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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
COMPANYS 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 stateof-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.

COMPANYS 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 worlds 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

TMT PROCESS

RAW MATERIAL (in bullet form)

COOLING BED
BILLET STORAGE
MECHANICAL TESTING

BILLET INSPECTION

BILLET SHEARING

BY PASS

(if 6m)

(if 3m)

CUT BILLET YARD

BILLET CHARGING

REHEATING FURNACE

BILLET DISCHARGE

ROUGHING MILL

INTERMEDIATE MILL

FINISHING ROLLER

IN CASE OF FAILURE

BARS CUT TO DESIRED


LENGTH

REJECTION

BUNDLING

SCRAP

PLACE IN WARE HOUSE

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

BS 4449-1
Green
(Cut in 6 m)

BS 4449-2
Blue
(Cut in 3 m)

Bs 4449-3
Yellow
(Cut in 6 m)

Special Grade
Red
(Cutting vary)

Billet
Chemistry
C
P
Si
S
Mn
C
P
Si
S
Mn
C
P
Si
S
Mn
C
P
Si
S
Mn

0.18-0.26%
<0.05%
0.15-0.3%
<0.05%
0.6-0.8%
0.26-0.3%
<0.05%
0.15-0.3%
<0.05%
0.6-0.8%
0.-0.24%
<0.05%
0.15-0.3%
<0.05%
0.55-0.65%
0.22-0.25%
<0.05%
0.-0.3%
<0.05%
1.05-1.15%

Carbon
Equivalent

Size to
be Roll

0.36-0.38
(For Xtreme bars
up to 25 mm)

12-16 mm

0.39-0.44
(For G-60 bars
up to 25 mm)

19-22 mm

Max. 0.35
(Only for 3/8
rolling)

9.5 mm

0.48-0.51

40 mm

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

3 Meter

6 Meter

Minimum
2.8 m

Minimum
5.6 m

Maximum
3.1 m

Maximum
6.2 m

PROCESS DIAGRAM OF MILL


CHARGING
GRIT

PASSING ROLLERS
AND SHEAR
ROUGHING MILL

BILLET

REHEATING
FURNACE

INTER-MEDIATE
ROLLERS

CONTINUOUS ROLLERS

SHEAR

REPEATOR
THERMO MECHANICAL
TREATMENT

COOLING BED

SHEAR

BAR
S

BUNDLING

TRANSFER TABLE

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 stacks 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 induceddraft 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
1. Furnace Capacity
2. Rate

Quantity or Values

3. Burners

4. Thermocouples
5.
6.
7.
8.

Numbers of skids
Outlet Temperature
Air-Fuel Ratio
Pusher Capacity

9. Charging Grid

160 Billets
31 metric tons/hour
62 billets per hour
19 burners (8 upper zone, 8
lower zone, soaking zone)
4 Automatic and 15 manual
8 Thermocouples
K type (Metal)
R type (Ceramic)
4 skids with water supply
Range 1100-1200 C
10:1 ratio
10 tons
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

APRON
CHANNEL

COOLING
BED

COLD
SHEAR

TMT

TRANSFER
CHAIN

PINCH
ROLL 4

BUNDLING

SHEAR 3

LOADING

DEVIATOR

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

COOLING TOWER

TMT COOLING TOWER

FURNACE COOLING
TOWER

COLD WELL

COLD WELL

MILL COOLING TOWER

COLD WELL

COLD WELL

CENTRIFUGAL PUMP

CENTRIFUGAL PUMP

CENTRIFUGAL PUMP

CENTRIFUGAL PUMP
MILL COMPLEX

Compress
or

Heat
exchanger

QUINCHING BOX

FURNACE SKITS

HOT WELL

HOT WELL

VERTICAL TURBINE PUMP

VERTICAL TURBINE PUMP

ROUGHING STAND

INTERMEDIATE ROLLING

FINISHING ROLLERS

SCALE PIT TANK

HOT WELL

VERTICAL TURBINE PUMP

MAKEUP WATER TANK-

5d. SPECIFICATION:
CLEAR WATER SYSTEM
COLD WELL
VOLUME:
CENTRIFUGAL PUMP
QUANTITY:
IN OPERATION:
FLOW RATE:
HEAD:
POWER:

103m3
2
1 at a time
190m3 /hr
40m
40hp

TMT WATER SYSTEM


COLD WELL
VOLUME:

103m3

CENTRIFUGAL PUMP
QUANTITY:
IN OPERATION:
FLOW RATE:
HEAD:
POWER:

3
2 at a time
225 m3 /hr
140 m
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:
IN OPERATION:
FLOW RATE:
HEAD:
POWER:

3
2 at a time
170 m3 /hr
40 m
40 hp

HOT WELL
VOLUME:

103m3

FURNACE
TYPE:
CAPACITY:
ZONES:
BURNERS:
SKITS:
WATER SKITS:

Reheating furnace
31 tons/hr
4
19
10
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:
IN OPERATION:
FLOW RATE:
HEAD:
POWER:

3
2 at a time
170 m3 /hr
40 m
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

9.5
12
16
19
22
25
28
32

70.91
113.41
201.4

0.56
0.89
1.58
2.23
2.99
3.86
4.84
6.32

283.64
380.29
491.07
616
804.57

Kg/ft
0.17
0.271
0.482
0.679
0.91
1.176
1.475
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

10
12
16
20
22
25
28
32
36
40

78.57
113.14
201.14

0.62
0.89
1.58
2.47
2.99
3.86
4.84
6.32
8
9.87

314.29
380.29
491.07
616
804.57
1018.29
1257.14

Kg/ft
0.188
0.271
0.482
0.752
0.91
1.176
1.475
1.926
2.438
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

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

Daily

MAINTAINANC
E FREQUENCY

Level of
Load Frame
Monthly

Annually

Oiling/
Greasing
Complete
Oil
Change
Oil Tank
Cleaning

Machine Load Frame

Chain Threaded Shaft

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 ASLs hospitability. It is expected that this technical guidance &
professional knowledge would be helpful in my future studies