Kashmir Ispat

8/12/2019 Kashmir Ispat

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PROJECT REPORT

ON

KASHMIR ISPAT


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ACKNOWLEDGEMENT

Perseverance, inspiration and motivation have always played a great role in the

success of any venture. At this level of understanding it is often difficult tounderstand the wide spectrum of knowledge without proper guidance and advice.

This report entitled "A STUDY OF PRODUCTION IN KASHMIR ISPAT" BARI

BRAHMNA (J&K) . I extend my sincere gratitude to MR. Sanjay Mishra for

granting me the opportunity to undergo my study in this organization and

continuously guiding me throughout the span of my study .I am also thankful to all

the team of this Unit who have given me their full cooperation and devoted their

valuable time for rendering me their needy services and guidelines during the

training period. With those sincere and precious efforts, I have been able to

complete my practical training successfully.

WITH SINCERE THANKS

PAYAL GUPTA


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PREFACE

Practical training is an important part of the theoretical studies. It is of an immense

importance in the field of management. It offers the student to explore the valuable

treasure of experience and an exposure to real work culture followed by the

industries and thereby helping the students to bridge gap between the theories

explained in the books and their practical implementations. Training plays an

important role in future building of an individual so that he/she can better

understand the real world in which he has to work in future. The theory greatly

enhance our knowledge and provide opportunities to blend theoretical with the

practical knowledge where trainees get familiar with certain aspects of industries,

like shop floor management, production process and industrial relations. I feel

proud to get myself trained at Kashmir Ispat (Bari Brahmna). Kashmir Ispat is a

leading TMT Bars manufacturer in J&K. I have taken up training in Production

Department and have studied and explained the production arrangement. I availed

this opportunity in a very satisfactory manner and have tried to cover each and

every aspect that. I came across during my training period.


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KASHMIR ISPAT

Kashmir Ispat is one of the largest manufacturers of TMT Bars in J&K State

located at SIDCO Industrial complex, Bari Brahmna, Jammu (J&K). It was

established by Dewan Bansal and now headed by Sahil Bansal (son of Dewan

Bansal).

The company is high profiled high tech rolling mill manufacturing TMT Bars of

top quality and as per BIS standards. The company is an ISO 9001 company

having its own source of raw material input from its sister concern i.e. M/s

Narbada Steel Limited manufacturing M.S Ingots/ Billets as per BIS Standards.

The company provides best quality products to end users, to their uttermost

satisfaction. The company has developed fast under the guidance of high visionary

Directors, having the experience in this field from last 40 years and dedicated staff.

The company has highly contributed to upliftment of the state economy. The plant

is highly equipped with full automated rolling and quenching process (EVCON

TURBO) compatible with Tempcore (Germany). The company is fully equipped

with quality control department, which ensures quality system from input on line

and finished product with strict vigil for best performance and high standards.

Adherence to to international standards, both in manufacturing process and quality

of products .Company has ISO9001:2008 QMScertification and also ISO14001:

2004 Certification which ensure the environment protection.


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SHAKTI TMT:

Kashmir Ispat high values the strong bond of relationship from petty consumer to

bulk purchasers, builders, architect,dealers, distributors keeping all in high

esteem with continuous interaction and

fulfilling the needs with dedication. Its

motto is to provide best quality to get

more and more repeat orders.

Why Kashmir Ispat

Company understands the importance of steel to customers and offers a TMT

construction bar that is like a 3 in 1: strong, with superior elongation and resistant

to corrosion. Worldwide, TMT is the most widely used technology to impart these

properties to construction grade bars.

TMT Process TMT is a superior technology in steel making, bringing to you International

product quality.

Construction bars that sell in the market need to conform to ISI specifications;

our bars offer you properties that are far higher than the ISI specs: in other words,

greater strength and superior elongation.

Our TMT technology ensures that corrosion is retarded. Traditional bars are

twisted to increase strength, but this builds up stress and consequently rusting starts

almost immediately. In case of TMT no twisting is required since a special Thermo

Mechanical Treatment used on the bar, resulting in lesser corrosion and longer life.


