Training overview

Ravi SHANKAR
Executive Trainee
Employee No.: A1578
Department: SMS(MECH)
 BSY
CCS CCD 1
3 2

DF Bay

TP Bay
RH LF LF

LP bay

Ramp
Hot Metal Area
Mixer TLC

Scrap Yard

Slag Yard

Lay out of Steel Melt Shop

DIFFERENT UNITS IN SMS
1.HOT METAL AREA
2.CONVERTOR BAY
3.LANCE SYSTEM
4.MATERIAL HANDLING SYSTEM
5.SCRAP YARD
6.SLAG YARD
7.GAS CLEANING PLANT
8.LADDLE HEAT FURNACE
lance Drive
 Rope Drive.
 AC Motor.
 Emergency Drive
Lance
 It is used to blow oxygen in the converter while blowing and Nitrogen while slag
splashing.

Construction:
 Three concentric Pipes:
- Inner Pipe – Oxygen (219 mm, 8.1 mm)
- Middle Pipe – Water Inlet (273 mm, 7.2 mm)
- Outer Pipe – Water Outlet (323 mm, 7.9 mm)
 Copper Tip (6 nozzles, 17.5°, sliding fitting)
 Sliding fit takes care of expansion.
Technical Data
 No of lance trolleys - 1
 No of hoists - 2
 Lance diameter - 324 mm
 Lance tip max height above ground level - 28690 mm
 Hoisting travel - 19440 mm
 Ratio of measurement gear (for rotary type LS) - 5:1
 Ratio of measurement gear (for absolute encoder) - 1:1
 Lifting speed range – 0…31mtr/min
 Emergency lift speed – 6.13 mtr/min
 Motor full load rated speed – 1475 rpm
 Positioning accuracy - +_ 10 mm
 Technical Data(contd.)
 No of electric motor – 04
 Motor rating hoist - 75kw
 Nominal rope load – 54 KN
 Maximum rope load – 108 KN
 Maximum required torque at motor – 437 Nm
 Motor full load rated torque - 485 Nm
 Lance interlocks and drives
 oxygen pressure maintained at 16-18 bar inlet (18 -20 bar shut off)
 water pressure maintained 11 bar at inlet.
 flow rate of water 185m3/hr.
 convertor should be in upright position.
 pneumatic system for lance drive and convertor tilt drive should be in healthy state.
 N2 pressure should be maintained.
 lance inlet outlet water temp.
 change in temp between inlet and outlet water temp in range of 5-8’c.
 Change in flow rate of water should be 2-5% between inlet and outlet.
 rope tension should be in the range 40<t<150KN
 GTLD (guide travel locking device) should be healthy.
 Encoder position system should be working to get the lance positions at different height.
 temp of lance drive motor is also maintained.
 OPERATING LANCE POSITIONS
 The rotary cam positions are marked by the capital letter R and one digit number,
which increments from the top -down to ‘0’- position.
 Top end buffer position - H1 (E1)
 Pneumatic limit switch position - H2 (E2)
 Upper emergency end position - H3 (E3, L1)
 Lance fixing clamp position - H4 (E4, L4/L5)
 Lance top end position - H5 (E5)
 Home and synchronization position - H6 (E6, L3)
 Lance synchronization position - H7 (E7 ,L3)
 Speed change position - H8 (E8)
 Lance converter interlocking position - H09 (E09, R1,L6)
 Open Oxygen valve position - H10 (E10,R2,R5)
 Oxygen close/speed change 2 position - H11 (E11,R3+6)
 Blowing position - H12 (E12)
 lance hoist drive system
 Each hoist drive motor is connected to a separate inverter, which is connected to the
converter PLC.
 Each lance can be lifted, lowered or stopped.
 The lance is lifted and lowered by an AC – motor which is fed by a VVVF unit.
 The lance can be lowered or lifted in slow, fast or variable speed. The speed reference
for the lance drive is routed through the PLC which gives two digital commands for
drive run (lowering or lifting) and an analogue signal (4-20 mA) proportional to speed

set point .
 The reference goes to the variable voltage variable frequency AC drive
board and the current builds up in the hoist motor. Once sufficient
current has been built up in the motors, the brakes open (brake opening
is completely controlled by AC drive board)
 In auto or manual mode the maximum of the lance speed depends on the
lance position. In local mode only slow speed operation is possible.
 The PLC has to send an analogue signal ramp to the drive inverter (as
standard ramp for speed change).
 In case of power failure or disturbance of the electrical drive system the
emergency pneumatic lifting of the lance takes place, if the lance was
positioned inside the converter or lance dome.
 Lance lifting signal sets a signal for the lance dome sealing valve for
nitrogen protection blowing, which is operated by the off gas system, if
the lance target position is outside the dome
SUSPENSION
The carriage is suspended by using two wire ropes of opposite lays. The ropes pass over two pulleys and
are wound over a rope drum. Maintenance required by rope is very less and also less failure rate.
Carriage:
Carriage is a rectangular platform with 8 rollers Balancer

on which it moves up and down in the guide. It is

connected with the drive through two wire ropes.
At the connection point, there is a balancer which
distributes the load on both the ropes even if
there is slackness in one rope or a small difference Rollers
in length is present

