STEEL AUTHORITY OF INDIA LIMITED
(A MAHARATHNA COMPANY)
SALEM STEEL PLANT
Summer Internship Report
DEPARTMENT OF ELECTRONICS AND COMMUNICATION
ENGINEERING
COIMBATORE INSTITUTE OF ENGINEERING AND
TECHNOLOGY
COIMBATORE-641 109.
Submitted by,
HARIPRAKASH A
ROHITH V
1
TABLE OF CONTENTS
S. Page
INDEX
No No.
1 ABSTRACT 3
2 INTRODUCTION 4
3 FEATURES OF SALEM STEEL 7
PLANT
4 PROCESS INVOLVED 8
5 STEEL MELTING SHOP 9
Electric Arc Furnace 9
Moulding and Casting 9
6 HOT ROLLING MILL 10
Slab ard 10
Reheatin furnace 11
De-scalar 11
Rou hin mill 11
Steckel mill 12
Laminar coolin 12
Down coiler 13
Coil ard 13
7 COLD ROLLING MILL 14
Bell Annealing furnace 14
Coil Building line 14
Sendzimir mill 14
Annealing 15
Pickling 15
Skin ass mill 16
Shearing and Slitting 16
8 ELECTRICAL REPAIR SHOP 17
9 MRSS 18
10 TELEPHONE EXCHANGE 19
11 C&IT 20
12 CONCLUSION 21
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INTRODUCTION
A state-owned enterprise in India is called a Public Sector Undertaking (PSU) or
a Public Sector Enterprise. These companies are wholly or partly owned by the
Government of India or one of the many state or territorial governments or both
together in parts. The officers working in these entities are gazetted officers. The
company stock is majority-owned by the government in a PSU. PSUs are
classified as central public sector enterprises (CPSUs, CPSEs) which are wholly
or partly owned by Government of India or state level public enterprises (SLPEs)
which are partly owned by state or territorial governments.
There are three types of government companies,
a) Maharatna companies (profit > 25000 crores)
b) Navaratna companies (profit 10000 — 25000 crores)
c) Miniratna companies (profit < 10000 crores)
There are 10 Maharatnas, 14 Navratnas, and 73 Miniratnas. There are nearly
300 CPSEs (central public sector enterprises) in total.
MAHARATHNA COMPANIES
I. Indian Oil Corporation Limited
2. Bharat Petroleum Corporation Limited
3. Hindustan Petroleum Corporation Limited
4. Oil and Natural Gas Corporation Limited
5. Coal India Limited
6. NTPC Limited
7. GAIL (India) Limited
8. Steel Authority India Limited
9. Power Grid Corporation of India Limited
[Link] Heavy Electrical Limited
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ABSTRACT
It's a great honour and privilege to be a part of SAIL (Steel authority of India
limited) a Maharathna company, which holds our nation's economy rate. Being a
part, is likely to feel, to achieve something new and make our nation proud. Really
grateful for his opportunity and had learnt a lot of things in Salem steel plant. The
Consumer satisfaction also places a vital role. Sail is consistently making the
customer to be happy to the core, by providing the quality products Hot Rolling
Mill (HRM) and Cold Rolling Mill (CRM) are the core process for iron making.
The robust equipment handled here, is periodically verified by undergoing the
preventive and predictive maintenance. In order to study the process that takes
place inside the steel plant industry. We selected to do internship in Salem Steel
Plant (SSP), and we successfully completed our internship on HRM, CRM, and
process taking place inside those mills. The process that we understood have been
submitted as the report. Hereby, we thank the Human Resources Department
(HRD) of SSP who gave this wonderful opportunity to learn something new, which
will be move useful to my future.
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Steel Authority of India Limited (SAIL) is an Indian government owned steel
manufacturing enterprise based in New Delhi, India. It is owned and operated by
the Ministry of Steel, Government of India with an annual turnover of INR 66,267
Crore for fiscal year 2018— 19. Incorporated on 24 January 1973, SAIL has 65,807
employees (as of 01-Mar-2021). With an annual production of 16.30 million metric
tons, SAIL is the 20 th largest steel producer in the world and the largest in India.
