Industrial Training Report

(Bhushan Steels Pvt. Ltd.)

Name
: ASHISH PRAKASH
Univ. Roll No.
: 1203340040
Academic Session : 2012-2016

SUBMITTED TOSUJEET SINGH

(Assistant Professor )

JSS MAHAVIDYAPEETHA

JSS ACADEMY OF TECHNICAL EDUCATION

DEPARTMENT OF MECHANICAL ENGINEERING

CONTENT
1.
0 Acknowledgement.3
2.0 Abstract ...............4
3.0 Company profile...5
4.0 List of departments visited in training..6
4.1 Saftey..7
4.2 Pickling..8
4.3 Rolling mills......10
4.4 ECL12
4.5 Annealing......14
4.6 Skin Pass Mill.................................................................................................17
4.7 Slitting............................................................................................................18
4.8 Narrow...........................................................................................................20
4.9 Utility................21
4.10 Mechanical Maintaenance.............................................................................22
4.11 Galvanising plant .......23
4.12.Quality system..26
5.0 Conclusion..28
6.0 References......29

ACKNOWLEDGEMENT

I would wish to express my gratitude to my H.O.D DEEPAK AGGARAWAL

for providing me the opportunity to explore studies beyond academics. I am also thankful to
BHUSHAN STEELS Ltd for allowing me to undergo the SUMMER TRAINING
PROGRAMME in their organization. At last but not the least I extend my thanks to all the
staff members for providing valuable information regarding the plant and processes that
formed the core of the training.

ABSTRACT
In 30 days of my industrial training I have learned about various processes such as cold
rolling slitting etc. I had a good exposure to these processes which added more to my
knowledge. I worked on galvanising plants in which galvanization process takes place,on
steel.basically zinc or aluminium coating is done on the steel,for increasing life of steel and
making it suitable for use, but at Bhushan steel they also coat steel with galume a mixture of
55% zinc + 43% aluminium + 2% silicon. Its coating is very effective and useful.silicon is
basically used just to improve adhesion of the other two material on the steel. Other products
of the industry are colour coated coil, hard tempered coil, billets, sponge iron, tubes, etc.

COMPANY PROFILE

TYPE : PRIVATE
FOUNDED IN : 1987
HEADQAURTERS : INDIA
KEY PERSONS : Brij Bhushan Singhal (Chairperson)
Neeraj Singhal (Managing Director)
INDUSTRY : STEEL
WEBSITE : www.bhushangroup.com

LIST OF DEPARTMENT VISITED IN TRAINING

1. SAFTEY
2. PICKLING
3. HITACHI- MILL
4. ECL
5. ANNEALING
6. SKIN PASS MILL
7. FINISHING
8. NARROW
9. UTILITY
10. MECHANICAL MAINTENANCE
11. GP
12. QUALITY SYSTEM
6

SAFTEY
An industrial safety system is a countermeasure crucial in any hazardous plants such as oil
and gas plants and nuclear plants. They are used to protect human, plant, and environment in
case the process goes beyond the control margins. As the name suggests, these systems are
not intended for controlling the process itself but rather protection. Process control is
performed by means of process control systems (PCS) and is interlocked by the safety
systems so that immediate actions are taken should the process control systems fail.
Total Safety is the place to go for all of your fire protection engineering, design and
installation services. Our fire safety experts include degreed engineers and NICET certified
designers who are recognized as leaders in the field of fire protection and safety engineering.
Members of our in-house engineering staff have an average of 25 years of experience
delivering successful projects throughout the United States, Europe, Central and South
America, as well as the Middle and Far East.

Fig ;- safety equipment

PICKLING

Pickling (metal)
Pickling is a metal surface treatment used to remove impurities, such as
stains, inorganic contaminants, rust or scale from ferrous metals, copper,
and aluminum alloy. A solution called pickle liquor, which contains strong
acids, is used to remove the surface impurities. It is commonly used to
descale or clean steel in various steelmaking processes.
Process
Many hot working processes and other processes that occur at high
temperatures leave a discoloring oxide layer or scale on the surface. In

order to remove the scale the workpiece is dipped into a vat of pickle
liquor.
The primary acid used is hydrochloric acid, although sulfuric acid was
previously more common. Hydrochloric acid is more expensive than
sulfuric acid, but it pickles much faster while minimizing base metal loss.
The speed is a requirement for integration in automatic steel mills that run
production at high speed; speeds as high as 800 ft/min (~243 metres/min)
have been reported.
Carbon steels, with an alloy content less than or equal to 6%, are often
pickled in hydrochloric or sulfuric acid. Steels with an alloy content greater
than 6% must be pickled in two steps and other acids are used, such
as phosphoric, nitric and

hydrofluoric

acid.

