Webinar--India challenge to become global in steel sector and opportunities for engg. Jan 2022.pptx

India challenge to become global leader in Steel

1. Indian challenge to become global in steel sector and opportunities for engineers. Milind Thosar --B.E.--Mechanical + MBA--Operations 1

2. Introduction :-- Hearty congratulations for reaching upto final year of Mechanical engineering after so much of hard work, clearing papers, assignments and may be living away from parents. Myself having practical experience of 30 years in different companies and nations e.g. Kareyn -- Dehradun --Uttaranchal, Maharashtra seamless limited-- Jindal -- Nagothane --Mumbai, Welspun -- Gandhidham --Gujarat, Libyan Iron and steel factory-- Misurata --Libya, Global Pipe company-- Jubail --Saudi arabia , ADPICO--Abu dhabi --UAE . Linkedin id https://www.linkedin.com/in/milind-thosar-93b38122/ 2

3. Milind Thosar –Visiting card 3

4. 4

5. World steel production China, India, others 5

6. World Steel Production-- 6 Year World Steel in MMT China steel in MMT India steel in MMT 2016 1 632 2016 1632 2017 1 735 2017 1735 2018 1826 2019 1874 2020 1878

7. Steel different processes 7

8. Comparison of nations on production / population efficiency. 8 China India Japan Russia USA Steel Production in 2020 in MMT 1056 100 83 73 73 Population approx. in Crores 144 138 13 15 33 Nation Steel efficiency in MMT/ Crores 1056 / 144 100 / 138 83 / 13 73 / 15 73 / 33 MMT / Crores 7.3 0.7 6.4 4.9 2.2

9. World top 15 steel companies. 9 Sr. No. Company Name Tonnage in MMT 1 China Baowu Group 115.29 2 ArcelorMittal 78.46 3 HBIS Group 43.76 4 Shagang Group 41.59 5 Nippon Steel Corporation 41.58 6 POSCO 40.58 7 Ansteel Group 38.00

10. World top 15 companies 10 Sr. No. Company Name Tonnage in MMT 8 Jianlong Group 36.47 9 Shougang Group 34.00 34 10 Shandong Steel Group 31.11 11 Delong Steel Group 28.26

11. Efficiency of steel production / population of nation 11

12. How to get job :-- ( 1 ) Matching job requirements in our resume :--We have to prepare for the job as per the requirement of companies in terms of education, e.g. class, % , physical strength, height, mental attitude, characteristics, training, certifications etc. ( 2 ) Skill generation - good seminar, project, vacation inplant training, practical certification may lead your in job or skills as per requirements e.g. my friend learned welding, inspection skills in vacation inplant training and got selected in steel company. 12

13. World steel –in INR Comparison 13 Sr. No. Title World Steel India Remark 1 Steel Production in MM 117 2 Average steel price in INR / MT 80,000 80,000 Approx. price of steel for 1 MT 3 Total value in Rs. 936000,00,00,000 4 Total value in Rs. Crores 936000 5

14. Iron ore The majority of mined iron ore is used to make steel and is found in ore containing hematite and/ or magnetite. The extraction of iron oxide is generally performed through a blasting and removal process from large open pit mines before it is crushed, screened, blended and pelletized for export or local consumption. Pellets are an ideal blast furnace feed because they are hard and of regular size and shape. 14

15. Iron ore 15 Iron Ore Crushed Iron Ore

16. Top 10 steel companies in the world 16 Rank Company Name Tonnage 1 Arcellor Mittal --India Europe 97 2 China Baowu Group- 96 3 Nippon steel corporation 51.68 4 HBIS Group 46.5 5 Korea POSCO 43.12 6 Shagang Group 41.1 7 Ansteel Group 39.2 8 Jianlong Group 31.19 9 India Tata Steel Group 30.15 10 Shougang Group 29.34

17. Iraq steel 2020 ( 1 ) Iraq old govt. plant at Basra , port city was having EAF—Electric arc furnace having capacity approx. 45 tonne . Iraq United Brother holding is taking over old govt. plant at Basra port city. It will have EAF—Electric arc furnace. Its capacity is 0.5 MMT per year. ( 2 ) Iraq annual production in steel in 2020 is approx. 2.6 MMT .In 2009, it was 0.2 MMT. ( 3 ) Iran steel production in 2009 was 18 MMT and increased to 36 MMT in 2020. Iran world rank is 10. ( 4 ) Pakistan annual steel production is 3.8 MMT in 2020 with world rank is 36. 17

18. Comparison of Iron, Sulphur , Phosphorous 18 Element Iron Sulphur Phosphorous Abbreviation Fe S P Melting point 1535° C 44 ° C Number of electrons 26 16 15 Density 7.86 gm/cm 3 2.06 gm/cm 3 1.8 gm/cm 3 Crystal structure Cubic Boiling point 447 ° C 280 ° C Electron configuration 1 s 2 2 s 2 2 p 6 3 s 2 3 p 4

