Pak steel intership report

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DEPARTMENT OF

MEHRAN UNIVERSITY OF ENGINEERING & TECHNOLOGY, JAMSHORO

(Internship Program Report)
PAKISTAN STEEL
NO. OF WEEKS :- 4 WEEKS INTERSHIP PROGRAM
Date : 14-06-2010 To 09-07-2010

Submitted To:
Incharge (Trg. Wing) HRD
Submitted By:
MOHAMMAD YOUNUS (08IN70)
WAZIR AHMED JATOI (08IN64)
SUHAIL AHMED PALIJO (08IN36)
SAEED AHMED JANDON (08IN34)
KAMRAN MEMON (08IN43)

PAKISTAN STEEL MILL KARACHI 1
PREPARED BY :MOHAMMAD YOUNUS & SUHAIL AHMED

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PREFACE
This report contains the information about those
departments which are visited by the internees. Whatever the
machinery seen and the processes are observed, attracting the
human mind and realizes the men what science has achieved and
what kind of mericals has been done by it. Basically Pakistan steel
mill is quite attention attracting industry it provides lot of
opportunities to see, to observe, to achieve and to get the lot of
experience about the industry as well as about the machinery.
The technology installed at Pakistan steel mill is the old one but due
to the hardworking labor it can compete the latest technology even
today.
This report may also contains the facts and the real figures of the
various departments which are very beneficial for our experience
and the also for the practical knowledge. The functions and the
details of their working and the process as well as the timing and
work break down structure is also mentioned in this report. This is
edit by the students of the INDUSTRIAL ENGINEERING AND
MANAGEMENT DEPARTMENT of the nominated university of
jamshoro named MEHRAN UNIVERSITY OF ENGINEERING
AND TECHNOLOGY JAMSHORO SINDH PAKISTAN. The
details of the students are as under:-

SUHAIL AHMED PALIJO (08IN36).

MUHAMMAD YOUNUS (08IN70).

WAZIR AHMED JATOI (08IN64).

SAEED AHMED JANDAN (08IN34).

KAMRAN AHMED MEMON (08IN43).

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ACKNOWLEDGEMENT
We are very thankful from the core of my heart
to honorable CEO, Pakistan Steel, MALIK ISRAR
HUSSAIN for providing us opportunity for training and
whose intelligent, wise and sound leadership has converted
manpower into wining combination by this industry into a
gold mine.

We wish to express my deep gratefulness to
MR. RIZWAN AHMED, Director (Personnel & HRD) for
his consideration and supervision. It was a memorable time
in Pakistan steel due to his kind concern.

We are also thankful to MR. NISAR A.
KHOWAJA, Incharge (Training Wing) and MR. YOUSUF
AYUB, Dy. Manager/ Incharge ( In- Plant Training) for his
precious advice and for he great encouragement and
cooperation, because of which We have successfully
completed our internship training of PAKISTAN STEEL
where we learned a lot.


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CONTENTS
UNIT’S DESCRIPTION PAGE
NO.
UNIT NO. 1 INTRODUCTION 07
• Brief History 08
• Location and Sites 09
UNIT NO. 2 PRODUCTION PLANING & CONTROL 10
• Introduction of Production, Planning 11
and Control.
• Objective of Production, Planning 12
and Control.
• Roll of Production Planning and 12
Control in Pak steel.
• Hot metal section. 13
• Steel making section. 16
• Rolling section. 17
• Budgeting and procurement section. 18
UNIT NO. 3
QUALITY CONTROL DEPARTMENT
• Quality, Quality Control. 19
• Quality Control in Pakistan steel. 20
• Quality Control section in Pakistan 20
steel. 21
i) RMHD Section. 21
ii) COBP Section. 23
iii) Sintering section. 25
iv) IMD Section. 26
v) SMD section. 28
vi) HSM section 33

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vii) REFRACTORY Section. 35
viii) CRM SECTION 40

UNIT NO. 4 MECHANICAL EQUIPMENT AND 43
REPAIR SECTION
• Maintenance 44
• Objectives of Plant maintenance 44
• Importance of the maintenance 44
• Maintenance section in Pakistan steel. 45
• M.E.R.S 45
• Maintenance of HSM 46
• Maintenance of SINTERING 48

UNITE NO. 5 INDUSTRIAL ENGINEERING 50
DEPARTMENT
• DEFINITION 51
• FUNCTION 51
• SALIENT FUNCTIONS’ OF I.E.D 51
• PRESENT EXERCISE. 51
• FUTURE PROGRAMME. 52
• WORKING OF I.E.D NOW A 52
DAYS. 52
• HAZARD ALLOWANCES


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INTRODUCTION

Steel is the main metal in the world
without steel the life became incomplete
because steel is used in many places where
no metal or non-metal thing can not be
used not only Pakistan there so much
demand of in steel in world steel is the
bake bone of any country it plays vital role
in the development of any country not only
in physical sense but also economically.
Similarly like other countries Pakistan has
decided to install its own steel mill because
before steel mill, the steel and the related
metals are the imported from other
countries. Before steel mill he was
dependents of other countries. But now he
is capable of producing 1.1milion ton of
steel mill by his own which is not sufficient
but quit helpful for the country from every
aspect foundation of steel mill was kept by
the legend Qaid-e-awam ZULIFIQAR ALI
BHUTTO in 1976 with the co-operation of
Russia who have transferred the latest
technology of that time and this project of
about billion approximately it was
completed in 1981.first time in Pakistan
the blast furnace started in 1981 to produce
pig iron further it was converted into steel
of different grades.
Pakistan steel mill is separated over 18000
acres out of which 10000 was fixed for
mill and rest of will be for the housing and
medical facilities Pakistan steel mill not
only provides the medicate facilities but all
type of facilities such as education, sports, completion and higher education
facilities etc due to Pakistan steel mill thousands of people are employed and
living the prosperous life.

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BRIEF HISTORY

The engineering goods industry is recognized the world over as most critical for the
development of self reliant and vibrant economy. This industry, however, depends heavily
on basic metals industry, specially the iron & steel industry for the supply of resource
inputs. the iron & steel industry, therefore holds the key To the sustained growth of the
engineering sector and hence to the development of the economy as whole. As such the
steel industry can be termed as mother industry to all modern industries, being the basic
source of metal for them.
In this perspective the importance of the national assets such as PAKISTAN STEEL,
which determined on their strength and ability to sustain the national growth rate, need not
be emphasized. Abundant steel, sufficient power and adequate Transport are otherwise
also absolute necessities for the rapid industrialization of developing countries today. If
one desires to find out what PAKISTAN STEEL has done for the country, one will have
to venture back in time, into the early 70s when PAKISTAN STEEL was only a dream on
paper.
By that time non-existence of an iron & steel making plant of a reasonable size in
Pakistan had shown its adverse effects on the industrial and economic development of the
country which continued to suffer various set backs because of dependence on import of
iron and steel products.
A stage had been reached when it had been realized that the import bill to meet all the
re3quirements of steel could not be supported indefinitely. In fact the idea of setting up of
a steel mill in the country had been cooking over the red hot coals of controversy since the
introduction of the first five year plan (1955-60) which laid emphasis on the domestic
production of iron and steel.
Debates over the manufacturing process, supply sources of the requisite machinery and
raw materials, plant site, domestic ore versus imported ore, ownership pattern, product-
mix and above all, foreign financing g credits, kept the projects simmering over as period
of two decades.
In 1968 beside other factors, it was considered by the Government that a basic steel
industry should be established in the public sector as public sponsorship of the project
would enable integrated development of steel industry in the country. in the light of this,
Government decided that the Karachi Steel Project should be sponsored in the public
sector for which a separate Corporation under the Companies act be formed, in the
pursuance of this decision Pakistan Steel Mills Corporation was setup as a private limited
company under companies act 1913 in the public sector on 2nd July, 1968 with the object
to establish and run Steel Mills at Karachi and other places in Pakistan.
In January, 1969, PAKISTAN STEEL concluded an agreement with V/O Tiajpromexport
of the then USSR for preparation of a feasibility report for the establishment of steel Mills
at Karachi. Subsequently in January, 1971 Pakistan and the USSR signed an agreement
under which the latter agreed to provide techno-financial assistance for the construction of
a coastal-based integrated Steel Mills at Karachi.


