LIST OF FIGURES

Figure no. Title Page no

Figure 1 Coke oven batteries 1

Figure 2 Transmission of pusher car 2

Figure 3 Blast Furnace no. 1 of Plant 3

Figure 4 Various positions of carriage movement of Strapping machine 14

 LIST OF TABLES

Table no. Title Page no

Table 1 Machine Over All Dimensions 11

Table 2 Strapping Head 11

Table 3 Strap Detail 11

Table 4 Strap Dispenser 12

Table 5 Ink jet printer 12

Table 6 Electrical Connections 12

 Contents

Front Page Page No

Declaration by student i

Certificate by supervisor (Forwarded by HOD/HOI) ii

Certificate by company iii

Acknowledgement iv

Abstract v

List of Figures vi

List of Tables vii

Chapter 1. Introduction 1

Chapter 2. About The Strapping Machine 6

Chapter 3. Specification of Machine 11

Chapter 4. Working of Strapping Machine 13

Chapter 5. Momentary Benefits 15

Chapter 6. Conclusion 16

Chapter 7. Summary 17

Chapter8. Bibliography 18

Plagiarism Report 19
Chapter 1
Introduction
The first and foremost thing is to know how the steel is made from ore to blooms which
requires basic knowledge of working of all departments in steel plant and their
importance . This is the reason why basic background study of whole plant is important.

1.1 Parts of Plant

1.1.1 The Raw Materials Handling Plant
RMHP is the first department of VSP where raw materials like Iron Ore, coking and non
coking coals etc., are stored and supplied to the other departments . It is very important
as large amount of raw material is imported from nearby port and has to be managed
according to the requirement of coke oven and blast furnace. Here 80 percent of
Australian coal is mixed with 20 percent Indian coal which is used in Coke Oven. The
transportation is carried out through conveyor belts, locomotives and trucks.

Fig.1 Coke oven batteries

1.1.2 The Coke Oven Department

A proper blast furnace of Plant require good quality of energy source in the form of coke
which acts as a reducing agent and supplies the heat. Coke is produced by heating of
crushed imported coking coal (which is less than 3mm size) in absence of air at
temperature of 1100 degree and for about 16 hours. A Coke Oven has of two empty
chambers namely coal chamber and heating chamber. In the heating chamber a gaseous
fuel such as Blast Furnace Gas, Coke Oven Gas etc., is burnt. The heat so generated is
conducted through the common will to heat and carbonize the coking coal placed in the
adjacent coal chamber. The most time for orientation was spent in coke oven only to
understand pushar car , charging car and guide car as these machines are involved in
continuous handling of batteries and feeding them.

1.1.3 The Sinter Plant

Sinter Plant is a place where lump of iron ore and coke is made as coke may stick on the
walls of the blast furnace . This was the place where very less time was spent on
orientation .Sintering is done in 2 number of 312 square metre, Sintering machines are
used for heating the feed on a continuous metal material belt made of pallets at twelve
hundred to thirteen hundred degree celsius.

Fig. 2 Transmission of pusher car.

1.1.4 The Blast Furnace Department
In a blast furnace department molten metal at high temperature is produced in tall vertical
blast furnace. The raw materials like limestone, sinter, iron ore and coke are discharged in
the hot blast at 1120 -1310 degree temperature and around 6 KSC pressure is fetched
from the bottom of the furnace.
The Plant has three blast furnace of 3200 cubic metre volume which are equipped with a
lot of mechanical and electrical machineries.
1.1.5 The Steel Melting Shop And Continuous Casting Department
In Steel Melt Shop , molten steel is brought by the use of locomotives from the blast
furnace .Here the liquid Steel consists of slag and dust which is then removed. Then
minerals and other materials are added to the pig iron based upon the requirement . After
the second metallurgy process the pig iron is sent to casting department through ladles
where single strand consists of ladle , tundish car , dummy car , TK rollers and cooling
system . The Vizag Plant consists of six-4 strand CCD machines capable of giving out 2.8
million tones/annum blooms of 250 X 250 mm and 250 X 320 mm size. The blooms are
6 mt long and after the process they are sent to Rolling Mills .