19. Pakistan Major steel plant ( 1 ) Pakistan govt. owned Pakistan steel Mill Karachi Sindh Pakistan. It is oldest steel plant. Govt. of Pakistan is working to revive it with Russian experts. www.paksteel.com.pk All  Grades including SAE 1006,  except SUP Series, or as specified below:-   150 x 150mm     Pakistani Rs.  92,454  . It seems higher side compared to India. ( 2 ) Aisha steel mill Karachi Sindh Pakistan having website https://www.aishasteel.com/ ( 3 ) International steel mill Karachi Sindh Pakistan. 19

20. Iraq, Iraq, Pakistan –steel production 2020 20 Sr. No. Iraq Iran Pakistan Steel Production in MMT 2.6 36 3.8 Population in Crore 3.8 8.5 21.7. Nations steel efficiency—MMT/ Crore 2.6 / 3.8 36/8.5 3.8/21.7 0.7 4.2 1.8

21. How to get job :-- ( 3 ) Social visibility :-- linkedin , facebook etc. Write in linkedin com , what project, you had prepared ? Name of your college ? Your participation in seminars, exhibitions, innovation contest is required. Create post relevant to your job, interest backed by achievements e.g. You worked in steel roller manufacturing company, then mention 10 rollers are inspected with micrometer , reduced rejection level from 10 to 5 % etc. ( 4 ) Job websites :--Keeping close contact with job website e.g. naukri.com, timesjob.com and newspapers etc. 21

22. Graph—steel Production--2020 Iraq, Iran, Pakistan 22

23. Comparison of Iron, Sulphur , Phosphorous 23 Element Iron Sulphur Phosphorous Oxidation states -2, + 4, + 6 One form P 4 O 10

24. Iraq –Major steel plant ( 1 ) AL ANMAA steel govt. plant Basra, port city. EAF steel melting. ( 2 ) Kurdistan , Iraq. Esfanahan steel . Induction furnace steel melting ( 3 ) POLTEKS DOGA group Irbil Kurdistan Iraq. Also known as F and F steel. 24

25. How to get job :-- ( 5 ) Resume preparation :--Good resume preparation as per TELCO TATA is e.g. reference of ad e.g. Daily dated , post applied --Graduate Trainee Engineer , First Name, Surname, father’s name etc, permanent address, temporary address, contact mobile numbers at least 2 , education qualification right from 10-th in tabular format e.g. exam, % of marks, class, year, board / university etc. , Project report, date of birth, place of birth, approx. age , references from college or industry, undertaking given information is true to the best of my knowledge and belief and no information is hidden. 25

26. How to get job :-- ( 6 ) Interview preparation :--For interview normally take 2 sets of resume with colour photograph and instructions as per company norms. Candidate with tie is preferred in big and reputed companies. Light colour shirt and dark colour pant is preferred. Do NOT take your parents for interview because it is considered that decision power of candidate is NOT matured. However , over mobile , you can contact your parents and take consent. 26

27. How to get job :-- ( 7 ) Job offer :--It should mention of following points--designation, registered address of company, name of the person who issued offer letter, designation of him, sign, date of offer, validity, bond period , termination and leaving conditions for both parties . For gulf companies, request for website address, factory address. Verify factory address by other Indians working in that nation so that you will NOT duped. 27

28. How to get job :-- ( 8 ) Checking company credentials --Before joining company, make sure company, gives service certificate 100 % because it is required in many good and reputed companies. It is required in foreign and govt. Companies. Having good service certificate is great asset. Please check company credentials before joining e.g. mirror.com, naukri.com, glass.com etc. Collect information about company from different sources e.g. ex-employees of company, present employee, tea canteen in front of company gate, suppliers etc. 28

29. How to get job :-- ( 9 ) Acceptance :--Willing to accept company terms and conditions e.g. location, duty hours, shift duty etc . Please verify actual working conditions from ex employees of that company. Check any bond conditon for service for 2 or 3 years in the offer letter. 29

30. Options open to Mechanical engineers :-- ( 1 ) Research and Development :--This is most liked department by students and most respected. But getting job in this department is VERY difficult e.g. Bajaj Auto ltd, Pune , will employe ONLY GATE percentile score 95 % candidates and those who had completed M.Tech . and or Ph. D. in respective subject. It is very DIFFICULT to work in this department as it requires too much knowledge. In smaller companies, selection is liberal but still good knowledge of Autocad , Catia and different softwares are required. ( 2 ) Production :- -Good man--machine-coordination is required. Go-getter attitude is preferred. Normally top management is recruited from this department. Top management feel that it is money earning department. Promotions and pay hike more in this department. Drawback --Less technical knowledge is developed. Accident chances more. ( 3 ) Maintenance 30

31. Options open to Mechanical engineers :-- ( 3 ) Maintenance :- --Knowledge increasing field. Much knowledge is required to solve the problem. Thank less job. May have to face bad words from management. Dress will become dirty. Can jump from one industry to other because of practical skills e.g. generator knowledge will be same irrespective of industry. It is required in different industries e.g. steel, power plant, chemical, dairy, non-ferrous, textile etc. Good physique and strength required to do job at odd place and duty hours. ( 4 ) Quality Control :---Good for girls. Routine job. Need good eyesight. Repetitive reading gives strain on eyes. Promotion chance less compared to production. Inspection training is preferred. 31