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The foundation stone of this vital and gigantic project was laid on 30th December,1973
the then Prime Minister of Pakistan., the mammoth construction and erection work, of an
integrated steel mills never experienced before in the country, was carried out by a
consortium of Pakistani construction companies under the overall supervision of soviet
experts.

PAKISTAN STEEL does not only have to construct the main production units but a host
of infrastructure facilities involving unprecedented volumes of work and expertise.
Component units of the Steel Mills numbering over twenty and each a big enough factory
in its own right were commissioned as they were august, 1985 with coke oven and by-
product plant coming on steam the first and the galvanizing unit the last. Commissioning
of blast furnace No. 1 on 14th August, 1981 marked Pakistan’s entry into the elite club of
iron and steel producing nations. The project was completed at a capital cost of Rs. 24,700
million. The completion of the steel mills was formally launched by the president of
Pakistan on 15th January, 1985.
PAKISTAN STEEL today is the country’s largest industrial undertaking having
production capacity of 1.1million tones of steel. The enormous dimensions of the project
can be visualized from the construction inputs which involved the use of unparalleled 1
29 million cubic meters of concrete, 5.70million cubic meters of earth work (secondly to
Tarbela Dam), 330,000 tones of machinery, steel structure and electrical equipment. It’s
unloading and conveyor system at Port Qasim is the third largest in the world and its
industrial water re3soervior with a capacity of 110 million gallons per day is the lar54gest
concrete reservoir in Asia. A 2.5 kilometers long sea water channel connects the plant site
to feed the sea water circulation system with 216 million gallons per day. The plant’s 2 km
long flyover which connects the steel mills with National Highway was the largest in the
country when built.
The above figures illustrate the massive civil works, intricate erect ions, installation of
sophisticate4d electrical and mechanical and equipment with the completion of
PAKISTAN STEEL, the local contractors gained the technical ability till the unknown to
them which they utilized later to undertake works worth millions of rupees/dollars both
within the country and abroad specially Middle East.

LOCATIOIN AND SITE:
PAKISTAN STEEL is located at a distance of 40 km South East of Karachi at Bin Qasim
in close vicinity of Port Muhammad Bin Qasim is a coastal site which lies on the National
Highway is linked to the railway network. It was found to be an ecologically preferable
location, alongside a tidal creek and having wind direction away from the city of Karachi.
PAKISTAN STEEL is spread over an area of 18,600 acres (about 29 square miles)
including 10,390 acres for township and 200 acres for 110 MG water reservoir. In addition
it has leasehold rights over an area of 7520 acres for mining of limestone and dolomite in
Makli and Jhampir areas of district Thatta.


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INTRODUCTION:-
Production planning and control as its name suggest that it is combination of three
departments:

1. PRODUCTION DEPTT:
2. PLANNING DEPTT:
3. CONTROL DEPT:

1-Production:

It is the process or procedure to develop to transform a set of input element like
men, material, machine and capital information and energy into ratio specified set
of output elements like finished products and services in proper quantity and
quantity to achieve the objectives of the enterprise

PLANNING:

1. Planning all aspects of the production, selling etc, are essential in order to
minimize intangibles.
2. Planning is the process by which a manager anticipates the future and discovers the
alternative courses of actions open to him.
3. Planning is the economic, rational, systematic way of making decisions today
which will affect the future e.g what will be done in future, who will do it and
where it will be done.
4. Infect every managerial work/act whether it would be physical or mental is
inexorably intertwined with planning.
5. Without proper planning the activities of an enterprise became confused.
6. Prior planning is necessary or very essential for utilizing the available facilities
(Men, material, machine, etc) to the best of the advantage.

CONTROL :

1. Controlling is the process that measures current performance and guides it towards
some pre-determined goals.
2. controlling involves:
Monitoring of the activities to make sure that the objectives are being met.
The initiation of corrective actions as required overcoming problems, if any
hindrance is occurred during the process.
Checking and the examination is required on the periodic basis to ensure
that the things are preceding as per plan.

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It is necessary to ensure that the orders are not miss-understood rules are
not violated and objectives have not been unknowingly shifted.
It is the continuous process that measures the progress of the operations
(compares) verifies them confirms with the pre-determined plan and takes
correctives actions if required.

OBJECTIVES OF THE PRODUCTION PLANNAING AND
CONTROL:-
• Effectiveness: goods to fulfill customers’ needs
• Maximizing output: maximum output with minimum input
• Quality control: Product/service quality meets planned quality specifications
• Minimize throughput time: conversion of RM to FG in minimum time
• Capacity: full utilization of men & machines
• Minimize cost: minimum cost of production
• Maintaining inventory: optimal inventory
• Flexibility: flexibility in production operations
• Coordination: between men & machines
• Capacity: plan for current & future needs
• Reduce bottlenecks: solve production problems early
• Maximize profit: minimize cost
• Production schedules: as per plan
• Routes & schedules: to optimize use of men, material & machinery
• Maintain performance: maintain standards

ROLE OF PRODUCTION PLANNING AND CONTROL IN STEEL
MILL:-
It is one of the main department of the steel mill basically its main function is to make
planning for the over all production either it is daily, weekly, monthly or annually.
It plays the role of the backbone in the steel mill. Without ppc steel mill is useless if you
really want to make it useful their must be ppc department. If any org. is working without
planning it has to bear heavy loss as well as the lot of wastage of the time and other factors
such as money, material, machinery. Planning is the single tool which minimizes that
effect and maximizes the profit.
In steel mill under the quit capable supervision of the production planning and control
deptt: almost all production deptt: are working. Due to large numbers of the department
ppc has divided them into the three groups. By grouping system it is easy to handle and
control. Details of the department are as under
There are 4 major groups:-
1. Hot metal section/department.
2. Steel making department/section.
3. Rolling section.

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4. Budgeting and Procurement section.
All these sections are further divided into various units or departments.

HOT METAL SECTION:-
It is the main section of the ppc department. It deals with the all type of the hot metal
and the raw material. It contains the following departments.

1. RAW MATERIAL AND HANDLIND DEPARTMENT.
2. SINITERING DEPARTMENT.
3. COCK OVEN AND BY PRODUCT DEPARTMENT.
4. IRON MAKING DEPARTMENT.

RAW MATERIAL AND HANDLING DEPARTMENT
Pakistan steel mill meets its raw material‘s requirement both from indigenous as well
as foreign sources locally available materials include:-
1).Limestone 5.)Bauxites
2).Dolomite 6).Magnetite
3).Fireclay 7).Chromites
4).Fluoride

Of these PAKISTAN STEEL MILL has also leasehold rights for limestone and
dolomite quarries located within the convenient distance of the works. Nevertheless
the basic minerals namely (iron ore, coking coal and manganese ore are imported
because of the indigenous non-availability In appropriate chemistry /quality and
quantity. Major raw material requirement at full production is given below:-

ITEM At 1.1MTPY
(IN THOUSAND TONNES).
IMPORTED:-
Coking coal 1050
Iron ore 1910
Manganese ore 28
Ferro-manganese 6
Ferro-silicon 3
Aluminum 2
Zinc 3
Fluorite 5
LOCAL:-
Limestone 390
Dolomite(sinitert grade) 185

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Dolomite(refractory grade) 46
Refractory clay 28
Silica sand 19

ITEM Location
IMPORTED:-
Coking coal Australia ,Canada
Iron ore Australia, Canada, Iran, India
Manganese ore Canada
Ferro-manganese Canada, Iran, India
Ferro-silicon India, Iran
Aluminum Australia, Canada
Zinc Iran, India
Fluorite India, Iran
LOCAL:-
Limestone Makli Distt: Thatta
Dolomite(sinitert grade) Jhumpir
Dolomite(refractory grade) Jhumpir
Refractory clay Balochistan
Silica sand Balochistan

BLENDING YARD:-
IT is the ground where blends are made by mixings the same material but ratio of
the % should be different.
BLEND:-
It is the mountain of the mixtures of the two materials of different % ratio.
Let have an example of the iron ore there are two types of the iron ore one is local and
other is imported.
Both these materials are mixed to attain the required % of the iron ore because the
imported iron ore is the expensive one so that we cannot used the imported iron ore at
all.


