ISWP Report - Kunal Vaidya

THE INDIAN STEEL AND WIRE PRODUCTS
LIMITED (ISWPL) JAMSHEDPUR

SUMMER INTERNSHIP
Duration: 9th May, 2022 – 01th July, 2022
Title
Complete Study of Rolling Practices and Recommendation for Yield

Improvement and Scrap reduction.
Author-
Kunal Vaidya
Student, Batch of 2023
Department of Mechanical Enigineering
Indian Institute of Technology (ISM) Dhanbad
Mob: +91 8806649336
1
(A Subsidiary of TATA STEEL LIMITED)
DECLARATION
I, Kunal Vaidya, declare that this project is being submitted to fulfill the Summer Internship at the
Indian steel and wire limited (ISWPL), Jamshedpur, and is a result of self-done work by me under the
guidance of my mentor and guide.
I further declare that, to my knowledge, the structure and content of this project are original and
have not been submitted for any purpose.
Kunal Vaidya
Student, Batch of 2023
Department of Mechanical Enigineering
Indian Institute of Technology (ISM) Dhanbad
Mob: +91 8806649336
2
Acknowledgment
A formal statement of acknowledgment will hardly meet the ends of justice in expressing a sense of
gratitude and obligation to all those who helped me complete this project report. I would also like to
express my gratitude and appreciation to those with whom I interacted and who helped me broaden
my horizon of knowledge and understanding of the Rodmill Department of the company. I
appreciate my project guide Vijayant Kumar sir, and my mentor Vinod Kumar sir, and Chandan sir for
their suggestions, which helped me proceed in the right direction about the project work.
The internship opportunity I had with Indian steel and wire limited (ISWPL), Jamshedpur, was a great
learning and professional development opportunity. Therefore, I consider myself very lucky as I was
allowed to be a part of it. I am also grateful for having a chance to meet so many wonderful people
and professionals who led me though this internship period.
At last, I would like to thank all the staff members and employees at ISWP for making my internship
an incredible journey.
3
Certificate
This is to certify that Mr. Kunal Vaidya, currently a Final year Bachelor in Mechanical Engineering
student at the Indian Institute of Technology (ISM) Dhanbad, has completed Summer Internship
Program for 8 weeks from 9th May 2022 to 01st July 2022 at the Indian steel and wire limited
(ISWPL), Jamshedpur.Under my guidance, he worked on the project titled "Complete Study of Rolling
Practices and Recommendation for Yield Improvement and Scrap reduction " During this tenure, we
found him to be sincere and hardworking. I take this opportunity to wish him all the best in future
endeavors.
Mr. Vijayant Kumar Mr. Vinod Kumar
4
Abstract
In a Industrial process which has huge production rate and demand therefore requires constant
processing with very less time and opportunity for the improvisation it is very important for a metal
forming process to be free from any defects that can lower its efficiency. Therefore for a production
sector it is the biggest challenge to design its process with maximum yield and to avoid the majority
of the losses which can be achieved by repetitive analysis and constant improvement of the process.
With the new types of technologies at reach it is possible for the manufacturing sector to automate
most of its processes which require manual control , operation and commanding.
Data availability in huge amounts can eventually predict the future trends and also the failures
occurring . All of these failures can be avoided which can also mean avoiding the accidents. TMT bars
and Wires have the exponentially increasing market as the growth of constrction sector . Hence such
technologies must be implemented which can compete for next few decades of modernization in the
market with its market competitors
5
Content
1. About the company…………………………………………………………………………………….07

