NAME : - Ayush Kumar SaxenaUniv.roll no. : - 131300104009Academic session : - 2013-2017

DEV BHOOMI INSTITUTE OF TECHNOLOGY AND ENGINEERING.

DEHRADUN (UTTRAKHAND)DEPARTMENT OF MECHANICAL ENGINEERING.

CONTENT

AKNOWLEDGEMENT………………………………………………….3

HISTORY OF THE COMPANY……………………………………….4-5

Company profile…………………………………………………………..6

VISION OF THE COMPANY……………………………………………7

POLICIES OF THE COMPANY……………………..........................8-9

LIST OF DEPARTMENT VISITED IN TRAINING………………..10

SAFETY DEPARTMENT…………………………………………....11-12

PICKLING DEPARTMENT…………………………………………13-14

ROLLING MILL DEPARTMENT…………………………………15-16

ECL DEPEARTMENT……………………………………………..17-19

ANNEALING DEPARTMENT……………………………………....19-22

SKIN PASS MILL…………………………………………………….23-26

QUALITY SYSYTEM……………………………………………....27-28

AKNOWLEDGEMENT

The internship opportunity I had with [BHUSHAN STEEL LIMITED] was a great chance for learning and professional development. Therefore, I consider myself as a very lucky individual as I was provided with an opportunity to be a part of it. I am also grateful for having a chance to meet so many wonderful people and professionals who led me though this internship period.

Bearing in mind previous I am using this opportunity to express my deepest gratitude and special thanks to the MD of [BHUSHAN STEEL LIMITED] who in spite of being extraordinarily busy with her/his duties, took time out to hear, guide and keep me on the correct path and allowing me to carry out my project at their esteemed organization and extending during the training.

I express my deepest thanks to Mr. S.K.GUPTA, Gernal Manager (HR&ADMN.) for taking part in useful decision & giving necessary advices and guidance and arranged all facilities to make life easier. I choose this moment to acknowledge his/her contribution gratefully.

I perceive as this opportunity as a big milestone in my career development. I will strive to use gained skills and knowledge in the best possible way, and I will continue to work on their improvement, in order to attain desired career objectives. Hope to continue cooperation with all of you in the future,

Sincerely,Ayush Kumar Saxena

HISTORY OF THE COMPANY

Year events 1983- The Company was incorporated on 7thJanuary, under the name of Jawahar Metal Industries Private Limited for the manufacture of cold rolled steel strips and steel ingots at Sahibabad Industrial Area, District Ghaziabad.

Bhushan Steel (BSL), earlier known as Bhushan Steel & Strips was incorporated in the year 1983.It is a globally renowned company and is one of the leading prominent players in Steel Industry. Backed by more than two decades, of experience in Steel making, Bhushan Steel is now India 3rd largest Secondary Steel Producer Company with an existing steel production capacity of 2 million tones per annum.

The company has three manufacturing units in the state of Uttar Pradesh (Sahibabad Unit), Maharashtra (Khopoli unit), and Orissa Plant (Meramandali unit) in India and sales network is across many countries. The company is a source for vivid variety of products such as Cold Rolled Closed Annealed, Galvanized Coil and Sheet, High Tensile Steel Strapping, Colour Coated Coils, Galume Sheets and Coils, Hardened & Tempered Steel Strips, Billets, Sponge Iron, Precision Tubes and Wire Rod..

BSL  clientele includes automobile and home appliances majors  like General Motor, Hyundai Motors, Ford Motors, Mahindra & Mahindra, Eicher Tractors, Ashok Leyland, LG Electronics, Whirlpool, Videocon, Daikin, Samsung Electronics, Godrej, Voltas, IFB, Carrier Refrigeration, Electrolux Group amongst others.The company is on due course o become a fully Integrated Steel & Power Company with market leading offerings in value added Steel in Automotive and White Good Segment with the quality  been approved by ISO 9002 and QS 9000.v

Recognition:

BSL has received ISO 14001:2004 certification for Environmental Management System.

