CHAPTER 3INDUSTRY PROFILE

PROFILE OF THE STEEL INDUSTRYSTEEL INDUSTRY IN INDIA Operating performance is the main drive of competitive of any company. Based on the parameter Indian steel industry is much below global standards. Although significant improvement has been observed in materials, energy and man power productivity, it is not in a position to complete with steel majors like PSCO, CS or NUCOR. India is placed in eighth position overall among the steel producing countries in the world.

Steel industry is becoming more and more competitive with every passing day. During the period 1960s to late 1980s the steel market used to be dominated by OECD organization for economic co-operation and development countries].

Steel industry in India is on an upswing because of the strong global and domestic demand. Indias rapid economic growth and soaring demand by sectors like infrastructure, real estate and automobile, at home and abroad, has put Indian steel industry on the global map. According to the latest report by International Iron and Steel Institute [IISI], India is the seventh largest steel producer in the world.

The origin of the modern Indian steel industry can be traced back to 1953 when a contract for the construction of an integrated steel works in Rourkela, Orissa was signed between the Indian government and the German companies Fried Kruppund Demag AG. The initial plan was an annual capacity of 500,000 tones, but this was subsequently raised to 1million tones. The capacity of Rourkela Steel Plant [RSP], which belongs to the SAIL [Steel Authority of India Ltd] group, is presently about 2million tones. At a very early stage the former USSR and a British consortium also showed an interest in establishing a modern steel industry in India. This resulted in the Soviet-aided building of a steel mill with a capacity of 1 million tones in Bhilai and the British-backed construction in Durgapur of a foundry which also has a million tones capacity.

The Indian steel industry is organized in the 3 categories. i.e., main producers, other major producers and the secondary producers. The main producers and other major producers have integrated steel making facility with plant capacities over 0.5 mt and utilize Iron ore and coal/gas for production of steel. The main producers are Tata steel, SAIL, and RINL, while the other major producers are ESSAR, ISPAT, and JVSL. The secondary sector is dispersed and consists of

1] Backward linkage from about 120 sponge iron producers that use iron ore and non-cooking coal, providing feedstock for steel producers;2] Approximately 650 mini blast furnaces, electric are furnaces, induction furnaces and energy optimizing furnaces that use iron ore, sponge iron and melting scrap to produce steel;3] Forward linkage with about 1,200 re-rollers that roll out semis into finished steel products for consumer use.

STRUCTURAL WEAKNESS OF INDIAN STEEL INDUSTRY Although India has modernized its steel making considerably, however nearly 6% of its crude steel is still produced using the out dated open heart process. Labor productivity in India is still very low according to an estimate crude steel output at the biggest Indian steelmaker is roughly 144 tones for worker per year, where as in western Europe the figure is around 600 tones. India has to do a lot of catching in the production of stainless steel, which is primarily required by the plant and equipment, pharmaceutical and chemical industries. Steel production in India is also hampered by power shortages. India is deficient in raw materials required by the steel industry. Iron ore deposits or finite and there are problems in mining sufficient amounts of it. Indias hard coal deposits are of low quality. Insufficient freight capacity and transport infrastructure impediments too hamper the growth of Indian steel industry.

STRENGTHS OF INDIAN STEEL INDUSTRY

Low labor wage rates Abundance of quality man power Mature production base Positive stimuli for construction industry Booming automobile industry

