A TRAINING REPORT ON

JINDAL GROUP
Submitted in the partial fulfilment of the Requirement for the award of Degree of Bachelor of Technology In Mechanical Engineering (Session 2010-2014)

SUBMITTED TO: Er. Kapil Arora ( H.O.D. E.C.E. Deptt.)

SUBMITTED BY:

Department of Electronics & Communication Engineering R .P INDERAPRASTHA INSTITUTE OF TECHNOLOGY, BASTARA(KARNAL)

CONTENTS
1. Acknowledgement 2. Introduction 3. Aim of Company 4. The Main Parts of Production 5. Mill Department 6. Eco Friendliness

ACKNOWLEDGEMENT
I am heartly thankful to all those people whose encouragement, guidance and support from the initial to final level enabled me to develop an understanding about this project. Lastly, I offer my regards and blessings to all those who supported me in any respect during the completion of this project. Finally, an honourable mention goes to Mr. Jagdish Singh Rautela (GENERAL MANAGER) and my family for their understanding and support on us in completing this project. Without helps of the particular that mentioned above, I would face many difficulties while preparing this project. Parbin Sangwan

INTRODUCTION Companies Of Jindal Group

Jindal Stainless Steel: Jindal Stainless is the largest integrated Stainless steel produce in India and the flagship of the Jindal Group. It is an ISO:9001 & ISO:14001 Company. Jindal Stainless Limited has its plants in Hisar and Visage and is setting up a Greenfield Integrated Stainless Steel project in Orrisa with a capacity of 1.6 million tones per annum. Jindals plant at hissar is Indias only composite stainless steel plant for the manufacture of Stainless Steel Slabs, Blooms, Hot rolled and Cold rolled Coils, 60% of which are exported worldwide. At Vizag, Jindal has aFerro alloy plant with an installed capacity of40,000 metric tones per annum. Jindal Steel & Power Plant: JSPL is one of leaders in Steel manufacturing and Power generation in India. JSPL is the largest private sector investor in the state of Chattisgarh with a total investment commitment of Rs. 10,000 Crores. It is also setting up a 6 million tonne steel plant in Orissa with an investment of Rs. 13,500 crores and a 6 million steel plant in Jharkhand with an investment of Rs. 15,000 crores . Jindal Power Limited, wholly owned subsidiary of JSPL, is setting up a 1000 MW O.P.Jindal super thermal Power plant at Raigarh, with an investment of over Rs. 4500 Crores. JSPL has also ventured into exploitation and mining of high value minerals and metals, like diamond, precious stones, gold, platinum group of minerals, base metals, tar sands etc. JSW Steel Limited: JSW Steel ltd. Is a fully integrated steel plant having units across Karnataka and Maharastra producing from pellets to colour coated steel. JSW was founded in 1982, when the Jindal group acquired Piramal steel ltd which operated a mini steel mill at Tarapur in Maharastra. The Jindals, renamed it as Jindal Iron and Steel Co. ltd (JISKO) now known as JSW Steel ltd. (Downstream). In 1994, to achieve the vision of moving up the value chain and building a strong, resilient company, JISCO promoted Jindal Vijaynagar Steel Ltd (JVSL) now known as JSW Steel Limited (Upstream). Hisar Plant, IndiaAt hisar, Jindal Stainless has Indias only composite stainlss steel plant for the manufacture of Stainless Steel Slabs, Blooms, Hot rolled and Coled rolled Coils, 60% of which are exported worldwide.

Precision Strips: The company produces stainless steel precision strips in various grades. These strips are produced in narrow 20-Hi mills in the precision cold rolling unit. Blade Steel: The company is exclusive producer of stainless steel strips for making razor and surgical blades in India. Coin Blanks: Besides suppliying CR strips to the government of India, the plant at Hisar houses a coin blanking line for supply of coin blanks to Indian mint and Mints in the global markets.