Figure 3. Blast Furnace no. 1 of Plant

1.1.6 The Rolling Mills
This Department consists of two major sections. They are
1. Billet Mill
2 . Bar Mill
1.1.6.1 Billet Mill:
The function of this mill is:

1.To produce billets of 125*125mm size with length range from 9.8to 10.2meters,
suitable for feed material in wrm.

2. Billets of 125*125mm and 32m length hot billets are used as feed material
for bar mill.

Break down mill area:

3.Hot bloom travels forward over the roller table under sequence control and is feed
from scale on the move by the de-scalar unit and is Finally positioned over the
roller table section having tilter unit. the tilting is done to make the bloom upright.

4.The upright bloom now enters the first stand of billet mill. These are seven stands
in the billet mill. In five box passes and one each of diamond and square
passes the blooms are reduced to 125mm square of 33m length with a finishing
speed of 1.3to1.6m/sec depending upon the bloom discharge temperature of
1100degree centigrade -1200degree centigrade.the draw-in speed of bloom varies
from0.256m/sec to 0.315m/sec depending up on the discharge bloom temperature.

5.A four crank shear installed behind the mill stands is designed to crop both
ends and to cut fixed billet length between 5.0 and 12.2m or to perform optimum
yield dividing.

Billet mill cooling bed area :

Billets meant for billet mill cooling beds are stamped on the move on the
head ends and are transferred to cooling Beds on the move by means of
discharge drums in the form of feeder screws, which after one full revolution,
push the billets Running on cooling bed roller table side-wise to a breake-plate,
where it comes to rest after a short braking distance.

1.1.6.2 Bar mill:

The mill has been envisaged to produce rounds, flats, and channel, equal and unequal
angles. But as per the Market demand, present product range is only plane bars of 16 to
40mm and rebars of 16 to 36mm diameter.

Roller hearth furnace area:

Billets mean for merchant bar mill are cropped at the font and rear end and generally
have a length of approximately 31.6m.these billets are transported with a speed of 2m/sec
to the inline two-stand roller hearth furnace. the rollers used here are water-cooled and
are separately driven. The billets enter the first strand of the bar mill at the normal entry
temperature of 1100degreecentigrade.

Cold shear and bundling: The bars after cutting to customer lengths by cold shear 12m
bundle by bundling machines, the bundles are weighed and strapped with steel plates,
displaying heat number, grade for further processing.

Rolling mill has two units. In Beginning 250 x 320 mm are converted into 125 x 125mm
which is then sent to light medium merchants mill and wire production mill.
Chapter 2
2.1 About The Strapping Machine
After going thorough study and analysis of the process, Light Mediums Merchant Rolling
Mill is being followed by one of the important bottlenecks for smooth production appears
to be binding machines. The problems with binding machines are Poor Packing, Loose
ties, Breakage of ties, Missing of identification of tags . Therefore the group felt, it is
worth while study the feasibility on strapping machines.The proposed strapping machine
model M410N-114 is made of ITW SIGNODE INDIA LTD. Each machine consists of of
different parts explained next.
2.1.1 Model Signode:
The M410N-114 strapping head is mounted on the vertical bed. The air powered M410N-
114 strapping head is designed for heavy-duty applications. Strap tension is adjustable up