2. Introduction………………………………………………………………………..……………………...08
3. Pre-Rolling Processes……………………………….……….……………………………...………...08
4. Rolling Processes …...……………………….……………………………………………….………...09
5. Yield Improvement and Scrap Reduction ……………………………………….…………...13
6. Reasons for the Yield Losses………………………………………..……………………………...14
7. Yield Loss calculation per Billet…………………………………….……………………..……...19
8. Suggested Remedies for Yield Loss and Scrap Reduction……………….…..…..…...21
9. Results ………………..…………………………………………………………………………….………..29
10.Conclusion ……………………….………………………………………………….........................29
11.Reference ……………………………………………………………………….……………..…………...29
6
1.About the company
Established in 1920, the Indian Steel and Wire Products Limited became the first wire drawing
company in the country. Nestled amidst the verdant surroundings of India's first industrial city,
Jamshedpur, the company gradually spread roots and is now a primary manufacturer of wire rods,
TMT bars, wires, welding products, nails, rolls, and castings.
A subsidiary of Tata Steel, we became a part of the global steel giant in 2003 and are committed to
the highest standards of quality and service. The Wire Rod Mill and Wire Mill are the conversion
agents of Tata Steel and Tata Steel Global Wires, respectively, wherein the parent plant supplies the
raw material and markets the finished good. We also are the proud pioneers in the rolls industry.
Marketed under the brand name 'JEMCO,' our rolling and casting products boast a prominent
presence across the globe. Under the brand name 'SPARK,' the electrodes and nails divisions also
form an integral part of the company's business venture. Our state-of-the-art Welding Technology
Centre, further augmented by the treasure of experience and expertise in welding consumables,
results in outstanding and paramount quality.
Spread over 350 acres, ISWP has a vast infrastructure comprising a township with 800 houses, a
hospital, a sports complex, and a health club for the officers, among others.
At ISWPL, we continuously endeavor toward higher levels of business excellence without

compromising our ethics and values. Our organization is diligent in its journey of scaling new heights
by providing a safe and healthy environment and being the epitome of change in the direction of a
better tomorrow.
JEMCO has the best melting furnaces to manufacture different grades and customized products like
rolls and engineering castings. JEMCO has two Arc Furnaces of 10 MT and 5 MT, which are used to
manufacture high-strength alloy iron, high-quality SG iron, and alloy steel rolls. The 8 MT coreless
induction furnace is used for small and medium-size Cast Iron, Steel, and SG Rolls. These furnaces are
also used for the manufacturing of various grades of engineering casting. The Dual Track Induction
Furnace of 0.75 MT and 1.5 MT is used for high alloyed low weight castings and rolls. These furnaces
also provide highly alloyed shell metal for static cast rolls. The wide variety of Furnaces offers
complete flexibility in producing rolls and engineering casting of different sizes and weights. Melting
is carried out using segregated scrap, pig iron, and ferroalloys to achieve the desired composition.
7
2. Introduction
This Project has been made to study the Rolling Processes. It includes concise information about the
Rolling processes and Yield loss points some methods that can be applied to reduce the scrap.
For the Rod Mill section nearly 3% to 4% of the material is lost while processing. This loss even if
looks smaller can add up to a huge number of lost material and capital.
3. Pre-Rolling Processes:
1. Billet Yard:
Raw material is stored here with help of cranes and placed on Billet bench.
2. Furnace:
With the help of Cold Pusher billets are placed into furnace at temperature of 1250 to 1300 degree
Celsius.
8
3. Hot Pusher :
Pushes one Billet by each towards Stand no.1.
4. Rolling Processes
• The Definition : Rolling is a metal forming process in which metal stock is passed through one
or more pairs of rolls to reduce the thickness, to make the thickness uniform, and/or to
impact a desired mechanical property. If the temperature of the metal is above
its recrystallization temperature, then the process is known as hot rolling. If the temperature
of the metal is below its recrystallization temperature, the process is known as cold rolling.
Types of Rolling Processes:
 Thread/Gear Rolling
 Shape Rolling
 Ring Rolling
 Tube Piercing
 Transverse Rolling/Roll Forging
 Skew Rolling
 Roll Bending
 Flat Rolling
 Controlled Rolling
9
Types of Rolling Mills:
Rolling mill type in the Rod Mill Department is Tandem Rolling Mill.
 Rolling Processes in Rod Mill
Functions
• Roughing :
Roughing area mainly focuses on Reduction of the cross section area by a huge margin in order to
mold the square cross section into circular it uses RTD guides.
10
• Intermediate :
Intermediate area has lesser temperature of the processing material therefore in order to avoid
the cooler ends in shear 9 it goes through head and tail cut and then a gradual decrease of
diameter.
• NTM (Non Twisted Mill):