32. Options to Mechanical Engineers :-- ( 5 ) Planning :--Good for those who want white collar job. Normally given after production experience . Good computer skills are required e.g. ERP--Enterprise resource planning, Microsoft word, excel, powerpoint etc. May need site visits to collect data. Less money compared to production department. ( 6 ) Marketing :---Good for outgoing and get-together attitude students. Need good language and marketing skills to generate orders. Need good personality including look, height, weight etc. 32

33. Options to Mechanical Engineers ( 7 ) Purchasing :--Good for those who like white collar job. Market knowledge increasing job. More respect from suppliers. Knowledge of different spare parts is required . Knowledge of commercial laws and transactions is required and inspection of spare parts is preferred. Less promotions compared to production. 33

34. My first job--Kareyn Precision Machines pvt ltd--1991-92 ( 1 ) Location :--Myself got job as Graduate engineer Apprentice in this company through Times of India ad. This company is located at village--- Manduwala , via-- Premnagar , Dehradun --248007--Uttaranchal . Atmosphere very cold compared to Akola . Also too much rain compared to Akola. ( 2 ) Society :--Myself was alone Marathi speaking employee in the company and village. Hence had to face many difficulties. ( 3 ) Experience :-- marking of castings on marking table. Testing of helical compression springs, leaf springs etc. Calculation of EBS, EOQ. . 34

35. My first job--Kareyn Precision Machines pvt ltd--1991-92 ( 4 ) Product range :--They were manufacturing machine hand tools e.g. chuck, drilling adapters, tapping adapters, spring loaded centres, lathe machine etc and Francis, Kaplan turbine governors. ( 5 ) Working conditions in Dehradun :-- Working and social conditions were as follows--( a ) 2 time subsidized food in factory canteen. ( b ) No factory accomodation and hence have to live in village where first 2 months were no toilet and hence have to go to Jungle in the morning. ( c ) Night guard duty in group to protect village from thieves e.g. chaddi baniadhari. ( d ) Fear of terrorist attack from Punjab 35

36. Maharashtra Seamless limited--Jindal--1992 --2003 ( 1 ) Introduction :--Myself received this job via Times of India ad. They had paid to and from fare. Their website address is www.jindal.com They are manufacturing seamless steel pipes from cross-piercing and elongation method. 160 mm round billet , length--800 mm to 1, 600 mm are heated in RHF--Rotary hearth furnace at temp of 1,200 --1,300⁰ celsius . 2 Motors of 1,600 HP pierce the billet in piercer. Then hot pierced bottle will pass through crimping machine, push bench, Loosening mill, SRM etc. In push bench , maximum speed of rolling is there ? Can you imagine ? 6 meters/ second i.e. 600 centimeters = 6000 millimeters / second with bush bench motor HP=2,000 and Nos =2 . 36

37. Maharashtra seamless limited--Jindal---1992 --2003 ( 2 ) Pipe manufacturing methods :-- Tell me the manufacturing methods. ( a ) Seamless pipe--Mechanical Piercer and Rolling method. Maharashtra seamless, Indian seamless, Chandan steel, Jindal Saw Nashik , ISMT Ahmednagar and Baramati etc. ( b ) Seamless pipe—Extrusion piercing press and rolling. Welspun speciality steel-- Dahej , Bharuch , Gujarat, Ratnamani Gujarat , Jindal Saw Nagothane Raigad . ( c ) Seamless pipe--Centrifugally casting method for sewage, water transport e.g. ( d ) Seamless pipe--Centrifugally cast and magnesium treatment. Known as Ductile pipes. 37

38. Piercer Rolling with plug 38

39. Maharashtra seamless limited-- Jindal ---1992 --2003 ( e ) ERW pipes--Electric resistance welded pipes. Maharashtra seamless, Zenith pipes--Khopoli--Maharashtra. ( f ) L--SAW--Longitudinally submerged arc welding.---Jindal--Gandhidham, Welspun--Bharuch ( g ) Spiral--SAW--Spiral submerged arc welding.--Welspun--Anjar, Jindal 39

40. Piercer machine with universal shaft. 40

41. Maharashtra seamless limited--Jindal--1992 --2003 ( 3 ) Expr as Purchaser :--My manager sent me for purchasing, quotations of oil seals, o--rings from Mumbai with samples for 3 days. His order was to get quotation at any cost within 3 days. Myself collected address of factory from catalogues etc. Went to Mumbai, mostly companies , had requested for drawing or keeping samples in their factory for 1 --2 weeks for taking drawing and then giving quotations. Hence NOT getting quotations from suppliers. Lastly got one supplier known as V. C. Polymers on western line who visited our factory ,nearly 8 months back and shown me drawings of sample. He checked the samples and co-related with drawings again. He had given quotation immediately with 20 % rise in prices. Our company had given order to him immediately. So in nutshell. “ God favours those who help themselves .” 41

