Report

INTERNSHIP REPORT

2013

AMRELI STEELS

NED UNIVERSITY OF ENGINEERING

AND TECHNOLOGY

INTERNEES:

1. MUHAMMAD ADEEL

2. SAMIULLAH

INSTITUTE:

NED UNIVERSITY OF ENGINEERING AND TECHNOLOGY

Submitted To:

AMRELI STEEL PVT LTD

DATE: 24-12-2013

ACKNOWLEDGEMENT

First of all, we thank Almighty Allah, most merciful, who bestowed us with the ability to

think, work and deliver what we were assigned to do.

Amreli steel industry is an excellent opportunity for learning and self-development. We

consider ourselves fortunate and honored to have so many wonderful people lead us

through in completion of this project.

Mr. Shabbir Hussain, executive manager, Plant Head of Amreli Steel monitored our progress

and arranged all facilities to make it easier; we choose this moment to acknowledge his

contribution gratefully.

My great thanks to Mr. Innayatullah, Senior Manager Maintenance, and Mr. Jamsheed,

Manager Mechanical Maintenance, who inspite of being too busy with their duties took

time out to hear, guide and keep us on the correct path.

We especially thank to all the engineers and workers who shared their valuable knowledge

during our internship.

Table of Contents

ACKNOWLEDGEMENT ................................................................................................................ 2

1. AMRELI STEELS.................................................................................................................. 5

INTRODUCTION: .................................................................................................................... 5

HISTORY: ................................................................................................................................ 5

COMPANY’S PROFILE: ............................................................................................................ 5

CROWNING GLORY: ............................................................................................................... 6

VISION: .................................................................................................................................. 6

MISSION: ............................................................................................................................... 6

AMRELI CERTIFICATIONS & AWARDS .................................................................................... 6

FLOW CHART ......................................................................................................................... 8

STEEL MELT SHOP BILLET COMPOSITIONS ............................................................................ 9

BILLET LENGTH REQUIREMENT ............................................................................................. 9

2. FURNACE DEPARTMENT ................................................................................................. 11

2a. SPECIFICATION: ............................................................................................................. 11

2b. FURNACE EQUIPMENTS ................................................................................................ 13

NATURAL AND MECHANICAL DRAFT: ............................................................................. 13

COMBUSTION BLOWER: ................................................................................................. 13

INDUCED DRAFT FANS (I.D FAN): ................................................................................... 14

HYDRAULIC PUSHERS AND EJECTORS: ........................................................................... 14

CHARGING GRIT: ............................................................................................................. 14

COMPRESSORS AND PUMPS: ......................................................................................... 15

2c. DETAILS (IN A NET SHELL) .............................................................................................. 15

3. MILLING ZONE ................................................................................................................ 16

3a. MILLING AREAS:............................................................................................................. 16

3b. FLOW DIAGRAM: ........................................................................................................... 17

4. THERMO MECHANICAL TREATMENT ............................................................................. 18

4a. MECHANISM: ................................................................................................................. 18

4b. ADVANTAGES: ............................................................................................................... 18

5. UTILITY DEPARTMENT: ................................................................................................... 19

5a. COMPRESSOR AND DRYING SYSTEM: ........................................................................... 19

SPECIFICATION: ............................................................................................................... 19

USE OF COMPRESSED AIR: .............................................................................................. 19

5b. WATER SYSTEM: ............................................................................................................ 19

5c. FLOW CHART.................................................................................................................. 20

5d. SPECIFICATION: ............................................................................................................. 21

CLEAR WATER SYSTEM ................................................................................................... 21

TMT WATER SYSTEM ...................................................................................................... 21

FURNACE WATER SYSTEM .............................................................................................. 22

MILL COMPLEX WATER SYSTEM ..................................................................................... 22

6. QUALITY CONTROL DEPARTMENT .................................................................................. 24

6a. PRODUCTS SPECIFICATIONS AND PROPERTIES: ............................................................ 25

XTREME BARS G-500W: .................................................................................................. 25

PRODUCT SPECIFICATION: .............................................................................................. 25

MECHANICAL PROPERTIES OF XTREME BARS ................................................................ 25

6c. DEFORMED BARS G-60 .................................................................................................. 26

