the breakdown of pearlite to ferrite and
prolongs the annealing cycle for production of ferritic structures. Tensile and yield strengths
increase with increase in manganese content in as-cast specimen, particularly in annealed
specimen. In normalised specimen, manganese provides good amount of hardenability.

(d) Sulphur: Removal of sulphur, below 0.018%, is very important and essential part of the
production of SG Iron. Sulphur reacts with magnesium and gives magnesium sulphide which
entraps in the casting, drosses and impairs the casting quality. Its content also affects the
spheroidization of graphite which is promoted by residual magnesium whose quantity is
affected by sulphur. Therefore, desulphurisation is very much essential to prevent the dross
inclusion.

(e) Phosphorus: As in grey iron, phosphorus forms the brittle phosphide network. It affects
ductility and toughness very badly and reduces the impact resistance. Phosphorus,
particularly above 0.08%, raises the brittle tough transition temperature range. Phosphorus is
therefore kept lower than 0.043% in most of the castings.

2. Residual Magnesium
Magnesium combines first with the excess sulphur in the base iron to form Mg 2S. The
magnesium sulphide formed readily floats to the surface where it can and should be removed.
However, excess quantities of magnesium sulphide slag resulting from higher sulphur

26
contents in the base iron may find their way into the castings giving rise to the dross defect.
Further it has been found that high sulphur content in the base iron entails higher minimum
residual magnesium contents required for satisfactory spheroidal graphite formation. Because
of the fading effect of magnesium with holding time of the treated molten metal, depending
upon the expected time of liquid metal disposal, suitable minimum residual magnesium
contents have to be aimed at for treatment.

3. Alloying elements
(a) Nickel: Nickel in small quantity is needed to promote pearlite like manganese but being a
graphitiser does not give rise to carbides unlike manganese. An optimum combination of
tensile strength, fatigue strength, impact strength and war resistant properties, characterises
such a structure. In normalised and quenched specimen, nickel promotes hardenability
without losing the ferritic structure and UTS, yield strength of the specimen.

(b) Molybdenum: Molybdenum promotes pearlite in as-cast ductile iron. It also retards
annealing cycle. Molybdenum is mainly employed to enhance strength and hardness in heavy
section castings. Molybdenum increases response to heat treatment and is primarily added
usually along with a certain amount of nickel for hardenability. Molybdenum and nickel
together in controlled proportions develop an acicular structure, which lead to high tensile
strength, toughness etc.

(c) Copper: Copper is used to a little extent as an alloy added prior to treatment with
magnesium. It decreases ferrite and quite competent to stabilize pearlite. Copper does retard
annealing, particularly at lower silicon contents. Copper decreases impact resistance and
raises the transition temperature. It affects formation of spheroidal graphite formation.

(d) Chromium: Chromium is very potent carbide and pearlite stabilizer and is particularly
detrimental for developing as-cast ferritic structure. On the other hand chromium is
occasionally added for wear resistance and for hardness in heavy section castings. Chromium
increases oxidation and corrosion resistance in the austenitic S.G. Irons. Silicon is employed
with chromium to reduce growth and to increase strength. [10]

Microstructural Analysis
Ferrite: It is a pure, ductile, flexible iron with little strength. This matrix has poor wear
resistance, but high impact resistance and good machinability.

Pearlite: It’s a mechanical mixture of ferrite and iron carbide (Fe 3C). It is relatively hard,
with moderate ductility. It has high strength, good wear resistance, moderate impact
resistance, and good machinability.

Carbide: Cementite (iron carbide) is a compound of iron and carbon, more precisely
intermediate transition metal carbide with the formula Fe3C.

27
Graphite Flakes: When the melt is exposed to O2, MgS, CaS and other S molecules can
dissolve and instead MgO and CaO forms. The enrichment of S increases in the melt
surrounding the MgO and CaO particles which promotes formation of graphite flakes instead
of nodules. It is the site at which stress concentration is occurred. It reduces the elongation
and increases in brittleness.

Nodule Count: The Nodule Count is usually defined as the number of graphite particles per
a specified unit of area. The terminology is usually expressed as the quantity of nodules per
square millimetre on a polished surface examined under a microscope at 100 magnifications
(100 X).