42. Maharashtra seamless limited-- Jindal --1992 --2003 ( 4 ) Indigenisation :-- Had prepared many drawings for whole plant. Preparing drawing will result in lower cost as it can be manufactured in-house or partly in-house. It increases the capability of company to get quotations from different supplier. It increases the capability of company in technology absorption. ( a ) Push bench chain failure was chronic problem in our plant. Myself prepared the drawing and increased the diameter of pin and problem is solved. American company quoted for INR 50 lakhs and Indian Baroda based company quoted only for Rs. 6 lakhs and worked fine with Indian company. Thus saving foreign exchange. ( b ) Prepared drawings of all oil hydraulics and pneumatics cylinders of hot rolling mill and finishing mill. Also inspected at vendor and fixed in our plant successfully. 42

43. Piercer tube mill at Ahmednagar Maharashtra ISMT 43

44. Maharashtra seamless limited-- Jindal --1992 --2003 ( 5 ) Maintenance and Development : --- ( a ) Converted the plant capability from 5 ½ to 7 inch outside diameter from mechanical maintenance side. Prepared drawings without support of consultant and seniors. Mannesmann Demag, Germany, quoted or estimated for 54 crore INR. But we have done it in less than Rs. 2 crore. Time taken approx. 1 year. Increase in production from 500 MT/ day to 800 MT/ day in 24 hours. ( b ) How you will check pipe at hydrotester machine and test pressure is 25,000 PSI. 44

45. Piercer tube mill at Baramati Pune ISMT 45

46. Maharashtra seamless limited-- Jindal --1992 --2003 Normal centrifugal water pump will create pressure upto 150 PSI. However piston pump--water will create pressure upto 100 kg/cm 2 and normally it is kept at 60 kg/cm 2 . Oil hydraulics piston pump or vane pump will create pressure upto 100 bar. Normal oil hydraulics pressure is 100 kg/cm 2 . 1 bar = 14.5 PSI . 1 bar =1.02 kg/cm 2 .So 25,000 PSI = 1,724 Bar = 1,758 kg/cm 2 . So it is done by pressure intensification process and NOT pumps. It is simple p1A1=p2A2 . p1 and A1 are the cylinder bore size and NOT piston side. More area is available at bore end and hence less pressure will create more pressure at piston rod end. E.g. Bore size = 150 mm = 15 cm . 46

47. Steel seamless pipe forged method 47

48. Oil Hydraulics cylinders Piston Bore = 150 MM , Pressure = 100 kg/ cm 2 Piston rod dia = 50 MM. Pressure = 112.5 kg/cm 2 100 Kg/cm 2 X 176.7 cm 2 = P1A1=P2A2 =P2 X 157.1 cm 2 48

49. Maharashtra seamless limited--Jindal--1992 --2003 Hence cross sectional area= A1=3.142 x r 2 = 3.142 x (7.5 cm) 2 =176.7 cm 2 . Assume piston rod size as 50 mm. Hence rod annulus area is =3.142 ( 7.5 x 7.5 --2.5 x2.5 ) = 3.142 ( 56.25--6.25 ) = 3.142 x (50 ) = 157.1 cm 2 . 1 Meter = 100 CM 100 kg/cm 2 x 176.7 cm 2 = p2 x 157.1 cm 2 . p2 = 112.5 kg/cm 2 . Output pressure/ Input pressure = 112.5 / 100 = 1.13 times . A ctually it is carried out in 2 or 3 stages and bigger cylinder sizes are taken so that pressure rise is significant. 49

50. Calculation with 150 mm bore and piston rod dia 50 mm 50 P1 Cylinder Bore and bore area Piston rod dia Annulus area of rod side P2 100 Kg/cm 2 150 MM = 15 CM = 2 X 7.5 CM A1= 3.142 X 7.5 X 7.5 = 176.7 CM 2 50 MM = 5 CM = 2 X 2.5 CM A= 3.142 ( 7.5 X 7.5 – 2.5 X 2.5 ) = 3.142 ( 56.25 – 6.25 ) = 3.142( 50) = 157.1 CM 2 P1 A1 = 100 Kg/cm 2 x 176.7 cm 2 = P2 X 157.1 cm 2 P2 = 112.5 Kg/ cm2

51. Calculation of Bore 400 mm and piston rod dia 200 mm 51 P1 Bore dia and Piston Area A1 Piston rod dia Annulus area piston rod side A2 P2 100 Kg/ cm2 Bore dia = 400 MM = 40 CM = 2 X 20 CM A1= 3.142 X 20 X 20 =1256.8 CM2 Piston rod dia = 200 MM = 20 CM = 2 X 10 CM A2= 3.142 ( 20 X 20 – 10 X 10 ) = 3.142 X 300=942.6 CM2 P1A1= 100 Kg/cm2 x 1256.8 = P2A2 = P2 X 942.6 CM2 P2=133.33 Kg/cm2

