© DANIELI CORUS [DC Document No. ——S«280422G1-J143-D001 Rang Jindal Document No, ev. JINDAL - GREEN FIELD B/F RAIGARH & TORANAGALLU, INDIA New Blast Furnace No.2, 2005 Blast Furnace Process PROCESS CONTROL BASIC ENGINEERING REPORT FURNACE COOLING FINAL | 28 JULI 2004 © DANIEL! CORUS Tighe reserved, Confdanial Ths dosurert i propared by Darvel Cave BV eniaiing valuable Knowhow owned by Daviel ‘Corus BV and supplied ony forthe specie uso as autrorzed by writen agreement This document shal nol be csclosed, used feproduced ether wholy or in part except in connection wth such authorabs use anc then any wih the prior wien consent of Dane Corus BV. This document mest not be used unt signed as checked nd aporaved by Dan Goris BV {© 2004 Danili Corus BV . War 7/ | [0 | _Juy 28,2004 Revised = SAopenrah | Rev.| Date Description =| Prepared by 7Agiproved | ‘ec PGRSRB. oF gOoaH Isa ea A? trgpeinsc! FCB. | Jindal Project No. TF Cope tot 48 [ESSEC RCT T ine BON anoczzn© DANIELI CORUS REVISION SHEET Rev Date ‘Section | Page ion 0 | Aug 2, 2604 Revised Jindal, Green Fils BE Page 2 of 8 sly 28, 2004 Document No: 2804226 1-J149-0001 Rev: 0© DANIELI CORUS Table of Contents REVISION SHEET... 2 1. INTRODUCTION 5 2 BOUNDARY CONDITIONS..... 5 3. PLATE COOLING WATER SYSTEM 5 a4 Table 1 — Details Plate Coolers 7 32 Thermal Loading .. 8 33 Table 2 Heat Loads on Cooling Members a 9 34 Plate Coolers... : soe Sieiiettta® 35 Pressure Drop Calculations 36 Setting-up and Operation 37 Circulation Pumps. 38 Emergency Water 39 Expansion Vessel 3.10 Leak Detection... B41 Water Supply... 3.12 System Pressure. 3.13 Restriction Orifices.... 3.14 Back-up Water 3.15 Drain System ... 3.16 Heat Loss Monitoring ....... 4 TUYERE COOLING... ose 44 Basis of design : 42 Pressure Drop Calculations. 43 Circulation Pumps... 44 Emergency Water... 45 Conclusions Tuyere Cooting System... 5. HEARTH SPRAY COOLING... 84 Introduction. 52 Hearth Sprays 53 Setting Up and Operation 54 Circulating PUMPS.....onsnnententnennnennenene 55 Emergency Cooling........ sindal, Green Fels BIE Page 3 of 49 July 28,2008 Document No.: 28042261~J143-D001 Rev: 0© DANIELI CORUS 56 Hot Water Pumps... ater nee seit 25 87 COOKING TOWET..wnssinnnniineinsinnnmninnniniiniinnnnennaneinttnnnnns 25 6. UNDER-HEARTH COOLING. : : 27 7. JACKET COOLING. 27 8. OPERATION AND CONTROL FOR TUYERE SYSTEM..... a4 LP-Circulating Pumps... 82 HP-Circulating Pumps. 83 Emergency Cooling... 84 Nitrogen Expansion Vessel...... as Make-up Control... 86 Pressure Control... ar Leak Detection : 88 Burden sprays... i 89 Totem top Gearbox Cooling Make-Up Water .. 8.10 Fumace Top Spray Water Booster Pumps.. 9 SOFTENED MAKE-UP WATER SYSTEM. .....cosccsssntnnnannnnnnesnnnn 36 10. INDUSTRIAL MAKE-UP WATER SYSTEM 38 1 PLATE/ PLATE HEAT EXCHANGERS. 7 40 12. SECONDARY WATER SYSTEM... 5 : “4 12.4 Circulation Pumps. 4 12.2 Cooling Tower... 243 13. EMERGENCY OVER-HEAD TANK : petted: 14. WATER BALANCE... 46 16. ATTACHMENT SPRAY NOZZLE FOR HSC. 49 dings, Groen Fie BF Page 4049 July 28, 2004 Document No.: 280422G1-1143.0001 Rev. 0© DANIELI CORUS 1. INTRODUCTION This document covers the process description of the cooling water facilities as a part of the Green Field Project - 2005 of JSPL, Blast Furnace No. 2. Aside from the cooling water process design criteria the description provides global information of the process control functionality, which is deemed essential for an operational point of view. Detailed information regarding the process control system functionality shall be obtained from Functional Design Specification (FDS), document 2B0422G1-R217-D010. awd 2. BOUNDARY CONDITIONS In the system the following boundary conditions are deemed imperative: The system pressure doesn’t exceed the design pressure of 1000 kPa (g); The pressure in the plate coolers must be above the gas pressure in the furnace, against gas blockade. The design pressure is 50 kPa above the local furnace pressure; ‘+ Total cooling water flow is 2462 m'h; ‘+ Inlet pressure for the plate coolers is 444.5 kPa(g) a, + The water pressure in the end of plates is 280 kPa(g) ( minimum (Lower stack), which is > 50 kPa (REWRO) above the furnace pressure at the level of the lower stack plates; «Incase of failure of the electrical pumps, the flow is proportionally divided over the different regions of the furnace (all regions reduced to around 80 % of nominal cooling water flow). The cooling system of the furnace wall is divided in 6 segments. Electrically driven pumps (E- pumps) supply cooled water (2462 m*/h) to the cooling plates, The system is pressurized by a pressure vessel with N2-blanketing in the vessel The plates are stitched using small bore (stitch) piping. One size (DN32) is applied: Flow Pressure drop No. of plates in a row Plates TO1-T03 6.0 min 39500 Pa 4 Plates RO4 6.0m'h 39700 Pa 30r4 Rew Plates R5-R12 68m%h 54500 Pa 4 Plates R14-R20 8.0 mh 75600 Pa 4 Plates R21-R32 8.6 mh 87400 Pa 4 Plates R33-R40 7.0m'h 8000 Pa 4 Plates R41-R47 61mh 44200 Pa 4 Plates R48-R54 6.0 mth 43100 Pa 4 ‘The pressure drop is inclusive the pieces of stitch piping between the coolers. For pressure profile refer to drawing 2B0422G1 J143 C001 3. PLATE COOLING WATER SYSTEM The furnace shell above and between the tuyeres is cooled by a total of 1320 plate coolers. The Jindal, Green Field BIE Page 5 of 49 uly 28, 2008 Document No. 28042261.1143-D001 Rev: 0© DANIELI CORUS area above the tuyeres consists of 1280 plate coolers. The plate coolers are connected in series of 3-4 plates each. These series of plates are arranged horizontally such that six separate sections exist in each zone above the tuyere level. The areas and the zones form panels, each having its ‘own feed and return manifold. The arrangement makes heat monitoring of the furnace possible. The plates are all of cast copper. The details of the different types of cooling plates are given in DC drawing numbers 2B0422G1-M358-C101, 2B0422G1-M358-C102 and 2B0422G1-M358-G101 til 2B0422G1-M358-G109. The plate cooling water system is a closed pressurized system with continuous softened cooling water circulation. The plate system cooling water circulation is 2462 m’shr. The water circulation is guaranteed with four (4) pumps. Three (3) electrically driven pumps operating in a duty/stand by mode and one (1) diesel driven pump for back-up use during an electrical power failure. The plate cooling system is an indirect cooling system. The heat transferred to the softened water at the cooling plates is removed from the cooling water in a plate/plate type heat exchanger to a secondary water system. The open circuit secondary cooling water is finally cooled using a four (4) cell cooling tower. ‘Raia Jindal, Green Fikd BF Page 6 of 48 duly 28, 2008 Document No 28042261-1143.0001 Rev. 0one sooo erie ozzroRe on wouso0g Seca 2 kor bre 1984 Ones. ae eae ae zee el ozeL TOL SedE 09 ozo | o9 | oat ov | sodas | 02 | ges | zor | Levesny a 09 ozo | 09 | ove oy | sodden | ov Lov € Z auosny €96 seed > oo ozs | 09 | ove or | seddoy | oF | 298 ’ usog od eo | oznosv | o9 | oro | zor | jorge | v2 | ese | zras | usog a +9 oe | oosiay | 9 cco z6t_ | seddoy | % Le oz-eL Ayo@ ‘seed zeor ve oos 09 | oesios | ee | jigoy | ¥% ze zee | RS BIS on 003 o9 | cosses | zor pie ve Lye oree | alppin 20M0} £96 a Sedo | ez | ise | ae | apow V9 oos | 09 | sos | oo seddoo, a i ; S505 EIS a 09 oos | 09 | ozs | a | jecdon | 2 | sco | veer | eS au 7a Gu] a a sei SaK 1 jeueg | orig 0 pue | mou | ug | smoy | ad ged | yyBuay soquiny | eure | sed | jeomen | orig | uoioy mold mois | vowesu | won | wom | teior | ereid | seveig | eBeony | s2}009 | eoeuing Sis]oo9 aieid SIeeg-LeigeL Ve© DANIELI CORUS 3.2 Thermal Loading The key to understanding the operation of a cooling system in highly loaded metallurgical furnaces is the formation of a skull on the hot face of the cooling element. Such a skull will be composed of ‘a mixture of solidified slag and metal formed by splashing, dripping and freezing, with a thickness varying between a few millimetres and 10 — 20 cm. The stability of the skull depends mainly on the cooling capability and the mechanical ‘adherence capacity’ of the cooling element. By its nature, the skull will have relatively good insulating properties During extreme heat loading, caused for instance by high temperature gas jets or process upsets, the skull may eventually become detached, but wil build up again shortly afterwards. This pattern of build up and then detachment of skulls can cause significant fluctuations in the thermal loading of the furnace lining with peaks in the range of 300,000 - 450,000 Wim?. Clearly, the design of the cooler should be capable of handling heat loads of this magnitude so as to avoid premature failure of the lining. The greater the cooling efficiency of the cooling element, the more stable will be the skull; and the longer it will remain on the cooler surface, and the better it will retain its insulating and protective properties. The net effect is that a highly efficient cooling system will usually result in lower overall heat losses from the furnace. Figure 1 Process Temperature Fluctuations be 1 2 3 4 § 6 7 8 9 10 Upper stack ae i Midele stack fs A A Lower stack Belly Bosh - Tuyeres Hearth indal, Green Field BIE Page 8 of 48 aly 28, 2004 Document No. 28042261-J143.001 loted© DANIELI CORUS 3.3. Table 2 - Heat Loads on Cooling