Nodularity: It is the shape of the nodules which shows the how effective Mg treatment is
done. Nodules is complete in rounded shapes means the nodularity is good and it shows high
ductility, mechanical strength and corrosion resistance.

Segregation: It is the distribution of nodules in metal. Improper segregation is act as a stress

concentration and form micro cracks near this area and specimen is failed and elongation is
decreased.

II. Centrifugal Casting Machine

a) Mould
A hollow container is used to give desired shape to molten metal or liquid material when it’s
cool and hardened is called mould. Molten metal is directly poured into the rotating mould,
with the use of runners. The centrifugal force drives the material towards the mould walls as
the mould fills. With all the molten metal in the mould, the mould remains spinning as the
metal cools. The cooling system is providing to the mould by submerging the mould in the
water with the help of inlet and outlet. After the casting has cooled and solidified, the
rotation is stopped and the casting can be removed from the mould with the help of extruder.

Figure 3. Mould

28
b) Core
A core is a device used in casting and moulding process to produce internal cavity. The core
is normally disposable item that is destroyed to get it out of the piece. The core is used in the
casting is made up of silica sand.

Figure 4. Core

c) Effect of mould powder

Mould powder is the important additives of producing ductile iron pipe; there is protection
pipe die, the favourable demoulding, can effectively reduce condensate depression, suppress
the multiple efficacies such as formation, the pore that breeds, eliminates cast pipes outside
surface and pin hole, nodularization, prolongation pipe mould powder working life of
carbide.

d) Effect of Innoculant
Ferrosilicon is added as Innoculant. Remelting causes reversion to flake graphite due to loss
of magnesium. Stirring of molten alloy after addition of nodulizing element evolves a lot of
gas, which gets dissolved in liquid alloy, and forms blow-holes in solid casting.

The contraction during solidification of nodular cast iron castings is much greater than that of
gray iron castings, which needs careful design of moulds to avoid shrinkage cavities in
solidified castings.

III. HEAT TREATMENT

a) Annealing
The purpose of annealing heat treatment in the case of SG iron castings is to have maximum
ductility and good machinability. After annealing, the microstructure consists of graphite
nodules in ferrite matrix.

29
b) Chain speed:
Chain speed plays a vital role in annealing. It is necessary to increase and lower the chain
speed to achieve the required structure and the chain speed is change as the pipe diameter
which is feeding to the annealing furnace.

c) Annealing furnace zone temperature:

It is very important to maintain the zone temperature i.e. from 950-960°C to achieve the
required properties.

In annealing furnace blast furnace gas is supplied to maintain the annealing furnace zone
temperature, if the supply from B/F gas is lower than required flow then we fire the LDO
(Light Diesel Oil) burners to maintain the zone temperatures.

Figure 5. Annealing furnace

4.4 Experiment procedure

Ductile iron pipes are made by Centrifugal Casting Machine (CCM) followed by molten
metal received from blast furnace after the receiving the molten metal the chemistry is
adjusted and superheated it in the induction furnace by adding MS scrap, Ferro-silicon,
Calcined Petroleum Coke (CPC).

After superheating molten metal is converted to ductile iron from cast iron by magnesium
treatment in converter and then sent to CCM for casting. The chemical composition and
temperature is always monitored at every location to ensure casting of the good quality pipes
and as per the standards/requirements.

The study involves the %contraction and %growth of the various pipes during the training. In
this study we observed some pipes of lower external diameter (LDE) hence the pipes are
refeeding to the annealing furnace for reannealing.

30
4.5 Result and Discussion
During the project study, numbers of pipes with varying diameters has been traced with
vision to observe the chances of dimensional changes during annealing process and pipes
with DN 900mm has been found with lower external diameter. The possible reasons for this
kind of issue have been analyzed, taking %contraction and %growth in consideration.
Background data in terms chemical composition, CCM and annealing furnace parameters of
the failed pipe has been analyzed and found satisfactory. Comparison of the LDERA and
dimensionally accepted pipe is carried out.

The operational data of DN: 900mm (LDERA) has been given in table No 13-16.

