FOREIGN TRAINING REPORT
The up-gradation of Roughing mill of HSM/SAIL/BSL is planned in
year 2014-15. The successful up-gradation and stabilization of
operation required trained manpower. It is very prestigious project
for the HSM and Bokaro Steel Plant. The future and growth of Bokaro
Steel Plant depend upon the successful up-gradation of the roughing
mill. For successful implementation of the project, a group of 40
(forty) executive from BSL & CET in two batches given
theoretical and on-site training at Daineli Training Centre in
Udine, Italy and site visit at Guefong Iron and Steel Company,
Tansang, China.The two batches compromise of the executive from
HSM, ETL, DNW, PROJECT and CET.The training schedule split in two
parts. In first parts, we were given theoretical input about
upcoming project and visit to Daneili Work Shop at Udine.The major
point of learning and observation at Daneili Training Centre, UDINE
are:1. Daneili documentation system for easy understanding of the
equipments drawings.2. In detailed input were given about upcoming
hydraulic system, their maintenance and safety aspect about
hydraulic system.3. The drawing of different hydraulic system like
RR2 HAGC, RR2 Entry Guide and RR2 edger were discussed in
details.4. The drawing different mechanical equipments like RR2
Edger, RR2 Spindle and HAGC were discussed in details.5. The
different aspect of roll cooling, descaling and lubrication were
discussed.6. Besides technical input we were also given managerial
aspect of new project, maintenance and safety.7. We also visited
the Daneili mechanical work shop at Udine. The visit to work shop
was very-very useful, as it is one of the best work shops that we
have ever seen. The work shop has advance machining tools and
testing facilities. In work shop we have seen the machining of mill
housing and machining, assembling and testing of the HAGC
cylinder.In second part of the training we were visited the Guefong
Iron and Steel Company, Tansang, China. It is one of best steel
plant, we have ever seen. The plant layout and housekeeping was
beyond our imagination. It has two Hot Strip Mill with a capacity
of 3.0MT and 3.5MT. The first Hot STRIP Mill was set up by Daneili.
The single stand reversible roughing mill is similar to the
proposed RR2 at HSM/BSL. The plant layout is such that the slab
from continuous casting is directly charged to the furnace at the
temperature of 7000C through roller table, saving a lot of energy
and heating time. There we have seen the operation and maintenance
of the RR2. There we visited the different hydraulic room, oil
cellars, pump houses and roll grinding shop. The detailed input
given to us will be discussed in next pages:
UP-GRADED FLOW DIAGRAM OF HSM
SCOPE OF UPGRADE
The scope of work will generally consider the following:
1. Installation of new 2Hi Roughing Mill with heavy edger at
location of R#2 / E#2.2. Upgrade / revamp the existing Stand
Roughing Stands R#3, R#4 & R#5 with introduction of hydraulic
work roll change system.3. New short stroke hydraulic AGC in R#5.4.
Modification & strengthening of attached edgers E#3, E#4 &
E#5 with provision of long stroke hydraulic Automatic Width Control
to improve width tolerances of transfer bar.5. Installation of new
passive heat shield on Delay Table with up-gradation of QWRC system
of Finishing Stands.6. Installation of new width gauges.7. Roller
table modernization with conversion to AC drives from DC drive.8.
Provision of new hydraulic & lubrication systems9. Introduction
of new automation systems.10. Air-conditioning & ventilation
systems.11. Machining & other modification jobs as may be
necessary.12. Interfacing / integration of modified systems with
existing electrics / automation.