Rust-

and

acid-resistant

chromium-nickel steels are pickled in a bath of hydrochloric and nitric

acid. Most copper alloys are pickled in dilute sulfuric acid, but brass is
pickled in concentrated sulfuric and nitric acid mixed with sodium
chloride and soot.
In jewelry making, pickling is used to remove the oxidation layer from
copper surfaces, which occurs after heating. A diluted sulfuric acid pickling
bath is used.
Sheet steel that undergoes acid pickling will oxidize (rust) when exposed
to atmospheric conditions of moderately high humidity. For this reason, a
thin film of oil or similar waterproof coating is applied to create a barrier to
moisture in the air. This oil film must later be removed for many
fabrication, plating or painting processes.

Disadvantages
Acid cleaning has limitations in that it is difficult to handle because of its
corrosiveness,

and

it

is

not

applicable

to

all

steels. Hydrogen

embrittlement becomes a problem for some alloys and high-carbon steels.

9

The hydrogen from the acid reacts with the surface and makes it brittle
and causes cracks. Because of its high reactance to treatable steels, acid
concentrations and solution temperatures must be kept under control to
assure desired pickling rates.

Waste products
Pickling sludge is the waste product from pickling, and includes acidic
rinse waters, metallic salts and waste acid.] Spent pickle liquor is
considered a hazardous waste by EPA.Pickle sludge from steel processes is
usually neutralized with lime and disposed of in a land fill. After
neutralization the EPA no longer deems the waste a hazardous waste. The
lime

neutralization

makes heavy

process

metals in

the

raises

the pH of

sludge

less

the

likely

to

spent
leach

acid

and

into

the

environment. Since the 1960s, hydrochloric pickling sludge is often

treated in a hydrochloric acid regeneration system, which recovers some
of the hydrochloric acid and ferric oxide. The rest must still be neutralized
and disposed of in land fills.The by-products of nitric acid pickling are
marketable to other industries, such as fertilizer processors

10

ROLLING MILLS
In metalworking, rolling is a metal forming process in which metal stock is
passed through a pair of rolls. Rolling is classified according to the
temperature of the metal rolled. If the temperature of the metal is above
its recrystallization temperature, then the process is termed as hot rolling.
If the temperature of the metal is below its recrystallization temperature,
the process is termed as cold rolling. In terms of usage, hot rolling
processes more tonnage than any other manufacturing process and cold
rolling processes the most tonnage out of all cold working processes.
There are many types of rolling processes, including flat rolling, foil
rolling, ring rolling, roll bending, roll forming, profile rolling, and controlled
rolling.
Hot

rolling

is

a metalworking process

that

occurs

above

the

recrystallization temperature of the material. After the grains deform

during

processing,

they

recrystallize,

which

maintains

an equiaxedmicrostructure and prevents the metal from work hardening.

The starting material is usually large pieces of metal, like semi-finished
casting products, such as slabs, blooms, and billets. If these products
came from a continuous casting operation the products are usually fed
directly into the rolling mills at the proper temperature. In smaller
operations the material starts at room temperature and must be heated.
This is done in a gas- or oil-fired soaking pit for larger workpieces and for
smaller workpieces induction heating is used. As the material is worked
the temperature must be monitored to make sure it remains above the
recrystallization

temperature.

To

maintain

a safety

factor a finishing

temperature is defined above the recrystallization temperature; this is

usually 50 to 100 C (122 to 212 F) above the recrystallization

11

temperature. If the temperature does drop below this temperature the

material must be re-heated before more hot rolling.
Hot rolled metals generally have little directionality in their mechanical
properties and deformation induced residual stresses. However, in certain
instances non-metallic inclusions will impart some directionality and
workpieces less than 20 mm (0.79 in) thick often have some directional
properties. Also, non-uniformed cooling will induce a lot of residual
stresses, which usually occurs in shapes that have a non-uniform crosssection, such as I-beams and H-beams. While the finished product is of
good quality, the surface is covered in mill scale, which is an oxide that
forms

at

high-temperatures.