Members Furnace | Height [ Area*” | Heat Heat | Cooling Waier Region m Flux Load Water Flow | Temperature mm Wim? | MW meh rise °C Upper 4375 jos [114.9 13 252 45 Stack +24 for IBP Upper 3160 86 309 27 256 89 Middle Stack Lower 2776 80 49 36 336 92 Middle Stack Lower 3744 iia | 637 72 619 70 Stack Belly 2800 6 487 43 384) 88 Bosh 3168 94 44.9 42 470 86 Tuyere 1533 43 4 06 120 64 Total 21556, 23.9 2462 Note: *1) Area based on inside diameter of plate cooler noses 3.4 Plate Coolers The plate coolers are designed as copper plate coolers and require tight specifications for shape, thickness, flatness and surface finish. The quality control and material selection for these plate coolers ensures high thermal conduetivity. In order to have optimum heat transfer between the plates and the refractory, close contact between refractory and coolers is of essence. Therefore both the coolers and the graphite have tightly fitting tapered machined surfaces. Furthermore to have the full benefit of the high conductivity refractories, no mortar or ramming material is applied between the plate coolers and the graphite. Jindal, Green Field B/F Document No: 28042261-J143-0001 Page 9 of 49 uly 28, 2004 Rev: 0© DANIELI CORUS 3.5 Pressure Drop Calculations ‘The pressure drop over the different parts of the cooling system shall be calculated, The results are: On furnace supply (at TOP) JSPL Bosh & Belly supply ring header JSPL Bosh & Belly plate cooler supply manifold JSPL Bosh & Belly plate cooler return manifold JSPL_KPa(g) El=+00000 Bosh & Belly return ring header SPL KPa(g) El=+00000 Lower stack supply ring header JSPL Lower stack plate cooler supply manifold JSPL Lower stack plate cooler return manifold JSPL Lower stack return ring header JSPL Middle stack supply line ring header JSPL Midalle stack plate cooler supply manifold JSPL Middle stack plate cooler return manifold JSPL_ KPa(g)E Middle stack return line ring header JSPL_ KPa(Q) E! Upper stack supply line ring header JSPL_KPa(Q) EI Upper stack plate cooler supply manifold JSPL_KPa(g)E Upper stack plate cooler return manifold JSPL_KPa(g) EI Upper stack return line ring header JSPL_ KPa(g) EI On furnace return (at TOP) JSPL_ KPa(g) El Which results in a total on-furnace cooling system pressure drop of © JSPL_ KPa In case two out of three of the electrical pumps fail, the break down will be as per below: ‘On furnace supply (at TOP) JSPL_KPa(g) El Bosh & Belly supply ring header JSPL_KPa(9) El Bosh & Belly plate cooler supply manifold JSPL_ KPa(g)El Bosh & Belly plate cooler return manifold JSPL_KPa(g) El Bosh & Belly return ring header JSPL_KPa(g) El= Lower stack supply ring header JSPL_KPa(g) EI Lower stack plate cooler supply manifold JSPL_ KPa(g)E Lower stack plate cooler return manifold JSPL_KPa(g) EI Lower stack return ring header JSPL_ KPa(g)E Middle stack supply line ring header JSPL KPa(g) El Middle stack plate cooler supply manifold JSPL_KPa(g) El=+00000 Middle stack plate cooler return manifold JSPL_ KPa(g)E! Middle stack return line ring header JSPL_KPa(g)E Upper stack supply line ring header JSPL_ KPa(g)E Upper stack plate cooler supply manifold JSPL_ KPa(g)E Upper stack plate cooler return manifold JSPL_ KPa(g)E Upper stack return line ring header JSPL_ KPa(g) El ‘On furnace return (at TOP JSPL_ KPa(g) El Which results in a total on-furnace cooling system pressure drop of JSPL KPa Jindal, Green Field Bi Page 10 of 50, su 28, 2008 Decument No. 28042261-1143-D001 Rev 0© DANIELI CORUS In case the back-up diesel pump is operating (total power failure, the break down will be as per below: ‘On furnace supply (at TOP) JSPL Bosh & Belly supply ring header JSPL Bosh & Belly plate cooler supply manifold JSPL Bosh & Belly plate cooler return manifold JSPL Bosh & Belly return ring header JSPL Lower stack supply ring header JSPL Lower stack plate cooler supply manifold JSPL Lower stack plate cooler return manifold JSPL Lower stack return ring header JSPL Middle stack supply line ring header JSPL Middle stack plate cooler supply manifold JSPL Middle stack plate cooler return manifold JSPL Middle stack return line ring header JSPL Upper stack supply line ring header JSPL Upper stack plate cooler supply manifold JSPL Upper stack plate cooler return manifold JSPL Upper stack return line ring header JSPL On furnace return (at TOP +Hold) JSPL Which results in a total on-furnace cooling system pressure drop of | JSPL_ KPa In case the emergency water supply is cut-in, the break down will be as per below: On furnace supply (at TOP) JSPL_KPa(g) El=+00000 Bosh & Belly supply ring header JSPL_ KPa(g) El=+00000 Bosh & Belly plate cooler supply manifold JSPL_KPa(g) El=+00000 Bosh & Belly plate cooler return manifold JSPL_ KPa(g) Bosh & Belly return ring header JSPL_ KPa(g) Lower stack supply ring header JSPL KPa(g) Lower stack plate cooler supply manifold JSPL_KPa(g) Lower stack plate cooler return manifold JSPL_KPa(g) Lower stack return ring header JSPL_ KPa(g) Middle stack supply line ring header JSPL_ KPa(g) Middle stack plate cooler supply manifold JSPL_ KPa(g) Middle stack plate cooler return manifold JSPL_KPa(g) Middle stack return line ring header JSPL_KPa(g) Upper stack supply line ring header JSPL_KPa(g) El Upper stack plate cooler supply manifold JSPL_KPa(g) EI +00000 ‘Upper stack plate cooler return manifold JSPL KPa(g) 00000 Upper stack return line ring header JSPL_KPa(g) El=+00000 (On furnace return (at TOP +Hold) JSPL_KPa(g) El +0000 ‘Which results in a total on-furnace cooling system pressure drop of JSPL kPa sindal, Green Feld Bi Page 11 of 50 uly 28, 2006 Document No: 28042261-1143.0001 he© DANIEL! CORUS 3.6 Setting-up and Operation The furnace plates require continuous constant flow of cooling water at or above the design rates, Normally all valves in the circuit are fully opened. Any excess pressure is throttled through restriction orifice plates when required for balancing the on furnace water distribution across the different sections. No restriction orifices have been determined to remove any excess pump ‘capacity. When butterfly valves shall not be used to throttle the flow. DC has envisaged restriction orifice plates in the following area's: Bosh cooling water return manifold (6 pcs) Belly cooling water return manifold (6 pes) Lower stack cooling water return manifold (6 pcs) Middle Stack cooiing water return manifold (6 pcs) Upper Stack cooling water return manifold @ pcs) The cooling water pressure in the return manifold shall be set at least 50 kPa(g) above the local furnace pressure and shall not drop below 200 kPa(g). The pressure of the lower stack return will be the limiting pressure for ensuring at least 50 KPa excess pressure. Plate circuit pressure is set via the nitrogen pressure control PIC-1301 at the nitrogen expansion vessel 3.7 Circulation Pumps The plate cooling system feature three (3) electrically driven circulation pumps: JSPL number: P1351A/B/C Make: ksB Flow: 1231 m*/h at 60 mic (guestimated) The plate cooling system included also a diesel driven back-up pump. JSPL number: P1351D Make: KSB Flow: 1800 m*/h at 50 mic (guestimated) The back-up pump will provide cooling water circulation in the event of a total power outage (also no booster pump available). Based on the system drop the back up pump will deliver a flow quantity of 1800 m*/h 3.8 Emergency Water In the event the back-up diesel pump fails to start, a so called zero or no flow situation has ‘occurred and the emergency water supply cuts-in. Emergency water flows from a 400 m’ overhead tank, which is elevated above ground level, under gravity, such that the pressure at TOP (Rewi0) level is 350 kPa(g). The emergency supply is connected via a set of automatic valves, one serving as supply valve and Jindal, Green Field BF Page 12 of 50 uly 28, 2004 Document No,: 28047261-1143.001 Rev: 0© DANIEL! CORUS the second valve as a dump valve. The emergency supply operates as a once-through system and discharges into the cooling water pond of the cooling tower CT-1302. As the available water pressure is 350 KPa(g) the expected water flow is 1000 m’sh (REE) 3.9 Expansion Vessel A make up waterlexpansion vessel ensures the water content of the system and acts as a buffer, while also acts as an expansion vessel. The top of the tank is pressurised with N2. The tank is equipped with a pressurisation valve and pressure relief valve. As the water level drops, N2 is added, while a rise in water level, due to make-up water supply or temperature rise of cooling water, the excess pressure is relieved The vessel with a volume of 16 m* provides a 15 m* working volume, which is based on an overall working level band of 3800 mm (100%). The normal process working level is set between 77% and 90%. The back-up process working level is fixed between 35% (LSL) and 90% (LSH) (R&WID). These fixed levels start and stop make-up water operation. ‘The water level in the vessel is monitored with a level transmitter LT-1301 and from the accurate reading the cooling water loss is derived. See also section 3.10 3.10 Leak Detection The closed cooling water system shall run with a minimum of make-up water. In normal operation the only make-up water is to balance sundry losses due to pump gland leakage, valve stuffing box leakage, etc, The rate of leakage is expected to lead to a top-up of the make up water/expansion vessel ones