52. Maharashtra seamless limited--Jindal--1992 --2003 Now we will consider bore of cylinder as 400 mm. Hence D1=40 cm ; R1=20 cm A1=3.142 X 20 X 20 =1,256.8 cm 2 . p1= 100 kg/cm 2 . Consider piston rod dia 36 cm. Hence R2=18 cm. A2=3.142 ( 400-324)=238.8 cm 2 p1A1=p2 A2 ; 100 kg/cm 2 x 1,356.8 cm 2 = p2 x 238.8 cm 2 ; p2=568.2 k g/cm 2 Output pressure / input pressure = 568.2 / 100 = 5.68 times . 52

53. Successive pressure intensification in stages 53 P1 A1 A2 P2 P1A1=P2A2 100 Kg/cm 2 1256.8 CM 2 942.6 CM 2 133.3 Kg/cm 2 100 X 1256.8 = P2 X 942.6 133.3 Kg/ cm 2 1256.8 CM 2 942.6 CM 2 177.7 Kg/cm 2 133.3 x 1256.8 = P2 X 942.6 177.7 Kg/cm 2 1256.8 CM 2 942.6 CM 2 236.9 Kg/cm 2 177.7 x 1256.8 =P2 X 942.6 236.9 Kg/cm 2 1256.8 CM 2 942.6 CM 2 315.9 Kg/cm 2 236.9 x 1256.8 = P2 X 942.6

54. Pressure Intensification in successive stages. 54 P1 Cylinder bore and Piston area A1 Piston rod dia and Annulus area A2 P2 P1A1=P2A2 100 Kg/cm2 Bore = 800 mm = 2 x 400 mm = 2 X 40 cm A1= 3.142 x 40 x 40 cm2 = 5027.2 cm2 Piston rod = 400 mm = 2 x 200 mm = 2 x 20 cm A2 = 3.142 X ( 40 X 40 – 20 X 20 ) = 3.142 ( 1600 – 400 ) = 3770.4 cm2 P1A1 = 100 Kg/cm 2 x 5027.2 = P2 X 3770.4 133.3 Kg/cm2

55. Pressure Intensification in stages 55 P1 A1 A2 P1A1=P2A2 P2 100 Kg/cm 2 5027.2 cm 2 3770.4 cm 2 P1A1 = 100 Kg/cm 2 x 5027.2 = P2 X 3770.4 133.3 Kg/cm 2 133.3 Kg/cm 2 5027.2 cm 2 3770.4 cm 2 P1A1 = 133.3 Kg/cm 2 x 5027.2 = P2 X 3770.4 177.3 kg/cm 2 177.3 Kg/cm 2 5027.2 cm 2 3770.4 cm 2 P1A1 = 177.3 Kg/cm 2 x 5027.2 = P2 X 3770.4 236.9 Kg/cm 2

56. Maharashtra seamless limited-- Jindal --1992 --2003 ( 5 ) Maintenance and Projects :--- ( c ) Oil hydraulics motor was having very big noise like bearing failure. Everybody thought some bearing or part failed inside the hydraulic motor. But problem was air sucked from one port and all ports tightened properly . Problem is solved. ( d ) Batch saw measuring cage problem that it was NOT working or not moving. It was pneumatic circuit. Nobody was able to solve it for last one year. Nearly 30 direction control valves are changed assuming that they are faulty. Myself collected information from workers, helpers. They told me that problem is coming any time and without notice. We feel that problem is due to pressure coming down. Myself had read few oil hydraulics books 56

57. Steel MSL Visitor gallery good visitors arragement 57

58. Maharashtra seamless limited-- Jindal --1992 --2003 In factory normally, air vessels are installed in the bay or factory. To decrease the pressure fluctuation, we have installed, air accumulator in pneumatic circuit and problem is solved. Hence “ TEAMWORK WORKS.” Problem which was NOT solved by my seniors for 1 year was solved. ( e ) Piercer billet pusher, pneumatic cylinder failure solved by correct specifications e.g. seamless tube and NOT welded tube. 58

59. Steel ERW pipe 5 roll design welder MSL 59

60. Abu Dhabi Metal pipes and profile LLC--UAE--2004 ( 1 ) Visa :-- To get engineering original degree stamped from UAE embassy, needed much efforts. E.g. went at 8 AM sharp at Mumbai office, before my number came for stamping, office was closed. Hence went 1 day before at 6pm sharp , stranded in Q as 1 st candidate and hence degree stamped on next day. There was no toilet nearby and public toilet was at 500 meters. So much struggle is required in life. www.adpico.com ( 2 ) Consultant :--Got selected from consultant Jerry Varghese, Mumbai. No money taken from me for sending outside. ( 3 ) Resignation :--After getting visa, air tickets in hand , then only given resigned from MSL. Hence have to give 3 months salary as per company rules. 60