The Hot Metal production capacity of the company will further increase and is
expected to reach a level of 50 million tonnes per annum by
2025. Smt. Soma Mondal is the current Chairman of SAIL.
Steel Authority India Limited operates and owns five integrated steel plants at
Bhilai, Rourkela, Durgapur, Bokaro and Burnpur (Asansol) and three special
steel plants at Salem, Durgapur and Bhadravathi. It also owns a Ferro
Alloy plant at Chandrapur. As a part of its global ambition, the company is
undergoing a massive expansion and modernisation programme involving
upgrading and building new facilities with emphasis on state of the art green
technology. According to a recent survey, SAIL is one of India's fastest growing
Public Sector Units. Besides, it has R&D centre for Iron & Steel
(RDCIS), centre for Engineering in Ranchi, Jharkhand.
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Native name Hindustan Steel Limited
Industry Steel
F ounded 19 January 1954; 67 years ago
Key people Soma Mondal, (Chairman)
Products Steel, flat steel products, long steel products, wire
products, Wheel & axle for Indian railways, plates
Revenue æ62,569 crore (2020)
Operating income æ6,594 crore (2020)
Net income æ1,926 crore (2020)
Owner Government of India (64.9%)
Parent Ministry of Steel , Government of India
Subsidiaries NSPCL
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FEATURES OF SALEM STEEL PLANT
Salem Steel Plant (SSP), a unit of Steel Authority of India Limited (SAIL), is a
steel plant involved in the production of stainless steel. It is located along the
Salem Bangalore NH 44 in the foothills of Kanjamalai in Salem district, Tamil
Nadu, India. The plant has an installed capacity of 70,000 tonnes per annum in its
cold rolling mill and 3,64,000 tonnes per annum in the hot rolling mill. It also has
the country 's first stainless steel blanking facility.
SSP supplies steel to BHEL-Trichy, HMT, Bharat Electronics Limited-
Bangalore and Indian Telephone Industries. Stainless steel is also exported to
over more than 37 countries including Spain, UK, Japan, Germany and
Switzerland. Between 1994—95, around 41,500 tonnes to as many as 27
countries
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PROCESS INVOLVED
The major facilities at the plant include,
Steel Melting Shop
Cold Rolling Mill Complex
• Hot Rolling Mill Complex
Stainless Steel Blanking Line
Salem Steel Plant specializes in the production of cold rolled stainless
steel in the form of coils and sheets. The raw materials are imported and also
supplied by Alloy Steel Plant m Durgapur. The steel melting shop 's annual
capacity is 1,80,000 tonnes of slabs per annum. The hot-rolling mill and
coldrolling mill have capacities of 3,64,000 and 66,600 tonnes per annum
respectively.
Public Sector Undertakings in India
Type
Steel
Industry
13 September 1981; 39 years ago
Founded
Salem, Tamil Nadu, India
Headquarters
Hot-rolled stainless steel
Products Cold-rolled stainless steel
SAIL
Owner
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STEEL MELTING SHOP
It is the place where the metal from the scrap yard is intended to pass through the
furnace, maintained at high temperature of range (16800 C-18000 C), once it
liquified, later on moulding and casting are involved. The primary raw material
for the SMS is stainless steel, were bought from many sources. Initially the metal
from scrap yard is loaded to a truck by EOT (Electric overhead travelling crane).
The carbon steel slabs are bought from sail Billai and Rourkella.
Electric arc furnace is used, having working temperature about (1680 -18000 C).
On basis of the required grade, metal is melted at the ranging temperature. Once it
is liquified, it is poured in the mould cavity (cuboid shaped cavity is used in Salem
steel plant) for moulding, latter on casting.
It is allowed to the air cooling (72 hours) for the toughness to be attained, for the
further process.
ELECTRIC ARC FURNACE
An electric arc furnace (EAF) is a furnace that heats charged material by means of
an electric arc.
Industrial arc furnaces range in size from small units of approximately one ton
capacity (used in foundries for producing cast iron products) up to about 400ton
umts used for secondary steelmaking. Arc furnaces used in research laboratories
and by dentists may have a capacity of only a few dozen grams. Industrial electric
arc furnace temperatures can reach 1,800 o c (3,300 OF), while laboratory units can
exceed 3,000 oc (5,400 OF).
MOULDING AND CASTING
Moulding: Moulding is the act of creating mould cavity.
Casting: Casting is the process of pouring the liquid metal into the cavity.
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HOT ROLLING MILL
Hot rolling is a metalworking process in which metal is heated above the
recrystallization temperature to plastically deform it in the working or rolling
operation. This process is used to create shapes with the desired geometrical
dimensions and material properties while maintaining the same volume of
metal.