Economic stability of a nation depends on the strong industrial base it enjoys. The Indian economy is on a new growth plan with burocracy in capital marketing positive growth in GDP, strong forex reserves and a remarkable growth by 8.2% in 2005-06 compared to 7.0% growth in 2004-05.manufacturing industry has growth at 10%[till April 05] as against 8.8% growth in april-2004, with brisk demand for steel, textiles, gem jewellery.GLOBAL SCENARIO Present China is the worlds largest crude steel producer followed by JAPAN and U.S.A is the largest importer of semi finished and finished steel products, Japan is largest export of the same. However, the world at large is grappling gone through the most difficult years between 1998-2002. India is the tenth largest producer of steel in the world. Recent development have amply demonstrative the mettle of the Indian Steel Industry to rise further and became a major player in the world. The iron and steel industries in India has 56 large scale and 80 mediums and small scale industries. These produce a wide range of iron and steel products which make absolutely self-confident. Over the past years not only the industry has been able to substantially match demand, it has also become largely self-confident in design engineering and to develop the new technology and implement the project indigenously. India has produced nearly 1200million tones in 2002-03. The total man power directly employed in iron distribution is about 1million making it. It is one of largest industries in India, and still the growth rating is increasing. In India steel is produced in primary and secondary sectors. Primary sector units are companies like TISCO in private sector and SAIL in public sector. SAIL has taken a massive modernization as its Durgapur, Rourkela and Bokaro plants of further improve quality and reduce costs. Primary sector units produce average, 14% of the total supplies accounted by the secondary sector.

MAJOR STEEL PRODUCTION STATES IN INDIA1. GUJARAT2. ANDHRA PRADESH3. KARNATAKA4. BIHAR5. ORISSA6. TAMILNADU7. WEST BENGAL8. CHATISGARH

MAJOR INDUSTRIES IN ANDHRA PRADESHVisakhapatnam Steel Plant ----------------VizagRam Dev Steel Plant ----------------HydAdithya Steels ----------------HydDhana Lakshmi Steels ----------------HydBalaji Steels ----------------Nellore

CLASSIFICATION OF STEELS Steel Industry can be classified into Integrated Steel Plants, and Induction furnace plants. Integrated Steel Plants are also called as primary steel producers. VIZAG,TISCO,SAIL etc, have a size of 1MTPA and produce steel from iron ore and coal using blast furnace and basic oxygen or open-heart process, these plants are highly capital intensive. Mini Steel plants that are typically of size of around 1-2.5 lakhs tones produce steel by melting scrap in an Electric are furnace. These plants have low capital cost but have higher variable cost, as they are power intensive. The induction furnace units are of lower capacities between 30,000-50,000 TPA unused in small scale sector cater to domestic requirements of low value added steel product. They are also highly power intensive. About 50% of the total demands are met mini steel plants. In our country there are many re-rolling units carrying the activities of producing finished steel products such as fro steel and structural section using the out-put of Electric are furnace and induction furnace units. Many mini steel plants are integrated , i.e., they combine the activity of both melting metal scrap and forming carbon steels together with the re-rolling of such steel into various finished products.

Steel is mainly used in:1. Machine and Plant Building 2. Automotive, Railway and Ship Building 3. Construction 4. Other Alloy Products

Following are the various factors affecting iron consumption Technological advancements Affordability of the ore freely Rules and regulations of the government International changes ,demand and supply Lifetime of the products and corrosion Availability of the required grade of iron Availability of the transport facility Credit availability Moisture and climate conditions Industry related problems The utilization of iron products in the construction activity was very less when compared to other countries we can conclude India is consuming less quantity of iron and steel where the construction activity is more , the second major consumer is infrastructure projects followed by various industries. Although the consumption rate is high, the Indian industry is having surplus production capacity through which it is targeting export markets.

Legal mechanism and Governing Body The department of iron and steel came into existence as a separate Department. It has become a par of the ministry of iron and steel. The main objective of the department include sectoral planning , promotion and regulation of the industry and monitoring the production , imports /exports/distribution of iron and steel products so that the economy did not phase the problem.