BSL has received ISO/TS 16949:2002 certification for Quality Systems

Milestone:

Most brilliant milestone in BSl journey of excellence is setting up of Steel and Power Plant in Orissa. On completion, the Plant will be one of the largest integrated Hot Rolled Steel and Power complexes of the nation.

BSL has emerged as the countries largest and the only CR Steel Plant with an independent line for manufacturing Cold Rolled Coils and Sheets up to a width of 1700mm, as well as Galvanized Steel Coils and Sheets up to width of 1350mm.

Bhushan Steel has transformed to 3rd largest producer of Cold Rolled Steel with an installed capacity of one million tons and sales of more than USD 1 Billion.

Focused on niche high value added segment of automobile and white goods, the company today is a leader in these segments.

The company is first to set up a high Tech Plant in 1996 to cater to auto mobile and white good sector, in technical tie up with Sumitomo Metals, Japan.

Finally, the company is profit making and paying dividend since its inception.

COMPANY PROFILE

Date of Establishment : - 07-01 1983

Revenue : - 1676.87 (USD in Millions)

Market Cap : - 8437.6450845 (Rs. in Millions)

Corporate Address : - Office No. 33, Basement, Mona Shopping Centre, J.P Road, Near Navrang Cinema Andheri (West)Mumbai

400058, Maharashtra. www.bhushansteel.com

Management Details

Chairperson - Brij Bhushan Singal MD - Neeraj Singal Directors - Vipin Anand, Rahul Sengupta, Rajesh Yaduvanshi, A K Deb, Kapil Vaish, Pankaj Sharma, Sahil Goyal , Pradeep Patni, Rakesh Singhal, Ashwani Kumar, M V Surya Narayana, BB Tandon, P K Aggarwal, Nittin Johari.

Business Operation : - Steel & Iron Products

Financials: - Total Income - Rs. 106592.778 Million (year ending Mar 2015) Net Profit - Rs. -12538.28 Million (year ending Mar 2015)

Auditors- Mehra Goel & Co, Mehrotra & Mehrotra

VISION OF THE COMPANY

The key to Vision is to use rigorous conceptual framework and to understand how that framework connects to the underlying DNA of enduring great companies.

A well-conceived vision consists of two major components —"CORE IDEOLOGY" and an "ENVISIONED FUTURE". A good vision builds on the interplay between these two complementary Yin-and-Yang forces; it defines "What we stand for and Why we exist" that does not change the Core Ideology and sets forth "What we aspire to become, to achieve.

It is true to say that most of our vision statements express an element of ambition.BSL's vision of total integration is a lot closer to realization today. Through seamless backward integration, BSL is consolidating its position on the entire steel value chain from iron ore to spedalized is surging ahead.

POLICIES OF THE COMPANY

Bhushan Steel is leading the technological revolution in Indian Cold Rolled Steel Industry today and defining new frontier of customer satisfaction. Be it through technology and product upgrades, R&D efforts or stringent quality control measures, company is consistent in its pursuit of value.

Bhushan Steel has earned a Quality Standards by getting many Certifications.

QUALITY POLICY

BHUSHAN STEEL LIMITED aspires to make the difference in Steel Industry by becoming the most favoured Supplier, producing the wide range of premium quality products by adopting the latest technology, processes and equipments. We are committed to provide value to our customers by providing the best of products and services through enhanced customer co-ordination, better team work and continual improvement of products, technology, and manpower and capability enhancement.

SAFTY AND HEALTH POLICY

BHUSHAN STEEL LIMITED hicanundali Ohrnkanil SAFETY & HEALTH POLICY Bhushan Steel limited is committed to provide Safe & Healthy work environment to its workmen through adoption of best technology and sound operating practices.

HR POLICY

Bhushan Steel recognizes that its Human Capital is an important source of its competitiveness.

It will pursue management practices designed to foster meritocracy.

Bhushan Steel shall strive to attract best available talent ensuring a diverse workforce.

ENVIRONMENTAL POLICY

Bhushan Steel Limited Is committed to protect environment by-

Ensuring continual improvement in environmental -.7 performance. Complying with applicable environmental legislations and regulations. Setting time bound environmental objectives to control various kind of environmental pollution like air, water, noise and solid waste etc.

