futnace

Charging area elements.
• No. of fixed skids = 5

• No. of movable skids = 5
• Capacity of charging grate = 34*165
• Eccentric shaft
• Disappearing stops
• Billet stopper
• PEDS
• Weighbridge
• Length measuring laser.
• Discard traverse
• Roller table
1 Copyright © 2010 Jindal Steel & Power Ltd.

Charging grate area

WALKING BEAM REHEAT FURNACE FOR BAR
MILL
• Digital furnace :- Burners doesn't fire continuously.
• Capacity :-
Cold charging :- 160 tph
Hot charging :- 190 tph
• Acceptable Product dimensions :-
Length :- 11500 to 12100 mm
Width :- 165/150
Thickness :- 165/150
• Discharging rate of reference product :- 45.90 sec.
• Residence time of product in furnace :- 72.32 minutes
• Max. discharging temp. :- 1250 ⁰c
3 Copyright © 2010 Jindal Steel & Power Ltd. contd…..
• No. of main burners :- 24
• No. of pilot burners :- 8
• Fuel used :- L.D.O or Mixed gas (Can be converted to H.F.O)
• Pilot fuel :- LPG
• No. of zones :- 6
i. Top preheating zone
ii. Bottom preheating zone
iii. Top heating zone
iv. Bottom heating zone
v. Top soaking zone
vi. Bottom soaking zone

Burners
Products to be
reheated COLD AIR
Recuperator
WASTE GAS
HOT AIR
Stack

Furnace overview

Walking beam

Lifting movement

Skids and posts

Furnace heating modes
• Heating modes
i. Heating up mode :-
a) Flow of LDO or gas pressure is low (up to 800 ⁰c ) to prevent
damages inside furnace.
b) Burners can lite up independently.
c) The applied air gas ratio is for complete furnace.
ii. Production mode :-
a) Burners always operate in pair, an interlock is used.
b) For scale strategies 1.10 is used in the soaking zone to ensure
no sticked scale, and 1.05 in all other zones.
c) Flow of fuel is not limited.

PURGE FUNCTION
• It is necessary to purge the furnace with cold air from the
combustion air fan every time the furnacestops for more than
30 minutes (shutdown furnace = safety key of LDO open or
mixed gas isclosed and pilot burners OFF).
• Done manually by operator according to time decided by
controller.
• Necessary to stop chocking of burners and cleaning of furnace.

Combustion air
• No. of C.A. fans :- 2

• Capacity of one C.A. fan :- 52900 Nm3/h .
• Pressure of one fan :- 1400 m.m.w.c.
• Exhaust air reference temp. :- 450 ⁰c
• Combustion air reference pressure :- 950 da.pa.

Combustion air circuit.

Recuperator

Combustion air pressure control
• The air pressure is measured at the general collector by a

relative pressure transmitter (PT1904) and sent to the
pressure controller (PIC1904)
• The inlet valve is controlled by the total flow requested by the
furnace corrected by the output of the pressure controller
• The controller corrects the valve position with the current
pressure and set point
• The set point is calculated from the LDO flow or the gas
pressure.

Calculation of set point .
• Set point calculation of combustion air:
• Working with LDO
– SPAir: Air Set Point (relative pressure)
– RefAirPres: reference air pressure used for orifice plate
calculation (relative pressure)
– MVTempAir: Air temperautre measurement(absolute
temperature K)
– RefTempAir: Reference air temperature used for orifice
plate calculation (absolute temperature K)
– MinRatioAG: Minimum air\LDOration zone entered by
operator (1 + excess air (%))
– RefRatioAG: Reference air\LDO ration (ratio from air and
LDO orifice plates calculation)
SP AIR = Ref. air pressure * ( MV temp. air/ ref. temp. air)

* ( min. ratio AG / Ref. ratio AG)2
• Working with mixed gas :-
• SPAir = (Spgas op2+ SPGasOp)/(Ref. gas pres. 2+ Ref. gas pres.)*
Ref. Air pres. * (MVTempAir / RefTempAir)* (MinRatioAG / RefRatioAG ) 2
where:
• SPAir = Air Set Point (relative pressure)
• SPGasOp = Operator gas Set Point, production or heating up (relative
pressure) (bar)
• RefGasPres = Reference gas pressure used for orifice plate calculation
(relative pressure) (bar)
• RefAirPres = Reference air pressure used for orifice plate calculation (relative
pressure)
• MVTempAir = Air temperature measurement (absolute temperature K)
• RefTempAir = Reference air temperature used for orifice plate calculation
(absolute temperature K)
• MinRatioAG = Minimum air/gas ratio for zone entered by operator (1 + excess
air (%))
• RefRatioAG = Reference air/gas ratio (ratio from air and gas orifice plates
calculation) (1 + excess air (%))