IRON AND STEEL FEDERATION OF INDIAPopularly known as FAI is an autonomous body established by Central Government and its office located at Delhi .The main objective of FAI is to bring all the iron and steel manufacturers under a common platform for exchange of ideas, transfer of technology and other matters pertaining to exercise duty and customs duty. The association takes all such sensitive & important problems that are commonly faced by manufacturers.Today the iron and steel industry is totally de-controlled by the central government and it has given entire right to the industrys to fix the selling price and marketing the products produced. The government controls the price of the products by making the necessary. India has become a part in the global economy, changes in the international markets will be reflecting in the Indian markets.ImportsEvery form has certain problems in the same way there is no shortage for the iron ore which is the basic raw material but the other key material needed for the production of the iron ore which is the basic raw material but the other key material needed for the production of the iron and steel is coal. Though India has huge reserves of coal the ash content is more so India has to import coal from other countries. So Indian companies has entered into some long-term contracts with coal producing countries. Some factories use oil products, which have to

Ex: Rainotino (Australia)To reduce the dependence the Indian companies are implementing the technologies to reduce the ash content in the Indian Coal and thus the economy is saved.

IRON & ITS ADVANTAGESIn Agriculture: Iron & steel Used in crop production equipments promotes Agriculture promotion Increase food growth Income in living standards of rural areas Productivity developmentIN INDUSTRY Iron and steel industry promotes Foreign Exchange Earning Employment Manpower utilization Technological Transfer and Development Industry Development Economic Growth Development of supplement industriesIN SERVICE The marketing and distribution of iron and steel promotes Domestic and world trade Research and development Bank service development Credit Facilities Transport and Storage services

CHAPTER 4COMPANY PROFILE

COMPANY PROFILEEstablished in 1987 G S Alloy Castings developed into one of Indias prominent jobbing foundry dedicated to producing superior steel castings ranging from 50 to 27000kgs. The Companys steady growth is a reflection of its commitment to customer needs and quality. We offer Cost effective solutions for the success of our customers.Team:Designation NameManaging DirectorG.Prasada RaoExecutive DirectorG.Srinivasa RaoDirectorG.SaralaGeneral ManagerK.K.RaoWorks ManagerS.S.Pillai (Unit II)Production ManagerKrishnam Kutti (Unit II)K.Radhakrishna (Unit II)Methoding ManagerM.Hanumantha Rao (Unit II)Qualitational ManagerCh.R.K.Ramu (Unit II)Qualitational Dept ManagerMr.RamanaMaintenance ManagerMr. RameshAdministration ManagerK.G.R.SundaramAccounts ManagerMr. Venkateswara RaoMarketing ResearchM.Hanuman PrasadCivil Works ManagerMr. RaghavayyaFertiling DispatchMr.RajendraMethods EngineerMr.ShyamAccouintantMs. LakshmiOffice InchargeMr. Rama RaoVISIONThe bottom line is to meet the requirements of the customers and they at G.S.Alloy develop products and solutions which suits the modern day demands of the customers. Their vision is to provide quality and contemporary information to the customers which can help them in furthering their business. Of course, they also keep in mind that the solutions at G.S.Alloy offer can optimize and improve the business process of the customers, which would surely take wise decisions for enhancing their horizons.Providing quality and technology products / services that surpass the expectations of the customers in their functionality, usability, reliability, performance, adaptability and supportability which help becoming market leaders with upward improvement of business performance is part of their vision.QUALITY POLICY:G.S Alloy Ltd., shall provide quality products services that exceed customer expectations in their functionality, usability, reliability, performance, adaptability and supporting to achieve market leadership and continual improvement of business performance, for this, the organization shall establish and review quality objectives to focus on

Technology Management for building Competence Quality Improvement Customer education Human Resource Development Customer Support Design and implementation QUALITY OBJECTIVES Establishment of HRD Process to train and nurture employees to realize their intrinsic talent. 100% increase in turnover every year Improve response time to customer requests Education of customers in regard to product / technology applicationR&DG.S.Alloy Casting is a knowledge driven company. Their continuous investment in R&D activities enabled them to develop innovative processes, products and technologies, by pioneering new ways of collecting and managing information and knowledge, they have strengthened and extended their R&D activities to diverse areas. The company has vast knowledge in comprehensive design, development assembly for diverse interfaces and applications from the concept.KEY FEATURESG.S.Alloy Casting manufacture quality steel castings up to 6,000 kgs. Single piece in unit I 34,000kgs. Single piece in unit II