Table 12. Chemical composition of LDERA

ELEMENT BF-44243 IF -1/1 CON- 22 HOPPER-21

C ~4.62 4 4.05 4.04
Si 1.29 1.74 1.84 1.84
Mn 0.395 0.421 0.415 0.391
P 0.0951 0.0938 0.0977 0.106
S 0.0514 0.044 0.00318 0.00843
Mg <0.0020 <0.00020 0.0418 0.0323
Ti 0.0792 0.0718 0.0737 0.0792
B <0.00010 <0.000010 0.00051 0.00055
Cr 0.00958 0.0134 0.0151 0.0141
Cu 0.00668 0.011 0.0105 0.0109
Al 0.00312 0.00364 0.0103 0.00846
Ni 0.00756 0.0108 0.01 0.0101
N 0.0033 0.00575 0.00814 0.0081
Mo 0.00613 0.00706 0.00692 0.00685
Sb <0.00050 0.00105 <0.00050 0.00063
Bi 0.00641 0.00633 0.00632 0.0063

Table 13. CCM Parameters of LDERA

Casting Speed 440 Max s Spigot prep. Time 3.45 S

Spigot low speed 10 max s Spigot cast time 8.0 S
Down bumper Speed 200 max s Ladle stop time 9.6
Pulling speed 500 max s Dc motor stop time 99. 0 S
Up bumper speed 180 max s Pull breakaway time 2.0 S
Dc socket speed 950 r/min vibration start time 0S
Dc high speed 1050 r/min vibration stop time 0S
Dc spigot speed 1050 r/min

31
 Dc cooling speed 1050 r/min
Dc low speed 45 r/min
Socket delay time 3.050 sec
Inoculation speed 40% rpm

Table 14. Annealing furnace zone temperature LDERA

Preheating zone 833°C

Heating zone 1 962°C
Heating zone 2 967°C
Soaking zone 1 978°C
Soaking zone 2 950°C
Rapid cooling 1 945°C
Rapid cooling 2 730°C
Slow cooling 1 736°C
Slow cooling 2 676°C

Mould No: 26 New mould

Mould ID: @30mm 945.3, @50mm 945.35, @100mm 945.53

Min: 940.2 Max: 946.0

Table 15. % Contraction and % growth of LDERA

As cast / before annealing Dimensions % Contraction

Pipe no 30mm 50mm 100mm Pipe no 30mm 50mm 100mm
After annealing % Growth
B02NB08K7 933.4 933.6 933.8 B02NB08K7 1.25 1.24 1.22
Pipe no 30mm 50mm 100mm Pipe no 30mm 50mm 100mm
The operational data of DN: 900mm pipe (dimensionally accepted pipe) has been given in
table No 17-20. 938.8
B02NB08K7 940 941.5 B02NB08k7 0.57 0.68 0.82
After Reannealing Dimensions % Growth
Pipe no 30mm 50mm 100mm Pipe no 30mm 50mm 100mm
B02NB08K7 941 942.3 943.5 B02NB08k7 0.81 0.93 1.03

32
 Table 16. Chemical composition of dimensionally accepted pipe

ELEMENT BF-44330 IF-1/1 CON- 17 HOPER-19

C 4.743 3.82 3.73 3.88
Si 2.182 1.72 1.85 1.89
Mn 0.377 0.391 0.454 0.444
P 0.1006 0.0771 0.107 0.935
S 0.0193 0.0209 0.00751 0.00895
Mg <0.0001 <0.0002 0.059 0.0373
Ti 0.1326 0.104 0.103 0.102
B 0.00087 0.00069 0.00081 0.00075
Cr 0.0071 0.0161 0.0167 0.0162
Cu 0.008 0.00827 0.00884 0.00871
Al 0.005 0.00565 0.00703 0.00588
Ni 0.004 0.00991 0.0106 0.011
N 0.0037 0.0005 <0.0005 0.00143
Mo 0.0012 0.00722 0.00737 0.0075
Sb <0.0004 0.00064 <0.0005 0.00148
Bi 0.0032 0.00135 0.003 0.00386