61. ADPICO--UAE ( 4 ) Air Travel :--First time in life was travelling for foreign, air travel etc. Carrying NARCOTICS, DRUGS is punishable crime in gulf countries with DEATH PENALTY. ( 5 ) Plant :--It was ERW pipe plant of Iranian management having size range 1 to 8 inch. Technology supplier was OTTO, Italy . ( 6 ) Termination :--Got terminated for slow work due to theodolite problem because reading in the morning taken was NOT valid in the afternoon. As per civil engineer, theodolite readings changes with temp. Even fraction of millimeter difference was NOT acceptable. Hence lost job. Lesson to learn to you is that “ Foreign jobs are highly RISKY.” Basic salary was UAD 4,800 = INR 72,000 . Got service certificate. 61

62. Welspun stahl Rohren limited -- Gandhidham --Gujarat--2004 ( 1 ) Offer :--Appointed as Manager--Mechanical Maintenance--ERW pipe plant --6 to 16” outside diameter. Technology supplier--Mannesmann Demag, Germany. Second hand machinery purchased from USA. India is very good in converting waste into WORTH. www.welspun.com ( 2 ) Condition:-- to join within 1 week or cancellation of offer letter. ( 3 ) Location-- Anjar, Gandhidham , Gujarat. Desert area of Gujarat and you will NOT see trees for kilometers. 62

63. Steel ERW pipe plant forming mill 63

64. Welspun stahl Rohren limited -- Gandhidham --Gujarat--2004 ( 4 ) Port :--Got chance to visit to JNPT, New Mumbai for clearance of customs for plant and machinery. ( 5 ) Less planning :--compared to Jindal for project execution. Jindal will employ all managerial staff before machinery arrival , at least 1 year in advance. Hence they get time to study drawings, discuss and modify drawings. Expected problems and solutions are discussed. In Welspun, they recruited managerial staff, when machinery was coming. 64

65. Steel ERW pipe slitting machine 65

66. Libyan Iron and steel company-- Misurata --Libya--2004--2010 ( 1 ) Interview :--Taken only 2 days leave in previous company for attending interview. But due to grace of god , selected. They had given 10 days time to live with family since initial posting was bachelor. Interview was conducted at JSW--ISPAT Dolvi ( 2 factory . Website address is www.libyansteel.com ( 2 ) Joining :--They had kept us in their guest house in Mumbai with advance of USD 500 in hand for pocket money. We were having tickets of Qatar airways. Our flight was at midnight from Mumbai and reached to capital Tripoli in the afternoon around 3 PM local time. By mistake, our company car had NOT came. We could NOT find any English speaking taxi driver in Tripoli. 66

67. Steel ERW coil slitting machine. 67

68. Libyan Iron and steel company--Misurata--Libya--2004--2010 Hence we have to contact to our company officials, who in turn talked with them in Arabic and we could get taxi for Misurata which was approx. 210 km away. ( 3 ) Joined :--Myself was selected for HSM--Hot strip mill and within 1 week transferred to SMS--Steel melting shop --billet caster area. Lesson to learn is “ BE PREPARED FOR UNFORESEEN CHANGES AND WORK”. ( 4 ) SMS-1 :--There was 90 tonne EAF with tap to tap time of approx. 120 minutes. Qty= 03 numbers for billet caster. Billet caster of 6 strands. Qty= 02 . Size of billet 160 x 160 mm square size and length= 6 meters. 68

69. Libyan Iron and steel company-- Misurata --Libya--2004--2010 ( 5 ) Average CCM :--sequence ratio was 7 heats. Reason was slide gate oil hydraulics cylinder of Ladle failure. Nobody was knowing the reason. Seniors felt it was problem of oil hydraulic circuit. Myself with try attitude decided to check internal leakage of cylinder and found leaking. Seal was changed and problem rectified. Now average CCM sequence ratio was 30 and sometimes reaching upto 40. One heat of CCM =90 Tonne. 7 sequence means = 7 x 90 = 630 MT . But with 30 x 90 = 2700 MT . See the difference. Everybody liked me solving this problem. Lesson to learn is “ Have a positive and will try to solve the problem attitude”. 69

70. EAF youtube https://www.youtube.com/watch?v=QgtAIhzNeaU 70

71. Steel EAF electrode 71

72. Steel –Electric arc furnace -3 electrode design 72

73. Libyan Iron and steel company-- Misurata --Libya--2004--2010 ( 6 ) Company policy :--was NOT to allow sick persons in the camp e.g. Hence they were repeatedly saying that keep health good and working and it is difficult to spare one working colleague for you in hospital. Myself had taken nearly NO leave in 2 years. In 5 ½ years, total medical leave was 6 days only and no other leave taken except annual vacation leave for India after 23 months. ( 7 ) Food : --In the morning, tea, coffee, milk as per your need was allowed. Everyday, bread, pav with butter, honey were available. One breakfast item e.g. paratha, Idli, Uttapam, as per Indian food was available. On weekly off day, special items were available with music. 73