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MASS PRODUCTION OF TMT RODS

MANUFACTURING PROCESS OF TMT BARS

It takes billets of size 100 mm2 from CCP and produces ribbed TMT bars of

various diameters.

The capacity is 0.28 million tone per annum thermo mechanically treated (TMT)

ribbed bars of dia. 8 to 32 mm.

Grade- Fe 415, Fe 500, Fe 550, Fe 415 D, Fe 500 D, Fe 550 D, Fe 600D

TMT 415, TMT 500, TMT 550, TMT HCRM

Input: billet of 100mm2 and 9m long

BASIC PROCESS

The processes of rolling of long products can be basically classified into following

heads:

A.Reheating: The reheating of inputs is done to make the material plasticallydeformable and pliable for rolling to give the desired shape and size. It is

done such that the rolling gets completed above recrystallisation

temperature.

B.Roughing: Roughing also called cogging is done to give the input a roughshape. The maximum reduction in cross section is given in roughing mill.

C.Intermediate Rolling: Intermediate rolling constitutes taking the roughingmill output as its input. Output of intermediate rolling is sent to finishing

mill.

D.Finished shape rolling: In finishing mill the finished profile shape is made.It takes metal from intermediate stands as its input. The reduction given in


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these stands is lesser as compared to roughing and intermediate mill.

Finished shape rolling is quality critical as the final output shape is made in

these stands. In case of TMT bars thermo mechanical treatment of bars is

done in this area.

E.Cutting and stamping: The finished bar is cut to desired lengths as percustomer requirement. Other activities performed here are cropping of ends,

cutting of samples for profile dimensional checking and cutting of samples

for destructive tests. In secondary mills stamping of cast number and other

details are done on the rolled products in hot condition. These are required

for identification and traceability of product and correlation with test results

of destructive tests.

F. Finishing: The finishing is done after the bar has been cooled to ambienttemperature. Finishing activities at different mills may involve all or few of

the following steps:

Straightening either by roller straightening machines or by pulling the ends 88

End finishing either by milling or cold cutting

Online non destructive testing of defects

Heat treatment

G.Inspection: Inspection is carried out by the producer and/or by customerdeputed agency and/or by third party to inspect the products and ensure no

defective products are sent to customer. Depending on the specifications,

customer requirement the inspection may be in all or few of the following

parameters:

Dimensional tolerances (section)

Length

Straightness

Squareness


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Surface Quality

Branding, colour coding and stamping

H.Dispatch: The products are sent to required destinations primarily by road.The activities involve documentation (preparation of dispatch advice (DA),

test certificate (TC). In some cases packaging is done prior to dispatch.

PROCESS

Reheating furnace has a two zone type arrangements for side charging and

discharging. The output of furnace is 70 TPH. Temperature inside the furnace is

1250 1300o C. Separating skids are used to placed the billets on the furnace

charging table. By using push-out bar, billets are discharged from the furnace to

the first mill stand. For this, there is a pinch roll arrangement near the furnace. A

pendulum shear is located between the pinch roll and first stand to cut the front end

of the billets. The mill has 13 horizontal stands in which 7 are roughing, 4

intermediate and 2 are finishing stands. In between 7 & 8 stands, a crop cum

cobble shear is provided to cut front end of all the rolled stocks passing out of the

7th stand. It is also used for cutting the rolled stock into pieces in case cobble is

formed. Four 180 repeaters provided between 9 & 14 stands (13th stand is not

there). These repeaters are provided to reduce the overall length of the mill. After

the finishing mills Thermax carriages are situated for spraying water at high

pressure on the rolled bars (to impart required structure). There is a rotary shear,which cuts the rod into the pre determined lengths, which are then accommodated

in the cooling beds. After this the bars are cut to final sizes (as per customers

demand) in the Bar Shears and sent to dispatch area after bundling and strapping.