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SINITERING:-
This plant has two sintering machines with an effective
sintering area of the 75 square meters.
After BMR the sintering area has increased to 90 sq.m thereby
increasing the annual production capacity from 1.5 million
tones to 1.8 million tones of the sinter. These machines
provide sinter to the iron making deptt: for production of the
hot metal /pig iron sinter is prepared by heating up an
amalgam or cake ,dolomite, limestone and iron ore.

COKE OVEN AND BY PRODUCT
PLANT:
There two cokes over batteries in this plan
and each battery consists of 49 ovens.
The first battery was commissioned von
17th April, 1981 where as the second one was
commissioned on 7th may,
1985. These batteries produce metallurgical
coke and other by by-products such as
coke oven gas ammonium sulphate.
Coal-tar etc. coke oven gas is used for
generating electricity by thermal power plant.
Coal-tar is a very useful item which
can be used for producing basic chemical products. It is utilized in the manufacturing
of the black carbon, insecticides and even some perfumes. PAKISTAN STEEL’S coke
is of the highest international standards. It not only sells in the local market is in
demand in many foreign countries also other coke is exported to the overseas markets.

IRON MAKING DEPARTMENT
There are two blast furnaces in the iron making
deptt: each B.F with an effective volume of
1033cm3 and has the capacity of the 1750 tones of
the molten metal/iron per day the 1st B.F went into
the production on 14th august 1981 while the 2nd
B.F also became operational on the independence
day in 1984.this plant also produces the by-
products called the granulated slag from both the
blast furnaces. It is about 250,000 tons per year.
This is also utilized in the slag cement, slag
wools; slag blocks for the buildings and the

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construction of the roads.
It also produces the gas utilized in thermal power plant for the generation of the
electricity. the molten iron produced by the iron making department called the pig iron
is not only sufficient for the internal demands of the Pakistan steel mill but numerous
foundries demands the pig iron in the country. This pig iron is measures up a/c to the
international standards and has been supplied to the various foreign countries such as
India, Bangladesh, Saudi Arabia, Indonesia, china, south Korea and Japan

STEEL MAKING PLANT/DEPARTMENT:-

In this plant two top-blown basic oxygen furnaces (linz-donawitz)
Converter of 130 tones charge weight each is installed which transform molten iron
into steel. In order cast molten steel in the shapes of the blooms, slabs, and billets. A
bloom caster and the billet caster are added in 1989and the two slab casters are also
installed in the plant blooms of 260*260mm size are used for making the billets in the
billet mill where as the slabs of the 150to200mm and width size of 700 to1550mm are
supplied to the 1700mm or hot strip mill for the manufacturing of the hot rolled sheets.
The cast billets of 80*80mm-150*150mm size produced in the billet caster are directly
marketed the first converter was commissioned on the 18th December 1982 and the
billet caster on the 22nd December 1982,first slab caster on the 10th august 1983and
the second on the 1st November 1983.

BILLET MILL(800mm):-
Prime quality rolled billets of the size 50*50mm to 100*100mm are being produced in
the billet mill which is most important plant of the Pakistan steel mill. Capability of
the manufacturing of the round billets of 56mm diameter has also been attained by the
Pakistan steel mill steel billets are utilized for producing, besides construction bars and
other products such as wire rods, nuts, bolts, balling hoops, rails, heavy structure
rolled sections, seamless pipes, gas cylinders etc. The 800mm billet mill was
commissioned on 11th October 1982.

CONTINOUS BILLET CASTER:-

In order to meet the demands of the billets in the market as well as to balance the
designed production capacity of the steel mill to cater for the market demand
PAKISTAN STEEL has set up a six strands continuous billet caster with production
capacity of 400,000 tones per annum, adjacent to steel making department.
Billet caster can produce billets in sizes of the 50*50mm,100*100mm,125*125mm,the
machinery and equipment were produced from M/s voest-alpine, Austria at the total
cost of Rs.167.7 millions .the project was commissioned on the 11th November
1989,product through the billet caster is more efficient and cost effective than through
bloom casting/billet re-rolling route.

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ROLLING SECTION
The rolling section has been further divided into the two sections.
1. Hot strip mill (1700mm).
2. Cold rolling mill.
3.
HOT STRIP MILL (1700mm).

With the commissioning of the hot stripe mill on the 25th December 1983.the
production of the steel sheets ,strips, coil commenced in the country.
The annual production capacity of the 1700mm hot strip mill is 790,000 tones. Cold rolled
sheets and stripes are also produced from the hot rolled coils and sheets, strips .Hot rolled
sheets and stripes are used for the manufacturing the pipes of the small, large and medium
sizes. Bodies of the cars and other vehicles, railway wagons transformers boilers big tanks
ocean going ships machines furniture and much more.

COLD ROLLING MILL:-
This plant is used for the production of the cold rolled coils which are more beneficial for
various types of works such as sheets pf the vehicles, as well as the body of the aero
planes and etc. An other assignment is also fulfilled which is of the slitting and shearing
these sheared sheets are used for the flouring, as well as ceiling and in various other
functions where there hot rolled sheets are not benefited.
CRM is the one of the largest and the cleanest department in the whole steel mill
.It is the one of the best deptt: which always remain clean, all the products of the steel mill
depend on the CRM deptt because each and every product has to pass from that deptt:
CRM contains following units or sections:
1. Continuous pickling unit.
2. Reversible unit.
3. Annealing furnace.
4. Tempering mill unit.
5. Combined slitting and shearing units.
6. Galvanizing unit.
7. Profile bending.

The most important section of the CRM deptt: is the single strand reversible mill which
has the annual production capacity of 200,000 tones .out of this 100,000tonnes can be
utilized to manufacture the formed sections and 90,000 tones are salable in the market as
the cold rolled sheets /coils. Cold rolled sheets and coils are used in the those industries
which are manufacturing the bicycles ,steel containers, drums, barrels, jerry can bodies of
the buses and other vehicles and steel furniture’s ,machinery parts instruments for oil and
gas etc. galvanized sheets are used for the manufacturing of the trucks, buckets ,iron
shuttering ceilings air-conditioning, ducts, ribbed sheets deserts, coolers utensils of the

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daily use, air-conditioners water heaters, and water tanks, etc all the units of the cold
rolling mill were commissioned b/w the February to December 1984.the operation of the
main cold rolling mill units marked the completion of the phase of producing 1.1 millions
tones of steel products.

BUDGTING AND PROCURMENT:-
Budgeting and procurement are two different phrases each phrase has its own actual
meaning as the phrase budgeting from its name it suggest the process of the making
budget of the org.
Each and every organization must have a separate budgeting section because until and
unless an organization .doesn’t prepare its budget, obviously it will bear heavy losses not
only in case of capital but due to not perfectly defined budget it’ll also remain at the
backside in all fields. Similarly in Pakistan steel mill the budgeting section is performing
its duties under the kind control of the production planning and control department.

FUNCTION OF THE BUDGETING SECTION:-

It’s first and for most function is to make budget for the whole organization. Sometimes
the budget will be out of the situation so in that case first to overcome all types of the
waste or extra expenses then the strategy is made. This will prove better for the
organization.


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QUALITY
Quality means the degree of perfection of excellence when applied to
manufactured produces. It not necessary means “the beat”. It should imply “the best for
money” that is the product should meet the desired requirement at lowest cost.
The word “quality” is meaning less until and unless the product made up of high quality
has specified used means product serve the specified function for which it is made.
Quality of product is relative terms and it can only be comparing some standards hence the
quality of product may be defined as the conformance to standard and speciation. Quantity
also has a considerable effect on quality and hence it becomes more complex to manger to
control and to achieve the quantity output.

QUALITY CONTROL
Basically “Quality control” we mean that those process or operation of testing
measuring and manufacturing components with a standard and then determining whether
it should be accepted, rejected, adjusted, or reworked.
It is off course more sensible to control the process so that the standard are being
maintained and that defective parts will not be produced instead of accepting or rejecting a
part after it has been manufactured thus the quality control means the systematic control of
those variable in a manufacturing process which affect the excessive.