At this stage main focus is not on reducing the cross sectional area but on finishing of the product.
Spiral gauging in Case of TMT bars.
Stand Wise Study of RollIng Processes

Important Parameters of Rolling Process
• Stand No
• Number of Passes
• Pass Profile
• Stock Size
• Entry Guide
• Exit Guide
• Types of Guides
RTD (Roller Twister Delivery Guide)
RE (Roller Entry Guide)
RF (Round Friction Guide)
Friction Guide
11
Roughing And Intermediate Stands
Stand No Number of Stock Size Entry Guide Exit Guide

Passes and
Pass Profile
1 4 Box 90.6×146 Friction Friction
2 4 Box 62.5×153.5 Friction RTD
3 4 Box 85×88 Friction Friction
4 4 Oval 58×101 Friction RTD
5 4 Round 69×70 RE RF
10 8 Oval 20.5×51 Friction RTD
11 8 Round 29.5×30 RE RF
12 12 Oval 16.5×38 Friction RTD
13 12 Round 23×23.5 RE RF
15 16 Round 18.9×19.7 RE RF
Non Twisted Mill (NTM) Stands
Stand No Number of Stock Size Entry Guide Exit Guide

Passes and
Pass Profile
12
16 2 Oval 10.7x20 Fixed Guide Nozzle
17 2 Round 13.7 820 A/1 Nozzle
19 2 Round 11.1 820 A Nozzle
24 2 Oval 4.4x8.2 Fixed Guide Nozzle
25 4 Round 5x57 820 A Nozzle
5. Yield Improvement and Scrap Reduction.

Methodology
• Identifying Yield Losses in Total
-Sources of Yield Loss
-Reasons of yield Loss
-Material and capital lost due to it
-Suggestions for Yield Improvement
• Identifying Sources of Scrap
-To know the reasons for Scrap production
-To find and suggest methods for Scrap reduction
Yield Losses in Rod Mill and Its Sources :
Yield Loss Source
1) Scales Furnace, Stands
2) Cobble Roughing, Intermediate, NTM , Roller table
3) Head and Tail end Crop Shear 9 , Shear 15
4) Uncooled Losses (TMT) Water box
13
5) Billet Bending Billet Yard
6) Rust Losses in Storage Storage Yards
7) Wrong Product NTM , Roller table, Decoiling unit
8) Finished Goods Losses Decoiling Mill
6. Reasons for the Yield Losses

1. Scales :
Oxidation of the hot billets due air contact of metal at high temperature.
2. Cobble :
*Roughing and Intermediate :
- Breakdown due to not proper selfing
- Guides not aligned properly (manual mistake)
- Roll Bearings , Roll selfing , Roll Gauging ( Not proper equipment)
- Equipment damage due to Cold metal
*Roller Table (Jamming) :

14
- Roller Table Hooking
- Motor Tripping 0 to 17 no motor
- Bad Quality of Metal
- Laying of Coil in Oval Shape
3. Shear 9 , Shear 15 :
To Avoid the cooled and non uniform ends which can bring complications for
further rolling.
15
4. Uncooled Losses in TMT:
There is time lag inside the waterbox between water flow and material passing therefore a
length of material remains uncooled and hence not having the quality required for TMT rods.
5.Billet Bending:
While shifting Billets from loaded trucks to Ground or to the Billet Bench due to power tripping
and failure in the electromagnet. Billets are straightened by use of hydraulic press , which delays the
process and eventually the process.
16
6.Rust Losses in Storage:
When Coils are shifted by the Cranes and kept for storage. Due to not proper protection from
atmosphere and storage facilities many coils are scrapped due to rust.
7.Wrong Product:
If the produced product doesn’t match the quality demanded then it is due to raw material
problems or due to defect in processing
17
8. Finished Goods Losses:
During Decoiling of the Coils there is scrap left behind in some quantities as all TMT bars are cut
in length of 12 m and also some length of coil is lost to testing.
18
7. Yield Loss Calculation per Billet
 Weight of one Billet = 1.170 tonnes