PRODUCT SPECIFICATION: .............................................................................................. 26

MECHANICAL PROPERTIES OF DEFORMED BARS G-60 .................................................. 26

7. OIL SYSTEM ..................................................................................................................... 28

8. RECOMMENDATION ....................................................................................................... 28

9. CONCLUSION .................................................................................................................. 29

1. AMRELI STEELS

INTRODUCTION: Amreli Steels is one of the largest manufacturers of steel reinforcement bars in Pakistan industrial hub; its plant uses one of the most modern hot rolling mill technologies in the industry and is capable of continuously producing straight bars up to 35 tons per hour. This translates into an annual production capacity of approx. 150,000 metric tons. ASL use state-of-the-art equipment and our high degree of automation enable it to produce a high quality product that falls well within established international standards.

HISTORY: Amreli Steels established in 1984, is the power house that drives the steel bar sales in Pakistan since many decades. Prior to 1984, the Company was operating manual re-rolling mills to manufacture mild steel bars. These rolling mills were dependent for raw material on the family-owned ship breaking business. What started off as a small family owned hand rolling mills business is today a professionally run corporate entity, a fully automatic state-of-the-art mill that produces quality steel bars on International Standards that are followed all over the world. With internationally educated young entrepreneurs, and some very experienced senior professionals in the family at the helm, the company is being steered into the 21st century with ideas that are sure to put the industry in awe. A well-educated and professionally trained staff is putting management ideas and vision into action and making a success story out of it. With traditional values like “Customer is King” and services that are second to none, Amreli has been consistently delivering good quality and timely deliveries which has given its customers confidence and have over the years developed a trust that is unrivaled in the industry today. With a database of customers spanning every major industry in the country, Amreli has been an industry leader since the two decades.

COMPANY’S PROFILE: Amreli Steels Limited is one of the largest manufacturers of Steel Reinforcement Bars in Pakistan. Situated in the industrial hub of Karachi, our plant uses one of the most modern hot re-rolling mill technologies in the industry and is capable of continuously producing straight bars up to 35 tons per hour. This translates into an annual production capacity of 150,000 metric tons. We use state-of-the-art equipment and our high degree of automation enables us to produce high quality products that falls well within established international standards.

At Amreli, we have created a strong culture based on values that have been a part of our long tradition. The hallmark of our success is our reputation as a company that generates and supports exceptional levels of opportunity, initiative and goodwill. During the past two decades, Amreli Steels has achieved many milestones that have contributed to its success today. We believe in using the most sophisticated re-rolling technologies available in the world and our strategic partnerships with the world’s most prominent re-rolling mill manufacturers has realized our dream to be truly unique, and the best in Pakistan.

CROWNING GLORY: With the recent addition of a state-of-the-art melt shop at Dhabeji, the company accomplished yet another milestone not only for itself but also for the nation. We are now producing our own high quality billets in our melt shop that are then transferred to our rolling mill where we are manufacturing the next generation 500MPA High Strength Deformed Bars (Xtreme G-500), the backbone of modern construction throughout the world.

VISION: We are committed to setup integrated steel manufacturing facilities, value added services and other diversified businesses with the employment of best human resources and systems implementation. We aim to achieve a high profitable growth rate, create value for our shareholders and customers, and to look after the well-being of our employees and their families.

MISSION: Amreli Group exists to carry forward its family legacy by maintaining its dominant position in trade and industry by being socially compliant and contributing to the well being of shareholders and employees.

AMRELI CERTIFICATIONS & AWARDS Amreli Steels is the only company in the steel industry so far which has received the prestigious 4th Consumers’ Choice Award by Consumers Association of Pakistan.

ISO 9001-2008:- In support of our quality policy, Amreli Steels has established a formal management system conforming to ISO 9001: 2008. We are an ISO 9001: 2008 certified company. PSQCA CERTIFICATION:- All our products are also approved and certified Pakistan Standards Quality Control Authority (PSQCA) Amreli have recently registered their plant under Self-Monitoring and Reporting Program (SMART), monitored by Pakistan Environmental Protection Agency under the umbrella of Ministry of Environment, Government of Pakistan.

