SAIL Rourkela Steel Plant’s Post

Modifications and Upgradations help Blast Furnace Department of SAIL, RSP improve efficiency Numerous up-gradations, enhancements, innovations and modifications have been carried out in the Blast Furnaces Department of SAIL, Rourkela Steel Plant recently, to enhance the operational efficiency, production and productivity of the Unit. Installation of a Centralized alarming system for all Hydraulics units of Blast Furnace #1 has helped in getting information at one place about different types of hydraulics failures. The efficiency of Coke belt Trolley system has been improved in lieu of Bus bars in Coke trolleys by introducing trailing cable system for Coke Trolleys 6.1 and 6.2. This has resulted in enhanced safety and ease of operation. Emergency power sources for PC-1 and Blast Furnace - 4 GCP were established, and an audio-visual alarming system was introduced for sensing high differential pressure during Coal Dust Injection at Blast Furnace - 4 CDI. Additionally, the Blast Furnace -4 CDI L1-Automation system was integrated with the main Level-1 server, and a firefighting diesel pump in Blast Furnace -4 CDI was revived. The innovations also included introducing chute jam sensors in the CDI coal yard to prevent frequent jamming and vibration sensors in Blast Furnace -4 CDI mill motor and ID fan motor for enhanced predictive maintenance. Digitalization of automation in bag filter management of CDI of Blast Furnace -4 and upgrading the PLC Allen Bradley 5/40E to Control Logix at Blast Furnace -1 INBA were also accomplished. Several modifications and replacements were executed to ensure smooth operations. These include replacing the driving disc and grinding table of CDI Mill -2, the dewatering drum sprocket in Blast Furnace -4 INBA, and the damaged portions of the torpedo ladle No. 1. New facilities, such as a mixed gas line and compressed air at LRS 2, were made functional, and a PCI lance testing arrangement was fabricated. Additionally, compressed air line laying at Blast Furnace -5 SGP South and North and various conveyor installations and replacements were completed to improve housekeeping and operational efficiency. #blastfurnace #production #Upgradation #modifications #digitalization #SAIL #RourkelaSteelPlant #steelindustry Steel Authority of India Limited

Electrode Regulation Hydraulic Cylinders in EAF:               - Introduction: The main physical principle of an electric arc furnace (EAF) is the transfer o energy from the electricity line to the furnace through heat radiation and conduction generated by an electric arc. The control of the EAF energy-transfer process is achieved by regulating the electric arc power and arc length that is acting on the position of the arc furnace electrodes and ensuring the application of a scheduled power profile. A reliable scheduled power profile is required for an efficient melting or heating operation. Components of an electrode regulation system are as follows: -         Mechanical devices – to support the electrodes (i.e. electrode arms) and to electrically connect them to the power transformer via high current flexible cables. -         Electronics and control – to compare the measurements with the required working point. -         Hydraulics – the electrode’s mechanical supporting structure is moved using hydraulic cylinders with hydraulic circuits and regulating valves. We encountered a major problem during our latest major shutdown for the electric arc furnace No. 2 in “EzzSteel El Sokhna Plant”. A hydraulic cylinder for Electrode Regulation System was leaking, the decision was made to dismantle it and overhaul inside the central hydraulic shop. After dis-assembling the cylinder, I was responsible for sketching and drawing all its components to understand how it works, try to repair this large asset. We identified the root cause of failure, issued a repair procedure, and currently we are working on the repair process. #steel #ElectrodeRegulationSystems #EAF #SteelMaking #Ezzsteel #hydraulic #Fluidpower #ElectrodeRegulation