JINDAL INDUSTRIES LIMITED (JIL) HISAR: Jindal Steel and Power Limited (JSPL) is an Indian steel and energy company based in New Delhi, India and a division of Jindal Group conglomerate. With annual turnover of over US$4 billion, Jindal Steel & Power Limited (JSPL) is a part of about US$17 billion diversified O. P. Jindal Group. JSPL is a leading player in steel, power, mining, oil and gas and infrastructure. Naveen Jindal, the youngest son of the late O P Jindal, drives JSPL and its group companies Jindal Power Ltd, Jindal Petroleum Ltd., Jindal Cement Ltd. and Jindal Steel Bolivia. The company professes a belief in the concept of self-sufficiency. The company produces steel and power through backward integration from its own captive coal and iron-ore mines. However, in terms of tonnage, it is the third largest steel producer in India. The company manufactures and sells sponge iron, mild steel slabs, ferro chrome, iron ore, mild steel, structural, hot rolled plates and coils and coal based sponge iron plant. The company is also involved in power generation. Jindal Steel and Power is a part of the Jindal Group, founded by O. P. Jindal (19302005). In 1969, he started Pipe Unit Jindal India Limited at Hisar, India. Jindal Stainless, a part of the $ 18 billion USD, OP Jindal group is the largest integrated manufacturer of stainless steel in India and is ranked as the 8th largest in the world, with a capacity of 1.8 million tons. A leader and a name synonymous with Enterprise, Excellence and Success, the companys ethos mirrors most characteristics similar to the metal it produces; Akin to stainless steel Jindal Stainless is innovative and versatile in its thought process; strong and unrelenting in its operations. JSL has crafted its success story by fully integrating its operations based on a strategy of both, backward and forward integration, starting from mining, melting, casting, hot rolling to cold rolling and further value additions . This has been the driving philosophy of the company from its one unit presence in the early 70s to its present multi- location presence across the globe. An ISO: 14001 compliant, JSL product range includes: Ferro Alloys, Stainless Steel Slabs, Blooms, Hot Rolled Coils, Plates and Cold Rolled Coils/ Sheets, Stainless Steel Strips for Razor Blade Steel and Coin Blanks for mints in India & EU.

AIM OF THE COMPANY:

The gamut of Jindal Hisar pipes and GI steel pipes is widely entered to different industries for specific purposes. These pipes are light in weight so easy to handle and transport. All these pipes are available in light material of fabrication and technical specifications in order to meet clients requirements. Features: Vision: 1.To be amongst the top 10 stainless steel producers in the world 2.To gain international recognition for cost leadership, Product innovation and Customer Satisfaction 3.To be admired as a socially responsible Corporate and a sustained value creator for all its stakeholders -Highly durable -High strength -Light in weight -Competitive price

MAIN PARTS OF PRODUCTION:

1. SHEARING: A punch (or moving blade) is used to push the work piece against the die (or fixed blade), which is fixed. Usually the clearance between the two is 5 to 10% of the thickness of the material, but dependent on the material. Clearance is defined as the separation between the blades, measured at the point where the cutting action takes place and perpendicular to the direction of blade movement. It affects the finish of the cut (burr) and the machine's power consumption. This causes the material to experience highly localized shear stresses between the punch and die. The material will then fail when the punch has moved 15 to 60% the thickness of the material, because the shear stresses are greater than the shear strength of the material and the remainder of the material is torn. Two distinct sections can be seen on a sheared work piece, the first part being plastic deformation and the second being fractured. Because of normal in homogeneities in materials and inconsistencies in clearance between the punch and die, the shearing action does not occur in a uniform manner. The fracture will begin at the weakest point and progress to the next weakest point until the entire work piece has been sheared; this is what causes the rough edge. The rough edge can be reduced if the work piece is clamped from the top with a die cushion. Above a certain pressure the fracture zone can be completely eliminated. However, the sheared edge of the work piece will usually experience work hardening and cracking. If the work piece has too much clearance, then it may experience roll-over or heavy burring

A SHEARING MACHINE HASMAINLY FIVE PARTS DE coiler

Pinch Roller Slitting Shaft Scraper Recoiler DECOILER: Roll slitting is a shearing operation that cuts a large roll of material into narrower rolls. There are two types of slitting: log slitting and rewind slitting. In log slitting the roll of material is treated as a whole (the 'log') and one or more slices are taken from it without an unrolling/rereeling process. In rewind slitting the web is unwound and run through the machine, passing through knives or lasers, before being rewound on one or more shafts to form narrower rolls. The multiple narrower strips of material may be known as malts (short for multiple) or pancakes if their diameter is much more than their width. For rewind slitting the machine used is called a slitter reminder, a slitter or a slitting machine - these names are used interchangeably for the same machines. For particularly narrow & thin products the pancakes become unstable, and then the rewind may be onto a bobbin-wound reel: the rewind bobbins are much wider than the slit width and the web oscillates across the reel as it is rewound.

