50th SMOC- SAIL Ranchi

Challenges in Maintenance during

Converter Relining period
Steel Melt Shop-1 Date-16th Feb to 17th Feb
Venue-SAIL , RANCHI

Presented by:-
Mr. Sadanand Naik
 Presentation Flow:-

1 Brief Introduction to JSW Steel Process flow

2 Steel Melt Shop-1 Facility

33 Mechanical Availability

4 Road Map and Challenges to reduce Campaign Repair

55 Roadmap and Challenges for Improvement

66 Improvement & Modification

7 Summary
 1 Brief Introduction to JSW Steel Process flow

Coking coal Fluxes

Non - coking coal Iron ore

Raw Material Handling System

Lump ore

Beneficiation Coke oven

Pelletization
Sintering

HMPT

Billet Caster Wire Rod / Re Bar Mill

Corex CRM
Blast furnace LHF, RH HSM
Converter Slab Caster
Iron Making Process Steel Making Process MILLS
 Presentation Flow:-

1 Brief Introduction to JSW Steel Process flow

2 Steel Melt Shop-1 Facility

33 Mechanical Availability

4 Road Map and Challenges to reduce Campaign Repair

55 Roadmap and Challenges for Improvement

66 Improvement & Modification

7 Summary
 2 Steel Melt Shop-1 Facility

Hot Metal Pre-Treatment Reladling Primary Secondary Steel Making

Caster
station Steel Making
Hot Metal Pouring
station area LHF-1

ARS
CASTER-1
CONV-1
HMDS-1 LHF-2
Down
Stream–
Slabs
HMPT-1 CASTER-2 /Mills
RH

HMDS-2
KR-1 CONV-2
LHF-3
CASTER-3

HMPT-2

HMDS-3
CASTER-4
KR-2 CONV-3
 Presentation Flow:-

1 Brief Introduction to JSW Steel Process flow

2 Steel Melt Shop-1 Facility

3 Mechanical Availability

4 Road Map and Challenges to reduce Campaign Repair

55 Roadmap and Challenges for Improvement

66 Improvement & Modification

7 Summary
3 Mechanical Availability
3 Mechanical Availability
 Presentation Flow:-

1 Brief Introduction to JSW Steel Process flow

2 Steel Melt Shop-1 Facility

3 Mechanical Availability

4 Road Map and Challenges to reduce Campaign Repair

55 Roadmap and Challenges for Improvement

66 Improvement & Modification

7 Summary
 4 Road Map and Challenges to reduce Campaign Repair
S . No ACTIVITY 2007(HRS) 2011(HRS) 2015(hrs)
1 Mouth Jam Lancing/Converter Washing 4 2 2
2 Emptying BMCS 5 3 2
3 HTC Cleaning 6 7 8
4 Tap Hole Plate Removal 1.5 Parallel with De-bricking Parallel with De-bricking
5 De-bricking(Inc. Tap hole Refractory) 10 8 6
6 HTC OUT 12 8 6
7 Maintenance of Horizontal & Vertical Tendon, Radiation Shield 12 0 0

8 Lip Ring 12 5 6
9 Tap Hole Plate & Block Fixing , Tap hole Lining 15 10 4
10 Relining Car IN , Load Testing 2 4.5 4
11 Relining 72 62.3 54
11.1 Bottom Layer 20 9 8
11.2 Bottom Cone Ramming 4 9 8
11.3 Bottom Conical Lining 16 10 8
11.4 Safety 0 8 7
11.5 Barrel Lining 16 10 9
11.6 Tap Hole Area Lining 6 8 7
11.7 Top Cone Lining 10 8.3 7
12 Relining Car OUT & Converter Covering 2 1 1
13 Hood Transfer Car IN 8 7 6.5(Inc. Cold Trail)
14 Cold trails 6 0 0
15 Pre-Heating 5 5 5
TOTAL (DAYS) 172.5(7.18DAYS) 122.8(5.11days) 104.5(4.35days)
4 Road Map and Challenges to reduce Campaign Repair
 Pareto Analysis for 2007 Campaign Activities :-
94.19 96.64 97.86 99.09 100
160 91.13
88.08
VITAL FEW 84.41 90
140 80.74
77.07
USEFUL MANY 80
72.17
120 66.06 70