In G.S.Alloy Casting Ltd they believe that the most valuable resource they possess is their people. People in the company are very much proud to be foundry men in serving Indian Engineering Industry since 1987. G.S.Alloy Casting is not just a gathering of highly skilled individuals, but a team.The company follows the policy of:Work with teamThink with teamLive with teamProsper with team &Build Team work

It is built not only on someones exceptional skills, but rather on collaboration and team work. Throughout years of growth, owing to investments into training, scrupulous selection procedures, competitive benefits and appealing career possibilities, they managed to assemble a mosaic of motivated, loyal and highly skilled professionals.G.S.ALLOYS MANUFACTURERS Cast Steel Alloy Steel Mn Steel Stainless steel Heat Resistant steel Nihard and Cast Iron Casting

G.S ALLOY PRODUCTS

PROCESS OF MAKING OF A CASTING1. ESTIMATION2. PATTERN MAKING3. MOULDING AND CORE MAAKING4. MELTING AND POURING5. KNOCK OUT6. HEAT TREATMENT7. FETTLING8. INSPECTION9. MACHINING10. DISPATCH

1. ESTIMATION AND SUBMISSION OF QUOTATIONReceived receipt to be studied and estimate according to their requirements and then prepare the quotation. This quotation will send to the customer with all details. After negotiations made by the customer, if the conditions are acceptable by the customer, deliver the order for manufacturing of the product.

Receipt of customer purchase order & Contract Review:

After receiving the purchase order and formal agreement, we should prepare the method card for manufacturing the produce: and also gai8ning of the production of the product in correct duration.

2. VENDOR FOR PATTERN MAKINGAccording to the customer supplied drawing the pattern shop in charge or pattern maker himself has to carefully go through and understand the written instructions, drawing views and then prepare the pattern.Production Planning:Production Planning is the routing of the Raw-Materials i.e. scrap to convert into the finished goods i.e., Castings. According to the availability of the raw materials, detailed equipments, production runs per tonnage of metal, order priority, finance, manpower, and the production may be planned.

Introduction:

Pattern: A pattern is the replica or modal of the desired casting It carries an additional allowance to compensate for metal shrinkage It Carries the necessary draft to enable its easy removal from the mould It carries additional protection, called core points, where cores are to be usedTypes of Patterns:a. Solid or single piece patternb. Two piece or split patternc. Multi piece patternd. Match plate Patterne. Sweep Pattern etc.,Pattern MaterialsAll patterns are subjected to wear due to the ramming and rapping that are necessary and the subsequent abrasive action of the sand.Pattern material should settle to with stand this wear and tear depending upon the no. of1. Wood2. Aluminum3. ThermocoalPattern Making ProcessLayout of pattern The complete construction of a pattern consists of two stages. The first stage is preparing a layout and the next is to shape the different parts. The layout preparation consists of measuring, making, and setting out the dimensions on a layout board including the allowances. The layout is as follows:

SEQUENCE IN PATTERN MAKING1. The layout is studied and the location of the parting line is decided.2. From the pattern layout the shape of the pattern layout is visual lord.3. The construction of the pattern is started from the main part of the body.4. The different parts are shaped by cutting, providing adequate draft on them.5. All the prepared parts are checked finally by placing the over the prepared layout.