Conserving resources like fuels, raw materials, water and energy. Developing green areas in and around the plant.

Communicating the policy to all employees and making them environmental aware workforce.

Displaying the policy and making it available to the public on demand.

Reviewing the policy once in a year or whenever there Is any change in operations to verify its suitability.

LIST OF DEPARTMENT VISITED IN TRAINING

S.NO Department HOD

1 Safety Mr. Sudhir Kumar

2 Pickling Mr. LR Singh

3 Rolling Mill Mr.Neeraj Sharma

4 ECL Mr. Manish sirsikar

5 Annealing Mr.Neeraj Gupta

6 Skin pass mill Mr.Satyaveer

7 Finishing Mr. AK Kansal

8 Quality System Mr. Deepak Agarwal

9 GP-1 Mr. R C Singh

10 Utility Mr. AK gupta

11 Mechanical maintenance Mr.Amit Sharma

12 Narrow Plant Mr.Sarvesh

13 Electrical maintenance Mr. Rajesh Gupta

SAFETY DEPARTMENT

Bhushan Steel is committed towards a safer and healthier work environment. For safety measures training we have a dedicated audio-video centre at all our plants. Every worker is provided with proper first-in-class safety equipment making it safe for them to undertake different tasks throughout the day.  Mock drills and seminars that are conducted on a monthly basis also help in cross-checking the safety knowledge and awareness amongst the workers, and bridge any communication gap that might exist between the workers and our safety department. Regular health check-ups are done at the plant, with compulsory participation for all workers to make certain that their health is not being compromised in anyway.

Everyone entering the plant has to go through a safety training program, in which we teach them all the basic measures that one needs to follow in case of emergencies and in general. The task here is to inform, educate and train employees and visitors in the vicinity of the plant about the hazards and preventive measures. A specifically shot safety video gives a proper demonstration of how different safety measures are being undertaken at Bhushan Steel. Mock drills are conducted every month with four mock drills witnessed by the respective district authorities every year.

With an extensive safety and health policy in place, a comprehensive system is built around the framework of the plants to manage safety measures of the highest order. It involves daily rounds by HODs of every department, appointment of safety captains, officers and internal as well as external safety audits to look into preventive and safety measures for the plant. A unique safety rewards and penalty program has been introduced with regular inspections and checks.

At our Odisha plant we also have a 6-bedded Occupational Health Center that stands in service with two 24-hours in-house doctors, adequate medical staff and ambulance.

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PICKLING DEPARTMENT

Pickling (metal)

Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic contaminants, rust or scale from ferrous metals, copper, and aluminum alloy. A solution called pickle liquor, which contains strong acids is used to remove the surface impurities. It is commonly used to descale or clean steel in various steelmaking processes.

Process Many hot working processes and other processes that occur at high temperatures leave a discoloring oxide layer or scale on the surface. In order to remove the scale the work piece is dipped into a vat of pickle liquor.

The primary acid used is hydrochloric acid, although sulfuric acid was previously more common. Hydrochloric acid is more expensive than sulfuric acid, but it pickles much faster while minimizing base metal loss. The speed is a requirement for integration in automatic steel mills that run production at high speed; speeds as high as 800 ft/min (-243 meters/min) have been reported.

Carbon steels, with an alloy content less than or equal to 6%, are often pickled in hydrochloric or sulfuric acid. Steels with alloy content greater than 6% must be pickled in two steps and other acids are used, such as phosphoric, nitric and hydrofluoric acid. Rust- and acid-resistant chromium-nickel steels are pickled in a bath of hydrochloric and nitric acid. Most copper alloys are pickled in dilute sulfuric acid, but brass is pickled in concentrated sulfuric and nitric acid mixed with sodium chloride and soot.

In jewelry making, pickling is used to remove the oxidation layer from copper surfaces, which occurs after heating. A diluted sulfuric acid pickling bath is used. Sheet steel that undergoes acid

picking will oxidize (rust) when exposed to atmospheric conditions of moderately high humidity. For this reason, a thin film of oil or similar waterproof coating is applied to create a barrier to moisture in the air. This oil film must later be removed for much fabrication, Plating or painting processes.

