PICKLING

The basic purpose of pickling is to remove the corrosion and other surface impurities from the baby coils. The baby coils are received from HR. The main components of the pickling plants are as follows.

1) COIL CAR
The coils are first loaded in coil car first from the ground these cars can move the up or down and toward and away from the decoiler. The coils cant be mounted on decoiler directly by crane.

2) UNCOILER
It basically consists of large and heavy duty spindle having mandrel. The blocks of mandrel can be expand or collapsed. Before the insertion of coil the block are closed and after insertion of coil the blocks are expanded to grip the coil internally. The spindle is equipped with 2.5 HP AC motor it rotates at low RPM. A pneumatic coupler is also attached to engage or disengage the motor with the mandrel. The whole platform can be moved along the axis of the spindle. It is also equipped with mechanical brake i.e. Band brake controlled pneumatically. The SUNBER roll is also shed over the coil to prevent the coil from self-opening after removal of the strip. Now with the help of PEELAR or FEED TABLE the coil Is bend upward and passed over the supporting rollrs. The purpose of bending the coil is o make sure that the coli travel along the desired path and not stuck into any other component.

3) FLATTNER
It consists of five steel roles it has two purposes: 1. To remove the scale and other impurities i.e. corrosion etc. so that acid is not wasted. 2. to straighten the initial bend and bend at the end of the baby coil. It is driven by DC motor of 50 HP a speed reduction gear box and another gear box which consists of five output shafts at the same speed. These five shafts are connected with five rollers with the help of universal joint. Two roller come on the upper side of the sheet and the remaining three from the lower side of sheet. The lower rollers are fixed while the upper rollers can move up and down both manually or with the help of hydraulic cylinder.

4) SHEAR CUTTER
T he next important element of the plant is shear cutter. It uses the shearing action to cut the metallic sheet for following reasons: 1. to make the edge of sheet straight. 2. to remove the damaged , bend or highly rusty portion of the coil. The cutter is operated with the help of hydraulic system.

5) CLAMP
After the shear cutter it comes clamp. There are two clamps the clamp are used to grip the sheet and stop them from moving. Mainly the clamps are used when we make holes in the sheet by the help of the punch. The clamps are installed at both side of the punch.

6) PUNCH UNIT
The hydraulic punch is available to make holes in sheet. Lets say that the clamp after the punch is clamp 2 and clamp before the punch is clamp 1. now the end of old coil is clamped by punch 1 and the start of new coil is clamped by punch 2. in this way a certain portion of the both coils are clamped and the punch is brought inward by the help of pneumatic system the punching action is performed by hydraulic system. These holes are used to fit the bolt so that the old sheet can pull the new one.

7) M.S. PINCH ROLL

After the attachment of bolt the sheet is now passed in between the pinch roll the purpose of all the pinch rolls are related to looping (explained ahead). This unit is equipped DC motor and speed reduction gear box. It should be noted that whenever the bolted portion passes in between any roller the upper roller is lifted to prevent the roller from damage.

8) ENTRY PIT
The pit is used to store the coil before punching because we ned extra sheet for punching as we dont stop the pickling operation during the punching process (as sheet continue moving). The storage of coil is called loop forming. We speed up the coil at at the entry side while its speed is same (slow) at pickling process so the extra coil gathers at the pit and used further.

9) MEASURING ROLLER
After the pit it comes a measuring roller . it is roller over which when bolted portion of the sheet passes over the operator pushes a button for the Automatic Squeeze Roll. Now it is reference when the bolt reaches near the any os SQUEEZE ROLLER in the acid or rinsing tank the upper roller is lifted up before and after the one foot of bolt.

10) SCALARS
These remove the scales of rust from the sheet and any other impurity attached from the pit to sheet. If the impurity or rust scales are not removed then they consume more acid and so much more acid is wasted. So scalars are used to remove the impurities mechanically before the chemical action.

11) ACID TANKS

The acid tanks are the places where the actual pickling action takes place.the first acid tank has concentration up to 2-8% and temperature of 700C. the tank is similarly fabricated as rinsing tank. At the end of first acid tank there are squeeze rolls which presses against the sheet from both sides. The core of the squeeze rolls are made of steel while the outer surface has rubber lining. The squeeze rolls prevent the acidic solution of acid tank one to enter into acid tank two. The acid tank-2 has concentration about 818% and temperature about 700C.

12) RINSING TANKS

After the acidic action the sheet is washed under high velocity jet of water in rinsing tanks. Rinsing tank-4 has supply of fresh water and steam supply by by Ushaped pipe having holes. The purpose of supplying of steam is to heat the coil so they are dried easily. After filling the tank-4 water enters tank-3 and then finallty reaches to tank-1. The rinsing tanks are discussed in detail in future.

13) AIR KNIFE

If the sheet is passed through the dryer without removing water from it then the dryer will leave rusty marks on the sheet. So it is first through air knife from which the high speed air flow across the sheet and removes the water from it.

14) DRYER
Now the sheet enters the dryer where the hot air is used to dry the sheet and remove the moisture fully. The dryer consists of large blower driven by electric motor and the air is heated by the steam.

15) DC PINCH ROLLER

Now the sheet passes through the DC pinch roller. Its basic purpose is loop formation at the exit pit. The upper roller is driven by the Universal Joint while the lower roller is free and rotates with the sheet. This roller is equipped with powerful DC motor and a gearbox.

16) PIT
This pit is eight meter deep. It is used to form the loop at the exit so that the bolts at the end of the sheets can be removed.

17) AC PINCH ROLLER

These are rubber rollers on which AC motor is attached the main purpose of these rollers are to draw the coil from the exit pit.