Dilution air control
• When working with LDO:-
• In order to protect the recuperator when the waste gases are
very hot, a dilution air control loop limits the waste gas
temperature before the recuperator by means of a cold air
injection.
• An independent fan supplies the air. Downstream of the fan
there is located a valve controlled by the regulation system.
The waste gas temperature is maintained constant modifying
the valve position.
• D.A. Fan capacity :- 8000 Nm3/h.
• Pressure :- 200 m.m.w.c.
• Set point for dilution air fan :- 790 ⁰c

Exhaust air control
• When working with mixed gas :- In order to protect the

recuperator when the combustion air is too hot, an exhaust air
control loop limits the temperature of the preheated air by
increasing the cold air flow through the recuperator.
• Set point for exhaust air :- 450 ⁰c.

Furnace pressure control
• The furnace pressure is measured at the furnace discharging
side by means of a differential pressure transmitter (PT 1900)
and sent to the pressure controller (PIC 1900).
• The pressure regulation valve (damper) is controlled by the
total air flow introduced in the waste gas duct corrected by the
pressure controller output.
• The controller corrects the damper position taking into account
the current pressure and set point.
• The pressure set point is accessible in Operator mode.
• An alarm displays in case of furnace high pressure (PAH 1900).
After a delay time (60 s), if the high-pressure alarm still exists,
the furnace will shut down.
• Set point for furnace pressure :- 0.5 m.m.w.c.

Air injection before damper
• In order to have a good control of the combustion air pressure
and the furnace pressure at low productions, a control loop
discharges part of the air supplied by the fans in the waste gas
duct.
• In the combustion air piping coming from the fans, upstream of
the recuperator, there is an outtake connected with the waste
gas duct upstream of the damper. In the connection pipe a
valve controlled by the regulation system is placed. The air
pressure is maintained constant modifying the valve position.
• It also protects the damper from the exhaust gases.

Control of recuperator by-pass
• In order to protect the recuperator against dew point attack
when the cold side tubes temperature is very low, a by-pass air
control lop limits the cold side tubes temperature by-passing
some of the combustion air.
• A by-pass pipe connects the cold air and the hot air. In this pipe
a valve controlled by the regulation system is placed. If
necessary some other valves are placed in the recuperator inlet
pipes. The temperature of the tubes is maintained over the
limit modifying the valves position.
• Set point for recuperator by-pass :- 250 ⁰c.

C.A. FANS

Damper and combustion air circuit

C.A. fans outlet

PILOT IGNITION
• No. of pilot burners :- 8

• Present in bottom soaking zone.
• Can be started after purge within delay of 30 min.
• Acts as a lighter for the main burners and fuel.
• Pilot line consists of one solenoid valve, one burner control unit
(to start and sense the burner firing), safety key, pressure
switches and control valves.
• Air is needed as the combustion agent.
• Flow of LPG and air is controlled manually.

Pilot line overview

Safety key operating conditions
• Comprises of two shut of valves.
• No failure of low gas pressure before safety key
• No failure of low pilot gas pressure after safety key (after delay
time once open the safety
• key)
• No failure of high pilot gas pressure after safety key
• No failure of pilot air pressure
• End of purge or temperature in zone 6 < 800 ºC. This purge will
be valid during 30 minutes.
• There is no high pressure in furnace for more than 60 s
• There is no heating emergency stop

Pilot Burner

L.P.G substation

LDO IGNITION
• No. of Main burners :- 24
• Present in each zone :- 4
• During heating mode acts independently and in production mode
fires in pairs.
• Air is used as combustion agent, and for atomizing.
• Pressure needed :- 6-7 bar.
• Flow of LDO is controlled manually.
• Firing order of burners is :-
12 – 7 – 4 – 11 – 8 – 3 – 10– 5 – 2 – 9 – 6 – 1