CUMM % DURATION
58.72
100
DURATION

60
51.38

80 44.04 50

40
60 72
30
40
20

20 14 12 12 10 10
8 6 6 6 5 5 4 2 2 1.5
0 0

Duration Cumm % Duration

ACTIVITY
 4 Road Map and Challenges to Reduce Campaign Repair

S No. CHALLENGES FROM(HRS) TO (HRS)

1 HTC OUT 12 6
2 Relining 72 54

3 Maintenance of Vertical , 12 0
Horizontal Tendon
4 Mouth Ring Segment 12 6
Replacement
5 De-bricking(including tap 10 6
hole)
6 Hood Transfer Car 14 7
IN(including Testing)
7 HTC Cleaning 6 8
8 Emptying BMCS 5 1
9 De-dusting Hood Removal & 6 2
fixing
10 Converter Mouth Cover fixing 2 1
& removal
 4 Road Map and Challenges to Reduce Campaign Repair
Challenges Plan Do Check Act Illustration
HTC OUT Eliminate the Wheel mounted Upper stack Wheel mounted
upper stack trolley provided maintenance trolley provided
maintenance for upper stack not required for upper stack
during HTC out. maintenance during HTC maintenance.
out.

Maintenance of Vertical Elimination of New Lamella Maintenance New Lamella

& Horizontal Tendon vertical & suspension time reduced. suspension
horizontal system system
Tendons. introduced. introduced.

Mouth Ring Segment Modified Mobile crane & Safe and time Mobile crane &
Replacement method to be standard platform saving job. standard
adopted. used in 9mts platform used in
instead of 0mtr. 9mts instead of
0mtr
 4 Road Map and Challenges to Reduce Campaign Repair
Challenges Plan Do Check Act Illustration

Reducing the duration of 1.
Refractory lining
1. Human fatigue
2. Handling procedure 2.
Strategy to reduce the
Human fatigue while working
at confined space
Redesign the Refractory
handling procedure
1. Introduce a local air 1. Provided Successfully
conditioning system, 2. Effective implemented. The
inside the converter utilization of the working personnel
2. Segregation of the space. carryout
pallets before hand as uninterrupted
per the sequence of refractory work
installation. mainly due to the
3. Increase the speed of improvement in the
the pallet handling hoist working condition.

De-bricking(including tap Reduction in mouth jam by Improved blowing practices Installed slag less Successfully
hole) adopting some new technology using Slag less lance post lance technology in implemented the
and practices. combustion method. all converter. technology.

Hood Transfer Car Eliminate the upper stack Wheel mounted trolley Upper stack Wheel mounted
IN(including water maintenance during HTC IN. provided for upper stack maintenance not trolley provided for
Testing) maintenance required during upper stack
HTC IN. maintenance

Slag Skirt Approach Eliminating manually fixing New fabricated stand Safe for work New fabricated
scaffolding. having easy removal & condition and less stand having easy
fixing. time required for removal & fixing.
fixing & removing
 4 Road Map and Challenges to Reduce Campaign Repair
Challenges Plan Do Check Act Illustration
Emptying BMCS Planned schedule Maintaining low Ensuring Maintaining low
for Campaign repair material level in minimum level of material level in
BMCS bunker material in BMCS BMCS bunker
before campaign bunker. before
campaign

De-dusting Hood Eliminated usage of Introducing de- Safe for working , Introducing new
Removal & fixing sling and chain block dusting hood less manual design of tackle
for replacement. handling tackle. intervention & in de-dusting
reduced crane hood.
involvement.