Table 17. CCM Parameter of dimensionally accepted pipe

Casting Speed 440 Max s Spigot prep. Time 3.7 S

Spigot low speed 10 max s Spigot cast time 8S

Down bumper Speed 200 max s Ladle stop time 8.6 S

Pulling speed 500 max s Dc motor stop time 99 S

Up bumper speed 180 max s Pull breakaway time 2S

Dc socket speed 900 r/min vibrator start-stop time 0S

Dc high speed 900 r/min Inoculation speed 35% rpm

Dc spigot speed 960 r/min

Dc cooling speed 960 r/min

Dc low speed 45 r/min
Socket delay time 3.350 sec

33
 Table 18. Annealing furnace zone temperature

Preheating zone 836°C

Heating zone 1 920°C
Heating zone 2 940°C
Soaking zone 1 942°C
Soaking zone 2 955°C
Rapid cooling 1 960°C
Rapid cooling 2 818°C
Slow cooling 1 700°C
Slow cooling 2 695°C

Mould No: 24

Mould ID: @30mm 945.5, @50mm 945.57, @100mm 945.62

Min: 940.2 Max: 946.0

Table 19. %contraction and %growth of dimensionally accepted

pipe

As cast / before annealing Dimensions % Contraction

Pipe no 30mm 50mm 100mm Pipe no 30mm 50mm 100mm
After annealing Dimensions % Contraction
B09PA16K9 934.0 934.2 934.4 B09PA16K9 1.21 1.20 1.18
Pipethe
During no project
30mm
study 50mm 100mm
it is seen that dimensional Pipe
issuenois becoming
30mm a 50mm 100mm
major concern,
B09PA16K9
leading 940.5 941.3
to the unnecessary 942.2
production losses. While B09PA16K9 0.69
comparing the operational0.76 0.83of
parameters
LDERA pipe with dimensionally accepted pipe, it is seen that the pipe facing LDERA issue
was casted using a fresh brand new mould. This kind of problem can be faced due to lower
internal dimeter of the mould providing more contraction of the metal during casting and less
growth after annealing.

34
5. Recommendations:

 Modification in the annealing furnace feeding pattern

The feeding pattern of the pipes is in random order as per the production but it is not
favourable for the homogeneous heating of the pipes. If pipes are fed in the furnace with
different diameters of pipes, then the soaking time required for the particular size pipes can
be provided. Pipes with larger diameter takes more heat and pipes with smaller diameters
takes lower heat, due to which the pipes with smaller diameter faces the issues of LD.

Figure 6. Annealing furnace pipes feeding

 Need rotation to the annealed pipes up to the temperature around 300-350°C

Pipes exiting from the furnace are held in idle condition without any prior action, this can
lead to formation of bend or ovality due to its self-weight. This can be avoided with the
application of rotating action to the pipes.

 Use of adequate innoculant powder

The use of innoculant powder plays vital role when it comes for casting of DI pipe. The use
of excessive innoculant powder results in the LDE and its insufficient application results in
HDE. Thus the innoculant powder must be used in the appropriate quantity to avoid these
issues.

35
6. References

[1] IPSS: 1-11-009-15 “Code of Practice for Safe Handling of Liquid Metal

[2] ILO Code of safety & health for Iron & Steel Industry

[3] SAIL Plants Safety Manual, Tata Steel Safety procedure

[4] Makar, J. M., Desnoyers, R., and McDonald, S. E. (2001). "Failure Modes and
Mechanisms in Gray Cast Iron Pipes." Underground Infrastructure Research 2001 - Waterloo,
Ontario. National Research Council, Canada.

[5]http://www.oceanproaquatics.com/temp/submittals/pipe/pacific%20states%20cast%20iro
n%20pipe/company%20history/evolution_of_cast_iron%20_pipe_standards.pdf

[6] Nayyar, M. L. (2002). Piping Databook. McGraw-Hill, New York.

[7] Rajan T.V., Sharma C.P., Sharma Ashok. Heat Treatment Principles and Techniques.
India, Prentice-Hall India, Jan, 2004

[8] Gulcan Toktas, Mustafa Tayanc, Alaaddin Toktas, Effect of matrix structure on the
impact properties of an alloyed ductile iron, Materials Characterization 57 (2006), p290–299.

[9] Cheng-Hsun Hsu, Kuan-Ting Lin, A study on microstructure and toughness of copper
alloyed and austempered ductile irons, Materials Science and Engineering A 528 (2011), p
5706–5712.

[10]Gandhi. R.N.“Engineering Properties and Applications of Spheroidal Graphite

Iron”.Proceedings of A Seminar Held in Bombay 21-22nd Feb,1970, Pub.:Institute of Indian
Foundrymen, 1971, p.129

36