QUALITY CONTROL IN PAKISTAN STEEL
As we have already discussed that the importance of the quality control in any
organization in the above section so in any time of organization either it is manufacturing
industry or service industry or it any corporation all are bounded towards the quality of
their product to meet their consumer demand and hence o increase the productivity.
Pakistan steel is the largest organization of Pakistan and it produces wide variety of steel
product to meet their consumer demand and hence the demand of customer can be
checked by ensuring the quality of product.
Therefore Pakistan steel have their separate quality control department (Q.C.D) situated at
he operation building of Pakistan steel mill.
Q.C.D is under the supervision of various engineer’s, superidents etc those have wide
knowledge and skills t check the quality of their product, process and also control the
quality of whole process in each and every department involving in production in which
further necessary action is to be taken.
In Pakistan steel mill raw iron ore is converted into the required product through various
departments all have different function and task to complete their job hence in every
department there is section or plant of quality of control namely called Q.C.D section of
particular production side.
Therefore quality control originally based on 12 sections which are as follows.
1) RAW MATERIAL HANDLING DEPARTMENT (RMHD)
2) COCK OVEN BY PRODUCT COBP
3) REFRACTORIES AND LIME PRODUCT SECTION
4) STEEL MAKING DEPARTMENT (SMD)
5) BILLET MILL

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6) IRON MAKING DEPARTMETN (IMD)
7) SINTRING SECTION
8) HOT STRIP MILL (HSM)
9) COMBINE SHARING AND SILITING (CSSU)
10) COLD ROLL MILL (CRM)
11) FINAL PRODUCT DISPATCH CONTROL DEPARMTENT (FPDC).
Above are the quality control section in every department and performing their job
pleasantly. Here we are going to describe each one by one.

RAW MATERIAL HANDLING DEPARTMENT

INTORUDUCTION

This is the very stage in which the raw
material is handle that has been taken either from local
resources or it taken taken from internationally.
RMHD section’s basically work about two particular
field i-e
i) Blending ii) Primarary stock
• Primarary stock is one which the various type of
raw material which is unloaded at jeetti and through
convare comes at RMHD and then to make pile through
layer’s of material, there are basically four type of pile are
there Pile1 and pile-2 containing material in lump form and
pile-3 and pile-4 of material in fine form.
• Blending is a section in which the mixture of two
or more than two material if to be mixed both of same
nature.

TYPES OF RAW MATERIAL

Not only iron ore there is many other material that has been taken either
locally or international and it can classified as follows
1) IRON ORE
The iron ore used is usually taken from international market but it also taken local as
well when required
a) Iron ore in LUMP form
b) Iron ore in FINE form
2) MAGNESSE
The manganese has wide application in making of various grade therefore pak steel
took manganese in two form i-e lump and fine.
3) QUARTIZIDE


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4) DOLOMITE
5) LIME STONE
6) SILICA SAND
7) BANTONITE CLAY.

PROCEDURE OF RHMD

The material that has come internationally is unloaded at JT.
There are two types of convare belt that has taken the unloaded material
i) 12’-1 ii)12’-2
There are two sampler is installed on each convere i-e
Sample no. 1 on 12’-1 and sampler no. 2 on 12’-2.
Whenever the ore flow over the convere the extreme of that ore is to be cutter and on
each sampler there is material box in which the cutter material is inserted until the
bucket is full the material is shifted down. After all that the reversing belt is there now
if the belt is moved forward there is sieve of -6mm to + 6 mm present.
The material less then under the size of 6 – 30, is to be sieved and drill down as fine
and which is not sieved is also taken from the surface and hence by forward moving
we get both lump and fine form of ore.
On the other hand if the material is moved in reversed direction there is
combine crusher to crushes further into the size of -10 to +10 mm. Now all these ore
(material) is further crushing & girding the metal is becomes very much powder like
sand is shifted to the process so that through various analyses they may get the
required %age of Fe content in crushed ore and hence observed the quality.

RAW MATERIL QUALITY CONTROL SECTION

At RMHD the quality control section is responsible to taken the sample
of raw material and make it in proper form by following a particular process and then
send it to the process lab so that to analyze the content of material and % age of their
presence in the material is also taken.


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COCK OVEN BY PRODUCT (COBP )

INTRODUCTION
COBP abbreviated as cock oven
by products. It’s the one that provide the cock as
a basicwith various other by products those were
necessary to regulate in various section as a fuel
as some of them also sell into the market after little
processing as a extra profit to the organization.

COBP FUNCTION

COBP works on to performs the following
actions,
COCK to convert COAL
COBP has major works to produce coal
through
cock so that it provided facility in the blast furnace
and
in converter as well as a fuel. When the coal is to be
taken from the battery one by one after that
quenching
of coal is to be done in two different fashion i-e dry or
wet quenching.
After quenching sieve analysis is to be done if the size
of cock is in b/w 25-80 mm the cock is continuously transferred to the blast furnace
and more the 80 mm size mean’s +80 mm is to be sell out and -25 mm is lying down
and make use of it if required.

BY PRODUCT OF COBP

COAL TAR, COCO ONE GAS, AMMONIA GAS.
• Ammonia gas after passing through sulfuric acid is to be manufactured as a by
product which is used fertilizers.
• Similarly coco one is also collected and this gas used as a burned in various
even it is also used in cock battery. The coco one gas has low colorific value
then natural gas but it is the by product so its provide facility as a fuel.
• Coal tar is major by product it is used as a fuel in various section and also used
in refractory bricks.


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COBP QUALITY CONTROL SECTION

COBP has a continuous process the cock comes through battery and
send it of required size to B.F but through sampler the sampler is also be taken after
every 6 hours and check the quality of the coal and then gives specification of the B.F
operator observers so now its depends upon B.F’s operator either he satisfied with the
specification given by COBP quality section or don’t he.
The quality of manufactured coal is to be checked by following process as we have
done in RHMD. The sampler take’s the sample of cock and sample is to crushed ,
grind and then make it into powder form which is then send to the process lab so that
to understand the chemical composition.
The most preferable composition of coal is as

Chemistry % age of material involved
Ash 12.2 %
Volatile 1.3 %
Sulphur 0.5 %
Carbon Remaining %age

In the quality section of COBP the strength of the coal is also checked through the used of
the drum tester.
At this stage the sampler of 25 mm to 80 mm is to be filled into the drum and revolve it
about 10 revolution now we have 2 types of sieve’s namely the 40 M and 10 M sieve there
fore the drum cock is to be spread over 40 M sieve.
Hence in sieving of the cock taken from the drum so to be passé most of particle down the
40 M sieve to 10 M sieve and further from 10 M to -10 M so the strength of the coal is to
be called is poor strength but on the other hand if the drum of cock present more of it past
over the 40 M sieve and some of the 10 M sieve so in this case it is called good strength
coal.


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SINTERING

INTRODUCTION

Sintering is one of the most important plant in pak
steel sintering with its material provide basis to B.F so
that it may produce the molten iron. The raw material either
comes locally or it may internationally in fine or lump form
so sintering basically make use of fine form of raw
material.

PROCESS OF SINTEIRND Q.C.D SECTION

First of all through conver’s raw material
comes and it put into the mixture. When the mixture is to
be filled by burner’s the quality observer has to observe
how to operate the mixture and this mixture is also called
the ball because it converts the fine forms of raw material into the balling drum
which revolves, the quality observer observed the mixture or sinter is properly mixed
or not and if he issue so that mixture to is send to the sintering machine now this
mixture is to be burned by applying heat from up side after wards these mixture cake
is fully burned and continuously cooling when of away from the hot blast and then this
cake is diminish by jaw crusher and tend the sinter to the blast furnace now remember
quality of sinter has major importance and hence it produce wonderful type of raw
iron.

SINTER COMPOSTION

As we know that nowadays the Pakistan steel facing a lot of problem due
to the lankness of raw material and many of its so now a day the composition of sintering
which is send to the B.F is as follow,

Chemistry % age of material involved
Fe 55.85 - 57.85
MnO 0.90 – 1.10
MgO 1.85 – 2.05
CaO 1.19 – 1.39
FeO 11.0 – 13.00
Al2O3 1.65 – 1.85


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SiO2 6.50 – 6.70

IRON MAKING DEPARTMENT

INTRODUCTION

In this department the raw iron is to be prepared through sinter and lump
form of iron ore means it is a stage in which the ore (fine + lump) form is to be
converted a metal form. The metal obtain from IMD is generally serve two purpose
either molted material is shipped into the SMD or it may go to foundry section to
shape it into the pig called the pig iron.