hydraulic connector

A centrifugal pump comprises several key components that work in harmony to facilitate fluid transfer. Here's a detailed breakdown: Impeller: At the heart of the pump, the impeller is a rotating component with vanes or blades. As it spins, it imparts kinetic energy to the fluid, generating a dynamic flow within the pump. Casing: Surrounding the impeller, the casing directs the fluid flow and helps convert kinetic energy into pressure. It plays a crucial role in maintaining the pump's structural integrity. Suction Pipe: The suction pipe is responsible for drawing fluid into the pump from the source. It ensures a smooth and continuous supply of liquid to the impeller. Discharge Pipe: This component carries the pressurized fluid away from the pump to its intended destination. The discharge pipe plays a vital role in maintaining the overall efficiency of the pump. Seals and Bearings: Seals prevent leakage, while bearings support the rotating shaft and impeller. Proper lubrication and sealing are essential for minimizing friction and enhancing the pump's lifespan. Shaft: The shaft connects the impeller to the motor. Its sturdy design is crucial for transmitting power and maintaining the rotational integrity of the impeller. Motor or Driver: Responsible for providing the necessary power to drive the impeller, the motor is a critical component. It can be an electric motor, engine, or any other suitable power source. 👉 Core Engineering 👈 #HeatExchanger #ShellAndTube #ThermalEngineering #ProcessEngineering #HeatTransfer #EnergyEfficiency #IndustrialEquipment #EngineeringSolutions #MechanicalEngineering #ChemicalEngineering #HeatExchange #HeatRecovery #EnergySavings #IndustrialDesign #EngineeringLife #EfficientTechnology #EnergyManagement #HeatExchangerDesign #CoolingSystem #HeatTransferFluid #centrifugalpump

Gear Pump Explanation A gear pump is a type of positive displacement pump that moves fluid by trapping it between interlocking gears and transferring it from the inlet to the outlet of the pump. Construction: A gear pump typically consists of two gears — a driving gear (the one connected to the power source) and a driven gear. These gears are housed within a casing. Inlet and Outlet: The pump has an inlet where fluid enters and an outlet where fluid exits. Gear Rotation: The driving gear is usually connected to a motor or some other power source, causing it to rotate. As it rotates, it drives the motion of the driven gear. Fluid Movement: As the gears rotate, fluid is trapped in the spaces between the teeth of the gears and the casing. As the gears mesh and rotate, these trapped volumes of fluid move along the casing from the inlet to the outlet side of the pump. Discharge: As the gears continue to rotate, the trapped fluid is forced out through the outlet of the pump. Sealing: The tight tolerances between the gears and the casing ensure that there is minimal leakage of fluid from the high-pressure side to the low-pressure side. Flow Control: The flow rate of the pump can be controlled by varying the speed of the gears' rotation or by adjusting the size of the gaps between the gears and the casing. Applications: Gear pumps are commonly used in various industries for pumping fluids such as oil, fuel, lubricants, and hydraulic fluids due to their reliability, simplicity, and ability to generate high pressures. Overall, gear pumps are efficient and reliable devices for moving fluids in a wide range of applications, from industrial processes to automotive systems. #Pumps #Gear #Mechanical #Engineering #OilAndGas #Petrochemicals #Hydrulic #Explanation

Gear Pump Explanation A gear pump is a type of positive displacement pump that moves fluid by trapping it between interlocking gears and transferring it from the inlet to the outlet of the pump. Construction: A gear pump typically consists of two gears — a driving gear (the one connected to the power source) and a driven gear. These gears are housed within a casing. Inlet and Outlet: The pump has an inlet where fluid enters and an outlet where fluid exits. Gear Rotation: The driving gear is usually connected to a motor or some other power source, causing it to rotate. As it rotates, it drives the motion of the driven gear. Fluid Movement: As the gears rotate, fluid is trapped in the spaces between the teeth of the gears and the casing. As the gears mesh and rotate, these trapped volumes of fluid move along the casing from the inlet to the outlet side of the pump. Discharge: As the gears continue to rotate, the trapped fluid is forced out through the outlet of the pump. Sealing: The tight tolerances between the gears and the casing ensure that there is minimal leakage of fluid from the high-pressure side to the low-pressure side. Flow Control: The flow rate of the pump can be controlled by varying the speed of the gears' rotation or by adjusting the size of the gaps between the gears and the casing. Applications: Gear pumps are commonly used in various industries for pumping fluids such as oil, fuel, lubricants, and hydraulic fluids due to their reliability, simplicity, and ability to generate high pressures. Overall, gear pumps are efficient and reliable devices for moving fluids in a wide range of applications, from industrial processes to automotive systems. #Pumps #Gear #Mechanical #Engineering #OilAndGas #Petrochemicals #Hydrulic #Explanation

