About UsSurana industries limited possesses a fully integrated state-of-the-art steel manufacturing plant at gummidipoondi, chennai. The unit is complete with the following facilities:
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\ninduction furnace for the manufacturing of mild steel ingots from heavy metal scrap
\nsteel plant for rolled products from mild steel ingots and billets (from 6mm to 36mm diameter)
\nhot rolled products like cold twisted deformed (ctd) bars, tor steel, thermo-mechanically treated (tmt) bars (known as surana tmt), mild steel wires, ms structurals and angels etc.
R\ncold rolled items
\nsurana industries manufactures high strength deformed steel bars (approved by bureau of indian standards association), thermo mechanically treated bars known as surana tmt, crs reinforcing bars, cold twisted deformed bars, mild steel rounds and mild steel structurals. The plant has an installed capacity to produce per annum 30,000 tonnes of mild steel ingots, and 1,09,800 tonnes of ctd bars and tmt bars.
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\nmodernization
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\nsurana industries limited is one of the major tmt (thermo mechanically treated) bars manufacturer located in chennai and sourced eurotherm del india limited to modernize their plant located at gummidipoondi around 45km from chennai.
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\nhighlights of the automation
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\ncomplete line automation
\ncomplete delivery starting from 11 kv vcb, 3150 kva dual secondary transformer, plc, mcc, drive panels, dc motors and field instruments.
R\ncut - to- length through plc
\nshttl for phase lock loop (pll) for flying shear control
\nhigh-speed profibus network
\nfrom concept to commissioning
\nbuild - in macros for diameter calculation, winder block, and cascade reference.
\nforward/ backward flying shear
\nautomation process- tmt line
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\nsurana tmt bars derive their strength from a controlled, in-line rapid water quenching process. Cooling is a process specifically developed to meet the demand for high-strength steel reinforcement bars with high ductility. Directly after the last rolling stand, the bar passes to the cooling system and is subjected to a short intensive cooling of the surface.
This leads to drastic reduction in surface temperature and surface hardening (martensite structure) whereas the core is largely unaffected. After leaving the cooling system, the exchange takes place whereby the core re-heats the surface, thus tempering the martensite. The thermal exchange is completed at the cooling bed and the resultant bar has a unique structure of tempered martensite at the periphery and a fine grain ferrite pearlite in the core. This provides the higher strength and ductility to the finished material.
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\nflying shear
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\nthe finished material called as billet passed through number of \"stands\" to make steel rods of length & diameter as per customer''s requirement, with typical steel processing speed of 5 to 10 meters per minute, which means the cutting has to be on online process without the need for stopping the steel rod.
This is why flying shear mechanism is required which can cut the steel rods as the rod goes by.
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\nthe basic speed of the flying shear should be at least 10 to 15% more than the speed rod is moving. This higher speed makes sure that there is no strain on the shear blade and that the rod is pushed ahead after the cut is made. If the speed is less than or equal to the rod speed, the rod will bend at the time of cutting. If the speed is too much there will be strain on the shear itself leading to faster wear and tear of the shear.
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\nthe sequencing of the drive and shear is done using a plc. The plc takes input of the limit switches (or cam switches) available in the shear to identify the position of the shear. |
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