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PAGE OF CONTENTS

INRODUCTION
EQUIPMENTS OF W.R.M
FUNCTION
MATERIAL OF LAYING HEAD
LUBRICATION SYSTEM
GEAR BOX
COMPARISION WITH OTHER COMPANIES
CONCLUSION

 ACKNOWLEDGEMENT

I wish to express my sincere gratitude to department head and

manager of J.S.W wire rod mill (vijaynagar) for providing me an
opportunity to do my internship and project work in J.S.W STEEL
VIJAYNAGAR WORKS.
I sincerely thank Mr. Pradeep sir, mechanical maintenance head and
Mr. Vishnu for their guidance and encouragement in carrying out this
project work. I also wish to express my gratitude to the officials and
other staff members of J.S.W STEEL who rendered their help during
the period of my project work.
I also thank Mr. S.S.GUPTHA SIR, and student coordinator Bharat
for providing me the opportunity to embark on this project
LOOP LAYING HEAD:
Laying head is used in wire rod mill in order to form coiled rings.in order to
understand the function of laying head let us look at the different operations
involved in the wire rod mill.

WIRE ROD MILL

Wire rod is a metalworking process used to reduce the cross section of a wire by
pulling through a single or series of drawing dies there are many applications
for wire drawing including electrical wiring cables, springs, spokes, paper clips
etc.in wire drawing process the wire is prepared by shrinking the beginning of
it, by hammering, filing, rolling or swaging, so the wire fit through the die, then
the wire is pulled through the die. As the wire is pulled through the die, its
volume remains the same, so as the diameter decreases the length increases. In
wire rod mill of JSW we use rolling operation for drawing the wire