18) GUIDER
GUIDERS are vertical rollers. Two rollers are attached with center inline on one side and other two on otherside the sheet is passed between them their distance

can be varied their main purpose is to keep the sheet straight and on the required track so that perfect rolling is achieved.

19) TENSIONER
The tensioner tighten the sheet and provide sufficient tension so that the smooth rolling is achieved. Tensioner is composed of five rollers. Two roller come on the upper side of the sheet and the remaining three from the lower side of sheet. The lower rollers are fixed while the upper rollers can move up and down both manually or with the help of hydraulic cylinder. Here the sheet is also lubricated with anti-rust oil a specific quantity of oil is added at first roller due to the squeezing action it is spread over the whole sheet on rolling the other side is also lubricated by the adjacent layer. This oil is very costly and the oil is collected and used again.

20) DEFLECTOR ROLLER AND FEED TABLE

The recoiler is located down then the height of tension unit so a deflector roller and feed table is used to assist the recoiling operation.

21) RECOILER
This is the unit which once again forms the coil after pickling operation, unlike uncoiler its mandrel is equipped with gripper that grips the start of the sheet to form coil. This unit is equipped with disk brake operated pneumatically.

PLANT COMPLIMENTARY SYSTEM

1) ACID SYSTEM
the new (pure) acid solution is built in Acid Recirculation Tank-2 (ART-2) by water and HCl (concentration 32% and specific gravity 1.16) from storage tank this solution is then passed through heat exchanger to heat the solution to the desired temperature. The acid is drawn from the tank and delivered to the Heat Exchanger by the help of pump 11-B. after heating the solution is delivered to the Pickling tank-2. the acid is drawn from the tank and feed back to ART-2. Initially the solution concentration is 20% but with the passage of time as the reaction takes place the concentration of acid decreases till 8%. Then this solution is feed to ART-1 with the help of pump 11-A and then feed to Picking Tank-1. the minimum concentration of acid at ART-1 that can sustain pickling operation is 2% so when the acid reaches this concentration the acid is drained to spent acid tank from where it is send to GP by the help of pump 11-C where it is treated with lime stone at GP and drained to sewage channel.

2) SCRUBBERS (ACID FUMES RECOVERY SYSTEM)

When acid is heated its fumes are formed. These fumes should be captured andreused from both economical and environmental point of view. So large ducts are attatched

to the all acid tanks, rinsing tanks and acid recirculation tanks. a vertical tower is mounted outside the plant and blowers are attached to these towers. The ducts from tanks are attached to the inlet of the blower. When the air is blown the water is sprayed over it by the help of pump15-C. this water captures the HCl fumes and We get acidic water at the bottom. Now this acid is discharged with the pump 15-E and can be sent to pickling Tank 1, Pickling Tankk-2, ART-1 or ART-2 as required

3) HYDRAULIC AND PNEUMATIC SYSTEM

following equipment on the plant uses the hydraulic and pneumatic system as folows HYDRAULIC EQUIPMENT PNEUMATIC EQUIPMENT 1. Uncoiler 1. uncoiler brake 2. Sunber roller (entry side) 2. uncoiler coupler 3. uncoiler platform 3. Clamps 4. Flatner 4. punch mechanism in and out 5. Shear cutter 5. squeeze roller 6. Punch 6. AC Pinch roller 7. Peelar 7. Recoiler Brake 8. 5-roller tensioner 8. Sunber roller (exit side) 9. MS pinch roller 10. DC Pinch roller 11. Scallers 12. deflector roller and feed table 13. Recoiler 14. coil out plate Steam system Q: major maintenance project you have attended. Q: what are the differences between the water and acid pump. Give parts detail and technanical answrs.

1) COUPLING
Both heavy duty water and acid pumps are connected to the prime mover (motor) with the help of coupling. The acid pumps are attached with ----------- couplings while the water tanks are attached with the ------ couplings.

2) SHAFT
The material for the main shaft of the acid pumps is en8. while it is made of stainless steel in case of water pump the shaft is then placed in a housing that acts like an oil tank. The tank is closed with the help of bearing housing and oil seal. To prevent oil leakage and the oil is used for the lubrication purpose of the bearing to run shaft smoothly. The portion of the shaft at the pump housing is covered axially with ceramic and radially a Teflon washer is attached to prevent the shaft from corrosive action of the acid.

3) SEAL
In water pump ordinary gland andstuffing box arrangement is used to seal the pump housing and shaft from leakage. While in acid pump a very costly component

Mechanical Seal is used. The reason for using mechanical seal is that it has no leakage while ordinary gland has leakage.

A) MECHANINAL SEAL
This seal is basically composed of two major portion Rotating End and Stationery End. The rotating end is composed of main housing in which a component below is used the graphite seal is attached to this below. There are springs on the outer housing. The clamp presses these springs such that the below and housing made contact. All the four the housing, below, clamp and graphite seal are attached together and mounted on shaft hence called rotating end. The other portion of the seal is called stationery end it is made of------------ . half of it resta in impeller housing and from other side it makes contact with the rotating end. Both the contact surfaces are very fine finished and are connected in such a way that no gap developed intermolecular attaraction and no leakage exists.

4) COOLING SYSTEM
Mechanical seals require cooling so water is circulated through a non metalic covering over the seal. If the cooling is not provided then the precise and precious components expand due to heating and seizes to move and hence destroying the seal. This type of cooling system is not present in water pumps.

5) IMPELLER
The impeller of water is made of CI or bronze both of these can't withstand the acidic solution. So PVDF impeller is developed to pump the liquid. Impeller of both the pumps are radial type with double curvature vanes over-hung. The axial thrust generated by the pump suction is relieved through the holes provided in the impeller hub.