It

is

usually

removed

via pickling or

the smooth clean surface process, which reveals a smooth surface.

Dimensional tolerances are usually 2 to 5% of the overall dimension.
Hot rolling is used mainly to produce sheet metal or simple cross sections,
such as rail tracks.
Cold rolling

Fig ;-cold rolling

Cold rolling occurs with the metal below its recrystallization temperature
(usually at room temperature), which increases the strength via strain
hardening up to 20%. It also improves the surface finish and holds
tighter tolerances. Commonly cold-rolled products include sheets, strips,
bars, and rods; these products are usually smaller than the same products
that are hot rolled. Because of the smaller size of the workpieces and their
12

greater strength, as compared to hot rolled stock, four-high or cluster mills

are used. Cold rolling cannot reduce the thickness of a workpiece as much
as hot rolling in a single pass.
Cold-rolled sheets and strips come in various conditions: full-hard, halfhard, quarter-hard, and skin-rolled. Full-hard rolling reduces the thickness
by 50%, while the others involve less of a reduction. Quarter-hard is
defined by its ability to be bent back onto itself along the grain
boundary without breaking. Half-hard can be bent 90, while full-hard can
only be bent 45, with the bend radiusapproximately equal to the material
thickness. Skin-rolling, also known as a skin-pass, involves the least
amount of reduction: 0.5-1%. It is used to produce a smooth surface, a
uniform

thickness,

and

reduce

the yield-point

phenomenon (by

preventing Luder bands from forming in later processing). It is also used to

breakup the spangles in galvanized steel. Skin-rolled stock is usually used
in subsequent cold-working processes where good ductility is required.

13

ELECTROCHEMICAL CLEANING

Fig ;- electrochemical cleaning

Electrochemical Cleaning (ECC) is a very effective process using the same
physics, equipment, and chemicals we use in our proprietary "spot"
electropolishing technique. Discovered when a customer had a product
residue issue that looked like classic "rouge" yet when industry accepted
de-rouging chemical applications were tried they proved completely
ineffective. In an experiment we used the spot electropolish procedure
whereby electrolyte was applied to the stained surface and the DC current
was activated and the "hand tool" was applied to and moved over the
surface the stain was removed immediately. Because of this discovery we
were able to completely clean 5,10,15K GALLON & larger vessels in hours
instead of days.
Once discovered this method has found several very cost effective
applications where ECC can be used in place of more expensive and less
effective chemical or manual processes while delivering a micro surface

14

improvement to the area being cleaned where optional processes at best

do nothing to improve and at worst can etch the micro surface.

15

Applications

De-rouging: ECC has been found to be very effective for removing rouge
for both electropolished and non-electropolished surfaces.

An added

benefit observed on items de-rouged using ECC is the rouge is very slow
to return.

Though conventional de-rouging and passivation methods

would yield a clean product contact surface the rouge would begin to
reform in a matter of hours. Equipment de-rouged using ECC has shown
the rouge resisted returning for months and in some cases years.
Grey Residue: On equipment with a sanded or mechanically polished
stainless steel surface only it is common to find a grey residue present
when the surface is wiped with an alcohol soaked cloth.

In many

instances the entire surface of a vessel, as an example, will be hand wiped

for hours using "clean wipes" until all of the grey residue has appeared to
have been removed. The vessel may then be passivated or cleaned in
place and allowed to dry only to have the grey residue return at visibly the
same concentration as observed before the cleaning operation.
It is believed this grey residue is made up of stainless steel powder
created by the sanding process and electrostatically adhered to the
mechanically polished surface (PIC). No amount of wiping or chemical
cleaning has proven to completely remove this residue. Understandably
Quality Control personnel find this condition unacceptable concerned if
the grey residue can be wiped off, it stands to reason it can come loose
during product processing and become an undesirable additive.
ECC can completely remove this grey residue in one application by
electrolytic action as metal is removed ion by ion with the very outermost
surface and any residue being removed. In dozens of applications this
condition has successfully been treated in one application eliminating grey
residue from the equation.