per shift. The quantity of water which is lost through leakage will be established in a rate of change function residing in the process control system. The sundry losses will be eliminated in the rate of change function, through an off-set factor and the outcome of the rate of change function will be in essence plate cooler leakage. When the leakage, which is expressed in m*/h, exceeds a pre-set limit an alarm FAH-1301 (alert) or FAHH-1301 (danger) will be generated. The alarm will be suppressed during a make-up water cycle. The following data will be recorded in the control system: Tank level will be trended (graphed) in control system [in %]; ‘Time between make-up actions will be logged in control system in [minutes]; Rate of change of water level (moving average) trended in the control system in [m*/h}; Cumulative make-up water quantity in [m°]. Based on a level transducer sensitivity of 0.4% the process control system senses a cooling water loss of 60 V/h. When the cooling water loss exceeds the alert level (1 m"/h) the Stack Diagnostics Screen shall be selected and the delta flows checked. In addition the screen 262 until 266 shall be selected. The danger level is set at 2 m’/h. With or without diagnostic directions, leak searching is a pertinent priority. For reference see document 2B0422G1-M143-D001 Of each section, the flow meter reading history shall be carefully compared with the actual Jindal, Green Field BIE Page 13 of 6 uly 28, 2008 Document No.: 28042261-1143-D001 Rov. 0© DANIELI CORUS readings. When the actual readings of the FE-1 (inlet) and FE-2 (return) flow meters differs more than the normal reading trends, itis a strong indication of a possible leaking cooler in the particular section. Furthermore the status of the flow circuit flow monitors shall be assesses from alarm status list in the process control system. The flow monitors will be set at 80% of the nominal flow. The setting is rather course but 20% <2 m'ih. Jindal, Green Field B/E Page 14 of 60 July 28, 2008 Document No.: 2804226 11143-D001 Rev: 0© DANIELI CORUS 3.11. Water Supply The plate system requires a total of 2462 m*/h of cooling water through the cooling plates. The process settings for important alarms and actions read as listed below: REWO Fumace Region [Line Sze] inlet | Flow Flow Flow Flow Flow | Alarm | Alarm | Alarm | Alarm mth mi min mh ; Fi-4301 | 2200 | 1970 | 1200 | 500 Cooling Water Supply | ONE5O | o469mim | (FAL) | (FALL) | (FALLL) | (FALLLL) | Cooling Water Loss 2 | (ET-1301) 1 (FAH) | (FAHH) 3.12. System Pressure The system pressure on the system is determined by the plate cooler outlet at the end of the circuit in the bosh Level Prescribed Elevation System pressure plate pressure cooler kPa(a) mm. KPa(a) Upper stack 380, 33359 By JSPL Middle stack 410 28984 By JSPL Lower stack 450 23049 By JSPL Bell ‘470 19304 By JSPL Bosh 480. 16768 By JSPL 3.13 Restriction Orifices To compensate for pressure drop variation of the 5 zones, in the bosh, belly, lower —, middle- and upper stack restriction orifices have to be inserted in the cooling water return lines. Level Stream Flow Number of | System Loss number REWO myn Plates Pa Upper stack 26 42.6 6 By JSPL Lower Middle ace 25 427 6 By JSPL Upper & Middle stack 7 bd o Peter Lower stack 24 7032 6 By JSPL, Belly 8 64 6 By JSPL Bosh 7 98.3 6 By JSPL sinds, Groon File BF Page 15 0f 50 July 28, 2004 Document No: 28042261.143-0001 Rev: 0© DANIELI CORUS 3.44 Back-up Water Leaking cooling members, i.e. plates, tuyeres, jacket shall be connected to the back-up cooling water. Therefore at each platform 4 cooling water supply manifolds are projected. The cooling water will be taken from the secondary cooling water system. The back-up water is softened industrial water. The basis for the sizing of the system is a cooling water requirement as follows: Plates: Average flow per circuit or plate of 9 m°sh, ‘© Maximum 5 leaking circuits or plates in the fumace. ‘Maximum flow of 45 m°h on the total furnace. Tuyeres: © Maximum 2 leaking circuits in the furnace. ‘+ Maximum flow of 2°20 = 40 m‘/n on the total furnace. Iron Notch jacket © Maximum flow of 1*20 20 m’/h on the total furnace. In case of a leakage of the jacket cooling, the leaking part has to be separated from the closed softened water system, as itis done with the cooling plates, For reference see Process Flow Diagram 2B0422G1-J143-C701, 3.15 Drain System The used water is initially returned to the troughs of one of the 34 cooling water manifolds. From the return trough the water flows back on gravity to the hearth spray water collection trough, from where it discharges into the cooling water pond (hot well) of the cooling tower. The troughs and drain lines have sufficient capacity to release the 45 + 40 m°/h spilled back-up water. For reference see Process Flow Diagram 2B0422G1-J143-C702 Jindal, Green Field BF Page 18 of 50 sly 28, 2004 Document No = 280422G1-143-0001 Rev. 0© DANIELI CORUS 3.16 Heat Loss Monitoring In order to obtain effective control of the blast furnace bosh and stack cooling there must be a means to monitor the removal of heat from the various zones of the plate coolers and to detect water loss into the furnace. The basis of the calculations requires a flow and temperature measurement on the inlet and the outlet from each monitoring zone. In order to complete the calculations the temperature of the cooling water entering each zone must also be known. In this case, infet and outiet temperature measurements are taken for the panels. The information made available is broken down in four groups: * Cooling water losses and heat flux per panel + Cooling water losses and heat flux per zone. * Cooling water losses and heat flux per column. ‘+ Cooling water losses for the entire stack, Example of presentation of heat flux per panel Jindal, Green Feld BF Page 17 of 50 ly 28, 2008 Document No: 2804221.J143.001 Fev 0© DANIELI CORUS 4, TUYERE COOLING 44 Basis of design ‘The tuyere cooling water circuit will be designed for 5000 kW, the Under-Hearth cooling will be 866 kW and the iron notch jacket cooling will be 187 kW. 4.2 Pressure Drop Calculations The tuyeres have a separate circuit for tuyere cooling (20 tuyeres). This cooling circuit is fed by 2 pumps of 750 m'/h each, Three (3) electrically driven pump (duty & standby) and one (1) diesel driven back-up pump. ‘Application Amount Flow Calculated Pump - mth Flow (m*th) Head mic Tuyere nose 20 20 400 By JSPL_| Tuyere bod} 20 20 400 By JSPL_ | Tuyere cooler 20 15 300) Under-hearth [32 pipes (REWO) | 10.9 (REWO) 350 Jacket 2 25 50 ‘Subtotal 71500 ] The pressure drop of the tuyere zone cooling over the different parts of the cooling system has been calculated, The results are: LP System On furnace supply (at TOP) By JSPL kPa(g) EL=+00000 Pressure in DN250 supply ring header Pressure tuyere cooling inlet manifold Pressure at tuyere body inlet Pressure at tuyere body outlet Pressure at tuyere cooler inlet Pressure at tuyere cooler outlet By JSPL kPa(g) EL=+00000 Pressure tuyere cooling return manifold By JSPL kPa(g) EL=+00000 Pressure in DN350 retum ring header By JSPL kPa(g) EL=+00000 On furnace return (at TOP) By JSPL kPa(g) EL=+00000 Which gives the total on-furnace cooling system pressure drop of ByJSPL kPa For reference see PFD 280422G1-J143-C301 Jindal, Green Fie BIE Page 18 of 0 uly 28,200 Document No. 28042201-J149-D001 Rov: 0© DANIEL! CORUS HP System ‘On furnace supply (at TOP) By JSPL kPa(g) EL=+00000 Pressure in DN200 supply ring header By JSPL kPa(g) EL=+00000) Pressure tuyere cooling inlet manifold By JSPL kPa(g) EL=+00000 Pressure at tuyere nose inlet By JSPL kPa(g) EL=+00000 Pressure at tuyere nose outlet By JSPL kPa(g) Pressure tuyere cooling return manifold By JSPL kPa(g) Pressure in DN350 return ring header By JSPL kPa(g) EL=+00000 (On furnace return (at TOP) By JSPL kPa(g) EL=+00000 Which gives the total on-furnace cooling system pressure drop of ByJSPL kPa ‘The pressure loss for the tuyere nose, tuyere body and tuyere cooler is as listed below: Flow Pressure drop Tuyere nose 20.0 myn 265600 Pa Tuyere body 20.0 m/h 111600 Pa Tuyere cooler 15.0 m’/h 52700 Pa The tuyere cooler circuit, as @ consequence, need a restriction orifice in each outlet circuit. The pressure drop across the orifice is By JSPL kPa. REWO ‘The tuyere cooling and under hearth cooling are combined. The under hearth flow requirement is 360 m°sh, jacket cooling 50 m°vh and as a result the total flow becomes 1500 m°h, The correct flows for the tuyere cooling and the under hearth cooling shall be balanced through throttling the globe Rea) valve in the supply of the under-hearth cooling circuit. ‘The tuyere nose flow is most critical since the nose may come in contact with molten iron and hence experience particular high heat fluxes. To ensure cooling high velocities are employed for the nose. The tuyere nose flows are from one ring main feeding from the HP booster pumps. The inlet end return flows from each tuyere nose are measured by electromagnetic flow meters FT-17018 until FT-1720S and FT-1701R and FT-1720R respectively. Low flow alarms and high differential alarms are monitored by the PCS. The outlet flows, but not the inlet flows, from each body and cooler are measured by electromagnetic flow meter FT-1601 until FT-1620 and FT-1501 until FT-1520 respectively. The inlet temperature