Lance
Seating
 Tension Measurement and Variation
Tension is measured at the pulleys . This gives an idea of slag/steel jam buildup over lance.
With the start of heat, tension in the rope decreases due to-
Thrust due to impingement of Oxygen on the metal at supersonic speed.
The dip in the tension is more if the dome plate touches the thimble gate.
Now as, the heat proceeds, slag/steel jam starts to stick on the lance. When LD gas production is maximum,
the quantity of the slag/steel jam also increases. Hence, increase in tension is faster .
When heat ends, the lance lifts. Thrust gets removed as well as dome plate too is on the lance.
Hence, there is a steep increase in tension
Slackness and Overload Protection
 Tension in ropes is measured at the pulleys in the lance system. This gives an idea of
slag/steel jam buildup over lance (in normal condition).

 Slackness: While lowering, lance is stuck in thimble gate. Protection is set at 40 kN. Lance
lifts from the seat and impact load on couplings.
 Overload:
 Lance is stuck inside thimble gate while lifting
 Jam build up is more.
So, coupling bolts may shear. Hence, Protection is set at 115 kN
Lance system features

 Elbows are mounted on extended platform. So, the load goes on

carriage.

 Dome Plate
Thimble gate is purged by Nitrogen in two layers to prevent gases
generated from coming out.
There is a dome plate of 1 m diameter on the lance at 10 m from
the lance tip. It has taper at the ends to give it a self centering
property and prevent one side loading of the carriage
 Latching Device-The carriage has two
latches at the back. These latches blocks
the downward movement of the carriage
when the carriage is above the upper safety Balancer
position, which is disengaged using a
manually operated spring return hinged
lever.
 Nozzle-This lance has 6 nozzles at an angle
of 17.5°. This has increased the Oxygen
flow rate to 480 Nm3/h , blowing time has
been reduced .
Rollers

Lance
Seating
Brakes

Electrohydraulic Thruster Brakes (AC)

 A brake drum is mounted on the motor shaft
 Dust Proof double seal present.
 Soft and smooth operation.
 Motor is stopped through regenerative braking.
 When the motor reaches 10% of its speed, brakes are
closed and they hold the shaft in that position .
Lance Exchange Mechanism

 Guide is composed of two

sections: Fixed guide and
movable guide.
 Lance drive and movable guide
are mounted on a car. The car
has vertical rollers with track to
prevent any Misalignment.
 To arrest the relative movement
of the movable guide and fixed
guide, there is a device called
GTLD (Guide Travel Locking
Device). This prevents the
misalignment of guide cages.
 Lance Centering
 In case of offset while centering of oxygen lance in the thimble
The off set is removed by fixing the water hose at the supply end.

The packing or plates are adjusted at the joined end

to remove any offset of the lance in the thimble
Regular Repair works
 Lance Changing:
Lance is changed after every 10-12 heats. This life can be increases when practice
of online Jam cutting is followed. Major reasons for changing lance are:
 Steel/Slag jam over lance.
 Lance tip gets punctured.
 Nozzles in the tip gets eroded.
 Lance is bent.
 Lance Repair:
 Lance tip changing
 Pipe bend
 Gasket damage
 Puncture in lance due to jam cutting
 Hose Repair and changing
BLOW START/STOP CONDITIONS
Lance change procedure
S .No Activity description Time Taken(minutes)

1 The three clamps of the oxygen and water line are de-clamped one 12-15
after the other.
The fresh and defect free lance is either placed in the jam cutting
stand or the side stand depending on the availability of space
2 The jam lance is shifted to the jam cutting stand started. 15-17
Crane released from jam cutting stand.
Crane carrying the fresh lance either from the jam cutting stand or
the side stand.
Fresh lance is carried by the lance to the lance changing position

3 After placement of the fresh lance clamping process started. 20-25

Clamping process and alignment over and the crane is unhooked
from the lance hook. Centering process complete from the local
control box
 Check list for inspection of lance system
1 Whether pneumatic valves are in open conditions or not.
2 Any nitrogen leakage are observed
3 Condition of couplings of motor, pneumatic motor and rope drum
4 Brake condition
5 Conditions of rope and rope fixing bolts on drum
6 Condition of balancer
7 Any other observations.