 Weight of the Finished Products per Billet/Per Coil
8 mm Coil Weight per metre = 380-390 gm/m
6 mm Coil Weight per metre = 210-220 gm/m
5.5 mm Coil Weight = 1.140 tonnes
Losses For 8mm TMT bars

• For 1 Section of 8mm
 No of Billets Rolled = 14001
 No of Cobble = 16
 Production in Tonnes : 15540 tonnes
 Weight of Scrap at Shear 9 per billet = 8 kg
 Weight of Scrap at Shear 15 per billet = 2.5 kg
 Weight of Scales produced in Processing(lost material) = 12 kg
 Weight of Uncooled Rings at Decoiling Mill = 15 front and 1 back ring = 16 rings
1 ring = 3 m : 16 x 3 x 385gm = 18.48 kg
 Weight of Scales produced in Decoiling Mill = 0.11 kg
 Weight of FG per billet = 1.122 tonnes
 Yield loss Percentage Calculation = (1170- 1109.9) x 100/1170 = 4.096%
Total Yield = 100 – 4.096 = 95.904%
Losses for 6mm TMT bars

• For 1 Section of 6mm
 No of Cobble =9
 Weight of Scales produced in Processing(lost material) = 12 kg
 Weight of Uncooled Rings at Decoiling Mill = 16 front and 2 back ring = 18 rings
1 ring = 3 m : 18 x 3 x 215 gm = 11.61 kg
 Weight of Scales produced in Decoiling Mill = 0.11 kg
 Yield loss Percentage Calculation = (1170 – 1110.3) x 100/1170 = 5.104 %
Total Yield = 100 – 5.104 = 94.896 %
19
Losses for 5.5 mm Wires
• For 1 Section of 5.5mm
 No of Cobble =13
 Weight of Scrap Produced at Roller table
 Weight of Scales produced in Processing(lost material)
 Yield loss Percentage Calculation =(1170 – 1140) x 100/1170 = 2.564%
Total Yield = 100 – 2.564 = 97.435%
Production Rate
For May 2022
• Total production 22730 tonnes
• Total Coils = 20480 (cobble not included)
Monthly Production(tonnes)
25000
20000
15000
Monthly Pro-
10000 duction(tonnes)
5000
0
287 348 409 470 531 593
44 44 44 44 44 44
8. Suggested Remedies for the Yield Losses and Scrap Reduction
• Scales Reduction:
• Cobble:
• Shear 9 , 15
• Water Box Losses reduction
• Billet Bending
20
• Rust losses
• Wrong Product
• Finished Good Losses
 Scales Reduction
Protective Coatings Increase Material Yield and Reduce Costs
Burning Loss Due to Oxidation
O2 + 2 Fe ↔ 2 FeO
O2 + 4 FeO ↔ 2 Fe2O3
CO2 + Fe ↔ CO + FeO
CO2 + 3 FeO ↔ Fe3O4 + CO
Characteristics of Protective Coating and its Use

• An anti-scale coating is applied on billets/ingots to be heated before charging them into the
furnace.
• Acts as a barrier between the metal and oxygen. Before heating, care is taken to apply a
uniform, impervious coating on the billet to be heated.
• Heat transfer from the heating medium to the metal unaffected by the coating, which also
reduces decarburization on billets during hot-rolling operations.
• No reaction with the steel surface; no release of toxic fumes during use, hot forging or
storage; and it is otherwise nonhazardous.
21
Protective Coating Increases Yield

• Total reduction in scale = 0.95 mm
• Percentage reduction in material loss due to mill scale by using anti-scale coating = 56.98%
• Approximately a 70% reduction in mill scale is achieved by anti-scale coating in hot rolling of
stainless steel.
• Scale loss of 2.14 kg was observed on billets without coating.
• Scale loss of 1.140 kg was observed on billets with a double layer of protective anti-scale coating.
• Percentage reduction in mill scale loss due to use of protective anti-scale coating = 47.00%
 Cobble
• Design of Modified Side Guide System:Add description
The side guide measurement system in finishing mill was found to be not accurate due to
backlash between the motor and gear box. A modified system was designed and installed in the
mill . The gap between two guides is measured by an incremental encoder. The output signal of
the encoder is connected to a counter module of a Programmable Logic Controller (PLC). The
output of counter module is processed by the central processing unit (CPU) of the PLC where
the signal is converted to analog values.
22
• Signal Analysis of Finishing Mill Parameters
• Study of Process Parameters
The thermo-vision photograph