is measured in the common supply line (TE-1501A). Outlet water temperatures are measured in each circuit from each tuyere (TE-1501R & TE-1601R) [REWO The temperature difference is displayed and high differential alarms will be generated, when 4 °C has exceeded. Overview: Circuit Measurement sindsl, Groen Field BF Page 19 of 50 July 28, 2006 Document No. 28047261~J143-0001 neal© DANIEL! CORUS Tuyere nose ‘TE-1701R until TE-1720R Tuyere body TE-1601R until TE-1620R Tuyere cooler ‘TE-1501R until TE-1520R 4.3. Circulation Pumps The tuyere cooling system feature three (3) electrically driven circulation pumps’ JSPL number: P-1551A/B/C Make: ksB Flow: 750 m*th at 50 mic (Head is guestimated) (REMI) The required flow shall be 1500 m°/h. The pumps will operate in the duty/stand-by arrangement. The tuyere cooling system included also a diesel driven back-up pump. JSPL number: P-1551A/BIC Make: KSB Flow: 1800 m°vh at 30 mic (Head is guestimated) (RENO) The LP system is provided with instrumentation giving indication of: (BREW) Fumace Region [Line Sie | Inlet | Flow | Flow] Flow | Flow Flow | Alarm | Alarm | Alarm | Alarm mth mth mm mh | Fiiso1 | 1350 | 1200 | 750 300 Cooling Water Supply | DN450 | i509 mm | (FAL) | (FALL) | (FALL) | (FALLLL) ‘The back-up pump will provide cooling water circulation in the event of a total power outage. Based on the system drop the back up pump will deliver a flow quantity of >800 m*/h, The tuyere belt will receive 585 m’/h (65%) at a pressure drop of Hold KPa, the balance flow (315 m3/h) is the under-hearth cooling volume. For the tuyere nose circuits, which requires a high fluid velocity a set of booster pumps are ‘envisaged. JSPL number: P-1571A/B Make: KSB Flow: 400 m*th at 60 mic (Head is guestimated) Jindal, Green Feld aE Page 20 of 50 ily 28, 2004 Document No: 260422611149-0001 Rev.@ DANIELI CORUS The HP system is provided with instrumentation giving indication of: REO Furnace Region | Line Size | Inlet Flow Flow Flow Flow | Alarm | Alarm | Alarm mth mh mh Fi-1701 | 360 320 200 400m%h | (FAL) | (FALL) | (ALLL) Cooling Water Supply | DN300 4.4 Emergency Water In the event the back-up diesel pump fails to start a zero or no flow situation has occurred and the emergency water supply cuts-in. Water flows from a 400 m? overhead tank (Tk-1003) REWG, which is elevated above ground level, under gravity, such that the pressure at TOP level 360 KPa(q). The emergency supply is connected via a set of automatic valves, one serving as supply valve and the second valve as a dump valve, The emergency supply operates as a once-through system and discharges into the cooling water pond of the cooling tower(s) As the available water pressure is 350 KPa(g) the expected water flow is 800 m°/h (REWIO)for the tuyere belt. 4.5 Conclusions Tuyere Cooling System The calculated total “On Furnace” pressure drop is Hold kPa between the TOP's. The overall system pressure drop is Hold kPa. The installed pressure head of the pump is Hold kPa, so as a result any remaining pressure of the pump station can be dissipated with an restriction, or a higher volume can be accepted. The nitrogen pressure in the expansion vessel should be set at Hold kPa(g) For reference see PFD's 280422G1-J143-C401 Jindal, Green Feld BF Page 21 of 0 July 28, 2004 Dooument No: 280422G1-J143-001 Rev 0© DANIELI CORUS 5. HEARTH SPRAY COOLING 5.1 Introduction Definitions The hearth shell heat load levels are varying in time and space. This means that the heat load distribution on the shell is not constant — both in vertical and radial position ~ and that the heat load levels vary in time too. Normally, heat load levels are higher at the tap hole positions and the zone below the tap holes. Furthermore, heat load levels may increase in time due to progressing wear of the hearth refractories. The heat load levels are determined by the process conditions and the hearth flow conditions. Higher flow velocities will result in higher heat load levels. Average Heat Load ‘The average heat load refers to normal operations and relates to average heat load levels on the entire hearth shell surface area viz. t/o bottom plate to the lower side of the Yo the hearth shell. The average heat load is 5 000 Wim2. Average Heat Losses The average heat losses equal the average heat load multiplied by the hearth shell surface area. The average heat losses — expressed in W — are used to determine the sizing of the off- furnace heat exchanger capacity. Maximum Heat Load ‘The maximum heat load relates to a vertical panel with a typical width of 1000 mm. The maximum heat load will determine the temperature pick-up of the (spray- / jacket-) cooling water whilst as- / descending along the shell. The maximum heat load at a particular panel could be several times higher compared to the average heat load ~ especially if a peak heat load is imposed to a high heat load vertical panel. The maximum heat load is particular important in determining the right water flow of a spray-cooling system and through a jacket-cooling system. The maximum design heat load level is set to 50 000 Wim2 Peak Heat Load The peak heat load relates to a localized panel area of 1000 mm height and 1000 mm wide: the total area exposed to such peak heat load levels is thus limited to 1 m2. The peak heat load could be significantly higher compared to the maximum heat load — especially taphole areas and the panels below the tapholes could be exposed to peak heat load conditions. Jel, Green Field BF Page 22 of 0 uty 28,2004 Document No. 280422G1.J143-0001 Rev. 0© DANIELI CORUS ‘The peak heat load in effect is unlimited as it is determined by the liquids flowing inside the hearth. Experiments have indicated that liquid metal at 1500 °C can result in heat loads in excess of 1 MW/m2. It is not necessary to design hearth shell cooling systems to meet this demand considering hearth shell failure limits. 5.2 Hearth Sprays The furnace shell in the hearth area, from just below the tuyeres, is cooled by a falling water film con the shell surface. This flm is created by spraying water onto the surface The hearth spray system operates continuously at a set flow when the furnace is in operation There are three sets of sprays: 1, 18-40 ND spray bars each positioned centrally between tuyeres at a level 900 mm below the tuyere centreline. Each spray bar supplies a spray water flow of approximately 5.6 m*/n equivalent to a total flow of 100 m'/h. ‘The purpose of these sprays is to create a water film immediately below the tuyeres. 2. 18-50 ND spray bars, each positioned to provide water spray around the complete circumference of the shell at a level of 3750 mm below the tuyere centreline. Each spray bar supplies a spray water flow of approximately 6.7 m*/h The total spray water flow is 120 m*/h. 3. The emergency taphole spray water flow is achieved with 2 spray bars The 2 bars provide water sprays under the emergency taphole, each spraying 2 m*/hr. Typically, the design of the sprays is based on 8 mm diameter holes inclined at 45° upward from the horizontal and on a 50 mm pitch. ‘The nominal water velocity through each hole will be between 1 m/s and 2 mis, The water from the sprays will drain down the shell into the furnace trough and be discharged via a ND350 drains system back to the cooler tower CT-1901 Two hot water pumps will feed the water to the cooling towers. The supply flow to the top of the cooling tower will be monitored for flow. The cooling tower cold water well will be provided with a level transmitter. Jindal, Green Field BE Page 23 of 50 uly 28, 2004 Document No. 28042261-1143-0001 Revs 0© DANIELI CORUS The hearth spray system is provided with instrumentation giving indication of: FSG Furnace Region _| Line Size inlet Flow Flow | Flow Flow Flow Alarm Alarm Alarm Alarm. mth mh moth mish, Fi-t901 | 200 180 110 45 Cooling Water Supply | ON200 | 56 mim | (FAL) | (FALL) | (FALL) | (FALLLL) 5.3. Setting Up and Operation The total flow to the hearth sprays can be regulated using the valve 200-BFV-HSC in line 200- HSC-001-10A, Each spray bar has a globe valve enabling the flow to be set, The flow to each spray bar should be set such that the water jets impinge on the shell and spread laterally to form a continuous film flowing down the shell. The jet velocity should not be too high such that there is excessive splashing at impingement onto the shell surface. In operation the hearth sprays must maintain a continuous constant flow of water over the shell The water return from the water collection trough will be directed into the cooling tower hot well 5.4 Circulating Pumps The hearth spray circuit has two (2) electrically driven circulating pumps: DCNos -PISS1A BB JSPLNos P1S51A&B Make: ksB Flow: 226 mth at 15 mic (Head is guestimated) REWO The two pumps will operate in a single duty/ one stand-by arrangement. Each pump will have a local control station with stop/start push buttons, The selection of the changeover logic can be carried out on the PCS using the following controls, for both the duty and standby pumps: Control Action Pump start The pump will start. Pump stop The pump will stop. Pump duty/ standby selector Will select either: Pumps A duty, B standby Pumps B duty, A standby In operation, the differential pressure generated across the running pump will be monitored by a differential pressure switch. Jindal, Grean Field BF Page 28 of 49 July 28, 2008 Document No: 28042261-1143-D001 Rev: 0© DANIELI CORUS The hearth spray circuit includes also a diesel driven back-up pump. JSPL number: P-1951C Make: KSB Flow: 226 m*/h at 15 mic (Head is guestimated) (REM) The back-up pump will provide cooling water circulation in the event of a total power outage. 