THE FOLLOWING ARE THE METHODS INVOLVED IN THE

PROCESS OF MAKING WIRE FROM BILLET IN WIRE ROD
MILL OF JSW
Billet handling area
Reheating Furnace
Billet Descaler
Insulated roller table
Breakdown mill
Roughing mill
Intermediate mill
Pre Finishing Mill (PFM)
No Twist Mill (NTM)
Reducing and Sizing Mill (RSM)
Laying head
Coil handling Area.
BILLET HANDLING AREA:
The billet handling area consists of several pieces of equipment designed to
select and move billets to the furnace to be heated before entering the mill.
Separating billet skids are used to separate and align cold billets, which are then
delivered to the furnace charging conveyor. A billet discard table is found on the
far end of the billet skids, used for depositing unused billets. The furnace
charging conveyors receives billets from the skids and advances them, one at a
time, to the walking beam furnace. Prior to entering the furnace, there is a
weigh station operated by an air cylinder lifting device.
REHEATING FURNACE
Following weighing, billets are rolled into the furnace the wire rod mill is
equipped with energy efficient walking beam furnaces which are normally
computerized controlled. The reheating furnace uniformly heats the billet to the
target temperature. In reheating furnace the billet is heated in three different
zones, preheating, heating, soaking zones the final temperature of the billet is
maintained at 1040^centigrade.at a time there are 80 billets present in the
furnace
BILLET DESCALER
The billet descaler, located at the exit of the heating furnace, uses water at a
high pressure to strip away the oxidization on the billet surface, or scale, formed
during heating. A roller table before the descaler and a powered roller after the
descaler both help to move the billet to the breakdown mill. Insulated Roller
Tables The insulated roller tables transport the product on motor powered
rollers, and also have a discard function which can remove the product from the
line of pass to a collection area for disposal. The insulated covers on each table
minimize heat loss before product enters the mill stands.
NO-HOUSING STANDS
In the roughing and intermediate mills, there are seven vertical no-housing
stands, designated as1V, 3V, 6V, 8V, 10V, 12V, and 14V. There are also seven
horizontal no-housing stands, designated as 2H, 4H, 5H, 7H, 9H, 11H, and
13H.the no-housing stands are used to decrease the area of cross section of the
billet by considerable amount.in no-housing stands the wire is passed through
different dies to obtain the required area of cross section.
CROP SHEAR
The 950mm crop and cobble shear is an open side, tail rod-type shear located
after Stand #6V.This shear is used for cropping front and tail ends of processed
sections during delivery through the mill as well as for continuous cobble
cutting, after which the short cut pieces drop into a scrap chute.
LOOPERS
An uplooper performs one primary function: it forms a tension free loop in the
product after the front end of a section enters the receiving stand. This loop
prevents interstand tensions which would affect the size of the section. The
uplooper consists of entry and exit idler rollers, a persuader roll assembly, and a
loop heightscanner to monitor the loop. A loop is formed by the persuader roll,
which is essentially a roller mounted on a pivoted arm. With the persuader roll
in its down position, the roller is below the mill pass line and the section being
rolled can pass above the persuader roll without deflection. In moving to the up
position, the roller moves through the pass line and deflects the product,
forming a loop. Monitoring of this loop allows speed control of the surrounding
stands to regulate tension.
PRE-FINISHING MILL
The Pre-finishing Mill (PFM) consists of two 230 mm stands in a Vee type
configuration. Each PFM consists of a roll housing assembly, cobble cover
assembly and drive housing assembly that connects to the drive motor through
means of a tandem coupling. The roll housing assembly in turn, contains the
rolls, guides and associated electrical components, oil lubrication, cooling water
and hydraulic systems.
WATER BOXES
The water boxes are part of the mills cooling process. This process, through
controlled and uniform cooling, produces rod with substantially uniform
physical properties throughout. The finished product is then suitable for further
rolling without additional heat treatment. The cooling process also aids
considerably in reducing scale and improves surface quality. Each water box
contains cooling zones and stripping zones, made up of a configuration of air
and water nozzles. The cooling zones spray water onto the rod, which is
drained, and returns back to the mill water supply. The air zones help strip away
water from the rod and also help to keep water from exiting the water box.
C&D Shear and Switch Trough
An 800 mm Crop and Divide Shear is located upstream of the NTM. This shear
is used for frontend crops, tail end crops, and chopping functions. The shear
runs continuously. The shear knife shafts are mounted on 800 mm vertical
canters and geared together at a 1 to 1ratio. The lower knife shaft is directly
driven by a motor via a drive coupling. The upper knife shaft is driven by the
shear internal gearing. A switch trough is positioned before the shear. The
switch trough traverses the product either to the pass line of the Mill, where the
product will be rolled through the mill, or to the centreline of the knives, where
the product will be cut.
Chopping shear
The purpose of the Chopping Shear, located downstream from the Chop and
Divide Shear (C & D Shear) is to cut diverted stock into short pieces for easy
disposal. Scrapped rod is diverted to the chopping shear when a cobble occurs
beyond the C & D Shear location. The shear runs continuously to be ready to
chop.
NO TWIST MILL
The No Twist Mill (NTM) consists of eight stands in a V type configuration.
Each NTM consists of a roll housing assembly, cobble cover assembly, a 3 gear
speed increaser, and bevel gear drive assemblies. The roll housing assembly in
turn, contains the rolls, guides, associated electrical components, oil lubrication,
cooling water, and hydraulic systems.
REDUCING AND SIZING MILL
The Reducing/Sizing mill provides the mill with: increased finished speed for
small diameter product. Single family rolling throughout the complete size
range precision tolerance product thermo mechanical rolling capability. Free
size rolling capability the rsm consist of four cantilevered mill stands in a "v"
type configuration. The first 2stands are of reducing type (230mm) and the next
two are of sizing type (150mm)
PINCH ROLLS
The Pinch Rolls located directly before the Laying Head and after the RSM.
The Pinch Roll before the Laying Head is used to apply a constant tension force
to the rod to prevent the rod from flopping in the water boxes during the coiling
process. The pinch roll also controls the speed of the rod through the laying
head after the tail end exits the last rolling stand.
LAYING HEAD
The laying head assembly takes straight finished rod from the pinch roll and
transforms it into coiled rings that are discharged onto the Stelmor conveyor for
further processing.
STELMOR CONVEYOR
The purpose of Stelmor conveyor is to convey the rod rings in an over lapping
pattern from the laying head to the coil reform tub. The stelmor conveyor
provides for adjustable cooling rates utilizing; fans, plenums, dampers and
covers to produce the desired metallurgical and mechanical properties of
specific grades of steel while operating in standard and retarded cool mode of
operation for rod cooling.
REFORMING TUB
The reforming tub is a circular chamber that directs and arranges the
convolutions from the Stelmor conveyor and forms a rod coil bundle around a
stem pallet for relocation to the loading area. A nose cone ensures that the rings
fall uniformly onto the coil plate or iris. During coil formation, the nose cone is
supported by the stem pallet. During coil removal, the nose cone is supported by
the iris.