LDO OVERVIEW

SAFETY KEY OPERATING CONDITIONS
• No pressure failure of instrument air (compressed air) and atomizing air
• No pressure failure of cooling water (timed)
• No low pressure failure of LDO PSL (1903A and PSL 1903B)
• No pressure failure of combustion air (PSL 1904A and PSL 104B)
• There is no high furnace pressure for more than 60 s
• There is no very high temperature before recuperator for more than 120 s
• Zone temperature > 800°C, or Pilots ON for zone 6, or LDO manual valves of
zones 1 to 5
• closed
• Purge finished
• LDO is selected for operation
• Mixed gas safety key is closed

LDO CIRCUIT

Burners overview

LDO BURNER

Diffuser block

Mixed gas ignition.
• No. of Main burners :- 24
• Present in each zone :- 4
• During heating mode acts independently and in
production mode fires in pairs.
• Air is used as combustion agent, and for atomizing.
• Pressure set point :- 450 da.pa.
• Flow of mixed gas is controlled by automatic shut off
valves.
• Firing order of burners is :-
12 – 7 – 4 – 11 – 8 – 3 – 10– 5 – 2 – 9 – 6 – 1

Mixed gas overview

Safety key operating conditions
• No pressure failure of instrument air (compressed air)
• No pressure failure of cooling water (timed)
• No low pressure failure of gas before safety key
• No pressure failure of combustion air
• No low pressure failure of gas after safety key (after a time delay when safety
key open)
• No high pressure failure of gas after safety key There is no high furnace
pressure for more than 60 s
• There is no very high temperature before recuperator for more than 120 s
• Zone temperature > 800°C, or Pilots ON for zone 6, or mixed gas manual
valves of zones 1 to 5 closed
• Purge finished
• Mixed gas is selected for operation
• LDO safety key is open and recirculation pump is stopped

Chapter -2 (d)
Heating control
Temperature control
• All zones are equipped with 2 thermocouples either mounted
on roof or sidewalls.
• The very high zone temperatures for the zones are 1350, 1300,
1200 for soaking, heating, preheating zones respectively, temp.
higher than these can cause zone shutdown for the particular
zone.
• Temperature set point is adjusted by the operator.
• The temperature controller than adjusts the heat demand for
the zone according to that.

Pulse firing control of burners
• The burners are ON or OFF depending on the heat demand.
During a cycle a burner is ON during the first period and OFF
the rest of the time. The time interval between two burner
ignitions is called “CYCLE TIME” (CT). The burner time "ON" is
called “WORKING TIME“ (WT).
• The CT is the same one for all burners, however the WT is
calculated for each burner row in the zone.
• Cycle time: 60 s (adjustable) “CT”
• Calculation of working time (WT)
If Hd(%) =10 to 90 %: WT = Hd(%) x CT / 100 = Hd(%) x 60” / 100
where:
• WT = Working time
• Hd = Heat demand
• CT = Cycle time
Copyright © 2010 Jindal Steel & Power Ltd.

46
cont…
• Compressed air is used for two purposes :-
a. For instruments
b. For atomizing of LDO.
• Pressure :- 6-7 bar.

Compressed air

Hydraulic overview
• Conditioning pumps :- 2 (one stand by and one working).
• Main pumps :- 4 (one standby and three working)
• Working pressure :- 160 bar.
• No. of valve stands :- 5
• No. of lifting cylinders for walking beam :- 4
• No. of transfer cylinders for walking beam :- 1
• No. of lifting cylinders for kick off :- 2
• No. of transfer cylinders for kick off :- 2
• No. of cylinders for alignment pusher :- 2

Hydraulic Powerpack overview

Charging area

Charging area functions
• Billet length measurement.
• Billet charging inside furnace.
• Billet alignment inside furnace.
• Positioning of billet to a reference position.

Charging elements.
•
Charging door Stopper
Alignment pusher Camera

Charging elements
•
Charging roller Laser

Walking beam

Walking beam elements
Lifting valve stand Lifting cylinder
Transfer valve stand Transfer cylinder

Discharging area

Discharging elements
Discharging door Discharging valve stand
Discharging roller and kickoff Discharging camera

TV. cameras
• There are two camera video systems installed in the furnace to
see the inside of the furnace.
• They are located one at the charging side and the other at the
discharging side.
• With this systems, the operator can control the position of the
product before manual operation.
• The TV monitors are located in the furnace control room.
• Each camera system is cooled by water and air supplied by a
small fan.
• The glass protecting the camera from the furnace is cleaned by
the air supplied by the fan. In case of fan failure the air is
supplied by the fan is replaced by compressed air.