5.5 Emergency Cooling If the diesel pump fails to start in an emergency then (after a 30 second timer has expired) a cooling water flow from the Over Head Emergency Tank (TK-1003) (RREMEO) will be initiated The emergency water flow will be from the overhead tank and through the furnace circuits on a once through basis. 5.6 Hot Water Pumps The hot water circuit has two (2) electrically driven circulating pumps: DCNos = P-1952A 8B JSPLNos —P-1952A&B Make’ ksB Flow: 319 m*/h at 15 mic (Head is gestimated) ‘The two pumps will operate in a single duty/ one stand-by arrangement. Each pump will have a local control station with stop/ start push buttons, The selection of the changeover logic can be carried out on the PCS using the following controls, for both the duty and standby pumps: Control Action Pump start The pump will start. Pump stop The pump will stop. Pump duty/ standby selector Will select either: Pumps A duty, B standby Pumps B duty, A standby 5.7 Cooling Tower The hearth spray cooling system has to absorb 5 kW.m? of heat. The lateral area of the hearth shell is 238.8 m2. The resulting heat load is 1194 kW (=4.3 Guih). In addition the back-up cooling water drains in the hearth spray system. The maximum return flow is 85 m3/h and the heat load is quantified as 390 KW, This will result in a cooling range of 3.78 °C The cooling tower shall be sized for the following conditions: Jindal, Green Fela IF Page 25 of 49 Jaly 28, 2008 Document No. 280422G1-J143-D001 Raa:© DANIEL! CORUS Tdb 44°C Two 24.63.°C (Dry season) & Tdb 35°C Twb 32.95.°C (Monsoon) Based on the cooling tower characteristic KaV/L = 1 and LiG = 1, the following parameters have been estimated Case 1 (Dry Season) Cold water temperature (Tew) Approach (Ta) Cooling range (Cr) Altitude CT Characteristic (KaV/L) UG ratio Enthalpy Enthalpy drive Dew point temperature Absolute Humidity at Tab Absolute Humidity at Twb Increment Evaporated quantity Drift and Loss Blow down Make-up Water quantity Case 2 (Monsoon) Cold water temperature (Tew) Approach (Ta) Cooling range (Cr) Altitude CT Characteristic (KaV/L) UG ratio Enthalpy Enthalpy drive Absolute Humidity at Tab ‘Absolute Humidity at Twb Increment Dew point temperature Evaporated quantity Drift and Loss Blow down Make-up Water quantity 27.2°C 1.85°C 3.78 °C 483m 1 1 77.18 kJhkg 16.78 kJlkg 24.83 °C 12.75 gikg 25.48 g/kg 12.73 gfkg 4.1. mith 0.5 mh 2.7 mth 7.3m 34°C 1.85 °C 3.78°C 483m 4 1 121.62 kJlkg 15.78 kdlkg 33.77 glkg 39.30 glkg 5.53 gikg 35.3 °C 1.76 mh 0.5 miih 4.2 meth 3.5 min As about 80% of the cooling occurs by evaporation, the dissolved solids and other impurities in the re-circulation water tend to concentrate. In order to control the concentration of the impurities in the water, proper chemical treatment, blow-down (purging) and fresh make-up must be ensured. Jindal, Groen Fila B/F Document No. 28042261.143.001 Page 26 of 49 uly 28, 2008 Rev. 0© DANIEL! CORUS 6. UNDER-HEARTH COOLING Under-hearth cooling is by water flow through 32 (BW) tubes (each 80mm (REWED) diameter) Tunning parallel east-west (Hold) in the bottom of the furnace. The total water flow, 350 mh, is measured at inlet and outlet (FT-1101A and FT-1101B) with low flows being alarmed and the difference between inlet and outlet flows monitored by PCS. Set point for low flow alarm 280 m’/h (80%) Inlet and outlet temperatures (TE-1101A and TE-1101B) are measured and high temperatures alarmed in PCS. Set points for alarm to be established during commissioning and initial operation. The arrangement of pipes are below the bottom plate. For leakage testing, each of the 32 (RENO) pipes can be isolated in the feed and retum side. If the pressure gauge shows a slight pressure rise during the test, this cooling pipe is ok. For check purposed each return line feature a thermowell. (BUN) 7. JACKET COOLING A closed-loop jacket-cooling system is installed at the taphole notch using softened water. This Jacket-cooling system will ascertain adequate cooling of the notch. The notch is exposed to dynamic high(er) temperatures and heat flux levels. Furthermore, the notch and the taphole are exposed to heavy mechanical loadings due to the clay-gun and taphole drill operations. Maintenance of spray-cooling systems at the taphole is normally difficult as access is limited, Fouling/scaling/etc. negatively affects the spray-cooling performance, Furthermore, spray-cooling capacity is limited and this system is ineffective in meeting hot metal heat load levels. The application of a jacket-cooling system ascertains minimum notch mechanical movements, maximum cooling efficiency and requires minimum maintenance. The cooling water is supplied from the LP tuyere cooling circuit. The jacket cooling circuit has to absorb 50 kW.m* of heat on average, while local peak heat load can be up to 1MWim?. The lateral area of the hearth shell is 1.77 m?. The resulting heat load is 88.5 kW. This will result in a cooling range of 3.05 °C The cooling water flow, 25 m*h per notch, is measured at inlet and outlet (FT-1921AS and FT- 1921AR) with low flows being alarmed and the difference between inlet and outlet flows monitored by PCS. Set point for low flow alarm 20 m*/h, The inlet and outlet temperatures (TE-1921AS and TE-1921AR) RENO are measured and high differential temperatures alarmed in PCS. Set point for high differential temperature alarm is 4 °C 8. OPERATION AND CONTROL FOR TUYERE SYSTEM 8.1 LP-Circulating Pumps The LP-tuyere circuit has three (3) electrically driven circulating pumps: DC Nos PISS1A/B/C JSPLNos — P1551A/B/C Make: KSB Flow: 750 m*/h at 50 mic (Head is guestimated) EU Jindal, Green Field BF Page 27 of 49 July 28, 2004 Document No,: 28042261-J143-0001 Rev.:0© DANIEL! CORUS ‘The three pumps will operate in a double duty/ one stand-by arrangement. Each pump will have a local control station with stop/ start push buttons. The selection of the changeover logic can be carried out on the PCS using the following controls, for both the duty and standby pumps: Control Action Pump start The pump will start Pump stop The pump will stop. Pump duty! standby selector Will select either: Pumps A+B duty, C standby Pumps B+C duty, A standby Pumps A+C duty, B standby In operation, the differential pressure generated across the running pump will be monitored by a differential pressure switch ie. Pump P1551 A Electrical PDS-1551 A P1551 B Electrical PDS-1551 B P1551 C Electrical PDS-1551 C These differential pressure switches will be set manually in the field. With the electrical duty pump, if the pressure rise across the pump falls below the differential pressure switch setting, and remains below for a time set in PCS, an alarm will be given and the electrical stand-by pump will be started. When the differential pressure over the stand-by exceeds the differential pressure switch setting and is maintained for a time set in the PCS, the original running pump will be stopped if itis still running (i.e. not tripped). The pump will be stopped even if its differential pressure switch had recovered to above its setting The LP-tuyere circuit will also have an back-up diesel driven pump. DC No. P1551 D. JSPL No. P1551 D. This back-up pump will provide circulation in the event of total electrical power loss. In operation if the duty fails and the stand-by pump does not start; or starts but fails to achieve the differential pressure switch setting (PDS-1551 D) within the time set in the PCS, the diesel pump will be started and an alarm given. The diese! pump is not designed to provide cooling water circulation for continued production on the furnace. The circulation available does allow the furnace operation to be shut down safely and give a period of time for repairs etc. 8.2 HP-Circulating Pumps Cooling water for the tuyere nose dindal, Green File BIE Page 28 of 49 July 26, 2008 Document No: 28042261.J143.0001 Revo© DANIELI CORUS The HP-tuyere circuit has two (2) electrically driven circulating pumps: DC Nos P1751A/B JSPLNos — P1751A/B Make: KSB Flow: 400 m*/h at 30 mic (Head is guestimated) RRENEG ‘The two pumps will operate in a single duty/ one stand-by arrangement. Each pump will have a local control station with stop/ start push buttons. The selection of the changeover logic can be carried out on the PCS using the following controls, for both the duty and standby pumps: Control Action Pump start The pump will start Pump stop The pump will stop. Pump duty/ standby selector Will select either: Pumps A duty, B standby Pumps B duty, A standby In operation, the differential pressure generated across the running pump will be monitored by a differential pressure switch. The HP tuyere cooling circuit does not feature a back-up pump in case of a electrical failure. The necessary cooling rate shall be provide by the LP cooling water pumps. The HP pumps will be bypassed through opening of automatic valve XV-1701. After the situation has been restored the valve shall be closed though operator intervention. Back flow is prevented by a