Converter Mouth Elimination of New fabrication Safe for working , New fabrication
Cover fixing & manual intervention cover introduced. covered using cover
removal and reducing time. tackle less introduced.
manual
intervention
Pareto Analysis for 2018 Campaign Activities:-
 Presentation Flow:-

1 Brief Introduction to JSW Steel Process flow

2 Steel Melt Shop-1 Facility

3 Mechanical Availability

4 Road Map and challenges to reduce Campaign Repair.

55 Roadmap and Challenges for Improvement

66 Improvement & Modification

7 Summary
 6 Roadmap and Challenges for Improvement

S No. CHALLENGES FROM(HRS) TARGET (HRS)

1 HTC car IN (including testing) 7 4

2 HTC OUT 6 5.5

3 HTC Cleaning 8 2

4 Mouth Ring Segment 6 3

Replacement

5 De-bricking(Including tap hole 6 5

refractory)
 6 Roadmap and Challenges for Improvement

CHALLENGES ACTION PLAN

HTC car IN (including testing) Mechanised system for fasteners tightening and
drive Up-gradation of HTC.

HTC OUT Mechanised system for fasteners removal and drive

up-gradation of HTC

HTC Cleaning Dust deposition can be avoided by modifying HTC

platforms.

Lip Ring Replacement Mechanised system for handling and replacement of

Lip Ring.

De-bricking(Including tap hole Complete washing without metal jam.

refractory)
 Presentation Flow:-

1 Brief Introduction to JSW Steel Process flow

2 Steel Melt Shop-1 Facility

3 Mechanical Availability

4 Road Map and challenges to reduce Campaign Repair.

55 Road Map and challenges for Improvement.

66 Improvement & Modification

7 Summary
 6 Improvement & Modification

S . No IMPROVEMENT ILLUSTRATION ADVANTAGES

1. Installation of  Belt life increased.

magnetic  Availability of Conveyor increased
separation in
BMCS path.

2 Re-circulation Better access from bottom for cleaning

tank manhole and disposal of sludge
provision at the Reduces the risk of a confined space job
bottom of the also reduced the job duration
tank.
 6 Improvement & Modification

S . No IMPROVEMENT ILLUSTRATION ADVANTAGES

3. Scrubber +38mtr  To clean the gas cleaning area from outside.

gas channel  Minimize the risk of working in confined space.
cleaning door  Reduced gas channel cleaning duration.

4. Access to flare  Easy and safe approach.

stack burners at Reduced time
+83mtr height.
 6 Improvement & Modification

S. IMPROVEMEN ILLUSTRATION ADVANTAGES

No T
5. Gas holder  Reduced nitrogen purging in gas holder by
Nitrogen 5hrs.
purging.  Reduced gas holder shutdown during
normalizing.

 Safe and easy approach for work.

6. Slag Skirt
Reduced time for fixing and removal.
approach
platform.
 6 Improvement & Modification

S . No IMPROVEMENT ILLUSTRATION ADVANTAGES

7. Sub-lance facility  Tap to Tap time reduced by 4min.

 Reduced usage of tilt drive and power
consumption.
 Safe for online temperature and sampling.

Sub-lance

8. Rapid Lance  Reduced lance changing duration from 2.5hrs

modification to 1.0hrs.
 Presentation Flow:-

1 Brief Introduction to JSW Steel Process flow

2 Steel Melt Shop-1 Facility

3 Mechanical Availability

4 Road Map and challenges to reduce Campaign Repair.

55 Road Map and challenges for Improvement.

66 Improvement & Modification

7 Summary
 7 Summary

 We could reduce the campaign, mainly by avoiding the unsafe practices, designing
tackles and parallel activities.

 Refractory total lining duration reduced 18hrs per campaign.

 Mechanical maintenance duration reduced 42hrs per campaign.

 Combining both refractory and mechanical maintenance duration we reduced total

60hrs.

 We are aiming a target of 4 days in the coming campaigns.

 Improving the primary and secondary de-dusting system would further reduce our
campaign duration.

 We completed the campaign including lower stack replacement in 6days 4hrs.