HISTORY

• In 1919, the Tata Steel plant in Jamshedpur was established, and it was
the first steel plant in India. The plant was set up by Jamshedji
Nusserwanji Tata, the founder of the Tata Group.
• By 1921, the plant had started producing structural steel for the plant
and machinery, which was imported from the US and UK. The design of
the plant was based on an Indiana rolling plant.
• In December 1922, the first hot dip tinning plant started rolling out
finished tinplate. By 1924, a total of six mills were in production, and
the company was producing almost 40% of India’s tinplate needs.
• In the 1950s and 1960s, Tata Steel expanded its operations and
increased its production capacity. The wire rod mill was established
during this period, and it was designed to produce high-quality wire
rods for various applications.
• In the 1970s and 1980s, Tata Steel continued to modernize its facilities
and increase its production capacity. The wire rod mill was upgraded to
produce a wider range of wire rod products, including cold-drawn wire
rods, bright wire rods, and wire rods with special coatings.
• In the 1990s and 2000s, Tata Steel continued to invest in its wire rod
mill, upgrading its equipment and technology to produce high-quality
wire rods with improved properties. The mill was also expanded to
produce wire rods with higher strength and durability.
• In 2004, the wire rod mill in Tata Steel Jamshedpur was modernized
and expanded to produce wire rods with even higher strength and
durability. The mill was equipped with state-of-the-art equipment and
technology, including continuous casting machines and rolling mills.
• Today, the wire rod mill in Tata Steel Jamshedpur is one of the largest
and most modern wire rod mills in the country, producing high-quality
wire rods for various applications, including construction, automotive,
and consumer goods. The mill is equipped with advanced technology
and equipment, and it is capable of producing wire rods with a wide
range of properties and specifications.
 BASIC LAYOUT
LUB-A CONTAIN #STAND NO-1 TO
#STAND NO-7
-IT PROVIDE SERVICE TO 7 GEAR BOX
LUB-B CONTAIN #STAND NO-8 TO
#STAND NO-13
+ C&C (CUP&CABBLE
SHEAR GEAR BOX)
LUB-C IS AS FOLLOWS:-
-CROP&DIVIDING SHEAR GEAR BOX
-CHAPPING SHEAR GEAR BOX
- NTM
-#STAND NO-16 TO #STAND NO-25
-10-MODULE HAS 1-STAND EACH
-3HI GEAR BOX
-IPR (INTERMIDIATE PITCH ROLL)
-LHPR(LAYING HEAD PITCH ROLL )
-LHGB(LAYING HEAD GEAR BOX)
-PFM(PRE FINISHING MILL)
-#STAND NO-14
-#STAND NO-15
PLANT LAYOUT’S OF ALL HYDRAULIC
AND LUBRICATION SYSTEM

HYDRAULIC SYSTEMS
 HYDRAULIC SYSTEM
OIL CAPACITY

OIL
Hydraulic System Tank Capacity(Ltr)
Grade

FCE Hyd. HLP 46 2000

Hyd GG HLP 46 6000
Hyd. AA HLP 68 2700
Roll balancing HLP 68 1000
Hyd. BB HLP 68 300
Hyd. CC HLP 68 300
TOTAL 12300
LUBRICATON SYSTEM
OIL CAPACITY
SYSTEM OIL Grade Tank Capacity
Lub. A SP 680 11000
Lub. B SP 320 7500
Lub. PFM Mobile Vacculine 533 6500
Lub. C Mobile Vacculine 525 100000
Charging Bed SP 460 0
IM guide lub, NTM SP 100 2000
GR1 & Gr2 SP 150 0
TOTAL 127000
PIPES USED IN SYSTEMS ARE:-
1)SS (STAINLESS STEEL)
2)MS (MILD STEEL)
3)CS (CARBON STEEL)

IN TERMS OF: -
CORROSION - SS>MS>CS
STRENGTH - CS>MS>SS
RADIUS - CS>MS>SS
PREFERENCE: -
SS>CS>MS
FITTING’S
-MALE STURD FITTING (SINGLE CONNECTOR)
-DOUBLE CONNECTOR FITTING
-TEE FITTING
-ELBOW FITTING
-BEND FITTING (90-DEGREE)
MAIN CRITERIA OCCURING DURING LEAKS :-
1) LOOSE OR IMPROPER FITTING
2) AT SEAL HEAD AT CYLINDER
3)CORROSION ON PIPES DUE TO EXTERNAL
SURROUNDING CONDITION’S
MAIN CRITERIA OCCURING DURING PIPEING
& CONNECTION DEFECTS: -
- EXCESS SURROUNDING TEMP AND
HUMIDITY LEVELS
- IMPROPER INSTALATION
CONSUMPTION OF HYDRAULIC OIL SHOULD
LIE UNDER :-