non-return valve down stream of the automatic bypass valve XV-1701 8.3 Emergency Cooling If the diesel pump fails to start in an emergency then (after a 30 second timer has expired) a cooling water flow from the Over Head Emergency Tank will be initiated. The emergency water tank which serves the whole of the blast furnace has 400 m? capacity and is located on adjacent high level (REV) such that the pressure at TOP level is 350 kPag. The emergency water tank supply is connected to the tuyere circuit via a automatic valves XV- 101A and XV-1018, This valve is configured to fall open. Hence if there is a total emergency loss of electrical power and/ or other services the valve will open. This valve can also be opened through the PCS. Hf the emergency water supply valve is opened by accidental loss of power/ services local to the valve then a non-return valve will prevent flow from the higher pressure circuit to the emergency water line. The emergency water flow will be from the overhead tank and through the furnace circuits on a once through basis. The emergency flow will be discharged immediately downstream of the furnace via an automatic emergency water return valve XV-1501C ( into the drain system and back to the cooling tower. Jindal, Green Field BIE Page 29 of 9 siuly 28, 2008 Document No. 280422G1-1143-000% Rev: 0© DANIELI CORUS Automatic valve XV-1501C is configured to fail close to prevent the valve opening, resulting in the circuit draining, if power/ services were accidentally lost at the vaive. To enable the valve to open in an emergency, when all power/ services are lost, an in-line instrument air reservoir (100 | capacity) has been included in the valve pneumatic system. Operating on the UPS power supply, the PCS, via the reservoir, will open the return vaive allowing the flow of emergency water form the tuyere circuit into the drain system. Similarly the PSC will close the return valve via the secondary solenoid valve, ensuring the circuit is not drained as the emergency water supply ends. Itis estimated that the emergency flow will be 800 (REWEIG) m*/h to the tuyere circuit. Depending on water demand by other parts of the JSPL site in an emergency, it is estimated the emergency flow can be maintained for at least 30 (RBWB) minutes. ‘The retum valve XV-1501C will be closed by PCS after the pre-set time or when normal pump circulation is re-established (any pump differential pressure healthy). Closing XV-1501C will be alarmed by the PCS. 8.4 Nitrogen Expansion Vessel The water volume and pressure of the tuyere system is monitored and controlled using the Nitrogen Expansion Vessel (ET-1501). The water level in the vessel is monitored by a level transmitter (LT-1501) with high and low level signals set in the PCS used to operate the make-up water system, Three level switches (LSL-1501, LSH-1501 & LSLL-1501) provide back up to the PSC signals. The vessel is 2250 mm diameter with a volume of 16 m*. The overall working level band is 3600 mm giving an available working volume of 15 m®. The normal working level between the high and low levels set in the PCS is 77 and 90%, though the level controller LIC-1501, while the back-up operates between 80% to 35%. These levels start and stop the make-up operation. The working volume below the PCS low level is 5.3 m* to allow leakage during the time for the isolation valve XV-1501J (REMM®) to close. The overfill volume above the PSC high level is 1.1 m?. Table for ET-1501 Level (mm) % Volume “Instrument Remarks im 0 0 05 380 10 251 TSUL-1507 1330 35 5.8 LSL-1501 3230 85 43.3 LSN Set point LIC-1501 3610 90. 14.9 LSH-1507 ) 3800 700 15.6 Due to fact that the tuyere cooling members are connected though flexible hoses with quick connect fittings, an unwanted flip off of the hose leads to a significant loss of containment. The sindsl, Green Field BIE Page 30 of 49 Jiuy 28, 2004 Document No.: 28042261-J143-0001 Rev: 0© DANIELI CORUS water will leak from two (2) sides (worst case). The cooling water loss is estimated at 135 m3/h. The make-up water quantity will meet that requirement. For such significant loss of containment, the hold-up time of the ET-1501 is 6 minutes only, without make-up water. As back-up make-up water, the industrial water serves that purpose. 8.5 Make-up Control ‘The expansion vessel ievel instrumentation has the following control actions: Rising Level Falling Level LSH-1501 1. HH level alarm 1. Cancel HH level alarm 2. Stop make-up sequence (If not stopped at H level) Lic-1501 1. High level set 2. Stop make-up sequence 1. No action Lic-1501 1. Low level set 2. Open tank isolation 1. Start make-up sequence valve (XV-1501) if closed. LSL-1501 1. Cancel LL level alarm 1. LL level alarm 2. Open tank isolation 2. Start make-up sequence valve (XV-1501E) {if not started at L level) LSLL-1501 4. Cancel LLL level alarm 1. LLL level alarm 2. Start make-up sequence (if not started at L level) 3. Close tank isolation valve (XV-1501E) ‘Two make-up pumps (P-1051 A/B) will supply make-up water from the Softened Water Make-up. Storage Tank (TK-1001) into the tuyere system as required. Under normal conditions one pump ‘shall operate with the other acting as standby. However the PSC control scheme will allow the. operator to manually select both pumps running if necessary, The pipe connection of the Nitrogen Expansion Vessel ET-1501 to the circuit includes an automatic isolation valve XV-1501E. If the water level in the vessel drops to fow low level (LSLL-1501) then XV-1501E will be closed. This prevents nitrogen passing to the main circuit if leakage continues. ‘Start Make-up Sequence: When water level in Nitrogen Expansion vessel ET-1501 reaches low level on LIC-1501 or LSL-1501 1. Start duty transfer pump P-1051A/B. 2. If the pressure is not proven (PSL-1001), start the stand-by pump and alarm ‘Stand-by Running’. 3. if the standby pressure is not proven (PSL-1001), an alarm shall be raised ‘Make-up Pump Failure’. Jindal, Green Ftd B/E Page 31 of 49 uly 28, 2008 vent No. 2804226 14143-0001 Rev:0© DANIELI CORUS 4, If the pressure is proven (PSL-1001), check pressure difference (PDS-1501B) is positive (Le upstream — downstream difference positive) and above valve set in PCS. Open the make-up valve (LV-1501A). ‘Stop Make-up Sequence: When water level in Nitrogen expansion vessel ET-1501 reaches High Level on LIC-1501 or LSH-1501 3. Close make-up isolation valve (LV-1501A) 4. Stop running make-up pump after a time delay of 120 seconds. Each time the make-up sequence is initiated and water is added to the system, the make-up flow rate (FT-1501B) and the time the make-up valve (LV-1501 A) is open will be recorded by the PCS system (FIQ-1501). This will allow the cumulative volume of make-up to the circuit be recorded in the PCS. In case no softened water is available as make-up water, the system automatically transfers to. industrial make-up water after a certain time delay. of 4 minutes. 8.6 Pressure Control The Nitrogen Expansion Vessel (ET-1501) will be fitted with a split range pressure controller (PIC- 1501), in order to maintain a constant pressure. If the measured pressure is higher than the setpoint then the vent valve (PV-1501B) will open, if the pressure is lower than the setpoint then the nitrogen supply valve (PV-1501A) will open, but only if the nitrogen supply pressure is greater than setpoint in PCS above the vessel pressure (PDS-1501A). Alarms will be raised in case of high or low pressure in the vessel (PIC-1501). If the nitrogen supply pressure falls to less than the desired setpoint in PCS, i. below the vessel pressure (PDS-1501A) then the supply valve (PV-1501A) will close in order to prevent flow from the vessel into the supply line. A nitrogen supply pressure, low alarm, will be generated by the PSC. The nitrogen pressure in the expansion vessel will be controlled, based on the water pressure in the tuyere outlet manifold, to maintain the water pressure in the cooling passage at least 50 kPa g above the furnace blast pressure — normal maximum 270 kPag. Pl-1501C should therefore be maintained at a minimum of 330 kPag by altering the setpoint of PIC-1501 With these pressures if there is a leak in a tuyere water passage, the leakage will be water into blast gas, not blast gas into water. 8.7 Leak Detection The closed circuit system is designed to run with a minimum of make-up water. In normal operation the only make-up anticipated is to replace the sundry losses due to pump gland leakage, valve grand leakage, etc. This rate of leakage is expected to lead to a top-up of the nitrogen expansion vessel about once per shift, this being an automatic action on reaching low level (LT- 1501 within the vessel. If the rate of fall of the level in the vessel increases, leading to more frequent topping-up operations, it indicates that there could be a leak in the circuit. Jindal, Green Field BE Page 32 of 49 sly 28, 2004 Document No,: 28042261-1143-D001 Rev 0© DANIELI CORUS Each make-up addition and the cumulative flow of make-up will be recorded in the PCS, as’ Actual time/ date of make-up valve opening and closing Duration between make-up valve opening and closing. Duration since last filing cycle. Mean flow rate when make-up valve open (mean of readings taken at § second intervals, but excluding first and last readings). * Cumulative flow of make-up. The following functions will also be recorded in the PCS: = Alarm to be given if the time between make-up operations is below a time set in the PCS. Based on a working volume of 2 m: in the expansion vessel between PCS high and low levels. (LIC-1501) the time set will be 1 hours i.e. once per shift. 