PINCH ROLLER: PINCH ROLLS comprise an entire family of non-reducing rolls that are used to redirect the travel of a strip mill product and to provide strip tension for a downstream process. Pinch rolls are used in nearly all the metallic strip producing industries including steel, aluminium, brass and bronze. These rolls are found in hot and cold strip mill applications and in specialty processing lines like continuous pickles. Regardless of the specific application, the pinch rolls must perform their function without negatively effecting mill productivity or product quality. One of the most demanding pinch roll applications is that of the hot strip steel mill coiler. Due to the constant desire to increase hot strip steel mill productivity, strip quality, and coil presentation, the coiler pinch rolls are now accepted as highly critical components in the hot strip steel mill. Consequently, it is for this pinch roll application that most of the technology advances in materials and mechanical design have taken place in recent past.

SLITTING SHART: Roll slitting is a shearing operation that cuts a large roll of material into narrower rolls. There are two types of slitting: log slitting and rewind slitting. In log slitting the roll of material is treated as a whole (the 'log') and one or more slices are taken from it without an unrolling/rereeling process. In rewind slitting the web is unwound and run through the machine, passing through knives or lasers, before being rewound on one or more shafts to form narrower rolls. The multiple narrower strips of material may be known as malts (short for multiple) or pancakes if their diameter is much more than their width. For rewind slitting the machine used is called a slitter reminder, a slitter or a slitting machine - these names are used interchangeably for the same machines. For particularly narrow & thin products the pancakes become unstable, and then the rewind may be onto a bobbin-wound reel: the rewind bobbins are much wider than the slit width and the web oscillates across the reel as it is rewound. Apart from the stability benefit it is also then possible to put very long lengths, (frequently many tens of kilometres), onto one bobbin.

SCRAPPER: Scrap consists of recyclable materials left over from product manufacturing and consumption, such as parts of vehicles, building supplies, and surplus materials. Unlike waste, scrap can have significant monetary value. However its versatility and appropriateness far outweighs the hard work it requires, or is perceived to require. Its effective use requires skill and concentration. An often overlooked advantage of scraping is the ability to take the tool to the work piece. When the work piece weighs several tons and towers over the worker, the apprentice's solution of chucking it on the mill is impractical, if not impossible. A skilled craftsman can wield a scraper and produce work that is the envy of his peers. This takes more time than the usual methods.

RECOILER: Recoiled is used for collecting the cutting coils which are cut according to the pipe size. It has a shaft on which coil is collected at different places and also has a frame and disc arrangement. As the size of the round is completed, it is removed and sends to the proper pipe mill, where pipe of this coils are made.

PIPE MILLS: This is the main part of the company. It is the backbone of the production of the company. There are eight pipe mills in the industry. One mill can take out from 2 to 12 pipes in one minute. It is adjusted according to the pipe size and accuracy. These are maintained by oiling and changing the old parts. 1.Mill-1: Capacity: 1, 1 , 1 , 2, 2 Speed: 6 pipes per minute 2.Mill-2: Capacity: 2 , 3, 4, 5, 6 Speed: 6 pipes per minute

3.Mill-3: Capacity: 1, 1 , 1 , 2, 2 , 3 Speed: 6 pipes per minute 4.Mill-4: Capacity: 1/2 & Speed: 6 pipes per minute 5.Mill-5&6: Capacity: 1/2, & 1 Speed: high speed 6.Mill-7: Capacity: 1/2 & Speed: high speed (10 pipes per minute) It uses horizontal speed accumulator. 7.Mill-8: Capacity: 1/2 & 2 Speed: high speed (10-15 pipes per minute)

MILL DEPARTMENT: The main parts of the mill are: 1 coil holder 2 cutting of coil and welding 3 guide polls 4 stamping, housing and guiding 5 power, side and pin rolls 6 electric resistance welding 7 cutting (bead scrap) and idling 8 cooling and sizing 9 cutting by the carriage 10 checking and quality 1. COIL HOLDER: The proper size of coil, according to the pipe size is fitted into the coil holder. It holds the coil and the centre of the coil is adjusted by this. It supplies the coil for other operations for making pipes.