16

Weld Scale and Discoloration: Prior to successful use as a de-rouging or

surface contaminant removal process, ECC was developed specifically for
removing weld discoloration directly on a weld or in the heat affected
zones adjacent to the weld.
The process utilizes a mild acid electrolyte solution and DC current that
when applied to a weld or heat affected zone (HAZ) very rapidly removes
discoloration. On large construction projects utilizing austenitic, superaustenitic or nickel alloys, weld discoloration has

ANNEALING

Annealing,

in metallurgy and materials

science,

is

a heat

treatment wherein a material is altered, causing changes in its properties

such as strength and hardness. It is a process that produces conditions by
heating to above the recrystallization temperature, maintaining a suitable
temperature, and then cooling. Annealing is used to induce ductility,
soften material, relieve internal stresses, refine the structure by making it
homogeneous, and improve cold working properties.
In the cases of copper, steel, silver, and brass, this process is performed
by substantially heating the material (generally until glowing) for a while
and allowing it to cool. Unlike ferrous metalswhich must be cooled
slowly to annealcopper, silver and brass can be cooled slowly in air or
quickly by quenching in water. In this fashion the metal is softened and
prepared for further work such as shaping, stamping, or forming.

Thermodynamics
Annealing occurs by the diffusion of atoms within a solid material, so that
the material progresses towards its equilibrium state. Heat is needed to
increase the rate of diffusion by providing the energy needed to break
17

bonds. The movement of atoms has the effect of redistributing and

destroying the dislocations in metals and (to a lesser extent) in ceramics.
This alteration in dislocations allows metals to deform more easily, so
increases their ductility.
The amount of process-initiating Gibbs free energy in a deformed metal is
also reduced by the annealing process. In practice and industry, this
reduction of Gibbs free energy is termed "stress relief"..
The relief of internal stresses is a thermodynamically spontaneous
process; however, at room temperatures, it is a very slow process. The
high temperatures at which the annealing process occurs serve to
accelerate this process.
The reaction facilitating the return of the cold-worked metal to its stressfree state has many reaction pathways, mostly involving the elimination of
lattice vacancy gradients within the body of the metal. The creation of
lattice vacancies is governed

and the migration/diffusion of lattice

vacancies are governed by Ficks laws of diffusion.

Mechanical properties, such as hardness and ductility, change as
dislocations are eliminated and the metal's crystal lattice is altered. On
heating at specific temperature and cooling it is possible to bring the atom
at the right lattice site and new grain growth can improve the mechanical
properties.

Stages
There are three stages in the annealing process, with the first being
the recovery phase, which results in softening of the metal through
removal of crystal defects (the primary type of which is the linear defect
called a dislocation) and the internal stresses which they cause. Recovery
phase covers all annealing phenomena that occur before the appearance
of new strain-free grains. The second phase is recrystallization, where new
strain-free grains nucleate and grow to replace those deformed by internal
18

stresses. If annealing is allowed to continue once recrystallization has

been completed, grain growth will occur, in which the microstructure
starts to coarsen and may cause the metal to have less than satisfactory
mechanical properties.

Controlled atmospheres
The high temperature of annealing may result in oxidation of the metals
surface, resulting in scale. If scale is to be avoided, annealing is carried
out in a special atmosphere, such as with endothermic gas (a mixture of
carbon monoxide, hydrogen gas, and nitrogen gas).
The magnetic properties of mu-metal (Espey cores) are introduced by
annealing the alloy in a hydrogen atmosphere.

Setup and equipment

Typically, large ovens are used for the annealing process. The inside of the
oven is large enough to place the workpiece in a position to receive
maximum exposure to the circulating heated air. For high volume process
annealing, gas fired conveyor furnaces are often used. For large
workpieces or high quantity parts Car-bottom furnaces will be used in
order to move the parts in and out with ease. Once the annealing process
has been successfully completed, the workpieces are sometimes left in
the oven in order for the parts to have a controlled cooling process. While
some workpieces are left in the oven to cool in a controlled fashion, other
materials and alloys are removed from the oven. After being removed
from the oven, the workpieces are often quickly cooled off in a process
known as quench hardening. Some typical methods of quench hardening
materials involve the use of media such as air, water, oil, or salt.

Diffusion annealing of semiconductors

19

In

the semiconductor industry, silicon wafers

are

annealed,

so

that dopant atoms, usually boron, phosphorus or arsenic, can diffuse into
substitutional positions in the crystal lattice, resulting in drastic changes
in the electrical properties of the semiconducting material.