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Ingot (raw material)

Furnace (1300 degree C)

Roughing stand

Intermediate stand

Finishing stand

Quenching Box (Thermo Mechanical Treatment)

Colling Bed

Testing (tencile machine)


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MAJOR EQUIPMENTS

Reheating furnaces: capacity of 30 tonnes per hour

Pinch rolls :for feeding of billets

Pendulum shear to cut the end of billets

13 horizontal roll stands;7 roughing stands, 4 intermediate stands and 2 to 3 are

finishing stands

Two 180 degree Repeaters to reduce the overall length of the mill

Crop cum cobble shear for cutting the front end of rolled stock after it comes out

from 7th mill stand. It is also used for cutting the rolled stock when cobble is

formed

3 thermax carriages for spraying water at high pressure on the rolled bars results in

the formation of martensitic structures.

Rotary shear

Bar shear for cutting rods into specified lengths required by customers

Quality Assurance

It ensures quality at every step, from the input of raw material to the final product

delivered on site. With a high automated plant and continuous checks at every

level and is able to produce the best quality re-bars in the state. The quality team is

equipped with modern testing facilities which ensure that the products meet

stringent norms and quality standards.

TMT Rebar in Sizes (in mm) :8,10,12,16,20,25,28, 32

Tencile484 N/mm2


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Yield Stress415N/mm2

Elongation18%

INSPECTION STAGES IN PRODUCTION OF TMT

RODS

INSPECTION STAGES

Inspection of TMT bars is carried in stages. The inspected billets are properly

marked and cut down to the required length for reheating. The inspected billets

must conform to certain IS standards

Policy: The identification and traceability of all materials and products at all

stages are established and

maintained.

Scope: The process coversidentification and traceability of the

product from receipt stage, in-

process inspection and final

inspection till despatch.

Procedure: The billets thus

produced are then surface checked, visually inspected and tested for chemical

composition. Any non-conforming material is identified and marked by red paint

and sent to rejection yard. The tested material is then colour coded by blue paint

and a Batch Number is given. It is then sent to the Rolling Mill raw material yard.


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Then visual inspection and chemical analysis of the material is carried out.

Thereafter, such tested material is given a Batch Number and stored in Rolling

Mill Raw material. Each such batch weighs 25 M.T. The Billets are then sent for

production in the Rolling Mill. During the production process, inspection at

various stages is carried out and any non-conforming product is identified and

segregated properly. The finished product is then subjected to final inspection and

a Lot Number is allotted to it before being stored in the finished product yard. The

finished product is properly tagged which carries the following information:

I. Name of the Company

II. Lot No.

III. Size of the product

IV. Grades

STAGE WISE INSPECTION DETAILS

A typical inspection stages of TMT rods

Figure 8(a): Incoming Material Inspection
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Figure 8(b): In Process inspection data collected for TMT rods
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Figure 8(c): Final Inspection stages of TMT rod
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TYPES OF DISTRIBUTION CHANNEL:-

Basically there are two types of distribution channel:-

1) Consumer distribution channel

2) Industrial distribution channel

The Company follow these two types of production and distribution system.

DIRECT

(ZERO LEVEL CHANNEL)

(TWO LEVEL CHANNEL)

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RETAILER

RETAILER WHOLESALER


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SWOT ANALYSIS

S: STRENGTH

Cheap

Scope for entry of private firms Much demand in local Low price Easily available Cheap labour Cheap land Flexibility for expansion

W: WEAKNES

Poor R & D wing is good, Poor work force Poor Lab facility Advertisement & publicity is poor Poor range & size Poor in customer trust & faith Poor sales technique and ability to customize Preparation is from its scrap only Poor in share market Poor mechanical and physical strength

O: OPPERTUNITIES

Good internal market More demand to common men


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Expansion facility Flexibility in future Distribution network

T: THREATS

Local competition Availability of raw materials Availability of power Poor response Unawareness to local people Poor lab facility


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PROBLEMS

Bearing breakage Roll break Rolling Defects

Slivers

Twist

Shear distortion

Burnt edges

Rolled in scales

Laps

Roll marks

Underfills

Buckle and kink

Camber

RECOMMENDATIONS/ SUGGESTIONS

They must use oil furnace instead of coal furnace. Workers are working without any safety measures, so the organization

should ensure that the workers should work using the safety equipments.

Documents

Kashmir Ispat