Introduction
Conducted from 07 April 2026 to 12 April 2026, this inspection focused on multiple critical components across the line, including immersion rolls, bridle and steering rolls, squeeze rolls, and furnace jackets. The objective was to restore geometric accuracy, improve strip movement, and enhance long-term equipment performance.
Introduction
Conducted from 07 April 2026 to 12 April 2026, this inspection focused on multiple critical components across the line, including immersion rolls, bridle and steering rolls, squeeze rolls, and furnace jackets. The objective was to restore geometric accuracy, improve strip movement, and enhance long-term equipment performance.
Project Overview
Client Location: JSL Kalinganagar – Combo Line
Inspection Period: 07-04-2026 to 12-04-2026
Scope of Inspection
Immersion Rolls (Pickling Line)
Bridle Roll & Steering Roll (STR 12 Down)
Bottom Squeeze Rolls
Furnace Jackets (5, 6, 7)
Steering Roll (STR 16)
This detailed dimensional inspection was aimed at identifying alignment deviations and restoring the line to near-design geometry.
Project Overview
Client Location: JSL Kalinganagar – Combo Line
Inspection Period: 07-04-2026 to 12-04-2026
Scope of Inspection
Immersion Rolls (Pickling Line)
Bridle Roll & Steering Roll (STR 12 Down)
Bottom Squeeze Rolls
Furnace Jackets (5, 6, 7)
Steering Roll (STR 16)
This detailed dimensional inspection was aimed at identifying alignment deviations and restoring the line to near-design geometry.
Immersion Roll Alignment – Pickling Line
The immersion rolls were inspected for both horizontal (X-axis) and vertical (Z-axis) deviations.
Key Observations
The majority of rolls showed minor deviations within ±0.5 mm in both directions. A few rolls, including MA3 IR1, MA2 IR4, and MA2 IR2, showed slightly higher deviation, but all remained within acceptable operating tolerances.
Engineering Assessment
The overall alignment condition was found to be stable and well-maintained, with no critical misalignment affecting strip flow or process continuity.
Immersion Roll Alignment – Pickling Line
The immersion rolls were inspected for both horizontal (X-axis) and vertical (Z-axis) deviations.
Key Observations
The majority of rolls showed minor deviations within ±0.5 mm in both directions. A few rolls, including MA3 IR1, MA2 IR4, and MA2 IR2, showed slightly higher deviation, but all remained within acceptable operating tolerances.
Engineering Assessment
The overall alignment condition was found to be stable and well-maintained, with no critical misalignment affecting strip flow or process continuity.
Bridle Roll & STR 12 Down Alignment
This section required immediate correction due to significant vertical misalignment.
Initial Condition
The STR 12 Down roll showed major deviation, with:
X-axis deviation: up to -0.90 mm
Z-axis deviation: up to -3.92 mm
This represented a critical vertical offset.
After Correction
Post-alignment readings showed major improvement:
X-axis deviation: -0.48 mm
Z-axis deviation: -0.31 mm
Engineering Assessment
Approximately 90% correction was achieved in the Z-axis, successfully restoring alignment within acceptable tolerance limits. The Bridle Roll was retained as the master reference axis, ensuring alignment consistency.
Bridle Roll & STR 12 Down Alignment
This section required immediate correction due to significant vertical misalignment.
Initial Condition
The STR 12 Down roll showed major deviation, with:
X-axis deviation: up to -0.90 mm
Z-axis deviation: up to -3.92 mm
This represented a critical vertical offset.
After Correction
Post-alignment readings showed major improvement:
X-axis deviation: -0.48 mm
Z-axis deviation: -0.31 mm
Engineering Assessment
Approximately 90% correction was achieved in the Z-axis, successfully restoring alignment within acceptable tolerance limits. The Bridle Roll was retained as the master reference axis, ensuring alignment consistency.
Bottom Squeeze Roll Alignment
This was one of the most critical sections of the inspection due to high initial deviation levels.
Initial Condition
Significant misalignment was observed:
SQ Roll 16: X deviation up to -6.20 mm
SQ Roll 17: Z deviation up to +9.40 mm
SQ Roll 19: X deviation up to -6.79 mm
Final Condition
After corrective alignment:
X-axis deviation: within ±0.6 mm
Z-axis deviation: approximately ±1 mm
SQ Roll 17 was disengaged and reset to restore proper geometry.
Engineering Assessment
A substantial alignment correction was successfully completed, bringing the system from a highly misaligned condition back to near-design configuration.
Bottom Squeeze Roll Alignment
This was one of the most critical sections of the inspection due to high initial deviation levels.
Initial Condition
Significant misalignment was observed:
SQ Roll 16: X deviation up to -6.20 mm
SQ Roll 17: Z deviation up to +9.40 mm
SQ Roll 19: X deviation up to -6.79 mm
Final Condition
After corrective alignment:
X-axis deviation: within ±0.6 mm
Z-axis deviation: approximately ±1 mm
SQ Roll 17 was disengaged and reset to restore proper geometry.
Engineering Assessment
A substantial alignment correction was successfully completed, bringing the system from a highly misaligned condition back to near-design configuration.
Furnace Jacket Alignment (5, 6, 7)
The furnace jackets were assessed using Jacket 6 as the master axis.
Observations
Minor deviations were recorded:
Jacket 5: approximately -1.02 mm (X), -0.25 mm (Z)
Jacket 7: approximately -1.08 mm (X), -1.10 mm (Z)
Engineering Assessment
The deviations remain within manageable limits. Fine tuning is recommended to improve thermal uniformity and strip tracking performance.
Furnace Jacket Alignment (5, 6, 7)
The furnace jackets were assessed using Jacket 6 as the master axis.
Observations
Minor deviations were recorded:
Jacket 5: approximately -1.02 mm (X), -0.25 mm (Z)
Jacket 7: approximately -1.08 mm (X), -1.10 mm (Z)
Engineering Assessment
The deviations remain within manageable limits. Fine tuning is recommended to improve thermal uniformity and strip tracking performance.
Overall Project Outcome
This dimensional inspection and alignment activity delivered significant performance improvements across the Combo Line.
Key Outcomes
Critical misalignments in squeeze rolls and STR 12 Down successfully corrected
Final alignment of all major rolls brought within tolerance limits
Master reference axes effectively used for systematic alignment consistency
Overall line geometry optimized for stable operation
This will directly improve:
Strip tracking
Surface quality
Equipment life
Reduced mechanical stress and vibration risk
Overall Project Outcome
This dimensional inspection and alignment activity delivered significant performance improvements across the Combo Line.
Key Outcomes
Critical misalignments in squeeze rolls and STR 12 Down successfully corrected
Final alignment of all major rolls brought within tolerance limits
Master reference axes effectively used for systematic alignment consistency
Overall line geometry optimized for stable operation
This will directly improve:
Strip tracking
Surface quality
Equipment life
Reduced mechanical stress and vibration risk