Hot rolling mill is a process of decreasing the slab thickness of range (140mm
220mm) to minimum thickness of about ( 1.6 — 2mm). The two metals handled
here is stainless steel and carbon steel. HRM in Salem steel plant is inaugurated in
the year 1995. The process Involved in HRM is,
Reheating furnace
• De-scalar
• Steckel
mill
• Down
coiler
REHEATING FURNACE
SLAB ROUGHING
DESCALER
YARD MILL
COIL LAMINAR
DOWNCOILER COOLING
YARD STECKEL
MILL
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SLAB YARD
The slab from the sheet melting shop is allowed to slow cooling (air cooling) for around
72 hours. Here both stainless steel and carbon steel slab are handled,
Capacity 25000Tonnes
Cranes used EOT (Electric overhead travelling crane)- 55 Ton
Semi - cantry crane 25 Tonnes
REHEATING FURNACE
The slab from the slab yard is preheated in the Induction furnace at the
recrystallization to change the microstructure for around I hour
Type LPG fired walking beam (Induction furnace)
Make Italimpianti
Capacity 55Tonnes/hr (Stainless steel)
70Tonnes/hr (Carbon steel)
Fuel LPG (37 Kg/Ton)
DE - SCALAR
This process is mainly camed out to remove the scales present in the surface of the
slab.
Medium Industrial water
Pressure 200 Bar pressure (204 kg/cm2)
Nozzle angle 150
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ROUGHING MILL
The roughing mill is made up of six independent rolling mill stands, the last four ofwhich
incorporate small vertical rolling mills called edger. Slabs heated in the furnace until they glow
bright orange-yellow are rolled through one stand
at a time to produce so-called transfer bars suitable for finish rolling.
Depending on the gauge, width, and grade of the product to be rolled, the average temperature
of the bar as it exits the last roughing mill normally ranges
from 1900 to 2100 0 Fahrenheit.
At constant volume and width, the roughmg mill is used to decrease the thickness from 220mm
to 25mm with 4 Hi reversmg rolling, the roller of having diameter 1060mm is used. The slab is
continuously fed into roller 4 times to change its thickness.
Output 25mm thickness (Automation)
Mechanism Screw Down Mechanism
STECKEL MILL
A Steckel mill is similar to a reversing rolling mill except two coilers are used
to feed the material through the mill. One coiler is on the entrance side and the other on the exit
side. The coilers pull the material through the mill; therefore, the process is more similar to
drawing than rolling. The material is fed back and forth through the mill until the desired thickness
is reached, much like a reversing rolling mill.
Hot rolling Steckel mill, mother unit for hot rolling mill.
The bar from the roughing mill passes to Steckel mill where the thickness is
reduced from 25mm tol.20mm. The entry and exit coiler furnace are to maintain the temperature
of coils.
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Hi reversing
Product: 2 -l Omm (Automation) Stainless Steel
I .6 -12mm (Automation) — Carbon Steel
LAMINAR COOLING
To reduce the size then it will be taken to speed the cooling process by water. To obtain
the optimal mechanical properties have inspection plates, such as physical size, smooth
Skin etc. Cooling the steels depends upon the type of the
steel, whereas Stainless steel means low amount of water is used compare to
Carbon steel.
Banks 24
Medium Industrial water
DOWNCOILER
After being blown dry strip is then passed into the coil winding machine (Down coiler).
Marking the weight, thickness, and roll with band and will have finished rolling. Ready to
send to clients.
Coil winding Hot coiling winding
COIL YARD
Finished winded coil is accumulated later on, if the metal is carbon steel, then packed to
consumers, if stainless steel then carried to CRM
Capacity 15000Tonnes
Crane Goliath Gantry crane-2 Nos.
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COLD ROLLIN
BFI 1
HOT ROLLING
COIL BUILDUP LINE ANNEALING
COIL
FURNACE
SKINPASS SENDZIMIR
PICKEUNG
LINE MILL SH
SLITTING
SHEARING LINE
LINE
HOT ROLLING COIL
Hot rolling coil from the hot rolling mill is the raw material for the CRM process, where only stainless-steel c
COIL BUILDUP LINE
It is the process of adding a small portion of metal in both head and tail end by using TIG welding, to avoid m
BELL ANNEALING FURNACE
The annealing process uses the application of heat in an annealing furnace or oven to change a material's stren
machinability and mechanical or electrical properties of the treated material.