COLOUR CODES OF PATTERNSPatterns are located with certain colors and shades in order to1. Identify quickly the main body of the pattern and the different parts of pattern2. Indicate the type of the metal to be cast3. Identify core prints, loose pieces etc.,4. Visualize the surfaces to be machined etc.,5. Indian Standards Red-Un machined area & Mn Steel also Yellow-Machined Area Black-Core printsAs per British standardBlue is for carbon steel on steel casting Loose pieces : Red strips on yellow base Stop off or Supports black strips on yellow background Parting Line : Red

MouldingThe prepared sand is packed rigidly around the pattern and when the pattern is with drawn a cavity corresponding to the shape of the pattern remains in the sand and is also known as mould cavity is filled with molten metal it produces a casting of the shape of the mould. The process of making mould is moulding.In Moulding process they use different types of sands:Types of Sands:1. Quarters Sand2. Silica Sand 3. Chromate Sand4. Zircon Sand5. Olivine Sand

Types of Mould1. Green Sand Mould2. Dry Sand Mould3. CO2 Mould

IN G.S.ALLOYS USING ONLY CO2 PROCESS ONLY 1. Green Sand Mould:Green sand moulds are prepared with retrial mould sands or with mixtures of silica sands bonding clay and water. In order to give the casting a green and bright surface and to prevent the sand from burning on the face of the mould, a layer of facing sand is given surrounding the pattern.

2. Carbon-Di-oxide Mould:This process is basically a hardening process for moulds and cores. The Sand mixture used in the process consists of pure dry silica sand and sodium silica binder. This mixture is rammer around the pattern in the mould or in the core box for core making either manually or by machines. As per packing the sand carbon-di-oxide gas is forced in to the mould or the core at a pressure of about 1.5 kgs / Cm2. The process of forcing the gas into the sand mass is called goosing. The passage of carbon-di-oxide through the sand containing sodium silicate produces carbonic acid in the aquas solution which causes rise the SIOP2 Na2O ration and the formation of colloidal silica gel. This hardness and forms bond between the sand gradients and provides strength to the mould or core.Immediately after gassing the moulds are ready for pouring so the cores for being placed in the moulds the gassing process usually taken 15 to 50 seconds.

APPLICATIONS1. This process has been widely used for making larger cores and in foundries for heavy ferrous castings.2. This Process is particularly suitable for heavy or thick walled steel castings.3. Beside steel, carbon-di-oxide process is also employed for producing ores for iron, aluminum and copper base ally casting.

CORECore: Cores are sand shapes, which form the contour of a casting that is not molded with patterns.Cores must have sufficient hardness as well as strength in both dry and green states. Otherwise the core will not able to support its own weight and withstand the force of molten metal.Core Sands: In G S Alloy Castings, the following sands are for making coresSilica sand, Zircon, Olivine, Quartz sand, Chromate sandCore Sand Properties:Hot strength, Green strength, collapsibility, core density, Refractoriness,Response to core making: Core Hardness, PermeabilityCore BindersCore binders serve to hold the sand grains together and impart strength, resistance to erosion and to breakage and degree of collapsibility.

Core MakingThe following steps are involved in core making:1. First some amount of facing sound sprayed in the entire area of core pattern. It gives good surface finish to core.2. Core sand is placed in the loose to the required level and sufficient ramming is given.3. Wires and rods are placed in the boy, to give handling strength, the molding sand placed again ands proper ramming is given.

Types of cores The cores used in the foundries are typed according to their shape and their position in the mould. The types horizontal core, vertical core, stock cores, Balanced cores, Cover cores, Hanging cores, Wing cores and Ram-up cores.

Core CoatingsCore coatings may be applied as liquids by spraying, dipping or brushing and as solids by dusting. Core coatings for steels casting work are largely based on silica flour, magnate or chrome ore as the refractory materials; core coatings for cast iron castings make the use of refractoriness of graphite.