Pneumatic drive

1 Oil level in pneumatic motor

2 Oil level in emergency gear box
3 Leakages in pneumatic system
4 Pressure at outlet of buffer vessel
5 Pressure after PRV
Tilt drive
1 Oil level in gear box
2 Oil level in emergency gear box
3 Oil level in pneumatic motor
4 Coupling conditions
5 Abnormal sound and vibrations
6 Foundation bolts and torque arm(
7 Oil leaks

Pedstal bearings

1 Greasing of bearing and seals

2 Expansion reading of bearing
3 Jam over shaft
4 Any sounds from the drive and non drive end of bearing
5 Any leakage from hoses
 CAMPAIGN REPAIR JOBS
equipment Assembly description

convertor Tap hole Existing tap hole plate was removed and replaced by a new structure for
tap hole plate
convertor Brick retaining 2 no retaining plate was fixed with shell by heating and weld by 7018
plate electrode
convertor Bottom stirring Cover plate and tuyers were replaced with new tuyers and tested for
leakage.
convertor Lip plate 6 Damage and jammed lip plate were replaced with new lip plate.

convertor Tilt drive Drive lubrication oil drained and lube filters changed

convertor Oxygen lance Pneumatic system of both lance were seprated with two 3 way valve for
system both lance
convertor Oxygen lance Left lance inlet water hose was replaced with new hose
system
 HOOD SHIFTING PROCEDURE DURING CAMPAIGN
REPAIR
Before the start of hood shifting few units should be shut down
ID fan,lance,convertor tilt,bmcs .
Inspection of stack for any leakge and depressurizing the cooling system by opening the the vent of expansion
vessel at the fin fan area.
Isolation of supply and return line of cooling system and DOME SEALING N2 LINE.
Water from the system should be drained to ensure complete evacuation of water.
The different flanges of hood connected to other system should be disconnected .All hydraulic and N2 lines
should be disconnected such as
Skirt inlet and return line, hood and stack drain,N2 line for chute ,radar sensor N2 line,lance dome sealing N2
line.
The entire load of the hood is now transferred to the hydraulic jack upto 6500 psi.
Lock pins for the spring hangers to be placed with the adjustment of turn buckle which should be tight after
locking the spring hangers .
The I bolts are opened and the hood is lowered by lossening of turn buckle.
The hydarulic jacks are lowered slowly to create gap between hood and stack.
And the hood car is shifted by the wheels mounted motor of hood car.
 GAS CLEANING PLANT
 COOLING CIRCUIT
CLEANING CIRCUIT
Discharge Circuit
 Comaprison of nmdc gcp and vsp gcp units.
 The connection between the hood and the cooling stack in vsp is expansion joint I BOLTS and in nmdc is
fixed joint
 The cleaning circuit in vsp consists of a scrubber unit which consist of 2 stage purification system .Primary
and secondary and double venturi system(flap) to control the operating gas flow pressure. Where as here
we have a single stage scrubber connected to wds(water droplet seprator) cone in which the vertical
movement of cone regulates the flow. path reversal of dust laden gases takes place and water stream goes
along with the flow.
 IN NMDC there is no provision for hydraulic seal pot and bottom condensate tank instead water is drained
using the siphon system.
 No provisions of explosion flap to regulate excess pressure developed in the cooling stack due to blowing
process
 Water management issue since water is in continuous circulation but here in NMDC water is not in a loop
water once goes through the process and routed to launders for cleaning at water treatment plant.
 SLAG YARD
 Cleaning of the reservoir the submersible
pump lines
Get choked due to waste and
Dirt accumulation of drain water.

The proposal to route

The waste water of AHU to the
Reservoir to act as a source
of water for spraying in
Slag yard .
 LADLE HEAT FURNACE
 Major issue is the development of jam in
the
hood of the ladle furnace during arcing
process
causing the hood to shift down under gravity.
The structure shown is mounted on the
transfer
Car and the two ends fits in the ladle
pedestal.

Which then is used for cleaning the jam

developed
Jam on the hood.

Fits into the pedstal of car

 TESTING OF GCP PIPLINE LINE
Depending on the working fluid the test is performed

Pneumatic testing using

Dry compressed air
Nitrogen
Testing pressure is 1.1 times the working pressure for 6 hours.

Hydraulic testing
Water as medium
testing pressure is 1.5 times the working pressure for 2 hours.
TESTING PROCEDURE
First the line to be tested is identified.
The line is isolated and the entire loop is closed ,
All the tapping taken from the pipe line are also closed ,the ends are blind
A pressure relief valve is provided which is set at a pressure of lesser of 3.5 bar or 10% of test pressure.
All the manufactured and pressure tested equipment are isolated from the lop like strainer,bellows,pumps.
Pressure in the loop is incremented to 50% of test pressure and after that is incremented by 10% of test pressure
While holding the test pressure al the welded ,threaded and flanged connections will be inspected with soap
solutions for any leakage.
The loop is isolated from the source of pressurizing agent like water pump or the nitrogen cylinder.
The certificates of the dial temperature and bourdon tube pressure gauge is checked while inspecting.
In case of any leakage the loop is depressurized and the leakage is fixed.
Once the loop is ready pressure and temperature reading are taken in the interval of 30 minutes .
THANK YOU