The Hydraulic Fluid Index (HFI) is a measure of

the amount of hydraulic fluid used by a system
relative to its reservoir capacity. It is a useful
tool for monitoring and controlling hydraulic
fluid consumption, which can help to identify
potential issues with leakage, contamination,
or inefficient system operation.
FORMULA TO CALCULATE: -

= CONSUMTION x 100
TOTAL CAPACITY
[NOTE- IF (HFI < 5) IS NOT SATISTFIED THEN
IT INDICATES THERE HAS BEEN A LEAKAGE
DURING CALCULATED MONTH.]
 FY-23
Present
Hydraulic OIL Tank
Department Stock Make up for the month
System Grade Capacity(Ltr)
1st May APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER JANUARY FEBRUARY MARCH
FCE Hyd. HLP 46 2000 420 0 210 0 0 0 210 210 0 1050 0 210
Hyd GG HLP 46 3000 0 0 0 0 0 210 0 0 0 0 0 0
Hyd. AA HLP 68 2700 420 840 630 840 210 1890 210 840 1050 1260 420 210
Roll balancing HLP 68 1000 0 0 0 0 0 0 210 0 210 0 0 0
Hyd. BB HLP 68 300 0 0 0 0 0 0 0 105 0 0 0 0
Hyd. CC HLP 68 300 0 0 210 0 0 0 0 105 0 0 0 210
WRM
Hyd. DD HLP 68 4000 210 210 210 420 0 210 0 210 210 0 210 0
Hyd. EE HLP 68 4000 0 0 0 0 0 0 0 0 0 0 0 0
Hyd. FF HLP 68 2800 0 0 0 0 0 0 210 0 210 0 0 210
TOTAL 20100 0 1050 1050 1260 1260 210 2310 840 1470 1680 2310 630 840 14910
HFI(<5%) 5.2238806 5.2238806 6.26865672 6.26865672 1.04477612 11.49253731 4.17910448 7.313432836 8.35820896 11.4925373 3.13432836 4.17910448
 FY-24
Present
Hydraulic OIL Tank Stock Make up for the month
Department
System Grade Capacity(Ltr)
1st May APRIL MAY JUNE JULY AUGUST SEPTEMBER OCTOBER NOVEMBER DECEMBER JANUARY FEBRUARY MARCH
FCE Hyd. HLP 46 2000 0 0 210 0 0 0 0 210 0 0 210 0
Hyd GG HLP 46 3000 0 0 210 0 0 0 0 210 0 210 0 0
Hyd. AA HLP 68 2700 420 210 210 315 315 1260 420 210 210 210 0 420
Roll balancing HLP 68 1000 210 0 210 945 315 210 630 420 630 210 210 420
Hyd. BB HLP 68 300 0 105 0 105 0 105 0 0 0 0 105 0
Hyd. CC HLP 68 300 0 105 0 105 0 105 0 0 0 0 105 0
WRM
Hyd. DD HLP 68 4000 210 210 105 0 210 0 105 0 210 0 210 0
Hyd. EE HLP 68 4000 0 0 0 0 0 0 0 0 0 0 0 0
Hyd. FF HLP 68 2800 0 210 105 0 0 0 105 0 0 210 0 0
TOTAL 20100 0 840 840 1050 1470 840 1680 1260 1050 1050 840 840 840 12600
HFI(<5%) 4.179104 4.179104 5.223881 7.313432836 4.179104478 8.358208955 6.268656716 5.2238806 5.2238806 4.17910448 4.17910448 4.179104478
 ADVANCEMENT
• Replacement of MS & CS Pipes with SS Pipes:
MS (Mild Steel) and CS (Carbon Steel) pipes
are being replaced with SS (Stainless Steel)
pipes due to their longer lifespan and reduced
risk of corrosion.
• Painting Pipes: Painting pipes though minor
effort but provides additional protection
against corrosion over time.
• Re-routing Pipes: Old piping structures that are
not easily accessible are being re-routed to
facilitate regular maintenance and reduce
leakages.
• Implementation of SS Fittings: SS fittings are
being used in oil pipes to minimize corrosion
and leakage.
• Covering Pumping Stands with Sheds: Pumping
stands are being covered with sheds to
prevent water from falling on them, thus
protecting traversing and clamping pipes from
corrosion.
• Changing Sprue on Pumping Stands: The sprue
on all pumping stands is being changed to
prevent breakdowns and heavy leakages.