PRELIMINARY INVESTIGATION REPORT

DC #5 SHELL PLATE LEAK

1.0

Event Date Time Heat No. A. : 05th November 2011 : 10:20 am : 5055443

DC# 5 shell plate below KT3 leak; happen during

tapping. The root cause of leakage was the bricks bad condition consequence from water leaking of panel WCP 1-9 at 15 October 2011 and loose of coupler supply water WCP 1-11 on 05 November 2011. Tap temperature high due to over arching worse the bricks condition.

B.
Date

History of Incident
Heat No.
5054917 5055097 5055204 5055338 5055377 5055405 5055413 5055422 5055432 5055433 5055438 5055443

Event
Slag penetrate below KT3 Patching with castable and gunning Panel WCP 1-9 leak F/hose cooling block KT8 leak Panel ECJ and RCP leak Tap temp 1651 C,O2 ppm 288 ppm Tap temp 1628 C,O2 ppm 556 ppm Tap temp 1630 C O2 ppm 745 ppm After hot repair Tap temp 1628 C O2 ppm 577 ppm Over shoot tap temp 1647C ladle preheater Gunning 1698kg Gunning 1528kg Coupler W/return WCP 1-11 loose Shell plate leak during tap

04.10.2011 15.10.2011 27.10.2011 29.10.2011 01.11.2011 03.11.2011 03.11.2011 03.11.2011 04.11.2011 04.11.2011 04.11.2011 05.11.2011

2.0

Preliminary Causes Based on our investigation, the leakage happens due to :1. The bricks area under KT 3 was very bad condition. The bricks heavy erosion due to effect of water leaking from WCP 1-9 at 15 October 2011 and water leaking from loose coupler WCP 111 at 05 November 2011. 2. Temperature high up to 1651oC due to overarching. Furnace operation increases the temperature for ladle parking, ladle preheater and after hot repair. The S.O.P required normal tap temperature only 1610oC and 1630 oC for ladle preheated. 3. DRI was very low quality with high silica content 3 % required furnace to use high amount of CaO 3500 per heat.

3.0

Equipment Damages i) ii) iii) iv) v) vi) Shell Plate under KT 3 Bricks area KT 3 Bottom furnace Sensor and Cable Limit switch Tapping lock post Hose cooling busbar Bottom electrode

4.0

Preventive Measure 1. To focus gunning at the high erosion bricks consistently. 2. Detail Check furnace condition once stoppage/onpeak schedule. 3. Dont delay the gunning activity schedule for safe mode. 4. Change the high erosion bricks or collapse bricks as quick as possible. 5. DR plant must plan for high quality DRI on the future consistently.

5.0

Cost Of Damages Shell Plate repair New Bricks Bottom electrode Busbar cooling hose Man Power Total Cost RM x RM x RM x RM x RM x RM x RM x RM xxxx

Bottom furnace Sensor and Cable Tapping lockpost limit switch

Prepared by, Mohd Zakaria Khamis Mohd Nasuha Abd Halim

Checked by, Mr. Abd Rahman Che Min

ATTACHMENT

KT3

KT8

Leak area

Picture 1: Shell plate leak below KT3

KT3

Picture 2: Brick condition below KT3 after incident

Picture 3: Below furnace