FLOW CHART

FINISHING ROLLER

INTERMEDIATE MILL

ROUGHING MILL

BILLET DISCHARGE

REHEATING FURNACE

BILLET CHARGING

CUT BILLET YARD

BY PASS

(if 3m)

BILLET SHEARING

(if 6m)

BILLET INSPECTION

BILLET STORAGE

RAW MATERIAL (in bullet form)

PLACE IN WARE HOUSE

BUNDLING

BARS CUT TO DESIRED LENGTH

SCRAP

REJECTION

IN CASE OF FAILURE

MECHANICAL TESTING

COOLING BED

TMT PROCESS

3 Meter

Minimum

2.8 m

Maximum

3.1 m

6 Meter

Minimum

5.6 m

Maximum

6.2 m

STEEL MELT SHOP BILLET COMPOSITIONS In Amreli, steel billets have different color coding according to their chemical composition and carbon equivalent number

ASL

Grade

Color

Coding

Billet

Chemistry

Carbon

Equivalent

Size to

be Roll

BS 4449-1

Green

(Cut in 6 m)

C 0.18-0.26%

0.36-0.38

(For Xtreme bars

up to 25 mm)

12-16 mm P <0.05%

Si 0.15-0.3%

S <0.05%

Mn 0.6-0.8%

BS 4449-2

Blue

(Cut in 3 m)

C 0.26-0.3%

0.39-0.44

(For G-60 bars

up to 25 mm)

19-22 mm P <0.05%

Si 0.15-0.3%

S <0.05%

Mn 0.6-0.8%

Bs 4449-3

Yellow

(Cut in 6 m)

C 0.-0.24%

Max. 0.35

(Only for 3/8

rolling)

9.5 mm P <0.05%

Si 0.15-0.3%

S <0.05%

Mn 0.55-0.65%

Special Grade

Red

(Cutting vary)

C 0.22-0.25%

0.48-0.51

40 mm P <0.05%

Si 0.-0.3%

S <0.05%

Mn 1.05-1.15%

NOTE:

o If P% is greater than 0.05 then cutting length should be 3m o If S% is greater than 0.05 then cutting length should be 3

BILLET LENGTH REQUIREMENT

o Billets greater than 3.2 m are cut to the length of 3 to ensure proper feeding in furnace

PROCESS DIAGRAM OF MILL

REHEATING

FURNACE

THERMO MECHANICAL

TREATMENT

CHARGING

GRIT

ROUGHING MILL

INTER-MEDIATE

ROLLERS CONTINUOUS ROLLERS

COOLING BED

PASSING ROLLERS

AND SHEAR

SHEAR REPEATOR

TRANSFER TABLE

SHEAR

BUNDLING BAR

S

BILLET

2. FURNACE DEPARTMENT

2a. SPECIFICATION:

FURNACE DETAILS:

Capacity : 140 billets Rate : 31 tons/hour Burners : 19 (15 manually operated, 4 automatic) Air-fuel ratio : 10 : 1 Number of skits: 10 Furnace zones : 3 ( Recuperator zone, Top & Bottom Heating zone, Soaking zone) Billet temperature at outlet : 1100-1200 oC Water skits for cooling : 7 Length limit : 3.2m

FURNACE ZONES:

RECUPERATOR ZONE:

No burner Billets are warm up by hot incoming air. Temperature 400-500 oC

TOP HEATING ZONE:

8 burners Max temperature 1280 OC 705000 kcal/hr Combustion Air flow 869 m3/hr (preheat-530 oC) Natural gas flow 85 m3/hr

BOTTOM HEATING ZONE:

8 burners Max temperature 1280 oC Natural gas flow 95 m3/hr 760000 kcal/hr Combustion Air flow 937 m3/hr (preheat-530 oC)

SOAKING ZONE:

3 burners Max temperature 1240 oC 430000 kcal/hr Combustion Air flow 530 m3/hr (preheat-530 oC) Natural gas flow 55 m3/hr

2b. FURNACE EQUIPMENTS The burning of gas, oil, coal, or other combustible material requires air. Insufficient air volume will result in wasted fuel. Too much air increases the amount of heat carried up the stack by the excess draft. Either extreme increases the cost and difficulty of controlling exhaust emissions.