Greasing system
• There is one centralised greasing system installed for the
furnace.
• This system is not controlled by the PLC. It is controlled from
one local control box.
• No. of greasing pumps :- 2 (one operating one standby)
• Time for greasing of whole system :- 12 minutes.
• However the timing can be changed with respect to need of
system.
• As soon as any point in the system gets pressurized the pump
stops
• Time interval between successive greasing :- 2 hrs.
• Grease pressure :- 110 bar

Cooling water overview

Cooling water in charging side.(ICW)

Cooling water in discharging side(ICW).

Cooling of kick off

Cooling of skids (ICW)

Cooling water through troughs (DCW)

Furnace efficiency
• Direct efficiency =Heat output in Kcal/Heat input in Kcal.
• Heat output = M*S* (T2-T1)
• Where M= mass of steel heated = 22411.312 MT= 22411312 kg
S = sp. Heat of steel = 0.12
T2 = final temp. of steel = 1100
T1 = initial temp. of steel = 30
• Heat output = 22411312*0.12*1100 = 2958293184 Kcal
• Avg. kcal/kg = 420
• Heat input = 22411312*420 = 9412751040 kcal
• Direct efficiency = heat output/heat input = 31.42%

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Charging area elements.

• No. of fixed skids = 5

1 Copyright © 2010 Jindal Steel & Power Ltd.

2 Copyright © 2010 Jindal Steel & Power Ltd.

4 Copyright © 2010 Jindal Steel & Power Ltd.

5 Copyright © 2010 Jindal Steel & Power Ltd.

6 Copyright © 2010 Jindal Steel & Power Ltd.

7 Copyright © 2010 Jindal Steel & Power Ltd.

8 Copyright © 2010 Jindal Steel & Power Ltd.

9 Copyright © 2010 Jindal Steel & Power Ltd.

13 Copyright © 2010 Jindal Steel & Power Ltd.

14 Copyright © 2010 Jindal Steel & Power Ltd.

• No. of C.A. fans :- 2

15 Copyright © 2010 Jindal Steel & Power Ltd.

16 Copyright © 2010 Jindal Steel & Power Ltd.

17 Copyright © 2010 Jindal Steel & Power Ltd.

• The air pressure is measured at the general collector by a

18 Copyright © 2010 Jindal Steel & Power Ltd.

SP AIR = Ref. air pressure * ( MV temp. air/ ref. temp. air)

20 Copyright © 2010 Jindal Steel & Power Ltd.

21 Copyright © 2010 Jindal Steel & Power Ltd.

• When working with mixed gas :- In order to protect the

22 Copyright © 2010 Jindal Steel & Power Ltd.

23 Copyright © 2010 Jindal Steel & Power Ltd.

24 Copyright © 2010 Jindal Steel & Power Ltd.

25 Copyright © 2010 Jindal Steel & Power Ltd.

26 Copyright © 2010 Jindal Steel & Power Ltd.

27 Copyright © 2010 Jindal Steel & Power Ltd.

28 Copyright © 2010 Jindal Steel & Power Ltd.

• No. of pilot burners :- 8

29 Copyright © 2010 Jindal Steel & Power Ltd.

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31 Copyright © 2010 Jindal Steel & Power Ltd.

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Copyright © 2010 Jindal Steel & Power Ltd.

• Pressure :- 6-7 bar.

47 Copyright © 2010 Jindal Steel & Power Ltd.

48 Copyright © 2010 Jindal Steel & Power Ltd.

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52 Copyright © 2010 Jindal Steel & Power Ltd.

Charging door Stopper

Alignment pusher Camera

53 Copyright © 2010 Jindal Steel & Power Ltd.

Charging roller Laser

54 Copyright © 2010 Jindal Steel & Power Ltd.

55 Copyright © 2010 Jindal Steel & Power Ltd.

Lifting valve stand Lifting cylinder

Transfer valve stand Transfer cylinder

56 Copyright © 2010 Jindal Steel & Power Ltd.

57 Copyright © 2010 Jindal Steel & Power Ltd.