Steel pickling is part of the finishing process in the production of certain steel products in which oxide and scale are removed from the surface of strip steel, steel wire, and some other forms of steel, by dissolution in acid. A solution of either hydrogen chloride (Hcl) or sulfuric acid is generally used to treat carbon steel products, while a combination of hydrofluoric and nitric acids is often used for stainless steel. Steel pickling and the associated process of acid regeneration result in the emission of hazardous air pollutants (HAPs).

Pickling Process.

ROLLING MILL DEPARTMENT

In metalworking, rolling is a metal forming process in which metal stock is passed through a pair of rolls. Rolling is classified

according to the temperature of the metal rolled. If the temperature of the metal is above its recrystallization temperature, then the process is termed as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is termed as cold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process and cold rolling processes the most tonnage out of all cold working processes.

There are many types of rolling processes, including fiat rolling, foil rolling, ring rolling, roll bending, roll forming, profile rolling, and controlled rolling.

Hot rolling is a metalworking process that occurs above the recrystallization temperature of the material. After the grains deform during processing, they recrystallize, which maintains an equiaxertrnicrostnictiire and prevents the metal from wo. Hardening. The starting material is usually large pieces of metal, like semi-finished casting products, such as slabs, blooms, and billets. If these products came from a continuous casting operation the products are usually fed directly into the rolling mills at the proper temperature. In smaller operations the material starts at room temperature and must be heated. This is done in a gas- or oil-fired soaking pit for larger work pieces and for smaller work pieces induction heating is used. As the material is worked the temperature must be monitored to make sure it remains above the recrystallization temperature. To maintain a safety factor a finishing temperature is defined above the recrystallization temperature; this is usually 50 to 100 °C (122 to 212 °F) above the recrystallization temperature. If the temperature does drop below this temperature the material must be re-heated before more hot rolling.

Hot rolled metals generally have little directionality in their mechanical properties and deformation induced residual stresses.

However, in certain instances non-metallic inclusions will impart some directionality and work pieces less than 20 mm (0.79 in) thick often have some directional properties. Also, non-uniformed cooling will induce a lot of residual stresses, which usually occurs in shapes that have a non-uniform cross-section, such as I-beams and H-beams. While the finished product is of good quality, the surface is covered in mill scale, which is an oxide that forms at high-temperatures. It is usually removed via pickling or the smooth clean surface process, which reveals a smooth surface. Dimensional tolerances are usually 2 to 5% of the overall dimension.

Hot rolling is used mainly to produce sheet metal or simple cross sections, such as rail tracks.

Material Specification:- Pickled HR coil/ annealed CR Coil of various Grades

Dimensional Specification:- Min. Max.Width 700MM 1700MMMaterial I/P Thickness 1.8MM (HR) 7.0MM Wt. of coil 3.0MT 30MT CR Thickness 0.11MM 6.95MM

Line Specification:-Maximum Speed 1200MPMTension 16 T max.

ECL DEPEARTMENT

Electrochemical Cleaning (ECL). Is a very effective process using the same physic. Equipment and chemicals we use in our proprietary "spot" electro polishing technique. Discovered when a customer had a product residue issue that looked like classic "rouge" yet when industry accepted de-rouging chemical applications were tried they proved completely ineffective. In an experiment we used the spot electro polish procedure whereby electrolyte was applied to the stained surface and the DC current was activated and the "hand tool" was applied to and moved over the surface the stain was removed immediately. Because of this discovery we were able to completely clean 5, 10,15K GALLON & larger vessels in hours instead of days.

Once discovered this method has found several v, cost effective applications where ECC can be used in place A more expensive and less effective chemical or manual processes while delivering a micro surface improvement to the area being cleaned where optional processes at best do nothing to improve and at worst can etch the micro surface.

Application

De-rouging: ECC has been found to be very effective for removing rouge for both electro polished and non-electro polish. Surfaces. An added benefit observed on items de-rouged using ECC is the rouge is very slow to return. Though conventional de-rouging and passivation methods would yield a clean product contact surface the rouge would begin to reform in a matter of hours. Equipment de-rouged using ECC has shown the rouge resisted returning for months and in some cases years.