74. Steel ladle furnace steel refining furnace 74

75. Steel ladle Jejuri ISMT Pune 75

76. CCM Continuous casting machine 76

77. Steel DRI Direct reduced iron plant Misurata Libya 77

78. Libyan Iron and steel company--Misurata--Libya--2004--2010 ( 7 ) Family visa :--, received after 1 year of work. Indian ISPAT school with CBSE syllabus was available. My house was from wood in which Europeans too will live. Company camp was having 24 hour security. Camp was having doctor, swimming pool, club, garden, playground, grocery shop, laundry, tea shop, barber shop etc. In our camp, Europeans, American, Turkey lived. ( 8 ) Production :--We have increased production of billet caster from average 10,000 to average 65,000 MT/ Month and one time high was 83,000 MT/ Month. Similarly in slab caster increased from 10,000 to average 40,000 MT/ Month and one time high was 53,000 MT/ Month. 78

79. Libyan Iron and steel company--Misurata--Libya--2004--2010 ( 9 ) EAF :-- , water is used to cool the refractory via water piped panels. If water is entrapped in liquid hot steel, then blast can happen. So we have to be alert all the time that is NOT leaked into bottom shell of furnace and there is NO leakage from any pipe, hose or any water circuit. Any impurities collected on the top of liquid steel are drained by tilting furnace or otherwise into pot known as slag pot. Slag is the word used for impurities floating on the top of liquid hot steel. Water is sprayed on slag pot top to cool the slag pot and keep slag pot life more. However sometimes water is trapped in the hot liquid steel of slag pot and BLAST was so severe that all the dust from the plant came down. Even 25 mm in front of eye was NOT visible. 79

80. Libyan Iron and steel company--Misurata--Libya--2004--2010 BLAST was so severe that all the dust from the plant came down. Even 25 mm in front of eye was NOT visible. This happened at 2 AM in the early morning. So you remain to be ALERT while on duty. In the night duty, you need to take proper sleep of 8 hours in the day or accidents can happen. Myself was at approx. 20 meters above the ground and on the furnace top with no proper way to come down. Imagine no visibility even upto 25 mm distance. So accident could have happen but god save. ( 10 ) Libyan govt. Rules : --Libyan govt. Is having compulsory military service for 1 month / year / till the age of 55 years and irrespective of the fact that whether you are holding which rank, job, govt. Employment or not etc. 80

81. Libyan Iron and steel company--Misurata--Libya--2004--2010 No govt. Employee can do strike as it is against the public order and convenience. If any employee is on strike, then govt. Can shoot him, anywhere inside the factory or outside. Carrying drugs or narcotics or wine means DEATH PENALTY in public or otherwise. Death penalty in front of lion in zoo with public to view was given. Death penalty to Indian doctor was given for negligence of duties. Hence in foreign countries, you have to be ALERT towards your duties. Boys and girls with scarf used to come in our factory for summer training. 81

82. Libyan Iron and steel company--Misurata--Libya--2004--2010 ( 10 ) Integrated steel plant :--with big port, power plant, gas based DRI--Direct reduced iron plant, SMS-I--Steel melting shop--Billet caster, SMS--II--Steel melting shop--slab caster, HSM--hot strip mill, CRM--Cold rolling mill--strip, Rolling mill-- TMT bars, wire rods etc, Water treatment plant etc. Compared to their Libya nation population of approx. 60 lakhs and they build it in 1990, it was GREAT ACHIEVEMENT for them. ( 11 ) Govt. :--During my time, late Muammar Gaddafi was president. He was president for nearly 38 years. He was toppled by democratic movement in the Libya. There was no eve teasing in Misurata or Libya, which myself had observed. 82

83. Libyan Iron and steel company--Misurata--Libya--2004--2010 ( 12 ) EAF furnace--Hose :--there was water hose failures. Can you tell me the reason of water hose failures ? Bad quality hose, more pressure, aging etc. But no of these. It was insulator failure i.e. current from conductor or electrode coming in the hose and failure. This was new knowledge to me. ( 13 ) DRI --direct reduced iron is iron having small spherical shaped ball having dia approx. 10 mm. It can catch fire in their storage bins due atmospheric oxidation. Hence they are kept in nitrogen atmosphere or nitrogen is mixed in the bin. 83

84. Libyan Iron and steel company--Misurata--Libya--2004--2010 ( 14 ) Hot briquetted iron comes in bigger size. Typical size range is 30--height x 50--width x 110 --length mm . Shape similar to shown in the drawing. Midrex company is world leader in DRI and HBI technology and as per them nearly no fire incidences in HBI shipping transportation. 84

85. Global Pipe company--Saudi--2012 ( 1 ) Introduction :--Myself was selected in this company as Senior Engineer--Mechanical Maintenance. Later promoted as Acting--Section Head--Mechanical Maintenance. This company produces L--SAW--Longitudinal submerged arc welding pipes having diameter from 16” to 64” . Length = 6 meter . Wall thickness= 6 to 50 mm. These pipes are mainly used in transportation of water, oil, gas, chemicals etc. This company is located in Jubail, Saudi arabia. www.globalpipe.com.sa 85