2. CUTTING OF COIL AND HOLDING: After finish of coil round, the coil at the end face is not proper to use by this cutter. And any other part which is not good is cut by this operation. This cutter is attached with a hydraulic cylinder. This cylinder gives pressure to the cutter housing by which the cutter comes down and cut the coil from proper place. After cutting of coil, another round of coil is welded from face by face. Welder with the help of electric welding is set which is near the cutter housing.

3. GUIDE ROLLS: These are the rolls which guides the coil to go and avoid the jumping of the coil. Guide rolls are placed at the centre. These are adjusted according to the piper size. In small pipes, guide rolls are used for placing the coil and supplying to other parts. 4. STAMPING, HOUSING AND GUIDING: Stamping is the main operation. A stamp is adjusted in a roll which contains the notations of the company. The stamping housing is attached with an air compressor. The coil is adjusted by the guide rolls and comes into the stamping roll. By the pressure of the air, stamping roll is pressed properly by the air compressor for giving the best stamp impression. After this operation, the coil is stored in a house. The operation is known as housing. This stored coil comes in when the coil is finished and another coil is attached by supplying the housing coil for other operations into the time the stamping do not take place. For this purpose, storing is done. The stored coil then goes to the guiding rolls. These guide rolls place the coil on proper place and guide the coil. These guide rolls are adjusted up and down and in slides. 5. POWER SLIDES AND FIN ROLLS: Performing and forming is done by these rolls. Power rolls are adjusted up and down. These rolls give the shape of pipe to the plan coil. Some shape is given by power and some by side rolls. After this, the combination of side, power and fin rolls come. Fin rolls have a fin. The fin is placed between the two faces of the coil which are almost in the shape of a pipe. Thus, the shape of the pipes is given to the coil with the help of these rolls.

6. ELECTRIC RESISTANCE WELDING: After the shaping of the coil, pipe shape is finished completely. Then a welding is done to give no leakage. Electric resistance welding (ERW) refers to a group of welding processes such as spot and seam welding that produce coalescence of faying surfaces where heat to form the weld is generated by the electrical resistance of material vs. the time and the force used to hold the materials together during welding. Some factors influencing heat or welding temperatures are the proportions of the work pieces, the metal coating or the lack of coating, the electrode materials, electrode geometry, electrode pressing force, electrical current and length of welding time. Small pools of molten metal are formed at the point of most electrical resistance (the connecting or "faying" surfaces) as an electrical current (100100,000 A) is passed through the metal. In general, resistance welding methods are efficient and cause little pollution. 7. CUTTING OF BEAD SCRAP AND IDLING: The bead scrap which comes on the pipe by the welding are removed in this process. and after the the surface of the pipes are made smooth. After this process, the pipe is idled by some rolls. The pipe is idled for proper size of the pipe. 8. COOLING AND SIZING: After the welding and cutting process the pipes are very hot. In these operation water taps are used but these is not sufficient so pipes are dipped in large water tanks. After cooling the pipes go to the sizing rolls. these rolls straightained the pipes properly. Thus sizing is done by these rolls. 9. CUTTING BY CARRIAGE: After completing all the process of pipe making, the pipe is cut according to the demand or mostly upto six meters. These pipes are moved by the help of a carriage and are cutted. Thus the operation of pipe is completed. A conveyor system is a common piece of mechanical handling equipment that moves materials from one location to another. Conveyors are especially useful in applications involving the transportation of heavy or bulky materials. Conveyor systems allow quick and efficient transportation for a wide variety of materials, which make them very popular in the material handling and packaging industries.

10. CHECKING OF QUALITY: -Hydraulic testing -Other testing Hydraulic testing: After conveyor the pipes are allowed to pass through hydraulic testing. these testing are done to assure that whether there is any leakage or not. All these testing are done on Hydraulic Machine. Other testing: After all operations, the quality of pipe is checked i.e. hardness, thickness, on welding, bending, bore, outer diameter, weight in kg/m etc. After the shaping of coil

SHAPING AND FINISHING DEPARTMENT:

COMMERCIAL DEPARTMENT: In this department, pipes are go downed with the help of cranes to godowns. And after it they go to different places in India. The demands of these pipes is in all over the country. So they go to all over the country. They are loaded into trucks and send to many places.