Normalization
Normalization is an annealing process in which a metal is cooled in air
after heating in order to relieve stress.
It can also be referred to as: Heating a ferrous alloy to a suitable
temperature above the transformation temperature range and cooling in
air to a temperature substantially below the transformation range.
This process is typically confined to hardenable steel. It is used to refine
grains which have been deformed through cold work, and can improve
ductility and toughness of the steel. It involves heating the steel to just
above its upper critical point. It is soaked for a short period then allowed
to cool in air. Small grains are formed which give a much harder and
tougher metal with normal tensile strength and not the maximum ductility
achieved by annealing. It eliminates columnar grains and dendritic
segregation

that

sometimes

occurs

during

casting.

Normalizing

improves machinability of a component and provides dimensional stability

if subjected to further heat treatment processes.Process annealing
Process annealing, also called "intermediate annealing", "subcritical
annealing", or "in-process annealing", is a heat treatment cycle that
restores some of the ductility to a work piece allowing it be worked further
without breaking. Ductility is important in shaping and creating a more
refined

piece

of

work

through

processes

such

as rolling, drawing, forging, spinning, extruding and heading. The piece is

heated to a temperature typically below the austenizing temperature, and
held there long enough to relieve stresses in the metal. The piece is finally

20

cooled slowly to room temperature. It is then ready again for additional

cold working. This can also be used to ensure there is reduced risk of
distortion of the work piece during machining, welding, or further heat
treatment cycles.

SKIN PASS MILL

After annealing, coils may require a final rolling called a temper pass, skin pass or planish
pass. This involves a controlled light reduction to establish the final thickness, impart the
desired surface finish, flatten the strip to improve shape and create the required hardness or

Fig ;- skin pass mill

21

COLD ROLL SLITTING / CUT TO LENGTH

Fig ;- cold roll slitting

22

Roll slitting, also known as log slitting, is a shearing operation that cuts a
large roll of material into narrower rolls. The log slitting terminology refers
back to the olden days of saw mills when they would cut logs into smaller
sections. They would also use these saw mills to cut iron rods into smaller
sections; see slitting mill. The multiple narrower strips of material are
known as mults (short for multiple) By today's definition, slitting is a
process in which a coil of material is cut down into a number of smaller
coils of narrower measure. Potential workpieces are selectively thin (0.001
to 0.215 in.) and can be machined in sheet or roll form. Slitting is
considered a practical alternative to other methods due to its high
productivity and the versatility of materials it can manage.

Soft materials
Several methods are available for soft materials like plastic films and
paper. Razor blades, straight, or circular blades are being used. Some
blades cut through the material while others crush the material against a
hard roll. Those are similar to knives and cut the material into narrow
strips, which are called coils when being rewound. The cutting blades can
be set to a desired width. Some machines have many blades to increase
the options of cutting widths, others have just a single blade and can be
set to a desired location. The slit material is being rewound on paper or
plastic cores on the exit side of the machine.
Examples of materials that can be cut this way are: adhesive tape, foam,
rubber, paper products, foil, plastics (such as tarps and cling wrap), glass
cloth, fabrics, release liner and film.Hard materials
For harder materials, such as sheet metal, blades cannot be used. Instead
a modified form of shearing is used. Two cylindrical rolls with matching
ribs and grooves are used to cut a large roll into multiple narrower rolls.
This continuous production process is very economical yet precise; usually
more precise than most other cutting processes. However, the occurrence

23

of rough or irregular edges known as burrs are commonplace on slit

edges.
Some customers require a steel to be of a particular thickness other than
the general increment sizes rolled in the hot mill or thinner than the
minimum thickness rolled in the mills. These steels are processed in the
cold roll reduction mill. These mills are capable of rolling steel to the
precise thickness that the customer orders and are a major part of the
steel strip production process. The reduction mill in the plant I worked had
four rolls in the mill that were stacked upon each other. This arrangement
is known as a two high mill. There are two working rolls between which
the strip is passed and two large back-up rolls, one on top of the working
rolls and one on the bottom. The back-up rolls apply the tremendous
pressures required to cold roll (reduce) the strip between the working rolls.

NARROW PLANT

In narrow plant the width of the coils being passed is small ranging from 110530 mm. Rolling is performed by 4 rollers without any intermediate rollers.
Here also annealing and ctl facilties are available. Instead of electrochemical
cleaning here rewinding operation is used.