86. Global Pipe company--Saudi--2012 ( 2 ) Saudi management :--Got chance to work with Saudi management and Korean-GM. Technology supplier was EEW, Germany. Machinery was sourced from different nations and companies. ( 3 ) Foreign training :-- They provided immediate foreign training to Indian workers in Malaysia. So Indian workers were much happy. Indian companies had NOT provided any outside training to me in last 13 years. So see the difference. Lesson to learn from it. “ Work in different nations and improve your skills. ” 86

87. Global Pipe company--Saudi--2012 ( 4 ) Different nationalities :--Worked with different nationalities e.g. Saudi, Pakistan, Jordan, Bangladesh, German, Turkey, Korean etc and was good experience. ( 5 ) Pipeline drawing :- -Water pipelines are normally below electrical lines. Water pipe if leaked then water should NOT fall on electrical cables to have spark, blast etc. But same was NOT followed in the drawing. Drawing was prepared by consultant and approved by our management. So they recognised the mistake. ( 6 ) Purchase work :--Even Though was selected for maintenance department, had to do many times purchasing work because no purchase personnel were hired. Lesson to learn, “Be prepared for different work too.”. 87

88. Global Pipe company--Saudi--2012 ( 7 ) Non-technical and technical approach :--- Their approach was technical as well as non technical in few cases. In medical examination of candidates, they were following technical approach. Every week, there was coordination meeting of all departments e.g. GM, dy. GM, Production, Maintenance, Marketing, Finance, Personnel, Quality etc. Non technical approach e.g. Marking table used for marking of tool room jobs. It should be of good quality and surface straightness must be good. Surface must be warped etc and from ISO--9000 companies. But management was insisting on making it from solid plate of 20 mm. municipality, civil defence authorities. But they had given contract to contractor before taking approval from govt. authorities. 88

89. Steel –L-SAW pipe plant 89

90. Global Pipe company--Saudi--2012 It is precision job and in India, it is always procured from reputed companies. Fire extinguishing system drawings must have approval local govt. I.e. Jubail municipality, civil defence authorities. But they had given contract to contractor before taking approval from govt. authorities. 90

91. Steel L—SAW pipe plant Global pipe 91

92. Selection in other companies Myself was selected in other companies ( 1 ) Sunflag Iron and steel company, Bhandara, Maharashtra. ( 2 ) Uttam steel limited, Khopoli--Raigad--Maharashtra--Cold rolling mill. ( 3 ) Remi--Metals now Welspun--Jhagadia--Bharuch--Gujarat. ( 4 ) Mahindra and Mahindra Tractor division--Kandivali--Mumbai. Foreign selections ( 1 ) JESCO--Jubail energy services company--seamless tube division--Jubail--Saudi arabia. ( 2 ) Emirates steel--Abhubhabhi--steel melting --UAE. ( 3 ) Viraj group--seamless pipe plant--Romania ( 4 ) Al Enma steel--Basra--Iraq --steel melting division ( 5 ) International steel services Inc--Madagascar--Africa--Sulphuric acid plant ( 6 ) South steel --Jizan--Saudi arabia--steel melting division. 92

93. 93

94. Steel sector--India and world--2016 94 Sr. No. Nation Steel production MMT in 2016 Population in Crore Production / population 1 China 808 140 5.77 2 Japan 105 13 8.07 3 India 96 133 0.72

95. Coming webinar by different specialist are ( 1 ) Energy Management—steel sector ( 2 ) Energy Management – ( 3 ) Steel strip rolling ( 4 ) Quality Control ( 5 ) Mechanotronics ( 6 ) Bearing 95

96. Questions can be asked in job interview ( 1 ) What is mean by steel ? Steel is an alloy of mainly Iron and carbon with maximum 2.21 % and other alloying elements e.g. Mn , Si, Al etc. ( 2 ) Which device, machine, you see in your college when it is working, it does NOT utilise electrical energy, solar energy and does work ? Door closure with combination of spring and oil hydraulics ( 3 ) Which oils are used in oil hydraulics pumps in India ? Enklo 68 , Enklo 48 etc. e.g. Hydrol 68 , 46 , 32 etc. ( 4 ) Different bearing manufacturing companies in India and world ? SKF, Tata Timken, ARB Bearings, Nachi Japan, Fag , NRB , 96

97. Questions for job interview ( 5 ) Any skill certifications, you received during the last 4 years e.g. welding, welding inspection, NDT –non destructive testing, fire mock drill, mechanical testing e.g. hardness tester, yield stress, ultimate tensile test etc, oil hydraulics ( 6 ) Any factory in-plant training, you had done ? Steel factory, State transport workshop, 2 wheeler repair workshop, 4 wheeler authorised garage etc. ( 7 ) Maximum % of carbon in cast iron ? 6.67 % ( 8 ) Can you assemble pump, gear box independently ? Yes. 97

98. Oil Hydraulics oil used in India 98

99. Thanks Thanks for patiently hearing my experience. Hope it will prove to be an asset to you. Please connect with me via linkedin.com and facebook etc so that we can help each other. Myself will be useful to you in live projects, getting information about company etc. 99

100. 100