LAYING HEAD:
The length of the wire rod which is finally rolled is very high usually it varies
from 2-19kmstorage and transport of the rod of this length is not feasible. Thus
for this purpose laying head is used which coils the rod. Hence laying head is
one of the most important parts of the mill. The laying head consists of a
spinning structure containing a spiral shaped path of piping to form and
discharge the rod. The laying head runs continuously during normal operation.
One complete rotation produces one ring on the cooling conveyor. The size of
the ring discharged is determined by the length of rod passing through the
laying head during the time required for one revolution. The offset between
successive rings on the cooling conveyor is determined by the distance the
conveyor moves during one revolution of the laying head.
It consists of the following parts
1.0 Laying Head Assembly
2.0 Safety Guard Hood (Cover)
3.0 Laying Pipe
4.0 Tail End Speed Up
5.0 Wobble Control
6.0 Drive System Stabilization
7.0 Tripper Control
8.0 Front End Orientation onto Conveyor
9.0 Lubrication
10.0 Air Wipe
11.0 Air Purge
12.0 Water Cooling
13.0 Television/Monitor
14.0 Unbalance Detector
15.0 Monitoring

1.0 Laying Head Assembly

1.1 Operation and Drive
The motors speed is regulated to follow either the NTM or RSM rod delivery
speed, depending on which mill stand the rod is being finished out of. Control
shall always limit laying head minimum speed reference to 95% of rod delivery
speed due to mechanical interference from resulting oversize ring. The Laying
head motor Speed Pulse Generator (mounted at non-drive end) issued for speed
regulation and also for the laying head position encoder system. The encoder
system is electronic-program-logic-controlled and is required to exactly match
main drive gear ratio. Over speed protection is provided in the PLC software
and also by a motor mounted over speed switch. The Over speed switch is a
MANDATORYSAFETY DEVICE. No substitution is allowed, such as
electronically monitoring pulse generator or encoder. The shutdown is set for
1310 motor rpm, which equates to 126.67 m/sec laying head speed. Rotation of
the motor is CW, facing
Non-drive end. The laying head motor is an AC 262kW motor with variable
voltage / variable frequency control and is powered by a fully regenerative
thyristor Power Converter. The motor is geared to the laying head via a 67 to 39
tooth increaser.(approximately 1.71:1)
2.0 Safety Guard Hood (Cover)
FUNCTION: The cover encloses the spinning pipe and contains the front and
tail end rings. Refer to Figure 1B.The cover is closed during normal operation
and is opened during maintenance. The cover is operated by a hydraulic valve
unit with a 2.2kW motor. The cover is opened and closed by a rotary hydraulic
actuator controlled by double solenoid, 3-position Cover Open / Close valve.
3.0 Laying Pipe
FUNCTION: The rotating pipe is the guide that transforms the straight rod into
rings.
4.0 Tail End Speed Up
FUNCTION: The Tail End Speed Up functions to maintain (speed up) the
required speed the Laying Head must travel, in unison with the pinch roll, for
tail ends so that large diameter rod will clear the Laying Head pipe.
5.0 Wobble Control
This function controls the laying head speed relative to the finished rod speed
which produces varying ring diameters. The Wobble Control is used primarily
on coarse/large size rod to allow the rings to nest better when they form in the
reform tub. The Wobbles applied when the front end of rod coil is on the
conveyor and is removed before the tail end arrives on the conveyor.
6.0 Drive System Stabilization
Special closed loop stabilization circuits and open loop lead (phase advance)
circuits are used to compensate for the following conditions:
1. The laying head inertia is several times more than motor inertia.
2. There is some backlash in the gearing between the laying head and motor.
3. During wobble control, the motor torque passes through zero frequently.
4. The laying head must undergo a rapid speed change during tail end speed up.
7.0 Tripper Control
FUNCTION
There are two sets of trippers (bottom trippers and side trippers) used to aid in
the control and delivery of the coil rings from the laying head to the conveyor.
SET-UP
1. Side trippers are generally placed in line with the lower deflectors and help
to contain the tail end rings.
2. The bottom trippers are used (manually adjusted) to give a consistent landing
area for the rings exiting the laying head. This helps to give a more uniform
pattern to the rings as they are placed on the conveyor.
8.0 Front End Orientation onto Conveyor
The Laying Head speed is automatically adjusted to orient the rod front end so
that it lies in a trailing mode to prevent snagging as it travels up the Stelmor
conveyor.
9.0 Lubrication
Correct lubrication pressure must be maintained to operate the laying head
drive. The lube Pressure switch initiates an alarm if pressure is not correct.