PROCEDURE OF IMD SECTION

At this stage the raw material or ore form is to be converted into the raw
metal from hence all the further process is based on this stage i-e when the coal of
required size (25 – 80) mm similarly various material’s taken from various
department depends upon the requirement and the order giving by PPC.
When the sinter of some composition is come from the sintering section and lump
form of iron ore is come from the RMHD both form as a charge in blast furnace and
hence when the charge in inserted into the blast furnace the operation of the blast
furnace is start by employing high pressure gas through tuyers. The operation of blast
furnace is depends greatly on the zones of blast furnaces because each zone have
different temperature to other.


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Zone’s of Blast Furnace
The blast furnace has the following zones with their temperature

Zones Temperature
Hearth 1700 – 1800
Bosh 1600 - 1500
Bally 600, 700, 800
Stack 800 – 1000
Throat 600 – 1000

High pressure in employed through tuyers and all charge inside reaction and hence as
a result it is to be converted into two things i-e molten iron or slage.
The iron has the high density and hence it is to be shifted down the blast furnace
where as the slag has low density is placed above the molted iron. Now through taping
whole first the iron is to be taking and filled it in the bowl and after that the slag is
also taken and it is also taken into the bowl.

Major Specification Of Typical B.F
Specification Value
Capacity 1750 tonn daily
Volume 1033 cubic m
height 96 m
Stack 800 – 1000
Throat 600 – 1000

BLAS FURNANCE QULAITY SECTION

Strictly speaking there is no quality section in blast furnace only the molten iron
whose sample is to be taken and that sample is send it the process labs so that they
applied very technique and using various parameters and then gives the specification
of he molten metal like to how much %age of carbon is places %age of sulpure,
phosphorus etc and give the report to the SMD section.


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STEEL MAKING DEPARTMENT SMD

INTRODUCTION
It is the one of the most important department of
Pakistan steel it’s not wrong if we called it as a heart
of Pak Steel. At this stage we prepared the steel of
required grade and shape into the various form casting
process slabs, blooms are the product of this stage.

PROCEDURE OF SMD

STEEL MAKING PROCESS THROUGH
CONVERTER
Hot metal is transported from the twp blast
furnace by rail cars in 140 tones open transfer ladles
and charged into the mixer by crane. The mixer acts
as a buffer storage vessel to accommodate variation
b/w iron production and the steel making operation.
To maintain the temperature in the mixer natural gas
burners heat the surface of the hot metal.
Hot metal is poured from the mixer into a charging ladle mounted on the self –
propelled rail car. During pouring the ladle car is positioned on a weighbridge.
The hot, metal is charged into the converter by crane.
After charging, the converter is rotated to a vertical position and one of the two water-
cooled oxygen lances nozzle relative to the liquid metal surface is important in order
to create the optimum reaction conditions.
To attain the desired carbon content in the refined and to oxidize other impurities a
calculated volume of oxygen is blow into the converter at a controlled flown rate.
During blowing process a pre- determined quantity of calcinated lime is added to the
vessel to produce a slag which aids the refining process. Fluoride is added for slag
fluidity control. Iron ore is sometimes added for temperature control. Coke can be
added for carbon control.
If the desired steel temperature and carbon contents are not attained then a re blow is
undertaken. When the end-point conditions are achieved, the converter is tilted is
poured into a 130 tones steel ladle through a tap hole. Alloying materials are added to
the ladle during tapping. Ladle additives, namely for ferromanganese and ferrosilicon,
are weighed out of storage bins and loaded into boxes which are transported by a fork
lifter truck to the steel ladle side of the converter. Two boxes can be positioned
together on a discharging device and the contents added to the ladle. Aluminum bars

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by bags of cokes breeze are added to the ladle by hand. For certain steel speciation
calcium silicates is also added to the ladle.
On completion of tapping, the steel ladle is moved by a self- propelled rail car into the
ladle bay of casting area. The converter is tilted in the opposite direction and the slag
is discharge into the slag pot, which is taken by a self- propelled a rail car to the slag
bay.

STEEL CONVERTER SPECFICATION
The various specification of steel converter’s used in SMD shop is as follows,

No. of converter’s 2 No.’s
Type Top blown oxygen converter
Capacity 130 tons capacity
Working volume 93 M³
Specific volume M³/T 0.68
Ration H/L 1.68
Mouth Dia 2430 mm
Inner Dia 4240 mm
Inner Height 7125 mm
Total thickness of wall brick work 920 mm
No. of bottoms 3 No.s for two converter’s
Total thickness of the safety lining Chrome magnesite
bottom brick work
Working lining Ten bonded dolomite
Lining life 400 heats
Rate of oxygen blowing 450 M³/min
Oxygen blowing time 18 minute (average)
Oxygen consumption 58 Cu.M/Ton.
Tap – to – Tap blowing time 40 Min/Heat
60 Max / Heat

MIXER
The mixer used has the following specifications

No. of Mixer One


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Capacity 1300 tones

CONTINOUS CASTING PROCESS
There are three machines, a 4-stand blooms caster and 2 stand slab caster and 6 stand
of billet caster.
The bloom and slab casters are similar in operation and the difference b/w the
instruments and control systems of the two types of machine are described in the
individual zone reports. The ladle from the steel making shop is moved by crane to a
prepared caster. When stabilization of chemical composition or temperature of the
steel is necessary the ladle is taken to a stirring station and nitrogen is blown through
and immersed lance. The temperature of the steel is measured before the ladle is
placed on a caster turret. When the ladle is positioned correctly on the turret arms the
crane is unhooked and an operating cylinder is fitted to the slide gate valve of the
discharge nozzle. The turret can accommodate two ladles, one in the casting position
and the other in reserve or awaiting removal.

A prepared tundish on a tundish car is positioned over the stands of the caster and the
immersion nozzle for each water-cooled copper mould id fixed in position. A mould is
sealed by the head of a dummy bar inserted through the rollers of the stand.
The turret is rotated to bring the ladle into the casting position above the tundish. The
slide gate valve of the ladle is opened and the tundish is filled to require level. The
tundish stoppers are opened and when the liquid steel in each mould reaches the
required level the respective mould oscillating mechanism and with drawl drive are
started. The continuous cast bloom or slab, on being withdrawn iron the mould, is
sprayed with water in the secondary cooling zone.
During casting the levels in the tundish and moulds are regulated. The casting speed is
set according to the steel temperature; the latter being measured periodically in the
tundish by means of an expandable immersion thermocouple. Water flow to the
secondary cooling zones is regulated as a function of casting speed.
Samples are taken, from the steel flowing into the tundish, for analysis at the express
spectrographic laboratory. The continuous cast bloom or slab is cut to specified length
the gas cutting section. A gas cutter clamps onto the cast steel at a pre-set length and
moves in synchronism until cutting is completed. The cut lengths are moved by roller
table, transfer car and crane to the stock yard.
Series casting can be undertaken if the interval b/w converter tapings allows a new
ladle to be placed on the turret before the slide-gate valve of the previous ladle is
close.
CASTING MACHINE SPECIFICATION
The various specification of continuous casting machines in SMD section are as
follows


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SLAB CASTER

No. of Machines 2 No.’s
No. of Strands Two strands each
Size : thickness 150- 200 mm
Size : width 700-1550mm
Type of machine Radial Curvilinear
Machine radius 10 meter
Casting speed 0.6-0.9 m/minutes
Capacity 825,000 T/year
Machine length
Mould top to last roller 22 meter
Mould top to cutter 36.5 meter
Metal flow control in mould Mono- block tundish stopper

BLOOM CASTER

No. of Machines 1 No
No. of Strands 04 No.s each
Size : 200 x 200 mm 260 x 260 mm
Type of machine Radial
Machine radius 12 meter
Cating speed 1.1-1.2 m/minutes
Capacity 400,000 T/year
Machine length
Mould top to last roller 20 meter
Mould top to cutter 30 meter
Metal flow control in mould Hydraulically operated mono-block
tundish stopper