88 Burden sprays Eight (8) Water Spray Nozzles are equi-spaced around the inside of the top of the furnace to provide cooling above the burden when high top gas temperatures occur. ‘The water is 22.5 m*/hr at 250 kPag above the nominal furnace top pressure of 150 kPag. This flow is provided by the booster pumps (see Section 8.10.) The operation is by a control loop provided by the PCS in which the water control valve opens/ closes on high’ low top gas temperature signal. The burden sprays will operate on an intermittent basis normally over a limited period. 8.9 Totem top Gearbox Cooling Make-Up Water The Totem Top (TMT) supplied by Totem Co. Ltd has a water system for gearbox cooling The primary water circuit of the gearbox cooling system is used to keep the rotating gearbox cool inside the furnace. The primary circuits is re-cooled via Heat Exchanger HE-5001 by the secondary cooling water system. Due to elevation of equipment this secondary cooling water is supplied by P-1362A/B. The system can be controlled in manual via the operator screen or automatic. Except for the pumps the system does not have any local controls, The gearbox water cooling process control consists of, + Pressurised water tank © Two (2) water tank level transmitters + Two (2) water tank level switches * Water tank make up valve + Water tank drain valve Jindal, Groen Fick 8 Page 33 of 49 uly 28,2008 Document No. 28042261-J143-D001 Rev 0© DANIELI CORUS . Two (2) water filters (E20) + Heat exchanger flow meter + Gearbox water flow meter «Two (2) cooling water temperature RTDs ‘The cooling water circulation pumps are: DC Nos. P5051 AB JSPLNos. P5051 A/B Make: KSB Flow: 25 m*/h at 30 mic (Head is guestimated) The pumps are located on plat form EL+37750, The pumps will be configured as "DUTY" and "STANDBY" Each pump will have a local control station with stop/start push buttons. The selection of the change-over logic will be carried out on the PCS using the following controls, for both the duty and standby pumps: Control Action Pump start The pump will start Pump stop The pump will stop Pump duty/ standby selector Will select either: Pumps A duty, B standby Pumps B duty, A standby With the duty pump, if the pump differential pressure falls below the pressure switch setting and remains below for a time set in PCS, an alarm will be given and the stand-by pump will be started. 8.10 Furnace Top Spray Water Booster Pumps The Furnace Top Spray Water Booster Pumps are dedicated to provide cooling and spray water to the burden, The pumps are: DC Nos, P-1451 AB JSPLNos. P-1451 A/B Make: KSB Flow: 160 m‘/h at 60 mic (Head is guestimated) The pumps are located in the hearth spray cooling pump house. The pumps will be configured as "DUTY" and “STANDBY”. Each pump will have a local control station with stop/ start pushbuttons. The selection of the changeover logic will be carried out on the PCS using the following controls, for both the duty and Jindal, Green Field BF Page 34 of 49 uly 28, 2004 Document No,: 280422G1-J143-D001 Rev: 0© DANIELI CORUS standby pumps: Control Action Pump start The pump will start Pump stop The pump will stop Pump duty/ standby selector Will select either: Pumps A duty, B standby Pumps B duty, A standby With the duty pump, if the pump differential pressure falls below the pressure switch setting and remains below for a time set in PCS, an alarm will be given and the stand-by pump will be started. Because of the possibilty of sol outlet filter (FIL-1402). the spray water, which could block spray nozzles, there is an When the top gas temperature has returned to a safe level, dictated by the top temperature controller TIC-1402, the valve TV-1402 will be closed and the pump P-1451A/B will be stopped after 120 seconds. The water supplies may operate on an intermittent basis, hence a spill-back line is included with the flow limited by restriction orifice (FE-1402RO). This line will maintain a minimum flow between 9 and 10 m*/hr through the pump. The water supply pressure of the spray pumps is monitored by PT-1402 which has a low pressure alarm in PCS, Jindal, Green Feld BIE Page 35 0f 49 uly 28, 2004 Document No.: 280422G1-s143-0001 Rev© DANIEL! CORUS 9. SOFTENED MAKE-UP WATER SYSTEM The tuyere cooling, plate cooling, Totem top and stove cooling water systems are closed circuits circulating softened water typically with additions of a corrosion inhibitor and a biocide. The closed circuits are to run with minimum requirement for make-up water. In normal operation there will be minor leakage from pump and valve glands ete, but this is not expected to be very high, typically up to 1 m? over 8 hours for each circuit, equivalent to one make-up operation per shift. With the failure of a plate or tuyere the leakage from the system will Increase significantly The plate, tuyere, hearth spray, Totem top, stove system and secondary cooling water system are served by a common Make-up System ‘Softened water is supplied by JSPL, where the supply being regulated by a float valve (LV-1001) which maintains a set level in the tank. REWO The softened water storage tank has a capacity of 100 m3, with dimensions § meter diameter and 5.6 m height (cylindrical part), with coned roof. The tank is provided with: + Visual level gauge (LG-1001) = Level transmitter (LT-1001) with high and low level alarms in PCS. High level to be set at 300 mm below overflow connections. Low level to be set at 600 mm above the outlet to the pump. = Level switch (LSL-1001) to give low level alarm switch is positioned 300 mm above outlet to pump. Table for TK-1001 Level (mmy % Working Nozzie Remark Volume m? a Bottom plate 200 Drain 300 0 o Pump suction 300, 0 0 Tank level - 600 54 59 LSL-1001 5600 100 104 Tank level + 5300 100 100 Overflow Two make-up pumps will supply water from the make-up storage tank to either cooling system as required Under normal conditions one pump will be duty, the other stand-by. The pumps are: Jindal, Green Field BF Page 26 of 49 July 28, 2008 Document No. 28042261-143-D001 Rev. 0© DANIELI CORUS DC No. P1051 AB JSPLNo. P1051 AB Make: KSB Flow: 150 m’/h at 65 mic (Head is guestimated) The duty make-up pump is started automatically on demand for make-up to either system. If the duty pump fails to achieve the required discharge pressure (PSL-1001) the stand-by pump will be started. The water supplies may operate on an intermittent basis, hence a spill-back line is included with the flow limited by restriction orifice (FE-1001RO). This line will maintain a minimum flow between 9 and 10 m/hr through the pump. The make-up system included also a diesel driven back-up pump. JSPL number: P-1051/C Make: ksB Flow: 150 m*/h at 65 mic (Head is guestimated) The back-up pump will provide MAREUBMAtSES0BpWy (REVG) in the event of a total power outage. The normal setting for pressure switch PSL-1001 is 400 kPag In addition to local start/stop pushbuttons on the drives, the following controls will be accessible through the PCS. Control Action Make-up system automatic! Will select either: semi-automatic selector Automatic (make-up sequence is activated as requested by the level control system (LIC-1301, LIC- 1501, LIC-1286 and LIC-5001) or Semi-automatic (operator can stop/ start the ‘equipment as required). Semi Automatic control Action Make-up sequence start ‘Start the pump (the sequence will be stopped manually or automatically by the PCS) Valve LV-1301/LV-1501, ect ‘Opens or closes the valves. Make-up sequence stop ‘Stops the pump. if level switch LSL-1001 indicates a low low level in the Make-up Tank 1001, both make-up pumps will be stopped or prevented from starting. Jindal, Green Field BF Page 37 of 49 uly 28, 2008 Document No,: 2B042261-J143-D001 Revs 0© DANIELI CORUS The control scheme also allows an operator, through the PCS, to start the stand-by pump when the duty pump is running. This enables the make-up rate to a circuit to be increased significantly should a high rate leak occur or the system is being refilled. ‘The pumps are provided with a spill-back line back to the make-up tank. This line has restriction orifice FE-1051RO with a Hold (By JSPL) mm diameter orifice to limit the flow to 10 m’/h, The make-up system is connected to the several consumers through automatic valves: LV-1301A of -—_ET-1301 of Plate Cooling System [REVO) LV-1501A of ET-1801 of Tuyere Cooling System {Bai0) LV-1286 —of__-—_—ET-1286 of Stove Cooling System LVv-5001 of ET-00of BRCU Cooling System respectively. When the duty (or stand-by) pump has started and the pressure switch PSL-1001 is satisfied, the difference in pressure between the make-up pump delivery and the make-up water expansion tank is checked by the PCS (PDS-1301B and PDS-1501B primarily) If the make-up pump delivery is more than 50 kPa above the circuit pressure the valve LV-1301A, LV-1501A,ect is opened to allow make-up. If the pressure difference (PDS-1301B or PDS-1501B, ect) is un-healthy, LV-1301A or LV-1501A will not open and an alarm will be given by PCS. To allow make-up to continue the operator must reduce the circuit