Correct lube pressure is a permissive requirement to start laying head drive.
The LOW lube pressure condition causes the following to occur:
After the laying head is running and a LOW pressure condition occurs, a
0.5second time delay is initiated. If the LOW pressure condition is present after
the time delay ends, the following functions take place:
a. The "scrap cut" mode for the crop and divide shear at the entry to the NTM
is initiated to divert the stock to the scrap chopping shear.
b. A timer (adjustable from 0-3 seconds) is started which initiates the closing of
the snap shear at the entry side of the NTM.
c. Once product has cleared the pinch roll and laying head as indicated by the
tracking system, the laying head drive is fast stopped.
10.0 Air Wipe
FUNCTION
 The air wipe, located at the rod entrance guide, strips water from the rod before
entering the laying head. The air wipe is controlled by the Air Wipe single
solenoid valve. The air wipe operates continuously whenever the laying head is
running.
11.0 Air Purge
FUNCTION
The Air Purge initiates a blast of air to the laying head pipe to remove sludge,
scale and water deposited by the rod. The air purge operates intermittently at the
billet front end and is controlled by the Air Purge single solenoid valve.
12.0 Water Cooling
FUNCTION
A water cooling jacket is used around the centre pipe to insulate the main
bearings from the heat of the traveling rod. This water is controlled by Cooling
Water single solenoid valve. Water is turned on by energizing the solenoid
whenever the laying head drive is running.
13.0 Television/Monitor
A camera is mounted above the entry tilt section of the conveyor, while a
monitor is located in main control pulpit to give a close-up view of ring
formation.
14.0 Unbalance Detector
FUNCTION:
The purpose of the Unbalance Detector is primarily for worker protection. The
laying head may self-destruct if the rotor becomes unbalanced.
15.0 Monitoring
The laying head is designed for manual and automatic operation. Operating
stations (upper and lower) help test, monitor, and adjust conditions that may
occur through the automated system.
MATERIALS USED IN LAYING HEAD ASSEMBLY
One of the most important aspects of product quality in a long rolling mill that
produces bar or rod in coil form is the quality of the finished coil. High-quality
coils have orderly rings within the coil and uniformity of the inner and outer
diameters for tangle-free payoff in downstream user operations, plus
compactness of the coil package for efficient storage and shipment. The ability
to obtain high-quality coil starts with the design and control of the equipment
upstream of the coil reforming station and continues through to the coil-
handling system. In a high-speed rod rolling mill, effective operation of the
laying head, a controlled cooling conveyor and a coil reforming tub are critical
to achieving successful operations at speeds over 100 m/s. The laying head must
form rings accurately and consistently so that they can be cooled uniformly and
form a good coil. Furthermore, a minimal degree of wear on the laying head
pipe helps avoid downtime from frequent pipe changes, which lowers
production. After proper cooling on the conveyor, the coil reform tub must
transform the ring package from the conveyor into a well-ordered and dense
coil, which can then be conveyed during further cooling, compacted and readied
for shipment.
CHALLENGES AT THE LAYING HEAD
The pinch roll and laying head determine the consistency of ring diameter and
placement on the cooling conveyor. This can be especially difficult on small-
diameter products rolled at speeds over 100 m/s. Closed-loop control of pinch
force and speed, plus rapid and repeatable roll close times, can be provided by
the Morgan Intelligent Pinch Roll. In the laying, a good coil package depends
on an efficient pipe path and tail-end control, stable pipe support and bearing
design, plus good speed control with front-end positioning and coordination
with the pinch roll operation (Figure 1).The most common laying head
problems faced by rolling mill managers are head- and tail-end formation,
packaging and pattern-related issues, as well as excessive pipe wear. Poor head
and tail ends and inconsistent ring patterns often cause delays at the reform
station. High rates of pipe wear result in frequent pipe changes.
IMPORTANCE OF THE MATERIAL
The laying of different wire rod sizes in uniform loops with the loop laying head
at high rolling speed is an important criterion. Further due to thermo mechanical
rolling for many grades has put more demand on the materials used for loop
laying head pipe. Which can withstand this conditions for a greater period of
time.
Types of materials used in jsw Wire Rod Mill
The different kinds of pipes that were used and are in use at present are as
following
P05 grade pipes
P91 grade pipes
SR series pipes