QUALITY CONTROL SECTION OF SMD


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The quality section of SMD containing no. of quality plant a various place taken fro the
material from IMD and shape into other slabs, blooms etc.
When the molted iron is to be taken from the IMD and then insert it into the mixer the
one of the quality observer has to look after the mixing process because any delay causes
the reduce the temperature.
When the molted iron through ladle insert into the converter the quality
observer has to take the sample of hot metal for analysis as it poured and the
temperature of the charge in the ladle is measured using an expandable
immersion thermocouple.
After blowing the converter is tilled and the temperature of the steel is
measured using an expandable immersion thermo couple. A sample is to be
taken for analysis at he express spectrographic laboratory with in the SMD
building.
The prepared steel in casting section to cast the blooms, slabs the quality
observer taken the temperature of steel and also see the tendish of mould is
properly positioned or not, the cooling system is also ok or not and afterwards
the ladle tap is open steel is casted in various blooms, slabs.
When the casted slabs, blooms getting cooled the quality observer received
various defects of casting because of cooling system these defects are as
o Longitude straight crack
o Longitudinal corner crack
o Auxiliary crack
o Technical
o Mixing
o Ballet etc
the quality observer mark the error and sent the casted slabs to yard section.
At the yard section the length and thickness (which is verifying) and also
the scarfing process is to be done through gas welding to determine the
stability of the crack slab after wards the verifying slab is going to HRM or
hot rolling section.

SUGGESTION

Whatever we observe in SMD section through whole analysis we found the following
those are needed to be change in order to increase the production.
The must be computerized application those gives the perfect composition of
manufactured steel when the air in blowing through lance because to observe the
composition’s specially the %age of carbon (C) and volume or air blowing to get the
required grade of steel through the observation of flame produce during blowing is
totally logical and requires too much experience on the other hand if the blowing
system is computerized which gives the minute to minute to change in composition.

Latest technology should be installed in order to prepare various type of steel instead
to produced steel of various grade.

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HOT STRIP MILL (HSM)

INTRODUCTION
It is one of the most important department
of pak steel. It is situated nearly to the SMD section.
It works to produce the coils of various grad, quality,
variety of the sheets / plates. The coils produced at
this section is either dispatch to sell or it may send to
the CRM for further processing. The manufactured
coil can also be send to the CSSU section if the
shearing or silitted bundle is required. The coils
produced through HSM which is dispatch into the
market varies in thickness and some time more thick
coil can also be dispatch if the required demand is
receive.

PROCEDURE
It is basically a forging process as a name
suggest hot rolled mean the red hoted slab of various
grade is rolled by high pressure and shape it into the
coil by passing through various pressing stand under a
heavy pressure.
It can be started when the verified slabs is to be taken
through yard section hence ensure slabs going over the
rolling section. First one by one slab are put it down
on the rollers now these slabs are measured and then put it into the furnace, the
furnace has a capacity to carry 32 slabs at a time and to heated them at a temperature
more then 1500 degree centigrade therefore rolled the quality observed obtain the
temperature of slab so that it may sustain the roller’s action and hence through control
room it is allowed to perform job.
Now at rolling action there are various stage over which the red- hoted coil has passes
through the following,


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VERTICAL STAND
Its function first to remove all the scrap
from the slab and 2nd the compressed the slab b/w
two rollers, the vertical also controls the width of
the slabs because when the slabs is to be
compressed through passes the width of it needed to
be maintain. After the water from a huge pressure
130 kg is to be applied on the compressed slab and
hence to avoid the compressed to stick each other.

UNIVERSAL STAND
It is one of the basic and it has the capacity to produce 35mm, 30mm,
25mm of thickness of coil (sheet) from 200mm. It also the width as well which is
necessary because when the sheet is to be compressed the width controlling is
necessary. Universal stand contain two type roller i-e back or press roller and working
roller. The coil obtain from universal stand is quit thick but it also has demanded in
market and many times pak steel has provided 35mm thickness of coil to shipping co-
corporation mostly , shipping corporation requires thick coil in making the body of
ship which is need to be to thick.
It is to be remembering that after universal stand the continuous supply of water is
necessary in order to avoid the sheets in the coil to stick each other.

FINISHING STAND
There are 7-finishing stand in this shop which produced the coil of
thickness 2, 3 mm from 30-35mm on final stand. Each stand has two rollers i-e
working rollers and back roller
The quality inspector at this is responsible to watch either posses is successfully done
or not the water which is supplied in proper manner or not and hence watch through all
this can we achieve the required thickness with tolerance or not.


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REFRACTORIES SHOP

INTRODUCTION
o The main purpose of the department is to produce
• Calcined lime for SMD and others.
• Tar bonded dolomite bricks for SMD.
• Fire clay bricks for different uses all-over the Pakistan steel mil.
o The department also deals with repair and installation of refractory bricks lining all
over the plant. It has also a limited capacity to undertake thermal insulation wherever
necessary.

MAJOR SECTIONS OF FIRE-CLAY SHOP
Raw material storage with Crushing Section.
Fire-clay Calcinations Section (Rotary Kiln).
Milling, Mixing and pressing Section.
Brick firing section (Tunnel kiln
Finished Product stockyard.)

MAJOR SECTION OF DELOMITE SHOP
Raw Material Storage with Crushing Section.
Dolomite Calcinations Section (Rotary Kiln)
Milling, Mixing and pressing Section.
Brick Firing Finished Product stockyard.

MAJOR SECTIONOF LIME SHOP


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Lime stone storage section.
Lime calcinations section (rotary kiln).
Waste heat boiler section.
Lime storage section.

a. FIRE CALY SHOP
Installed capacity = 30,000 M.Tons
No. of production lines = 05

MAIN EQUIPMENTS

No. of toggle pressure = 02, Pressing force = 630 tons
No. of friction pressure = 04, Pressing force = 200 tons
No. of Tube mills = 03 capacity = 2T / Hr
No. of rotary kiln = 01, charging rate = 2.50- 3.0 tons / hr

b. DOLOMITE SHOP
Installed capacity = 7,600 M.tons
No. of production lines = 02.

MAIN EQUIPMENTS

No. of hydraulic presses = 02, Pressing force = 1600 T
No. of Tube mills = 01, capacity = 2 T/hr
No. of roll crusher = 01, capacity = 2.5 T/hr
No. of rotary Kiln = 01, charging rate = 2.3 – 2.5 T/hr

C) LIME SHOP

Installed capacity = 87500 M.tons
No. of production lines = 02

MAIN EQUIPMENTS

No. of rotary Kilns = 02, capacity = 20 T/hr
Length = 75 m
Dia = 3.6 m
No. of heat recovery boilers = 02, capacity = 16-18 T/Hr each
No. of shaft coolers = 02, = steam generation


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CHEMICAL COMPOSITION OF RAW MATERILAS
The raw material used for production of fireclay bricks, Tar bonded
Dolomite Bricks and Lime should meet the following requirement.