to 20,000 N. The working components for the head are easily accessible for inspection
and the replacement. The sealing mechanism is protected by a face gate, which exposes
the sealing jaws only during the tensioning cycle. Strapping head feeds the strap around
the bundle (strap gets guided in the chute), grips the leading end, pulls the extra length of
the strap, provides the set tension and seals the joint in that position. All these operations
are done automatically in the sequence with the help of electro-pneumatic valves and
controls.The strapping head houses a seal magazine to hold a maximum of 170 seals. The
seal magazine enables automatic insertion of the seals during the strapping operation. The
seal magazine is built in with the head. It's got a seal ejector at the top. This seal ejector
ejects the seal in the jaws of the head at the beginning of every strapping cycle. Jaws hold
seal lightly till the extra length of the strap is taken up and tensioned. After this the
notching of the seal and cutting of the strap takes place. The head is also inbuilt with a
provision to mount the InkJet Printing head, which has an interfacing with the PLC for the
printing subject as per the instruction from the Computer. The Strap path is designed
specially for maintaining the gap between the UP head and the strap to enable the correct
printing characters on the strap.
2.1.2 Bed& slide: The
M410N-114 head is mounted on the slide that is fabricated of heavy gauge steel plates
and machined. The slide with head is guided on hardened & ground guide ways that are in
turn mounted on fabricated and machined bed. The keeper plates retain the slide with
head and it is moved front & back by a Hydraulic cylinder / electric motor with suitable
transmission mechanism to match the sealing position with product centre line of various
sizes. The whole assembly is mounted vertically on the machine carriage.
2.1.3 Strap chute system:
The strap chute system is made in two parts, one is pivoted and the pivoted bracket is
mounted on the movable slide on top of the head. The other part of the strap chute is
mounted to the bottom face of the head. The part pivoted on the slide is connected to a
Pneumatic cylinder. When this chute segment swings, a loop path is formed over the
drcurnference of the bundle. In open (swing back) position strap chute clears the bundle
on the conveyor. The strap chute is fabricated out of steel plates and sections. Raps
around the entire chute confine the strap, but permit a controlled release during take-up&
tensioning. Provision is made to open a part of the fixed strap guide, by a pneumatic
cylinder, to print on the strap.
2.1.4 Carriage and mainframe:
The existing machine mainframe and carriage of the wire-tying machine is retained for
the strapping machine. The bed & slide with strapping head, strap chute assembly,
cylinders for head & strap chute movement are mounted on the carriage which is guided
in the main frame and it is driven by an electric motor. The main frame is guided on
existing track. ITW will decide on receipt of the Order, whether to use a new Main ' frame
or continue with the old Main frame based on the detailed design of the strapping m/c.
2.1.5 Track for the machine:
The existing track provided for the movement of the wire-tying machine for applying
multiple wire tie will be used. Now it is proposed three machines stationary in fixed
position in each .bay and one stand by machine will be positioned in between the two
bays and it moves either side on the existing tracks depending on the requirement. The
existing track is retained for this purpose.