NATURAL AND MECHANICAL DRAFT:

Air can be supplied to the combustion process by Natural or Mechanical draft Natural draft simply refers to the use of a chimney or stack to induce an upward flow of air. The stack effect pulls air into the combustion chamber. The amount of air flow depends on the stack’s height and diameter, the prevailing wind velocity, and the resistance of the burner mechanism or fuel bed itself. The demand for air-cleaning apparatus on combustion systems, particularly oil and coal, has increased the overall system resistance to such an extent that natural draft alone is seldom sufficient. Mechanical draft is accomplished in one of two ways: when air is blown or forced into the combustion chamber it is known as forced draft. When the air is drawn through the combustion chamber it is called induced draft. Balanced-draft is when both forced and induced drafts are used; the system is termed a balanced-draft system. The fans or blowers used for induced-draft applications are larger and more expensive than those used for similar forced-draft applications. The combustion process itself creates gases and elevated temperatures that expand the exhaust airstream, requiring fans with greater volumetric capacity than would be required on the supply side of the combustion process to supply clean, ambient air. Also, the hot exhaust serves to lower the density of the airstream, so density corrections must be applied to the fan static pressure (SP) to overcome the actual system resistance. The fact that the exhaust or flue gases are hot often requires induced-draft fans to be of a construction suitable for higher temperatures.

COMBUSTION BLOWER:

Air Flow = 17000 m3/hr Air Temperature = 30 ‘C Motor = 90KW, 2 poles USED FOR: Supply Fumes & Vapors

WORKING:

As the rotor rotates; the air entrapped between the rotor blades is radially and

circumferentially accelerated and pushed in to the side cavity. Here it is pressurized and

pushed back to the rotor blades where it is again radially and circumferentially

accelerated. It will then push along a special path through the Impeller and side channel till

it is discharged into the discharge port. Thus leaving the blade tip, the air flow around the

housing contours back down to the root of the succeeding the blade where the flow pattern

is repeated. The Impeller rotates with absolutely no contact between it and the casing. This

means that no lubrication is required; guaranteeing 100% oil free operation. Since there is

only one moving part it has got maximum operating reliability and totally maintenance free.

INDUCED DRAFT FANS (I.D FAN):

Air Flow = 7700 m3/hr Air Temperature = 30 ‘C Motor = 30KW, 2 poles USED FOR: Remove Flues Gasses from Furnace and Discharges it to Outside

WORKING:

Induced Draft (ID) fans are used to create a vacuum or negative air pressure in a system or stack. Our centrifugal blowers are used to maintain elevated ventilation, resulting in increased system efficiency. In the boiler industry ID Fans are often used in conjunction with FD fans to maintain system pressure which is slightly lower than ambient.

HYDRAULIC PUSHERS AND EJECTORS:

These pushers are generally used to push raw ingot into furnace, while the ejectors are used to eject heated billets out of the furnace. These kinds of products are generally installed in the backside of the furnace in rolling mills.

PUSHERS/EJECTORS DETAIL:

Hydraulic Cylinders = 2 Push Force = 100 tons -150 tons Working pressure: 31.5MPa Oil = Hydrol VG 32

CHARGING GRIT:

It is use to transfer stock billets to recuperative chamber of furnace. Working principle involves the movement of counter weights, counter weight moves by the force of 2 hydraulic cylinders. Magnetic crane charge billets from stock pile to charging grit

COMPRESSORS AND PUMPS:

Compressors: A compressor is a machine for raising a gas - a compressible fluid - to a higher level of

pressure.

Pumps: A pump is a machine for raising a liquid - a relatively incompressible fluid - to a higher

level of pressure or head.

Details: No of pumps = 3 Motor rpm of compressor : 1490 rpm

Flow rate : 313 lit/sec

No of compressor = 2 Type : Screw type

Model : GA110W

Nominal working pressure: 8 bar

Maximum pressure : 8.5 bar

2c. DETAILS (IN A NET SHELL)

Parameters Quantity or Values

1. Furnace Capacity 160 Billets

2. Rate 31 metric tons/hour

62 billets per hour

3. Burners 19 burners (8 upper zone, 8

lower zone, soaking zone)

4 Automatic and 15 manual

4. Thermocouples 8 Thermocouples

K type (Metal)

R type (Ceramic)

5. Numbers of skids 4 skids with water supply

6. Outlet Temperature Range 1100-1200 ‘C

7. Air-Fuel Ratio 10:1 ratio

8. Pusher Capacity 10 tons

9. Charging Grid Hydraulic system

2 cylinders

Counter weight balance

3. MILLING ZONE

INTRODUCTION:

Milling zone consists of rollers that define the size of the bars. In Amreli steel, there are total

18 rollers in milling zone.