taken in April 2017 after descaler
is shown in Figure-5.
Temperature variation across
0
slab width was about 60 C which
was the main factor
for creating strip waviness in the
mill.
23
Based on the study report,
the shop had taken actions
in reducing temperature
variations across slab width by
improving reheating furnace,
descaler and roll cooling
systems. This has resulted in
decrease of temperature variation
across strip width from
o o
25-30 C before to 5-10 C as
shown in Figure-6
0
was the main factor
24
mill.
o o
shown in Figure-6
25
0
was the main factor
mill.
o o
shown in Figure-6
26
0
was the main factor
mill.
27
o o
shown in Figure-6
0
was the main factor
mill.
28
o o
shown in Figure-6
0
was the main factor
mill.
29
o o
shown in Figure-
0
was the main factor
mill.
30
o o
shown in Figure-6
0
was the main factor
31
mill.
o o
shown in Figure-6
32
0
was the main factor
mill.
o o
shown in Figure-6.
33
0
was the main factor
mill.
34
o o
shown in Figure-6.
The thermo-vision photograph after descaler is shown . Temperature variation across slab width was
about 60 0C which was the main factor for creating strip waviness in the mill.
Based on the study report, the shop had taken actions in reducing temperature variations across slab
width by improving reheating furnace, descaler and roll cooling systems. This has resulted in
decrease of temperature variation across strip width from 25-30 oC before to 5-10 oC as shown.
Thermovision pictures of slab after descaling Thermovision pictures after last finishing stand
 Shear 9 , 15
• Only fractured part of Head and Tail must be removed by the Operator
• Currently Shear15 cuts length of 1.5 m instead of 0.75 m
• Regular maintenance of the Operating systems and sensors.
• Implementation of Machine learning programmes for accurate results
35
 Water Box Losses Reduction
36
 Separate water supply systems for each water boxes, as shown in line diagram below
Replacement of Coiling System with Straight Bar System

• It will avoid the extra efforts for the Decoiling Mill
• It will minimize the losses due to uncooled rings as it will become easy for segregation of
uncooled material.
• Once segregated, initial uncooled part can be cooled manually.
37
 Billet Bending
Avoiding Power Trip in the Billet yard area
38
 Rust Losses
• Development of the Warehouses

• Develop ways to for Rust resistance of FG
 Finished Good Losses

 Shear 9 and 15 cutting length
In order to Avoid FG losses for TMT bars length of Coil can be adjusted to obtain just at multiple of
12 metres
Billet size = 130 x 130 x 9 m
Stock size at S9 = 41 x 41 weight removed=8 kg(61.86cm)
Stock size at S15 = 18.9 x 19.7 weight removed=2.5 kg(87.3cm)
39
9. Results
• Yield obtained per Billet