FIRE CLAY BRICKS

Semi flint Clay Plastic Clay
Al2O3 48.0 % (Min) 36.0 (Min)
Al203+ Ti02 content 51.0 % (Min) 39.0 (Min)
Fe203 content 2.0 % (Max) 35.0 (Max)
SiO2 content 30.0 % (Max) 50-55 %
Alkali 0.005 % (Max) 0.05 % (Max)
L.O.I (lost of ignition) 15.0 % (Max) 14.0 % (Max)
Refractoriness 1790°C 1710°C
Fraction size if in coming material 0.300 mm 0-300 mm
Source KUNDIAN KUNDIAN
(Mianwali) (Mianwali)

RAW DOLOMITE

RAW DOLOMITE
MgO 19.0 % (Min)
CaO content 33.0 % (Max)
SiO2 content 1.0 % (Max)
Al2O3 + Fe203 + 2.0 % (Max)
Ti02+ Mn3O4
L.O.I (lost of ignition) 45-47 % (Max)
Fraction size if in 3-80mm
coiming material
Source PAIKHEL
(Mianwali)


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LIME STONE
LIME STONE
CaO content 53.5 % (Min)
MgO content 1.2 % (max)
SiO2 + Al2O3 content 1.2 % (max)
Fe203 content 0.8 % (max)
L.O.I (lost of ignition) 43-45 %
P contents 0.060 % (max)
Fraction size if in coiming material 20-50mm
Ti02 content 0.25 % (max)
S content 0.025 % (max)
Source MAKLI

FIRE CLAY BRICKS (Finished Products)
Chemical composition and properties

Fe203 content 2.4 %
SiO2 content 42 %
Al2O3 content 47.8 %
CaO content 0.9 %
MgO content 1.3 %
Ti02 content 3.4 %
L.O.I (lost of ignition) 0.18 %
Size variation +1 to -1 mm
Porosity 22.0 % (min)
Density 2.3 g/cm³
Mechanical strength 150 Kg/Cm² (min) 230
Kg/Cm² (average)


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DOLOMITE BRICKS
The chemical composition of calcined dolomite

MgO 34 % (min)
SiO2 2 % (max)
Al2O3 + Ti02+ Mn3O4 4 % (max)
L.O.I (lost of ignition) 1 % (max)
Density 3 g/Cm³

Properties of Tar bonded dolomite bricks / blocks are

Density 2.9 g/Cm³ (min)
Mechanical strength 250 Kg/Cm³ (average)
Size variation Length = +3 to -3 mm
Width = +2 to -2 mm
Height = +1 to -1 mm


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COLD ROLLING MILL (CRM):
This plant is used for the production of the
cold rolled coils which are more beneficial for various
types of works such as sheets pf the vehicles, as well as
the body of the aero planes and etc. an other assignment
is also fulfilled which is of the siliting and shearing
these sheared sheets are used for the flouring, as well as
celling and in various other functions where there hot
rolled sheets are not beneficial.
CRM is the one of the largest and the cleanest
department in the whole steel mill. It is the one of the
best department which always remain clean, all the
products of the steel mill depend on the CRM
department because each and every product has to pass
from that department

CRM contains following units or sections,

i) Continuous pickling unit.
ii) Reversible unit.
iii) Annealing furnace.
iv) Tempering mill unit.
v) Combined slitting and shearing units.
vi) Galvanizing unit.
vii) Profile bending.

Any type of raw material or coil come to CRM department it has to pass all
above mentioned units then that product can be said that it is the completely finished
product. The coil at time of entering in the CRM department is of about 14 tons but at the
time of discharging is of 5 tons sometime for special purpose its weight is increased from
5 tons to 10 tons and the thickness of the coil is below 4 mm ,at CRM it is further reduced
to 1.4 - 1.6mm.

DISCRIPTION OF THE VARIOUS SECTIONS AND THE QUALITY
CONTROL


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CONTINOUS PICKLING UNIT.
It is the unit where the coil came from the hot strip mill (1700mm) by the
underground conveyer belt which directly connects the HSM and the CRM. when the
coil reach at the pickling section there is lifter fixed in the machine whose work is to lift
the coil and wear it on the uncoiler which uncoils the coil and stretch it to the length of
about 5-6m through the coils after that these coils are dipped into the acid bath where all
types of scales has been removed and then goes to the an other stand where its width is
maintained by trimming the rough edges, it is set as follows:
1250 1220
1030 1000
950 900.
After that it passes through gracing stand where it is grecced / oil is applied to coil as it
can be kept prevented from the corrosion and the natural effects.

FUNCTION OF THE PICKLING UNIT:-
The most important function is defined as “hot rolled coils are pickled in order to
remove the scales and layers of the “FeO”iron oxide by the emersion of the sheet into the
hydrochloric acid (HCL)”.

QUALITY CONTROL IN THE PICKLING UNIT.
In the pickling unit quality control only keep an eye on few of important things which
are mentioned as under:
the coil coming from the hot strip mill either it is usable or defective.
the coil’s specifications written on the heat card are correct or not. such as
o heat number
o slab number
o length, width and thickness.

the width at the time of trimming is as per requirement or not.
proper greecing is done at end of the pickling unit. It is done for prevention of the
corrosion.

REVERSIBLE STRAND:-

It is the machine where thickness of the coil is further reduced to the required
size. The is passed through the reversible strand its length is minimized from 3.5mm to
1.45mm or 1.4mm,the coil is passed through the strand according to its thickness
sometimes it passed three times and sometimes it is passed 5 times but counting always
should be in odd numbers not in even. The emulsion solution is used in which 40% of oil

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and 60% of the water is included. The solution used is so much expensive about
Rs.750/lit.

Parts of the reversible strand:-

i) uncoiler
ii) working rollers
iii) supporting/back up rollers.
These are the main parts of the reversible strand. it produces the two types of the coils one
is seen to the galvanizing plant and an other send to the annealing furnace.

QUALITY CONTROL AT REVERSIBLE STRAND.

At the reversible machine mostly there are two most important things to be checked.
The width of the coil
The surface of the coil
There are so many defects sometimes appears on the 0surface of the coil.
Edge waveness
Buckling
Marking
Bubbles
Coil break
Pores

ANNELING FURNACE:-
It is the furnace which is used to improve the internal structure of the coil or to
increase the strength of the material.

MAIN PARTS OF THE ANNELING FURNACE
Main stand .
Tower
Furnace (moveable).
Stove
In annealing furnace at a time there are 4 coils of width 950mm and 3 coils of
the width 1220mm can kept. Duration of the furnace is minimum 18-44 hours depending
on the grade of the coil. Internal atmosphere of the furnace is of nitrogen gas and the
heating process takes places in absence of the oxygen/air. After discharging from the
furnace these coils are cooled


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MAINTENANCE
Today, in modern industry, equipment and a machinery are a very
important part of the total productive effort than was the case years ago. Moreover,
with the developments of special purpose and sophistical machines, equipment and
machinery cost a lot more money and there fore their and does time becomes much
more expensive. For this reason, it is vitally important that the plant machinery should
be properly maintained.

OBJECTIVES OF PLANT MAINTENANCE

i) The objective of plant maintenance is to achieve minimum breakdown and to
keep the plant in good working condition at he lowest possible cost.
ii) Machines and other facilities should be kept in such a condition which permits
them to be used at their optimum (profit making) capacity without any
interruption or hindrance.
iii) Maintenance division of factory ensures the availability of the machines,
buildings, and services required by other section of the factory for the
performance of their function at optimum return on investment whether this
investment be in material, machinery or personnel.

IMPORTANCE OF THE MAINTENANCE
i) The importance of the plant maintenance is varies with the type of the plant
and its production.
ii) Equipment breaks down leads to the inevitable loose of production.
iii) An improperly maintained or neglected plant will sooner or later requires
expensive and frequent repairs, because with the passage of the time all
machines or other facilities (such as transportation facilities), buildings, etc
wear out and need to be maintained to function properly.
iv) Plant maintenance plays a prominent role in production management the plant
break down create problems such as,
• Loss in production
• Rescheduling of production
• Spilet material (because sudden stoppage of process damages in-
process materials).
• Failures to recover overheads (because of loss in production hours).
• Need for over time.
• Temporary work shortage- workers require alternative work.


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MAINTENANCE SECTION IN PAK STEEL MILL
Basically the maintenance section of pak steel can be divided in
various sections or shop depends upon the nature of work which is under consideration.
The maintenance section of pak steel mill can be classified as
i)Pulse mechanical
ii) Central maintenance department (CMD)
iii) Mechanical Equipment and Repair Shop (M.E.R.S)
and various other section those involve in providing the facilities to the production side for
their smooth production run.
Maintenance can be done in the following fashion in any production side,
• Prevantory maintenance
• Break down / emergency maintenance
• Capital maintenance
• Modernize maintenance
Preventary Maintenance
It is one in which we check the plant before starting production either is it ok or
it is not before as we know that the production giving section those were interlink to each other
and hence any type of damage in one part causes to stop the continuality of production and
hence the productivity.
Capital maintenance
The designer of plant section observing the actual life of plant and it can be done when
plant fully maintain, such type of maintenance can be done in year, a month, a day, its upon the
nature of the plant whose maintenance is to be done.
Modernize maintenance
It is one in which the modernize method require to handled the situation hence provide the
flexibility in the plant in order to increase the productivity.