P05 grade pipes:

In jsw P05 grade pipes were used in the past
The chemical composition of P05 grade pipe is:
P5 C Mn P S Si Cr
0.15% max 0.30-0.60% 0.025% 0.025% 0.50% max 4.0-6.0%
Mo
0.45-0.65%

Its mechanical properties are

Tensile strength: >415 MPa
Yield strength : >205 MPa
Elongation : >22%
Its output range was 2500-3000 tonnes and the cost of P05 grade pipe is 56,000
rupees.

Later it was replaced by P91 grade pipes because of their better performance
when compared with P05 grade pipes
Composition and mechanical properties of the P91 grade pipe are as following
P91 grade pipe:
P91 C Mn P S Si Cr
0.08-0.12% 0.30-0.60% 0.02% 0.01% 0.20-0.50% 8.0-9.5%
Mo
0.85-1.05%
In this pipes the percentage of C, Mn, P, S, Si are reduced and the percentage of
Cr, Mo are increased
Mechanical Properties:
Tensile strength: 585-760 MPa
Yield strength : >415 MPa
Elongation : >20%
Clearly the tensile and the yield strength of P91 grade pipe are greater than the
P05 grade pipe
Its outer diameter is 48.3mm
Its inner diameter is 34mm
Its output/life range is 4000tonnes

SR series pipes:
Recently series pipes are introduced for coiling along with P91 grade pipes
Features:
It is able to produce consistent ring pattern at high speeds with significantly
increased pipe life
In SR series pipes, new material replaces worn sections of laying head pipe
through a controlled Self-regenerating" process during rolling. The
regeneration shifts the wear zone up to 150mmwithout affecting the laying head
dynamic balance this shifting of wear zone results in a dramatic improvement in
pipe life, which can be further enhanced with proprietary pipe material
It contains two pipes one inner pipe and one outer pipe. The inner pipe material
gets hardened at elevated temperatures so that the pipe can with stand the wear
and tear even at this conditions.
These are also called as revo tech pipes
The inner diameter of this pipe is-19.5mm
It is used for coiling the wires of diameter ranging in between 5.5-8mm
The cost of SR series pipes is 6Lakhs rupees
The estimated life is 130,000 tonnes which is achieved in ideal conditions. The
output/life that we are getting in JSW is 35,000-40,000 tonnes, the practical life
is low because different grades of pipe are being coiled and that to at high
temperatures. The production can also be increased by the proper maintains of
the parts and spare parts like deflector plates, entry tech plates, balancing
weights, checknut, wipers, pinch roll entry and delivery pipes, etc.

LUBRICATION SYSTEM:
Lubrication in an integrated steel plant is a major challenge with numerous
types of lubricants and various types of equipment. The wire rod mill
equipment work under various operating parameters; like from extreme
heavy load to very high speed, low temperatures to high temperatures,
dusty polluted environment to humid acid environment. Therefore proper
selection of lubricant is much essential for smooth operation in steel plants
and reliability of equipment. The equipment in rolling and finishing group
are subjected to high impact loads , water and scale ingress, high
temperature near reheating furnaces and higher speed and unit loads.
In Steel plants equipment reliability & better maintenance practices are
very important which directly affects the productivity & equipment
Health. While selecting lubricant for steel plants equipment these factors
must be taken into consideration load, speed, surface finish of the
interacting surfaces and rise in temperature etc. we also need to look at two
very important aspects namely the factors concerning engineering
requirements and the factors concerning requirements pertaining to the
service condition. The majority of engineering requirements are met by
selecting proper viscosity of the oil (called lubricant grade) while the service
condition requirements are met by selecting proper additive package for the
lubricant ( called lubricant type).
Lubricant used
In JSW wire rod mill the lubricant used for loop laying head assembly is
Mobil Vacuoline 525 and the lubrication system is of oil, wet, low-pressure
type. Mobil Vacuoline 525 is an extra high performance heavy duty circulating
oil specifically designed to meet the critical requirements of high speed Rod
Mills, manufactured by Morgan Construction Company and Danieli. They are
formulated from high quality base stocks and a proprietary additive system to
provide enhanced film strength, anti-wear and anti-scuff properties. The oil have
good wettability and provide extra oil retention and thin film protection against
rust and corrosion on gears, shafts, bearings, adjusting screws and all housing
sections. Mobil Vacuoline 525 have excellent anti-wear properties that
eliminates scuffing and scoring of high-speed gearing. The Mobil Vacuoline 525
possess good demulsibility that is retained under conditions of severe water
contamination.