24

UTILITY
BOILER
A boiler is a closed vessel in which water or other fluid is heated. The fluid does not
necessarily boil. (In North America the term "furnace" is normally used if the purpose is not
actually to boil the fluid.) The heated or vaporized fluid exits the boiler for use in various
processes or heating applications, including water heating, central heating, boiler-based
power generation, cooking, and sanitation.

25

The pressure vessel of a boiler is usually made of steel (or alloy steel), or historically of
wrought iron. Stainless steel, especially of the austenitic types, is not used in wetted parts of
boilers due to corrosion and stress corrosion cracking.[3] However, ferritic stainless steel is
often used in superheater sections that will not be exposed to boiling water, and electricallyheated stainless steel shell boilers are allowed under the European "Pressure Equipment
Directive" for production of steam for sterilizers and disinfectors

Fig ;- boiler
COMPRESSOR
An air compressor is a device that converts power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized air (i.e., compressed air). By one of
several methods, an air compressor forces more and more air into a storage tank, increasing
the pressure. When tank pressure reaches its upper limit the air compressor shuts off. The
compressed air, then, is held in the tank until called into use. The energy contained in the
compressed air can be used for a variety of applications, utilizing the kinetic energy of the air
as it is released and the tank depressurizes. When tank pressure reaches its lower limit, the air
compressor turns on again and re-pressurizes the tank.

26

Fig ;- compressor

AIR CONDITIONING

Air conditioning (often referred to as A/C, AC, or aircon) is the process of altering the
properties of air (primarily temperature and humidity) to more comfortable conditions,
typically with the aim of distributing the conditioned air to an occupied space such as a
building, house or vehicle to improve thermal comfort and indoor air quality. In common use,
an air conditioner is a device that lowers the air temperature. The cooling is typically
achieved through a refrigeration cycle, but sometimes evaporation or free cooling is used. Air
conditioning systems can also be made based on desiccants

GALVANISING PLANT

27

Fig ;- galvanizing plant

Metal protection
In current use, the term refers to the coating of steel or iron with zinc. This
is

done

to

prevent galvanic

corrosion (specifically

rusting)

of

the ferrous item. The value of galvanising stems from the relative
corrosion resistance of zinc, which, under most service conditions, is
considerably less than those of iron and steel. The effect of this is that the
zinc is consumed first as a sacrificial anode, so that it cathodically protects
exposed steel. This means that in case of scratches through the zinc
coating, the exposed steel will be cathodically protected by the
surrounding zinc coating, unlike an item which is painted with no prior
galvanising,

where

scratched

surface

would

rust.

Furthermore,

galvanising for protection of iron and steel is favoured because of its low
cost, the ease of application, and the extended maintenance-free service
that it provides.
28

The term galvanizing, while correctly referring to the application of the

zinc coating by the use of a galvanic cell (also known as electroplating),
sometimes is also used to refer to hot dip zinc coating (commonly
incorrectly referred to as hot dip galvanizing). The practical difference is
that hot dip zinc coating produces a much thicker, durable coating,
whereas genuine galvanizing (electroplating) produces a very thin coating.
Another difference, which makes it possible to determine visually which
process has been used if an item is described as 'galvanized', is that
electroplating produces a nice, shiny surface, whereas hot dip zinc coating
produces

matte,

grey

surface.

The

thin

coating

produced

by

electroplating is much more quickly consumed, after which corrosion turns

to the steel or iron itself. This makes electroplating unsuitable for outdoor
applications, except in very dry climates. For example, nails for indoor use
are electroplated (shiny), while nails for outdoor use are hot dip zinc
coated (matte grey). However, electroplating and subsequent painting is a
durable combination because the paint slows down the consumption of
the zinc. Car bodies of some premium makes are corrosion protected
using this combination.
Electroplated steel is visually indistinguishable from stainless steel when
new. To determine whether a part is electroplated or stainless steel, apply
a magnet. The most common stainless steel alloys (including those used
for bolts and nuts) are not magnetic or only very slightly attracted to a
magnet.
History
Originally, "galvanization" was the administration of electric shocks (in
the 19th

century also

termed Faradism,

after Michael

Faraday).

It

stemmed from Galvani's induction of twitches in severed frogs' legs, by

his accidental generation of electricity. This archaic sense is the origin of
the meaning of galvanic when meaning "affected/affecting, as if by a
shock of electricity; startled". Its claims to health benefits have largely
been disproved, except for some limited uses in psychiatry in the form
29

of electroconvulsive therapy (ECT). Later the word was used for processes
of electrodeposition.