2.1.6 Strap Dispenser DPAM 1000:

Strap coil held in the dispenser, which releases the strap as requires by the head during
feeding and takes the extra length of the strap back during take-up and tension. The strap
is routed through a hopper, which moves vertically on guide rods. Sufficient length of
strap is fed, such that the hopper remains in the bottom most position, at the beginning of
the cycle. As the strap is fed, the hopper going up compensates it. The hopper moves
down under gravity during take-up and tensioning. An electric motor feeds the strap to fill
the hopper. The dispenser is mounted on an idler conveyor attached to the machine
carriage and moves integral with the machine main frame for the case of stand by
machine. For stationary machines it is proposed to mount on the floor near the machine.
2.1.7 Continues Ink Jet printer:
The required data to identify the coil is printed on one of the straps applied on the bundle.
A non - contact form of high speed ink jet printer is mounted on the fixed part of the strap
guide system which is designed inbuilt with the strapping head and is programmed to
print automatically on the strap, receiving the data to print from the PC where in operator
can manually enter the data to be printed or else VSP PC should give the soft data to ITW
server for necessary printing operation. The printer head is mounted in the strap guide
path. The printer fetches a continuous stream of ink through a nozzle. The whole stream
is then broken down into identical droplets at a rate of up to 120000 per second. These
droplets are selectively charged and deflected to print dot matrix characters. Undeflected
characters are re-circulated.Machine at each bay and stand by machine is provided with
the above printer assembly.However to provide uninterrupted on line printing of data, the
stand by machine which has printer assembly shall be positioned at the strapping area,
hence we are not providing any facility in our machine for automatic insertion of tags.
The ink jet printer has programming facilities for batch coding and sequential numbering.
It has a memory to storage capacity to store 5 messages and 5 logos. Red colour ink shall
be used for printing hence the strap colour shall be preferably Black, yellow or zinc for
better visibility of printed matter.
2.1.8 Electrical control system:
New electrical control system will be provided for the operation of the strapping machine.
To operate various hydraulic & pneumatic cylinders, motors and other accessories in
desired logic and sequence, an electric control panel is provided with a programmable
logic controller with necessary control and interlocking elements between the MILL PLC
and ITW PLC. This has various contactors, timer relays and other electrical accessories.
Control desk has various push buttons for manual and automatic operations. By
considering the smooth and less breakdown time we are considering two independent
PLC for the two strapping bays.The ATM 80 up gradation of required hardware and soft
ware would be made by VSP. However, ITW will try to match the strapping machine
with the existing mill requirements and will extend necessary support for the
modifications required in the existing line. For this VSP should provide the PLC software
softcopy and the development software, PC - PLC communication cable for VSP PLC
and related manuals to ITW in advance.Cabling between the electrical cabinet and the
pulpit closer to the strapping machines shall be in scope of ITW. However, VSP should
assist ITW in wire routing and trench details.ITW PLC control panels will be located near
the strapping m/c [ a new Control room should be built by VSP for this with AC facility].
The horizontal movement of the Strapping m/c on the track is done thru PB station by the
supervisor and once the location of the strapping m/c is frozen, the same will remain
unchanged until it is moved again. The strapping m/c location should be determined such
that it does not foul with the roller conveyor elements and bear huggers and lowering
arms.
2.1.9 Pneumatic components:
As described above, the strapping head is operated by various pneumatic elements like
pneumatic cylinders, motors etc., through various pneumatic solenoid valves. The
minimum pressure of air required is 6 Bars. The non- availability of this pressure may
lead to insufficient strap tension and possible malfunctioning during the notching and
strap cutting process. The machine is fitted with a pressure switch, which automatically
stops the machine as soon as the pressure drops below 5 Bar. Each machine is provided
with complete set pneumatic control valves which are used to operate the strapping
machine head part .
2.1.10 Compressor and drier:
As the performance of the machine depends on the minimum pressure available and the
presently available pressure is 3 bar or less than 3 bar, we are recommending two
numbers stand alone dedicated compressors of 525 cfm-7 bar working pressure capacity
along with a filter and drier and receiver at LMMM. Each compressor can serve three
fully automatic M410N - 114 power strapping machines.The drier provided is of the
refrigerated type. The advantage of this type'of a drier is that there is no air loss involved
during the drying process. The structure is very compact and the drier maintains a
constant dew point at all times.The air filter is of the compressed air type. This filter is
designed to remove solid particles up to 5 microns and moisture and oil droplets. It
incorporates a cleanable filtering media of porous ceramic cylinders, complete with
automatic drain tap. The ceramic media retains on its surface the piping dirt and rust. The
water and oil condense to drops while passing through the pores of the filter media, which
is periodically drained through automatic condensate discharge valve. These filters are
effective for air temperature of 45 deg. C.
Chapter 3
3.1 Specification of Machine

Table no 1 Machine Over All Dimensions

Height 4185mm
Width 1650mm
Length 8100mm

Table no 2 Strapping Head:

Model M400N-114
Mode of operation PNEUMATIC
Strap Feet and Take up rate 1500-2000 MM/SEC
Strap tension 20,000 N MAX
Joint Type DOUBLE NOTCHED
Seal magazine capacity 150 PIECES
Seal type 114M (NESTACK)
Seal application AUTOMATIC

Table no 3 Strap Details:

Type Magnus grade painted & wax coated
Width 31.75mm
Thickness 0.89mm (min)
Material IS -5872 GRADE-1
Zinc coating & corrosion resistance test Is-9844
 Table no 4 Strap Dispenser
Model DPAM1000
Mode Electrical
Max strap coil wt 500kg

Table no 5 Ink jet printer

Lines of print Two
Speed 1.5m/s max
Ink type MEK Dye based blank ink
Max no. of characters /min 1000
Character height range 1-11mm
Display 4line x 40 character LCD display