Hydraulic cylinders for electrode clamping application are an essential part of the electric arc furnace (EAF)/ Submerged Arc Furnace (Ferro furnaces)/Ladle Refining Furnace (LRF) This design is unique and proves to be operation friendly and a worker’s friend operating with zero hassle and downtime. This indegeniously designed beast is best for continuous operations and is comparable to other global giants in the field proving the Indian status of manufacturing at the global podium. Got a furnace? Setting up one ? Hydraulics??? ‘See hydraulics think of us’ INDPAC

Valve is involved in the engine top intake and in exhaust holes. In the intake is allow air and fuel into the cylinders and in the exhaust it allow gases out of the cylinders. #Engineering #MechanicalEngineering #Valve

A #gear #pump is a type of positive displacement pump commonly used in hydraulic systems. It moves fluids by using the action of rotating gears to transfer fluid from the inlet to the outlet. Here’s an overview of its structure and components: 1. Casing: The casing (or housing) encloses the internal parts of the pump, providing protection and support. It also helps direct fluid flow and maintain pressure. 2. Gears: Driving Gear: The primary gear connected to the power source (like a motor) that initiates rotation. Driven Gear: This gear is turned by the driving gear. Both gears interlock, creating a sealing and pumping action as they rotate. Gear pumps can have external or internal gears, with external gear pumps having two meshing gears side-by-side, while internal gear pumps have one gear inside the other. 3. Shafts: Shafts hold the gears in place and allow them to rotate within the casing. The driving shaft is connected to the driving gear, and the driven shaft holds the driven gear. 4. Inlet and Outlet Ports: Inlet Port: Located where the fluid enters the pump. As the gears rotate and create a void, fluid is pulled into the inlet. Outlet Port: Located where the fluid exits the pump under pressure after being moved through the gears. 5. Bearings: Bearings support the shafts and gears, ensuring smooth rotation. They also help maintain the alignment of the gears to prevent leakage and maintain efficiency. 6. Seals: Seals prevent fluid from leaking out of the pump casing around the shafts, maintaining pressure and efficiency. Working Principle As the driving gear rotates, it turns the driven gear, trapping fluid in the spaces between the teeth of the gears and the casing. This fluid is then transported from the inlet side to the outlet side. As the gears mesh on the outlet side, they push the fluid out, creating a steady flow under pressure. Gear pumps are simple, reliable, and capable of handling viscous fluids, making them ideal for applications in industries like oil, chemical processing, and hydraulics. #GearPump #HydraulicPumps #PositiveDisplacementPump #MechanicalEngineering #IndustrialMaintenance #HydraulicSystems #FluidPumps #PumpTechnology #IndustrialPumps #HydraulicEquipment #FluidTransfer #EnergyEfficiency #Matrix_Mnara #علم_يبنى_أثر_يبقى Matrix Mnara

A centrifugal pump comprises several key components that work in harmony to facilitate fluid transfer. Here's a detailed breakdown: Impeller: At the heart of the pump, the impeller is a rotating component with vanes or blades. As it spins, it imparts kinetic energy to the fluid, generating a dynamic flow within the pump. Casing: Surrounding the impeller, the casing directs the fluid flow and helps convert kinetic energy into pressure. It plays a crucial role in maintaining the pump's structural integrity. Suction Pipe: The suction pipe is responsible for drawing fluid into the pump from the source. It ensures a smooth and continuous supply of liquid to the impeller. Discharge Pipe: This component carries the pressurized fluid away from the pump to its intended destination. The discharge pipe plays a vital role in maintaining the overall efficiency of the pump. Seals and Bearings: Seals prevent leakage, while bearings support the rotating shaft and impeller. Proper lubrication and sealing are essential for minimizing friction and enhancing the pump's lifespan. Shaft: The shaft connects the impeller to the motor. Its sturdy design is crucial for transmitting power and maintaining the rotational integrity of the impeller. Motor or Driver: Responsible for providing the necessary power to drive the impeller, the motor is a critical component. It can be an electric motor, engine, or any other suitable power source. Please DM for credit/removal #HeatExchanger #ShellAndTube #ThermalEngineering #ProcessEngineering #HeatTransfer #EnergyEfficiency #IndustrialEquipment #EngineeringSolutions #MechanicalEngineering #ChemicalEngineering #HeatExchange #HeatRecovery #EnergySavings #IndustrialDesign #EngineeringLife #EfficientTechnology #EnergyManagement #HeatExchangerDesign #CoolingSystem #HeatTransferFluid #centrifugalpump