22730 x 100/ (20480 x 1.170)= 94.86%
• Yield loss per Billet = 100- 94.86= 5.14%
• Capital loss behind a Billet and Finished Good
5.14/100 x 23,229.35 Rs = 1193.96 Rs
• Monthly Losses Due to Cobble
= 38 x 23,229.35 = 8,82,715.3 Rs
10. CONCLUSION
 The production of the Company is pretty much impressive and demanded by market for
its quality and brand but with the new tools and technologies at hand it is necessary for
such firm to introduce new automation methods in the operating sector rather than
dependence on the manual operating. Eg, machine learning
 For the machining part flexibility of the process needs to be much more than its present
condition in order for the company to be sustainable according to the future.
 At present there is much less scope for the testing part of any process at the company for
any new changes. This issue needs to be resolved by developing some simulation methods
Eg, Ansys . Or else with the help of some model based testing.
 Data collection at various departments regarding Raw material , Production , Failures
should be widely increased for the purpose of proper analysis.
40
 Only three types of products are manufactured in Rod mill department when it has
potential to increase a lot making process flexible and decreasing the time for section
change.
11. Reference
 https://iswp.co.in/
 “Reduction of Mill Scale generated by Steel processing”
https://www.researchgate.net/publication/
288874180_Reduction_of_mill_scale_generated_by_steel_processing
 “Protective Coatings increase material Yield and Reduce Costs”
https://www.forgemag.com/articles/84248-protective-coatings-increase-material-yield-and-
reduce-costs
 “Anti Scale Protective Coatings”
https://steelplantspecialities.com/anti-scale-protective-coatings/#
 “Scale development on steel during hot strip rolling”
file:///C:/Users/kunal/Downloads/gruppofratturaojs,+Journal+manager,+1227-4752-1-CE
%20(1).pdf
 “Reduction of Cobble Generation in Hot Strip Mill”
https://www.researchgate.net/publication/
329644069_Reduction_of_Cobble_Generation_in_Hot_Strip_Mill
 “Selection of Effective Control factors for TMT Bars using Taguchi”
https://www.ijeat.org/wp-content/uploads/papers/v8i6S3/F12600986S319.pdf
 “Industrial Warehouse of cold rolled wire. The wire coils are stacked off the stack”
https://www.dreamstime.com/industrial-warehouse-cold-rolled-wire-coils-stacked-off-stack-
image141649078
41

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THE INDIAN STEEL AND WIRE PRODUCTS

LIMITED (ISWPL) JAMSHEDPUR

Duration: 9th May, 2022 – 01th July, 2022

Complete Study of Rolling Practices and Recommendation for Yield

Mr. Vijayant Kumar Mr. Vinod Kumar

1. About the company…………………………………………………………………………………….07

At ISWPL, we continuously endeavor toward higher levels of business excellence without

Types of Rolling Processes:

 Rolling Processes in Rod Mill

• NTM (Non Twisted Mill):

Stand Wise Study of RollIng Processes

Stand No Number of Stock Size Entry Guide Exit Guide

1 4 Box 90.6×146 Friction Friction

2 4 Box 62.5×153.5 Friction RTD

3 4 Box 85×88 Friction Friction

4 4 Oval 58×101 Friction RTD

6 4 Oval 38×84 Friction RTD

8 6 Oval 31×69 Friction RTD

10 8 Oval 20.5×51 Friction RTD

12 12 Oval 16.5×38 Friction RTD

14 16 Oval 15×28 Friction RTD

Non Twisted Mill (NTM) Stands

Stand No Number of Stock Size Entry Guide Exit Guide

17 2 Round 13.7 820 A/1 Nozzle

18 2 Oval 8.7x16 Fixed Guide Nozzle

19 2 Round 11.1 820 A Nozzle

20 2 Oval 6.7x14 Fixed Guide Nozzle

21 2 Round 8.9 820 A Nozzle

22 2 Oval 5.5x11 Fixed Guide Nozzle

23 2 Round 7.2 820 A Nozzle

24 2 Oval 4.4x8.2 Fixed Guide Nozzle

25 4 Round 5x57 820 A Nozzle

5. Yield Improvement and Scrap Reduction.

Yield Losses in Rod Mill and Its Sources :

Yield Loss Source

1) Scales Furnace, Stands

2) Cobble Roughing, Intermediate, NTM , Roller table

3) Head and Tail end Crop Shear 9 , Shear 15

4) Uncooled Losses (TMT) Water box

6) Rust Losses in Storage Storage Yards

7) Wrong Product NTM , Roller table, Decoiling unit

8) Finished Goods Losses Decoiling Mill

6. Reasons for the Yield Losses

*Roller Table (Jamming) :

 Weight of one Billet = 1.170 tonnes

Losses For 8mm TMT bars

Losses for 6mm TMT bars

8. Suggested Remedies for the Yield Losses and Scrap Reduction

Characteristics of Protective Coating and its Use

• Study of Process Parameters

The thermo-vision photograph

Replacement of Coiling System with Straight Bar System

Avoiding Power Trip in the Billet yard area

• Development of the Warehouses

 Finished Good Losses

• Yield obtained per Billet

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