MECHNICAL WORKSHOP: A workshop is a room or building used for manufacture or repair of goods. It is the main department of the company. All the parts used in the machines are made in this work shop with the help of machines. This workshop has the following machines: Lathe Drilling Machine Boring Machine Milling Machine C.N.C Machine Slitter & Planner Machine Shapes Machine

ELECTRICAL WORKSHOP: In this workshop, all types of electric jobs are done by the workers. In this workshop, all kinds of motors are blended by binders and others works of fitting are done by the fitters. Thus all the electric works are done in electric workshop.

QUALITY ASSURANCE DEPARTMENT: This department is guided by Quality Control Manager and it performs the below mentioned functions: To device and follow system as per ISI standard requirements. TO support to achieve zero defect products. Continuous production in process rejection store work.

Quality- A Prerequisite

Machine
1. Universal Testing Machine

Purpose
For material Testing ( mechanical properties )

2.

Non-Destructive Testing Eddy Current Testing Machine

For online flaw detection on weds

3.

Hydro Testing Machine

For Testing Strength

4.

Vickers Micro Hardness Tester

For Checking Micro Hardness on Welds, Heat Affected Zone and Material

5. 6. 7. 8.

Digital Ultrasonic Thickness Gauge Mandrills and Fixtures Hydraulic Press Bending Machine

For Checking thickness of Pipes For Welding Root Bend Test For Flattening and Weld Ductility Test For Pipe Bend Test

TESTINGEQUIPEMENTS&FACILITIESINQUALITYASSURANCE LABORATIES:
Metallurgical Testing Laboratory (Hot Rolling Division) Sr. No. 1. 2. Universal Testing Machine Metallurgical Microscope 100 T, FIE make, Model UTM Neophyte 21, Model MHP-1004, Carl Zeiss Jena, With Climax Image Analysis System 3. Ultrasonic Testing Machine Modsoni make, Model Galilio 100 Kraut Kramer, USN 52(Germany) 4. 5. 6. 7. Impact Testing Machine Brinell Cum Vickers Hardness Tester Rockwell Hardness Tester Surface Hardness Tester Model: IT 30,FIE Model: HMO 1177 Leipzig Alfred Model: RAS, FIE Model: SJ20IP, Japan Equipment Details

QUALITY CONTROL: 1. Raw material testing 2. In process quality check: -At Slitting section -At Mill Section -At End Facing Section -At Dispatch section 3. Special checks: -Thickness, Material Defects, Visual defects, Physical & Chemical Testing -Diameter, Weld Test, Elongation, Tensile Testing -Visual inspection QUALITY POLICY: We at Jindal industries ltd are commuted to become one of the most conscious manufacturers of steel tubes maintaining highest standards of quality conforming to BIS standards and to satisfy our consumers. This Shell is achieved by: Continuous interaction with the consumers to ascertain their quality expectations and product mix. Training and development of employees to inculcate quality culture in the company. Use of appropriate technology and equipment. Optimum utilisation resources.

TOLERANCES:
1. Thickness: -Galvanized +5%, -5% -Black +8%, -8% (Better than ISI) 2. Weight: -Single tube (Light series) +10%, -8% -Single tube (Medium & Heavy) +10%, -10% 3. Length: -Normal +6,-6, 0.02/0.03 -Random length 4 to 7 meter or as specified by customer. ECO FRIENDLINESS: At our stainless steel plants, the challenge faced is to make stainless steel without adversely impacting the environment. Jindal Stainless has a formal environment protection in place since inspection. We recognize the importance of our environment, and that of our children and our commitment is unwavering in this respect. Jindal Stainless ltd. Compiles with the requirements of State Pollution Control Board. Having received the ISO 14001 certification, the company has a full-fledged environment department that manages the existing facilities for pollution control. It has a sewage treatment plant for domestic affluent whose treated water is reused for horticulture purpose as well as in industrial applications.