This

remains

useful

and

broadly

applied

technology, but the term "galvanization" has largely come to be

associated with zinc coatings, to the exclusion of other metals.

Zinc coatings

Zinc coatings prevent corrosion of the protected metal by forming a

physical barrier, and by acting as a sacrificial anode if this barrier is
damaged. When exposed to the atmosphere, zinc reacts with oxygen to
form zinc oxide, which further reacts with water molecules in the air to
form zinc hydroxide. Finally zinc hydroxide reacts with carbon dioxide in
the atmosphere to yield a thin, impermeable, tenacious and quite
insoluble dull gray layer of zinc carbonate which adheres extremely well to
the underlying zinc, so protecting it from further corrosion, in a way
similar to the protection afforded to aluminium and stainless steels by
their oxide layers.
Hot-dip galvanizing deposits a thick robust layer that may be more than is
necessary for the protection of the underlying metal in some applications.
This is the case in automobile bodies, where additional rust proofing paint
will

be

applied.

Here,

thinner

form

of

galvanizing

is

applied

by electroplating, called "electrogalvanization".

As noted previously, both mechanisms are often at work in practical
applications. For example, the traditional measure of a coating's
effectiveness is resistance to a salt spray. Thin coatings cannot remain
intact indefinitely when subject to surface abrasion, and the galvanic
protection offered by zinc can be sharply contrasted to more noble metals.
As an example, a scratched or incomplete coating of chromium actually
exacerbates

corrosion

of

the

underlying

steel,

since

it

is

less

electrochemically active than the substrate.

30

Fig ;- Galvanized surface with visible spangle

The size of crystallites in galvanized coatings is an aesthetic feature,
known as spangle. By varying the number of particles added for
heterogeneous nucleation and the rate of cooling in a hot-dip process, the
spangle can be adjusted from an apparently uniform surface (crystallites
too small to see with the naked eye) to grains several centimetres wide.
Visible crystallites are rare in other engineering materials. Protective
coatings for steel constitute the largest use of zinc and rely upon the
galvanic or sacrificial property of zinc relative to steel.

QUALITY CONTROL
Quality control is a process by which entities review the quality of all
factors involved in production. This approach places an emphasis on three
aspect
1. Elements such as controls, job management, defined and well
managed

processes, performance

and

integrity

criteria,

and

identification of records
2. Competence,

such

as

knowledge,

skills,

experience,

and

qualifications
3. Soft

elements,

such

as

personnel integrity, confidence, organizational

culture, motivation, team spirit, and quality relationships.

31

The quality of the outputs is at risk if any of these three aspects is

deficient in any way.
Quality control emphasizes testing of products to uncover defects, and
reporting to management who make the decision to allow or deny the
release, whereas quality assurance attempts to improve and stabilize
production, and associated processes, to avoid, or at least minimize,
issues that led to the defects in the first pun For contract work, particularly
work awarded by government agencies, quality control issues are among
the top reasons for not renewing a contract.
"Total quality control", also called total quality management, is an
approach

that

extends

beyond

ordinary

statistical

quality

control

techniques and quality improvement methods. It implies a complete

overview and re-evaluation of the specification of a product, rather than
just considering a more limited set of changeable features within an
existing product. If the original specification does not reflect the correct
quality requirements, quality cannot be inspected or manufactured into
the product. For instance, the design of a pressure vessel should include
not

only

the

material

and dimensions,

but

also

operating,

environmental, safety, reliability and maintainability requirements,and

documentation of findings about these requirements.

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Fig ;- quality process

33

CONCLUSION
IT GIVES ME IMMENSE PLEASURE TO SAY THAT I HAVE
SUCESSFULLY UNDERGONE 30 DAYS OF INDUSTRIAL TRANING
IN BHUSHAN STEEL LTD. IT WAS A LIFETIME EXPERIENCE . I
LEARNED A LOT OF NEW THINGS ,AND LOT OF NEW WAYS OF
SOLVING A PROBLEM. I WANT TO CONCLUDE MY REPORT ON A
POSITIVE NOTE AND I HOPE THAT THE EXPERIENCE WHICH I
GOT WILL ALSO B FRUITFUL IN MY CAREER AHEAD.

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REFRENCE
1.www.bhushan-group.com
2. Wikipedia.com
3.Ghosh and Malik-Production Enginnering

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