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ANNEALING
Annealing is a heat treatment process used mostly to Increase the ductility and reduce the
hardness of a material. This change 111 hardness and ductility is a result of the reduction of
dislocations in the crystal structure of the material being annealed
SHOT BLASTING
Manufactured metal parts aren't ready for use right out of the mould. They often need a coat of
paint, powder coating, or welding work. But before this can happen, the surface of the metal part
must be clean.
Shot blasting prepares metal parts for further processing like painting or powder coating. This
step is necessary to ensure the coat adheres properly to the part. Shot blasting can clean off
contaminants like dirt or oil, remove metal oxides like rust or mill scale, or deburr the surface to
make it smooth.
PICKLING
Pickling is a metal surface treatment used to remove impurities, such as stains, inorganic
contaminants, rust or scale from ferrous metals, copper, precious metals and aluminium alloys.
Metal surfaces can contain impurities that may affect usage of the product or further processing
like plating with metal or painting. Various chemical solutions are usually used to clean these
Impurities.
Strong acids, such as hydrochloric acid and sulfuric acid are common, but different applications
use various other acids.
SENDZIMIR MILL
A Z-Mill (Sendzimir) Mill is a machine for rolling steel. Unlike a traditional rolling mill this 20-
high cluster mill configuration utilizes cascaded supporting rolls to apply force on the small
work rolls in the centre. This allows the
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ELECTRICAL REPAIR SHOP-SALEM STEEL PLANT
The Electrical Repair Shop at Salem Steel Plant is responsible for the maintenance, repair,
testing, and overhaul of electrical equipment used throughout the plant. It ensures
uninterrupted electrical supply and safe operation of machinery.
Major activities include:
• Repair and maintenance of AC and DC motors
• Maintenance of transformers, alternators, and generators
• Overhauling of switchgears, circuit breakers, contactors, and relays
• Testing of insulation resistance, continuity, and earth resistance
• Maintenance of control panels and motor control centers (MCCs)
• The shop plays a vital role in minimizing downtime by quick fault detection and
rectification, ensuring high plant availability and safety.
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Power Generation in MRSS (Modernization & Revamp of
Salem Steel Plant)
Power generation in MRSS ensures reliable and continuous power supply for all plant
operations such as rolling mills, furnaces, utilities, and auxiliary systems.
Sources of Power:
State Electricity Board (TANGEDCO) supply
• In-house power generation
• Emergency diesel generators
Power System Features:
• High-voltage power received at 230 kV / 33 kV substations
• Step-down transformers supply power at 11 kV, 415 V
• Distribution through ring main units (RMU) and switchyards
• Proper load management and protection systems
• The MRSS power system is designed for energy efficiency, reliability, and safety,
with protective relays and SCADA-based monitoring.
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Telephone Exchange Service – Salem Steel Plant
The Telephone Exchange Service provides reliable communication within the
plant and with external agencies. It plays a critical role in coordination, safety,
and emergency communication.
Key features include:
• EPABX / IP-based telephone exchange
• Internal extension numbers for departments
• Hotlines for emergency and safety operations
• Integration with intercom and paging systems
• Maintenance of underground and overhead communication cables
• This system enables quick decision-making and efficient plant operations.
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C & IT Section (Communication & Information Technology)
The C&IT Section manages the digital and communication infrastructure of
Salem Steel Plant. It supports automation, networking, and data management.
Major Responsibilities:
• Maintenance of LAN, WAN, and fiber-optic networks
• Support for plant automation and SCADA systems
• Server maintenance and data backup
• Cybersecurity and access control
• Support for ERP systems (SAP)
• CCTV surveillance and access control systems
• The C&IT section ensures secure, reliable, and real-time information
flow, enabling modern steel plant operations.
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CONCLUSION
For an Engineering student a learning combination of theory and practice is a valuable asset
which helps in understanding the core principles of business by the way of first-hand experience.
This internship training in Salem Steel Plant has given me such a great experience about all the
managerial functions, which is going on in the company. It also helped me to understand the
exact mechanism of working of the various departments.
After completing this internship, I could be able to understand much more about the Salem Steel
Plant the MNC which is the most reputed name in the corporate world. Salem Steel Plant known
for its quality products.
This knowledge will help me well to establish myself in the corporate World.
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