Table no 6 Electrical Connections

Mains voltage 415V
Control voltage 24V
Power consumption 9KV

3.2 Man power required

One person (semi-skilled) would be required for all the five strapping Machine at
LMMM, to load strap coils on to dispenser and seal stack on the seal magazine as and
when seal magazine is exhausted and also one More person is required to enter the date
to be printed on the printed key board.
Chapter 4
4.1 Working of Strapping Machine
The sequence of the operation is as follows:
 As soon as the bundle or stacked products are brought to the strapping zone, sensors
provided across the roller conveyor senses the bundle and signal is given to initiate
automatic strapping. Also VSP PLC will provide a "Bundle in Position" signal to ITW
PLC.
 The strap is then held against the strap guide and the product data, which is pre-fed
manually in the pc / or fed from the VSP PC to ITW PC automatically, is printed
along the length of the strap.
 Simultaneously the machine carriage moves forward towards the bundle, the
movable strap chute of the machine swings forward above the bundle and closes the
loop to guide the strap around the bundle and the slide with strapping head & chute
assembly moves up to position the sealing in line with the centerline of the bundle.
 The air motor on the strapping head rotates in the forward direction and feeds the
strap through the closed strap chutes.
 As soon as the leading edge of the strap reaches the head the jaws grip it and the face
gate opens.
 Once again the machine carriage moves forward to touch the head to the product face.
 With the head at product signal, the air motor on the head starts rotating in the
opposite direction in the high speed low torque mode and the strap starts coming out
of the strap guide flaps.
 As the last strap gate on the head is opened, a limit switch gets actuated and the air
motor starts pulling the strap in the high torque low speed mode.
 The forward motion of the head is stopped by a limit switch which is actuated when
the head is about to touch the bundle.
 The head motor continue to draw the strap till the tension in the strap achieves the
preset value.
 As the desired tension (adjustable) is achieved the notching and cutting mechanism
are activated and the seal first notched and then the strap cut.
 After the sealing the carriage with head & strap chute system moves back to
intermediate position.
 Now the bundle moves to next strapping position, during this the strap feeding
operation will be completed. The movement bundle is positioned the head moves
forward to touch the product and does the strapping.
 Bundle keeps on moving till the desired no. Of straps are being applied.
 Once the required straps are applied, the top strap chute swivels back to its home
position and the slide with head & strap chute assembly moves down to home position
simultaneously.
 Now the machine carriage moves to its home position and the above-mentioned
processes gets repeated for every bundle.
 The no. Of straps for various lengths of bundles shall be pre programmed in the
system.

Fig.4. Various positions of carriage movement of

Strapping machine
Chapter 5

5.1 Momentary Benefits

The actual time taken for the movement of the carriage from the original home position to
feed strap position = 7 sec
The time taken for the modified home position for the actual home position = 4 sec
The time reduced by using modified home position = 3 sec
The time saved per cycle = 3+3 = 6 sec
The no. of bundles per hour =19 bundles/hr
The time saved per hour = 19 x 6= 114 sec
The no. hours per one shift = 8 hrs
The time saved for one shift= 8 x 114=912 sec
The no. of shifts per day = 3 shifts
The time saved per day (in single line production) = 3 x 912 = 2736 sec
The time saved per day (in two line production) = 2 x 273 = 5472 sec
The shutdown days per month = 4 days
The average working days per month = 26 days
The time saved per one month =26 x 5472 =142272 sec
The time saved per year = 12 x 142272=1707264 sec= 474.24hrs
Chapter 6
Conclusion
After weeks of training and orientation in Plant, strapping machine was the topic selected
as the machine is a pneumatic system where the strap is used for binding a bundle of steel
rods after the steel rods are ready for storage or dispatchment . By modifying the home
position of strapping machine we can increase the productivity. The time saved by
modifying home position is 474.24 hrs per year.
Chapter 7
Summary
This Summer Internship helped me to understand and analyze the steel manufacturing
processes and working of strapping machine. For a Mechanical Student it’s important to
be through with basic Metallurgical, Production, and Mechanical processes. After the
internship program we get to know the implementation of machines and its relation to the
production unit. In Steel Plant was Industry chosen for this Internship as it has more than
five department spread around thousands of acres of land with lot of machines such as
locomotives, conveyor belts, pusher car, charging car, guide machine , lathe machine,
milling machine, grinding machine , strapping machine , magnetic cranes , rolling
machines ,etc. Strapping machine was the topic selected by me to present in this report as
it helped me understand a pneumatic system which are very rare.
Chapter 8
Bibliography

1. LMMM Manuals – Information about strapping machines have been taken from
this manual.
2. WRM Manuals – Information about rolling mills has been taken from this manual.
3. SMS Manuals- Information about second metallurgy has been taken from this
manual.
4. Coke Oven Manuals- Information about batteries have been taken from this
manual.
5. www.vizagsteel.com
6. www.signodeindia.com
PLAGRISM REPORT