MECHANICAL EQUIPMENT AND REPAIR SECTION
( M.E.R.S)
It is one of the most important maintenance section in pak steel mill. As the name suggest
mechanical equipment repair section means they are involved in repairing the equipment
those are necessary in order to run the smooth production.
The shop work can be start when plant observer observes the lack in a machine by varying
the product and hence obtain the defects now he is responsible to submit these defects to
the plant top management (DM/GM) now the letter is to be issued through the plant with
the machine which requires necessary maintenance and send it to the MERS section.


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Once the letter has been received by maintenance section now the concerned maintenance
section is responsible to arrange all the resources, manpower’s and those necessary things
and after that are schedule for the team now these team ether general or shift.
The requires is to be taken by logistic section
If the maintenance is large so the maintenance authority analysis the whole
problem and then planned the huge maintenance by using the following network
technique’s
• Critical path method (CPM)
• Program evaluation and review technique (PERT)
Once the schedule is made and according to that schedule the
maintenance team has to work over the concerned section.
Now we discussing the department in which we went with MERS maintenance team one
by one.

HOT STRIP MILL (HSM)

As we know that they HSM is one of the most
important department because it converts the red-
hoted slab into various coils and hence it produce the
coil.
In order to achieve the maximum efficiency the
maintenance of HRM is necessary. The procedure as
we have already discussed the plant technician
observer the defect in the running plant and submit the
report to the official and then official send letter to the
concerned maintenance section and hence the
maintenance team’s then responsible to comes in the
concerned department.
MERS assign’s the in charge of maintenance observe
the nature of the job and hence schedule the manpower
according to their skill about the specific job.
e.g
FURNANCE
The furnace used in HSM is one which converts the slab into red hoted form so that the
slabs easily further to roll and hence in last the coil is produce.
The furnace have its own importance and any lacks in furnace may causes to stop the
smooth production therefore in order to achieve maximum productivity in maintenance of
furnace is necessary.


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The maintenance section involves major to remove the defects in furnace like to change
the bricks i-e refractory inside the furnace and it is very to look after the active life of the
refractory.

VERTICAL STAND
Vertical stand is one of the most important it is the first which causes to compress 200mm
thick red hoted slab into the 35mm thickness means it provided basis to other stand for the
further reduce in thick, the key feature of the vertical is that with reducing the thickness it
also control the width of the coil.
The importance of vertical is also to the great extent and properly handled it necessary
which requires a lot of effort by department as well as the maintenance section.
The defect’s occur in vertical stand are mostly as follows the rollers used are some times
replaced and some times sanded for the polish the surface of the roller, sometimes defects
occur and hence some guiding provided by welding and some time the punk plates has to
change and many other defects that can occur and hence the maintenance section is
responsible to over all this defects in order to increase the life of the vertical stand and
hence to increase the productivity.

UNIVERSAL STAND
After vertical the sheet is further rolled in universal stand therefore maintenance section is
also to look after the universal stand and replaced the necessary parts if required and hence
to remove the defects that can be occur during processing. The one of the most major
defect is that the roller is to replaced when their life to be end when they are not in a
position for further grinding and many other parts and things are there depends upon the
nature of the defects.

FINISHING STAND
Once the sheet is obtain from the universal stand the next step is to finishing stand to
further reduce the thick ness and 3mm approximately hence the finishing stand has its own
importance hence the maintenance of the finishing is necessary mostly the maintenance
teams work to change the damp working role and also change the taper rolling heating
inside the cup etc there is many other parts that’s has been replaced or may be welded if
required.
In HSM there is various other part which requires maintenance but here we are not
concerned with all that.


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SINTERING

It is also the one of the most important section is uses the
fine form of ore and convert it into the sinter from by
passing through various process and hence this sinter is
used in blast furnace in order to obtain the molted raw
iron.
To avoid complete break down because of the
maintenance in sintering plant machine -1 is allowed to
running and machine -2 is lying down steadly for
maintenance purpose similarly other concerned part to
machine-2 are also lying down for maintenance purpose
where as the machine-1 performing for the continuity
of the work.
On maintenance day the maintenance has come from
various of its section is responsible to perform the
various some of them that we have seen in sintering shop
which are as follows.

BALLING DRUM

It is used to mixed the sinter and also make the fine into the ball form, now these balling
has to be done by removing flaws and replacing various tools and also fastening various
parts, some of the few important consideration in balling are as follows,
Ring belt is checked and replaced if possible
Gear (driven) and pinion (driver) which rotates the drum is also check and make certain
operation in order to improve their workability.
To adjust the alignment up and down, left and right to support the wheel.

CHRGING DRUM

The material come from conveyer is to be charge over the charging drum so its
maintenance is also much necessary, some necessary action which is to be taken are as
follows
• To check the bearing , map
• Electric arc welding is used to insert flaws

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• Scraper is used to clean the cut and check the charge
• Charge gate has to check and to set it.

PILOT CAR
It is also important part for the continuously of sintering process and hence requires
maintenance as few achieve those have been taken
To check slide plate bars wheel, bearing, and proper lubrication.

CRUSHER

When cake is prepared and is totally burned now the cakes is crushed through jaw crusher
and insert it into the conveyer bucket and now the sinter which crushed sent to the B.F.
The maintenance section is responsible to take the following necessary action.
To check all the jaw’s and hence to repair the jaw’s as well.


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INDUSTRIAL ENGINEERING
DEPARTMENT
DEFINITION:-
Industrial engineering can be defined as the “The engineering which
maximizes the profit by reducing the resources by the best utilization of the tools,
equipments and the industrial techniques.”

FUNCTION:-
Industrial engineering department encompasses activities, which are concerned
with the organized and effective utilization of the manpower with the aim of increasing
the productivity of the organization.

SALIENT FUNCTIONS OF I.ED:-
1. To analyze the requirement of the temporary manpower demaned on the regular
basis by the different departments and to curtail wherever possible.
2. To prepare the directorate-wise daily attendance of the Pakistan steel mill for a
bird eye view of the competent authority.
3. To collect the monthly manpower returns from all departments of the Pakistan
steel for the various studies of the cases and analytical comparisons of the man
power.
4. To asses’ requirement of the temporary workers demanded for the different
projects/specific works.
5. To monitor and allocation of the hazards allowance.
6. Analysis and recommendation for the various types of the contract manpower
including through heeded trust.
7. Monthly recommendation for the allocation of the department-wise overtime
limits.
8. Time-to time preparation of the analytical comparison of the rationalized, regular,
temporary and other holding manpower on the department /directorate basses
directed.
9. Category-wise revision of the wages of the daily wagers and salaries of the
contract employees, whenever desired.

PRESENT EXERCISE:-
IED is conducting an exercise for the requirement of daily wages workers to complete
each project/assignment on the basis of the nature of the job, its inevitability and number
of the persons/duration required for.


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FUTURE PROGRAMME:-
Conduction of the exercise to find out the shortcomings in the area where their
deployment is not in accordance to their suitability and induction of the qualified
engineers with respect to required disciplines.

WORKING OF THE I.E.D NOW A DAY:-
Now a days it is working on the following things;-
1. Attendance.
2. Hazards allowances.
3. Control on the distribution of the uniforms among the employees.
4. Controlling the man power.
5. Keeping the records of the temporary and daily wages employees.

HAZARDS ALLOWNCES;-
There are four categories:-
1. A-ONE(Most hazardous place)
2. A(less than A-one)
3. B(less than A).
4. C(less than B).
There is lot of difference in allowances rates between these categories. These type of
incentives are introduced first time in the Pakistan steel mill in 1984.the committee is
formed whose is responsible for the hazard allowances.


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PREPARED BY

Name: Mohammad Younus

Fathers Name: Mohammad Anwar Qureshi

Surname: Qureshi

Nationality: Pakistani

Date of birth: 24th November 1988

Place of Birth: Hyderabad

Domicile: Hyderabad Urban

Profession: Student

Degree: Graduation (B.E Industrial
Engineering & Management)

Year of Study: Final year.

Roll No. 08IN70

University: Mehran University of Engineering
and Technology (M.U.E.T) Jamshoro.


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Pak steel intership report

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