Features
Good protection against rust and corrosion through a balanced high
performance lubricant formulation, Outstanding anti-wear performance,
Excellent water separation characteristics, High resistance to oxidation and
thermal degradation.
Advantages and Potential Benefits
Fewer unscheduled stoppages and lower maintenance costs, Excellent
protection of critical bearings and gearing, Rapid separation of water for
smooth, efficient operation, reduced downtime and undiminished wear
protection, Long oil charge life and avoidance of costs of unanticipated
production interruptions.
Characteristics
Viscosity Index, ASTM D 2270: 99
Pour Point, C, ASTM D: 97 -21
Flash Point, C, ASTM D: 92 264
Specific Gravity @15.6 C kg/l, ASTM D 1298: 0.88
Demulsibility at 82C, ASTM D1401 Minutes to 3ml: 25
Demulsibility for non-EP oils, ASTM D2711, ml water: 39
CST @ 40C: 92.7 1
CST @ 100C: 10.7
Further water nozzle system is used for cooling loop laying head. For better
performance of the equipment proper maintenance of lubrication system is
required
GEAR BOX
Gearbox plays an important role in the system of power transmission. It is
designed to speed and torque conversion by providing a source of rotational
energy to another device with the gear ratios.
In the gear box of loop laying head we have a bevel gear is used for power
transmission as input and output shafts are at 90 degrees to each other and
laying head motor is an AC 262kW motor with variable voltage/variable
frequency control and it is powered by a fully regenerative thyrirstor power
convertor.
Motor is geared to laying head via 67 to 39 tooth increaser the gear ratio is
approximately 1.71:1
The gear system actually helps in converting the linear motion of the rod into
circular motion in order to form the coils
COMPARISION WITH OTHER STEEL PLANTS
J.S.W
All the equipment of J.S.W Wire rod mill is of latest and high performing
The key features of the mill is
high speed wire rod mill (120 m/s) low sulphur and phosphorus content
(0.005%-0.035%)
low tramp elements
excellent mechanical and consistent chemical properties
dimensional accuracy is guaranteed by an automated thickness control
system using advanced numerical models
sizes 5.2,5.5,6.5,7,8,9,10,12,14,16,18,20,22mm
grades low carbon, medium carbon, high carbon welding electrode

All this grades and sizes are effectively coiled by the loop laying head
The J.S.W wire rod mill uses sr series, P91 series pipes as laying head pipes
Which have an excellent output range of 40,000 tonnes/pipe to coil wires of
different sizes and different grades
The intelligent pinch roll and laying head pinch roll are highly advanced and
automated
When compared with some steel plants like sms group J.S.W is well advanced
and outstands in it performance, (sms group have advanced to new standards
which are comparable to J.S.W)

Sms group J.S.W wrm

The mill annual production capacity 180,000 t 600,000 t
Sizes 5.5 to 20 mm 5.2 to 22mm
Max speed 70 m/s 120m/s

Even though it is well advanced in its equipment it can try different designs for
loop laying head like twin pipe mechanism
MORE FLEXIBILITY WITH
TWIN-PIPE LOOP LAYING HEADS
The layout of the twin-pipe loop laying head makes the wire rod production
more flexible:
With two identical parts, mill owners minimise standstill times for maintenance
work or carry out quick size changes thanks to laying pipes with different
inside diameters.

Conclusion:
Apart from this the remaining standards are up to date and there nothing much
to improve