ORGANIZATION OF PROJECT NUMBERING Job Number Contract Items
Equipment Code JET Bill of Material Parts from Marketing Spare
Parts Sub Supplier Documentation Assembly Drawing 8.NNNNNN.L
Assembly Drawing 6.NNNNNN.L Detail Drawing 4.NNNNNN.L
JOB NUMBER
DP0ACB01
JET NUMBER
DP0ACB010960 = JET Number 09.60
DANIELIS NUMBERING DRAWINGS AND OTHERDOCUMENTS NOT CLASSIFIED AS
SHOWN PREVIOUSLY
MAINTENANCE TASKS1.Lubrication1) lubrication table for
components2) lubrication standard2.Condition Monitoring1) vibration
analysis2) temperature monitoring3.Preventive maintenance1)
inspections2) alignment3) preventive maintenance time-table4)
repair components5) tools required4.Extraordinary maintenance1)
replace faulty components2) replace damaged components
NEW DESCALER DESCRIPTION
The descaler removes scale from the transfer bar using high
pressure water.The main components of the descaler are as follows:
Top metal cover to contain the high pressure water and scale Top
and bottom headers with multiple nozzles across the length of the
headers
Descaler Maintenance NotesThe following are some notes related
to Mechanical Maintenance activities:1. Regular testing must be
done on the descaler system to ensure it is working properly2. Test
the nozzle spray pattern3. Test individual pumps4. Test combination
of pumps5. Test individual headers6. Test combination of descaler
headers
Entry Side guide Description
The Entry Side guides at the Vertical Edger E2 are used to guide
the bar into the Edger and Roughing Stand RR2 and keep it
centered.Design Features:1. The entry side guides consist of two
(2) sections of movable side guides (one trailing).2. The leading
entry section of the side guides is connected to a fixed point on
both sides near the exit side of the approach table using pivot
pins.3. The free end of each side guide is connected to a second
set of side guides mounted on each side of the table to the two (2)
ram arms by pivot pins.4. Operator and drive side guides are
mechanically synchronised through rack and pinions.5. The
sideguides are made of welded steel, each guard supported on two
(2) rams [total four (4) rams].
RR2 EDGER DESCRIPTION
The Vertical Edger E2 is used to keep the bar width within the
set tolerance values and to improve the edge quality.Design
Features:1) Top driven type - rolls driven through a gear drive
coupled with vertical motors.2) Edger housings designed to
withstand both the separating forces of rolls combined with the
push and pull forces between Edger and reversing mill. Steel
structures connection between edger housing and mill housings.3)
Roll opening adjustment by hydraulic cylinders with position
transducers.4) Pull back cylinders included for clearance take-up
between roll housing and cylinders.5) Edging rolls vertically
mounted in roll housings provided with tapered roll face.6) Edging
rolls cooling by means of external headers.7) Feed rollers mounted
on entry and delivery side of edger, rollers externally water
cooled.
RR2 MAIN STAND DESCRIPTION
The 2-Hi Reversing Finishing Mill is used for the rolling of hot
steel slabs in three reversible passes.Design Features:1) Two High
Reversing Roughing Mill.2) Mill work rolls individually direct
motor driven by means of cardan shaft type spindles.3) Top mounted
long stroke hydraulic cylinders for HAGC.4) Hydraulic work roll
clamping system.5) Feed rolls on entry and delivery sides of
mill.6) Pass line adjustable by shims at the bottom of WR.
DESCRIPTION OF TOP WORK ROLL BALANCE OF RR2
The function of this unit is to provide top work roll balancing
and assure proper contact force between the WR chocks and the HAGC
Cylinders.Design Features:1. The top work roll chocks are suspended
by a yoke hanger bar.2. The top work roll assembly is hydraulically
balanced by one (1) cylinder located in the housing separator.3.
The balancing cylinder is hydraulically locked during Work Roll
changing.4. The locking pins must be inserted every time work will
be done on this unit or in the area under it inside the mill
stand.
DESCRIPTION OF HAGC OF RR2
The HAGC system is used to control the roll gap so as to ensure
the proper bar thickness.Design Features:1. The high pressure roll
force cylinders are controlled by servo valves, which are connected
to the cylinders by manifold blocks.2. Two position transducers are
used to measure the cylinder position.3. The pressure transducers
installed on the manifold blocks measures the cylinder pressure in
order to determine indirectly the rolling load.4.
DESCRIPTION OF RR2 SPINDLE SUPPORT
The Spindle Support supports the weight of the spindles.Design
Features:1. Independent supports for top and bottom spindles.2.
Vertical balance unita. Spindles riding in split, anti-friction
spherical roller bearingsb. Bearings housed in spindle support
cartridgec. Independent balancing system for top and bottom spindle
is provided.d. Top and Bottom spindle cartridges hydraulically
positioned through link and pin arrangement.