3a. MILLING AREAS: Milling zone is divided into three different areas:

Roughing area

Intermediate area

Finishing area

Thermo Mechanical Treatment Area

ROUGHING AREA:

Roughing area is characterized by RM-28. It consists of three rollers. It has a lifting table for lifting the billets. It also contains drop wall for dropping the billet. It has five passes, each pass removes (22-25) % area of billet.

INTERMEDIATE AREA:

It is designated by I-1, I-2 and I-3. Each of these contains two rollers which reduce the area of billet and increases the

length. After I-3, the billet`s both ends are cut by shearing machine.

FINISHING AREA:

It is designated as C-1, C-2….C-10. Number of rollers can be adjusted according to the size of resulting bar. The both ends of the bar are cut down after C-4 roller.

THERMO MECHANICAL TREATMENT AREA:

It is rapid cooling of a work piece to obtain certain mechanical properties. It consists of five different inlet and outlet passages for different sizes of bar. It has five normal pressure nozzles and three back pressure nozzles.

3b. FLOW DIAGRAM:

FURNACE RM-28 PINCH ROLL 1

I-1 I-2 I-3 PINCH ROLL 2

SHEAR 1 C-1 C-2 LOPPER-1 C-3 C-4 NEGATIVE REPEATER

PINCH ROLL 3

SHEAR 2

C-5 C-6 LOPPER

2 C-7 C-8

LOPPER 3 C-9 C-10 TMT PINCH ROLL 4

SHEAR 3 DEVIATOR

APRON CHANNEL

COOLING BED

COLD SHEAR

TRANSFER CHAIN

BUNDLING LOADING WARE HOUSE

4. THERMO MECHANICAL TREATMENT

In TMT chamber, the hot deformed billet introduced through roller guide. It has five lines for

passing of billet. The selection of lines depends on the final size of the product.

4a. MECHANISM: Five nozzles continuously supply water to get the martensitic structure on the case by

quenching process, While the inner core remain soft because of the formation of pearlitic

structure by self-tempering phenomenon. 3 nozzles are supplying water in counter flow to

remove water from the bar at the end. Time of the travel of the bar should be fast to avoid

the formation of martensite to large depth.

Water used in quenching is recycled and transferred back to cooling tower; some amount of

water is evaporated during quenching which is fed using overhead tank to maintain the

desired level of water.

4b. ADVANTAGES: Major purpose of thermomechanical treatment of steel

Higher yield strength Improved toughness Improved weldability Higher resistance to brittle cleavage Higher resistance to low-energy ductile fractures Good cold forming, particularly by bending Lower costs which are possible by using hot-rolled rather than heat treated sections.

Achieving desired properties with fewer amounts of alloying elements thereby reducing the production cost.

5. UTILITY DEPARTMENT: The function of this department is to supply water for the cooling of machines (e.g. furnace,

rollers, TMT etc.) This department consists of the following main parts:

a) Compressor and drying system b) Water system

5a. COMPRESSOR AND DRYING SYSTEM: In Amreli steel limited, there are two compressors of Atlas Copco. One runs at a time while other remains on standby.

SPECIFICATION:

Type : Screw type Model : GA110W Maximum pressure : 8.5 bar Nominal working pressure: 8 bar Motor rpm of compressor : 1490 rpm Power input : 110 KW Flow rate : 313 lit/sec

USE OF COMPRESSED AIR:

To make air-fuel mixture for furnace SNG plant Push rod Furnace opening Deviator Grease gun Rolling flapper (drop wall)