Grey Residue: On equipment with a sanded or mechanically polished stainless steel surface only it is common to find a grey

residue present when the surface is wiped with an alcohol soaked cloth. In many instances the entire surface of a vessel, as an example, will be hand wiped for hours using "clean wipes" until all of the grey residue has appear. To have been removed. The vessel may then be passivated or cleaned in place and allowed to dry only to have the grey residue return at visibly the same concentration as observed before the cleaning operation.

It is believed this grey residue is made up of stainless stool powder created by the sanding process and electro statically adhered to the mechanically polish. Surface (PIC). No amount of wiping or chemical cleaning has proven to completely remove this residue. Understandably Quality Control personnel find this condition unacceptable concerned if the grey residue can be wiped off, it stands to reason it can come loose during product processing and become an undesirable additive.

ECC can completely remove this grey residue in one application by electrolytic action as metal is removed ion by ion with the very outermost surface and any residue being removed. In dozens of applications this condition has successfully been treated in one application eliminating grey residue from the equation.

Weld Scale and Discoloration: Prior to successful use as a de-rouging of surface contaminant removal process, ECC was developed specifically for removing weld discoloration directly on a weld of in the heat affected zone. Adjacent to the weld. The process utilizes a mild acid electrolyte solution and DC current that when applied to a weld or heat affected zone (H.) very rapidly removes discoloration. On large construction projects utilizing austenitic, super- autarkic or nickel alloys, weld discoloration has historically been removed by mechanical polishing, blasting or a harsh chemical application, all of which alter the appearing when compared to untreated surround', surfaces. The proce. Has also

been shown to improve corrosion resistance in the. Areas comparable to that of the surrounding base metal.

ANNEALING DEPARTMENT

Annealing, in metallurgy and materials science, is a heat treatment wherein a material is altered, causing changes in its properties such as strength and hardness. It is a process that produces conditions by heating to above the recrystallization temperature, maintaining a suitable temperature, and then cooling. Annealing is used to induce ductility, soften material, relieve internal stresses, refine the structure by making it homogeneous, and improve cold wowing properties.In the cases of copper, steel, silver, and brass, this process is performed by substantially heating the material (generally until glowing) for a while and allowing it to cool. Unlike ferrous metals—which must be cooled slowly to anneal—copper, silver and brass can be cooled slowly in air or quickly by quenching in water. In this fashion the metal is softened and prepared for further wo. Such as shaping, stamping, or forming. Thermodynamics Annealing occurs by the diffusion of atoms within a solid material, so that the material progresses towards its equilibrium state. Heat is needed to increase the rate of diffusion by providing the energy needed to break bonds. The movement of atoms has the effect of redistributing and destroying the dislocations in metals and (to a lesser extent) in ceramics. This alteration in dislocations allows metals to deform more easily, so increases their ductility.The amount of process-initiating Gibbs free energy in a deformed metal is also reduced by the annealing process. In practice and

industry, this reduction of Gibbs free energy is tenned "stress relief". •The relief of internal stresses is a thermodynamically spontaneous process; however, at room temperatures, it is a very slow process. The high temperatures at which the annealing process occurs serve to accelerate this process. The reaction facilitating the return of the cold-worked metal to its stress-free state has many reaction pathways, mostly involving the elimination of lattice vacancy gradients within the body of the metal. The creation of lattice vacancies is governed by the Arrhenius equation, and the migration/diffusion of lattice vacancies are governed by Fick's laws of diffusion. Mechanical properties, such as hardness and ductility, change as dislocations are eliminated and the metal's crystal lattice is altered. On heating at specific temperature and cooling it is possible to bring the atom at the right lattice site and new grain growth can improve the mechanical properties.