MeltingThey are using inductotherm Dual track system, and rated capacities of 12 MT + 15 MT, 5 MT, 2.5 MT, 1 MT, 0.5 MT. The total amount of liquid metal per heat is 34 MT and single piece casting poured so far as 16.5 MT. Both top pouring ladles of 5 ton, 2Y2 and 1 Ton and bottom pouring ladles of 15 MT, 12 MT, 20 MT, 35 MT. Immersion pyrometer, and radiation pyrometers are used for measuring the temperature of molten metal. Oil fired ladle, Pre-heated to maintain the ladle temperature at 600 Deg.C.HEAT TREATMENT CYCLE OR PROCESS Casting will be heat treated as per the customers specification if customer specification insists for a particular heat treatment cycle, which shall be followed. If customers specification does not insist for a specific heat treatment cycle, the heat treatment cycle will be selected keeping in view of mechanical properties to be achieved and desired microstructure. Heat treatment temperature, Cooling medium will be selected depending upon material type, grade, mechanical properties to be achieved, material specification and required grain. Soaking time will be selected depending upon the casting material and section thickness. Usually soaking time will be one hour for every 25 mm thickness of casting from exposed surface to heat. For calculating soaking time maximum section thickness of the casting will be taken into consideration.

Heat-TreatmentSl.No.ProcessTemp CSoaking timeCooling Media

1Homogenizing900-9503 Hours upto35 * CF/L cool

2Normalizing900-9505 Hours

3Annealing900-9503 Hours

4Tempering900-950FLOW HT Los shut

5Annealing900-950FLOW HT Los shut

CLEANING OPERATION AND EQUIPMENTThe series of operations in the cleaning department may be classified as follows:1. Surface cleaning, interior and exterior casting2. Trimming, the removal of fins, wires and protuberances at gate and riser locations.3. Finishing, final structure cleaning, giving the casting its outward appearance.

Surface CleaningCleaning Operations ordinarily follow the removal of gates and risers. However, surface cleaning may facilitate gate removal. For instance, the elimination of sand from the casting favors sawing and torch cutting so that surface cleaning may be done before the gate removal in the case of non-ferrous alloys and sometimes steel. When flogging is used in steel or C. It is easier to perform the surface cleaning after gate removal. One of the surface cleaning methods is shot blasting.

TrimmingEither after, before or during the initial surface cleaning, the casting sare trimmed to remove fins, gate and riser pads protruding beyond the casting surface, chaplets, wires, parting line flash, or other appeared damages to the casting which are not a part of its final dimensions.

ChippingPneumatic chipping hammers may be used to remove fins, gate and riser pads, wires and to remove corers. A variety of hammer and chisel sizes are used for various casting alloys.GrindingGrinding or Snagging of castings is practices to remove excess metal. Two principal types of grinders are employed for these purposes: portable grinders, and swing frame grinders. In addition, Specialized machines such as disk grinders, Betts and cutoffs may be used.

Visual InspectionCertain types of casting defects are immediately oblivious upon visual examination of casting cracked castings, tears, dirt, blow holes, scabs, metal penetration, severe shifts, run outs, poured short, swells or strains, cracked mould or cores and numerous other defects can be identified by the inspector. Casting defects of this type are usually associated with defective moulds, cores, their materials of construction. Flask equipment, the operations of molding and core making and the rest of the factors in making and pouring the mould.

Dimensional Inspection:Dimensional inspection of castings involves the principles of gauging as it is applied to my machine elements. Surface plates, height and depth gauges, layout tables, dividing heads, non-gauges, snap and plug gauges, templates, dies contour gauges etc., as used in slandered layout and inspection procedures may be applied to castings.Careers:They believe that their main strength is their people. They are their assets and they are the ones who make them realize their vision.The Present business scenario is highly competitive and technological advances are making this environment more and more competitive thus making each individual to motivate himself to a higher level of performance. For this, they provide an able and positive environment that motivates their employees and thus ensuring their success.They believe in continuous education to their employees and they strive to provide best training facilities to enable them to develop not only in their professional lives but in their individual lives as well.G.S.Casting firmly believes that the success of the company is the sum total of the efforts and capabilities to their team members. They constantly strive to align people to their core value proposition and core values, promote career development, and seek two-way feedback through informal and formal means.A Career at G.S.Castings MeansOpportunity to learn & Grow continuously Opportunity to become a domain expertOpportunity to work on latest technologiesChallenging assignmentsA world class working environmentWork with professional managementAlong with excellent rewards