5b. WATER SYSTEM: The water system can be divided into 4 sub-systems

1. Clear water system

2. TMT water system

3. Furnace water system

4. Mill complex water system

5c. FLOW CHART

Compress

or

Heat exchanger

MAKEUP WATER TANK-

VERTICAL TURBINE PUMP

HOT WELL

QUINCHING BOX

CENTRIFUGAL PUMP

COLD WELL

TMT COOLING TOWER

VERTICAL TURBINE PUMP

HOT WELL

FURNACE SKITS

CENTRIFUGAL PUMP

COLD WELL

FURNACE COOLING TOWER

VERTICAL TURBINE PUMP

HOT WELL

SCALE PIT TANK

FINISHING ROLLERS

INTERMEDIATE ROLLING

ROUGHING STAND

MILL COMPLEX

CENTRIFUGAL PUMP

COLD WELL

MILL COOLING TOWER

CENTRIFUGAL PUMP

COLD WELL

COOLING TOWER

5d. SPECIFICATION:

CLEAR WATER SYSTEM

COLD WELL VOLUME: 103m3 CENTRIFUGAL PUMP QUANTITY: 2 IN OPERATION: 1 at a time FLOW RATE: 190m3 /hr HEAD: 40m POWER: 40hp

TMT WATER SYSTEM

COLD WELL VOLUME: 103m3 CENTRIFUGAL PUMP QUANTITY: 3 IN OPERATION: 2 at a time FLOW RATE: 225 m3 /hr HEAD: 140 m POWER: 160 KW HOT WELL VOLUME: 103m3 QUENCHING BOX Five lines are present in quenching box It is used for thermo mechanical treatment VERTICAL TURBINE PUMP QUANTITY: 4 IN OPERATION: 2 at a time FLOW RATE: 230 m3 /hr HEAD: 20 m POWER: 40 hp

FURNACE WATER SYSTEM

COLD WELL VOLUME: 103m3

CENTRIFUGAL PUMP QUANTITY: 3 IN OPERATION: 2 at a time FLOW RATE: 170 m3 /hr HEAD: 40 m POWER: 40 hp

HOT WELL VOLUME: 103m3 FURNACE TYPE: Reheating furnace CAPACITY: 31 tons/hr ZONES: 4 BURNERS: 19 SKITS: 10 WATER SKITS: 7 VERTICAL TURBINE PUMP QUANTITY: 3 IN OPERATION: 2 at a time FLOW RATE: 180 m3 /hr HEAD: 20 m POWER: 40 hp

MILL COMPLEX WATER SYSTEM

COLD WELL VOLUME: 214m3

CENTRIFUGAL PUMP QUANTITY: 3 IN OPERATION: 2 at a time FLOW RATE: 170 m3 /hr HEAD: 40 m POWER: 40 hp

HOT WELL (SCALE PIT TANK) VOLUME: 235 m3

MILL COMPLEX It consists of following units: Roughing stand Intermediate rollers Finishing rollers VERTICAL TURBINE PUMP QUANTITY: 3 IN OPERATION: 2 at a time FLOW RATE: 190 m3 /hr HEAD: 40 m POWER: 40 hp

6. QUALITY CONTROL DEPARTMENT Continuous investment in plant automation and modification has developed a sophisticated operation, which enables Amreli Steels to maintain a well established reputation for manufacturing Hot Rolled Bars with dimensional accuracy, superior quality and first class service to its customers. Our products fulfill the following requirements of steel reinforced concrete:

High yield strength High tensile strength with standard elongation High bond strength Uniformity and reliability

At Amreli Steels great emphasis is placed on rigid quality control policies. Our testing facilities include an electro-hydraulic universal testing machine with a testing capacity of 100 tons in addition to a mechanical 60 ton universal testing machine. The staff of the testing facility is professionally trained by foreign experts to use the machines and deliver accurate results. The company maintains a modern testing laboratory where each heat produced is tested against International Standards (ASTM A-615 & BS 4449:2005). Both destructive and non-destructive techniques are used to characterize materials for their mechanical and physical properties. Universal Tensile Strength testing machines are used for these purposes which are calibrated using standards traceable to National and International Standards. As one of the largest producers of Quality Steel Bars in Pakistan, the company policy is to continually satisfy its Customers in terms of Consistent Quality, Timely Delivery and Excellent Service. Major Quality control operations involves

` `

QUALITY CONTROL

Visual Inspection

Billet length

Measurements Billet Weight Measurement

Mechanical Inspection

Tensile Test of Sample of

final product

Bend Test of Sample of

final product

Chemical Inspection

Etching of Sample of

final product

6a. PRODUCTS SPECIFICATIONS AND PROPERTIES:

Xtreme Bars

Deformed Bars

XTREME BARS G-500W:

Amreli Steels products are manufactured from our own prime quality steel billets. Roll sizes ranging from 9.5mm to 40mm diameter, in regular and specific lengths as per customer requirements.