Stages

There are three stages in the annealing process, with the first being the recovery phase, which results in softening of the metal through removal of crystal defects (the primary type of which is the linear defect called a dislocation) and the internal stresses which they cause. Recovery phase covers all annealing phenomena that occur before the appearance of new strain-free grains. The second phase is recrystallization, where new strain-free grains nucleate and grow to replace those deformed by internal stresses. If annealing is allowed to continue once recrystallization has been completed, grain growth will occur, in which the microstructure starts to coarsen and may cause the metal to have less than satisfactory mechanical properties.

Controlled atmospheresThe high temperature of annealing may result in oxidation of the metal's surface, resulting in scale. If scale is to be avoided, annealing is carried out in a special atmosphere, such as with endothermic gas (a mixture of carbon monoxide, hydrogen gas, and nitrogen gas).The magnetic properties of mu-metal (Espey cores) are introduced by annealing the alloy in a hydrogen atmosphere.

Setup and equipmentTypically, large ovens are used for the annealing process. The inside of the oven is large enough to place the wo.piece in a position to receive maximum exposure to the circulating heated air. For high volume process annealing, gas fired conveyor furnaces are often used. For large workpieces or high quantity parts Car-bottom furnaces will be used in order to move the parts in and out with ease. Once theannealing process has been successfully completed, the workpieces are sometimes left in the oven in order for the parts to have a controlled cooling process. While some workpieces are left in the oven to cool in a controlled fashion, other materials and alloys are removed from the oven. After being removed from the oven, the workpieces are often quickly cooled off in a process known as quench hardening. Some typical methods of quench hardening materials involve the use of media such as air, water, oil, or salt. Diffusion annealing of semiconductors In the semiconductor industry, silicon wafers are annealed, so that dopant atoms, usually boron, phosphorus or arsenic, can diffuse into substitutional positions in the crystal lattice, resulting in drastic changes in the electrical properties of the semi conducting material.NormalizationNormalization is an annealing process in which a metal is cooled in air after heating in order to relieve stress.

It can also be referred to as: Heating a ferrous alloy to a suitable temperature above the transformation temperature range and cooling in air to a temperature substantially below the transformation range. This process is typically confined to hardenable steel. It is used to refine grains which have been defamed through cold work, and can improve ductility and toughness of the steel. It involves heating the steel to just above its upper critical point. It is soaked for a short period then allowed to cool in air. Small grains are formed which give a much harder and tougher metal with normal tensile strength and not the maximum ductility achieved by annealing. It eliminates columnar grains and dendritic segregation that sometimes occurs during casting. Nornializing improves machinability of a component and provides dimensional stability if subjected to further heat treatment processes. Process annealing Process annealing, also called "intermediate annealing", "subcritical annealing", or "in-process annealing", is ahttreatment cycle that restores some of the ductility to a WO. Piece allowing it be worked further without breaking. Ductility is important in shaping and creating a more refined piece of WO. Through processes such as rolling, drawing, forging, spinning, extruding and heading. The piece is heated to a temperature typically below the austenizing temperature, a. held there long enough to relieve stresses in the metal. The piece is finally cooled slowly to room temperature. It is then ready again for additional cold working. This can also be used to ensure there is reduced risk of distortion of the work piece during machining, welding, or further heat treatment cycles.

SKIN PASS MILL

After annealing, coils may require a final rolling called a temper pass, skin pass or planish pass. This involves a controlled light reduction to establish the final thickness, impart the desired surface finish, flatten the strip to improve shape and create the required hardness or temper of the material.

COLD ROLL SLITTING / CUT TO LENGTH

Some customers require a steel to be of a particular thickness other than the general increment sizes rolled in the hot mill or thinner than the minimum thickness rolled in the mills. These steels are processed in the cold roll reduction mill. These mills are capable of rolling steel to the precise thickness that the customer orders and are a major part of the steel strip production process. The reduction mill in the plant I worked had four rolls in the mill that were stacked upon each other. This arrangement is known as a two high mill. There are two working rolls between which the strip is passed and two large back-up rolls, one on top of the working rolls and one on the bottom. The back-up rolls apply the tremendous pressures required to cold roll (reduce) the strip between the

working rolls. The working rolls are usually about two to three feet in diameter while the back-up rolls are about seven to eight feet in diameter. The rolls are made of high alloy steel so they can withstand the tremendous pressure they are under while rolling without deforming.