PRODUCT SPECIFICATION:

Yield Strength: 500 MPA (min) Ultimate Tensile Strength: 575 MPA (min) Rm/Re= T.S/Y.S: 1.15-1.35 Elongation [%]: 14% (min) Amreli Xtreme Bars (ends cut) manufactured to BS 4449-2005

MECHANICAL PROPERTIES OF XTREME BARS

XTREME G-500W Bar Size, mm Area, mm2 Kg/m Kg/ft

9.5 70.91 0.56 0.17

12 113.41 0.89 0.271

16 201.4 1.58 0.482

19 283.64 2.23 0.679

22 380.29 2.99 0.91

25 491.07 3.86 1.176

28 616 4.84 1.475

32 804.57 6.32 1.926

6c. DEFORMED BARS G-60 Roll steel bars Grade 60 conforming to ASTM A615 in sizes ranging from 10mm to 40mm in standard 12 meter lengths. Also roll specific lengths in these sizes on order. These bars are rolled from our own manufactured steel billets and are quality assured for consistency & reliability.

PRODUCT SPECIFICATION:

Yield Strength: 420 MPA (min) Ultimate Tensile Strength: 620 MPA (min) Rm/Re= T.S/Y.S: 1.46-1.57 Elongation [%]: 9% (min) Amreli Deformed Bars (ends cut) manufactured to ASTM A615M

MECHANICAL PROPERTIES OF DEFORMED BARS G-60

DEFORMED BAR G-60 Bar Size, mm Area, mm2 Kg/m Kg/ft

10 78.57 0.62 0.188

12 113.14 0.89 0.271

16 201.14 1.58 0.482

20 314.29 2.47 0.752

22 380.29 2.99 0.91

25 491.07 3.86 1.176

28 616 4.84 1.475

32 804.57 6.32 1.926

36 1018.29 8 2.438

40 1257.14 9.87 3.009

UTM MAINTAINANCE SCHEDULE FLOW CHAT

Maintenance Schedule for:

1. Electro-Hydraulic Universal Testing Machine WA-2000 2. Electro-Hydraulic Universal Testing Machine WA-100

MAINTAINANCE FREQUENCY

Daily

Cleaning

1.Table

2.Jaws/Grips

3.Force Measuring Unit

4.Exterior

Oil Level

Check 1.Tank Oil Level

Oil Leakage

Check

1.Hydraulic Pipe Joint

2.Clamping Shaft

3.Oil Tank

4.Pressure Valve

Bolt/Screw

Tightening

1.Jaws/Grips

2.Jaws Holder

3.Bend Pin

4.Bend support

Monthly

Level of

Load Frame Machine Load Frame

Oiling/

Greasing Chain Threaded Shaft

Annually

Complete Oil

Change

Oil Tank

Cleaning

Oil Tank

7. OIL SYSTEM

a. HYDRAULIC SYSTEM

POWER PACK

Power pack uses axial piston pumps to increase the pressure of oil. There are 3

nitrogen cylinders to store pressure that can be used if the requirement

increases. There is an ELM machine that cleans oil and separates iron from oil

by working on the principle of electrostatic induction. Pressure generated by

power pack is used in following sections:

Push rods

Ejector

Bar turn (rough mill)

Chain conveyer

b. Lubrication system

Lubrication system is used to provide lubrication to moving parts especially

gear boxes.

The lubrication system involves:

Pumps

Heat exchangers

Filters etc

8. RECOMMENDATION Safety procedures are not good. Mill should ensure labor / employment protection. Safety precautions were lacking in the plant. It should be made compulsory for the workers to at least wear the glasses, gloves and helmet, cap where applicable, as:

“Quality makes no sense without YOU & ME”

9. CONCLUSION

Training at Amreli Steel Ltd. is really a true learning experience. It has not only taught the utilization of bookish knowledge into practical field but also the ethics of professional life. This internship would remain the part of magnificence memories for the reason of ASL’s hospitability. It is expected that this technical guidance & professional knowledge would be helpful in my future studies