Because of this the rolls are ground in a large lathe using a very large grinding wheel on a movable carriage. Depending on the surface finish required of the strip the working rolls will either have a highly polished (mirror like) finish or a dull finish on them. All working rolls are ground on the lathe in the mill to a highly polished surface periodically. The rolls that have a dull finish on them are shot blasted after grinding to produce the desired surface.After grinding to a polished surface the rolls that need a dull finish are placed on a large carriage which has a set of rubber rolls on it. The carriage then travels on a small rail track into a large enclosure and the door is closed down. On top of this enclosure is a large hopper filled with fine steel balls called shot. This shot is very small in diameter (about half the size of a BB or smaller) and is very hard. It is fed down a chute and using either compressed air or a impeller type system it is accelerated to high speed (in excess of a hundred miles per hour) and blasted against the surface of the roll. The rubber rolls on the carriage rotate causing the steel roll to rotate so all its surface is exposed to the shot blast. The shot comes in a variety of sizes and hardness grades and different types are used depending on the type of surface finish required on the rolls. After a predetermined cycle time the roll is removed from the Wheelabrator, as it is called and is ready to be used in the mill.

A saddle type conveyor runs along the side of the reduction mill. Steel coils are place on this conveyor by overhead cranes using the

same .C. hook as at the entry and exit ends of the pickle lines. This saddle conveyor moves the coils along to the reduction mill where they are lowered onto a frame at the entry side of the mill. A transfer saddle operated by the mill operator moves out to the frame and picks up the coil and moves it back into the feed mandrel on the entry side. The operator cuts the strap, freeing up the loose end of the coil. He opens a space between the work rolls and feeds the end of the exit side. On the exit side is another expandable mandrel the same as the catcher mandrels of the hot mills and pickle line. The entry operator feed the strip until the exit operator can catch the end in the open segment of his mandrel, expanding it and trapping the end of the strip. The entry operator then closes the gap in the working rolls down on the strip. Pressure (thousands of tons) is applied by the back-up rolls by means of hydraulically operated screws, to the wowing rolls and the reduction rolling process begins. If the thickness of the steel needs to be greatly reduced, the strip will be passed back and forth between the rolls a number of times with the rolls adjusted for each pass. Due to the great amount of pressure exerted in the reduction process the steel strip becomes very hot. In order to prevent the steel from becoming hot and sticking to the work rolls, the rolls are flooded with a coolant consisting of 95% water and the other 5% water soluble oil. The end of the strip that is in the exit mandrel is not released in the multiple pass process nor is it completely unwound from the entry mandrel. In the final pass through the reduction mill, the portion that was not reduced from the entry end is trimmed off in a set shears just before they enter the work rolls to the exit side. A transfer saddle on the exit side then moves the coil back onto the conveyor that runs beside the mill.

QUALITY SYSYTEM

Quality control is a process by which entities review the quality of all factors involved in production. This approach places an emphasis on three aspects 1. Elements such as controls, job management, defined and well managed processes, performance and integrity criteria, and identification of records2. Competence, such as knowledge, skills, experience, a. Qualifications3. Soft elements, such as personnel integrity, confidence organizational

The quality of the outputs frisk if any of these three aspects is deficient in any way.

Quality control emphasizes testing of products to uncover defects, and reporting to management who make the decision to allow or deny the release, whereas quality assurance attempts to improve and stabilize production, and associated processes, to avoid, or at least minimize, issues that led to the defects in the first pun For contract work, particularly work awarded by government agencies, quality control issues are among the top reasons for not renewing a contract.

"Total quality control", also called total quality management, is an approach that extends beyond ordinary statistical quality control techniques and quality improvement methods. It implies a complete overview and re-evaluation of the specification of a product, rather than just considering a more limited set of changeable features within an existing product. If the original specification does not reflect the correct quality requirements,

quality cannot be inspected or manufactured into the product. For instance, the design of a pressure vessel should include not only

the material and dimensions, but also operating, environmental, safety, reliability and maintainability requirements, and documentation of findings about these requirements.

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