pressure by reducing the nitrogen pressure set point for the expansion vessel. If the pressure difference (PDS-1301B or PDS-1501B, ect) becomes unhealthy after valve LV- 1301A or LV-1501A has opened, then the vaive will close again and an alarm will be raised. Softened water, having the following quality, will be supplied to the plant and retained in the softened water storage tank 1002: pH 7.0 TDH <5 ppm of CaCO3 ci 40 ppm Conductivity 250 uS/em 10. INDUSTRIAL MAKE-UP WATER SYSTEM As the the tuyere cooling, plate cooling, Totem top and stove cooling water systems are closed circuits circulating with softened water, the open (re-)cooling circuits, GCP, SGP operates with industrial water quality. Industrial water is taken in at the industrial water surge basin, where two pumps P-1052AVB brings the water to the industrial water storage tank 1003, which is located in the tower construction Jindal, Green Feld BF Page 28 of 8 July 28, 200 Document No,: 28042261-1143-D001 Rev. 0© DANIELI CORUS beneath the emergency water overhead tank. The make-up water runs down on gravity to the various consumers as listed below: LV-1301B of -_—_ET-1301 of Plate Cooling System LVv-1302 of CW-1302 of Secondary Cooling System LV-1501B of ET-1501 of Tuyere Cooling System LV-1901 of CW-1901of Hearth Spray Cooling System LV-1286B of _—_ET-1286 of Stove Cooling System LV-5001 of ET-50010f BRCU Cooling System Industrial water is supplied by JSPL, where the supply being regulated by a float valve (LV-1002A) which maintains a set level in the surge basin. The industrial water storage tank has a capacity of 500 m3, with dimensions 10 meter diameter and 6.8 m height (cylindrical part), without roof Industrial water is supplied by P-1052A/B, where the supply being regulated by a float valve (LV- 10028) which maintains a set level in Tk-1002. Any overflow runs back to the surge sump. ‘The pumps are provided with a spill-back line back to the make-up tank. This line has restriction orifice FE-1052RO with a Hold (By JSPL) mm diameter orifice to limit the flow to 10 m*/h. Industrial water, having the following quality, will be supplied to the plant and retained in the industrial water storage tank 1002: pH 72-75 TDH 100 — 200 ppm of Caco3 cl 10- 15 ppm TDS 50 ~ 100 ppm Fe 0.05 0.1 ppm Conductivity 1000 ~ 3000 uS/em Turbidity 5-10 ppm Table for TK-1002 Level (mm) % Working Nozzle Remark Volume m? 0 0 0 Outlet ND250 6365, 93.5 500 Normal level 6500 96 510 ‘Over Flow _ | ND250 6664 98 523) L-1002 _[ LAHH-1002 6528 96 512, 11-1002 LAH-1002 6120 90 480 LT-1002 LAL-4002 | 5780 85 456 T4002 [ LAL-7002 Jindal, Grean Fie BF Page 29 of 43 July 28,2006 Document No. 28042261-143-0001 cut© DANIELI CORUS 41. PLATE/ PLATE HEAT EXCHANGERS The plate and tuyere circuits provide indirect cooling with heat loads from the furnace to the primary cooling water transferred to secondary water by plate/ plate heat exchangers. The secondary water is in turn cooled by the cooling tower CT-1302, There are three heat exchangers: 1, Plate system DC Ni, HE-1301 A The design data of this unit is: Heat Load Primary Water Flow Primary Water Temperature Drop ‘Secondary Water Flow Secondary Water Temperature Rise Primary Side Pressure Drop Secondary Side Pressure Drop 2. Tuyere System DC No, HE-1501 Heat Load Primary Water Flow Primary Water Temperature Drop Secondary Water Flow Secondary Water Temperature Rise Primary Side Pressure Drop Secondary Side Pressure Drop 3. Standby DC No. HE-1301 B 26 MW 2462 m*/hr 84°C 2600 m/hr 80°C 0.8 kPa (design be verified by JSPL) 1.0 kPa (design be verified by JSPL) 7MW 1500 m*/hr 35°C 980 m*hr 5.3°C 0.8 kPa (design be verified by JSPL) 0.3 kPa (design be verified by JSPL) This unit is designed for 26 MW heat load and is of the same design as the plate system unit, but can also operate at the conditions for the tuyere system. In operation, the heat exchanger pressure drops may vary dependent on actual conditions. The primary and secondary water temperature differences given above are for the design heat load. In operation the differences will be lower, up to 5% lower. For both the plate and tuyere primary systems the inlet and outlet water temperatures are indicated as well as the pressures. Plate circuit Inlet Outlet & Inlet Jindal, Green Field BF Document No,: 28042261-I143-001 TI-1301AD & PI-1301AD TI-4301AA & PI-1301AA TI-1301BD & PI-1301BD Page 40 of 43 uly 28, 2004 Rev.:0© DANIELI CORUS Outlet TI-1301BA & PI-1301BA Tuyere circuit inlet TL-1501AD & PI-1301AD Outlet TI-M501AA & PI-1301AA The three heat exchangers are connected to common inlet and outlet manifolds for both primary and secondary water flows. Isolation of the standby heat exchanger on the primary side is provided by valves and spectacle plates. ‘The spectacle plates being included to ensure there is no leakage between tuyere and plate primary circuits. 12. SECONDARY WATER SYSTEM 12.1 Circulation Pumps The secondary water flow to the heat exchangers is softened industrial water supplied by the ‘secondary cooling water circulation pumps. There are four (4) electrically driven, operating in a triple duty — standby arrangement and a diesel driven back-up pump. DC Pump Nos. P-1361 A/B/C/D JSPL Pump Nos. P-1361 A/B/C/D Make: KSB Flow: 1260 m°/h at 36 mic (Head is gestimated) In operation the heat exchanger inlet and outlet valves will be fully open for both primary and secondary flows. The primary flow will be set by the total circuit resistance. The secondary water flow will be established by a restriction orifice in the outlet line. le + Plate System Heat Exchanger HE-1301 A Secondary Water Flow 2600 m*/hr Restriction Orifice FE-1301A-RO Design Orifice Diameter ....mm (by JSPL) + Tuyere System Heat Exchanger HE-1501 Secondary Water Flow 990 m*/hr Restriction Orifice FE-1501-RO Design Orifice Diameter Mm (by JSPL) * — Standby Heat Exhanger HE-13018 (BBB) Jindel, Green Feld BF Page 41 of 49 uty 28, 2008 Document No,: 2804226 1-1143-D001 Rev. 0© DANIELI CORUS Secondary Water Flow — Plates 2600 m*shr Restriction Orifice FE-1301B-RO Restriction Orifice Diameter .... mm (by JSPL) or Secondary Water Flow - Tuyeres 900 m*/nr Restriction Orifice FE-1501B-RO Design Orifice Diameter ... mm (by JSPL) For the standby water instrumentation provided is: = Common inlet temperature TI-1302A with high alarm in PCS. = Outlet temperature from each heat exchanger Plate Th1301F Standby Th1301G Tuyeres Th1501C each with high alarm in the PCS. Note: High temperature alarm setpoints will depend on the average temperature of secondary water leaving the cooling tower in normal steady operation. The common inlet temperature TI-1302A high alarm will be set at 5°C above the average cooling tower temperature. The outlet temperature high alarm for plate tuyere and standby TI-1301F, TI-1301G and Tl- 1501C high alarms will be set at 15°C above the average cooling tower temperature. + Inlet Flows to Heat Exchanger HE 1301A or B and HE-1501: Nominal Flow 3590 m*/hr (RED) Jindal, Green Fete BE Page 42 of 49 Jily 28, 2008 Document No.: 28042261-1143-001 Rev.:0© DANIELI CORUS 12.2 Cooling Tower The secondary cooling system has to absorb the heat of the furnace cooling systems, except the hearth spray cooling system The break down of the required enthalpy drive is given below: Plate Cooling System Tuyere Cooling Water System Under-Hearth Cooling System Jacket Cooling System Hot Blast System Totem Top Cooling System Hydraulic System Totem Top Hydraulic System Cast House Total 23900 kW 5000 kW. 870 KW 480 kW 1400 kW 120 kW 30 kW 30 kW 31530 KW The cooling tower shall be sized for the following conditions: Tdb 44°C Twb 24.63.°C (Dry season) & Tdb 35°C Twb 32.95.°C (Monsoon) Based on the cooling tower characteristic KaV/L = 1 and L/G = 2.17, the following parameters have been estimated: Case 1 (Dry Season) Cold water temperature (Tew) Approach (Ta) Cooling range (Cr) Altitude CT Characteristic (KaV/L) UG ratio Enthalpy Enthalpy drive Dew point temperature Absolute Humidity at Tab Absolute Humidity at Two Increment Evaporated quantity Drift and Loss Blow down Case 2 (Monsoon) Cold water temperature (Tew) Jindal, Green Field BF Document No,: 280422G1-J143-D00t 32.2°C 76°C 73°C 483 m 1 247 77.18 kdikg 66.4 kJikg 16.8°C 12.75 glkg 44.2 glkg 31.5 ghkg 54.2m'h Hold m°sh Hold m‘/h 35.0 °C Revo Page 43 of 9 uly 28, 2004 Revo© DANIELI CORUS Approach (Ta) 45°C Cooling range (Cr) 73°C Altitude 483m CT Characteristic (KaV/L) 1 UG ratio 2.47 Enthalpy 121.6 kdlkg Enthalpy drive 66.4 kJ/kg Absolute Humidity at Tdb 33.7 gikg Absolute Humidity at Twb 62.5 gikg Increment 28.8 glkg Dew point temperature 32.6°C Evaporated quantity 49.6 mh Drift and Loss Hold m°/h Blow down Hold m°sh 13. EMERGENCY OVER-HEAD TANK The common, “emergency” source supply, main branches into’ Zone’ Normal Flow Emergency Flow Mii Mine Plate Zone Once-Through Supply, 2462 1000 Tuyere Zone Once-Through Supply. 1500 800 Hearth Spray Zone Once-Through Supply 250 120 Hot Blast System Once- Through Supply 111 80 Back-up cooling Once- Through Supply 85 60 (max) The emergency supply shut-off valve will be opened when a low-low-low flow of the cooling zone cooling supply main occurs. The emergency water flows on gravity from the emergency supply ‘over head tank to the cooling members and return via the return through in cooling towers. Any excess water overflows to the sewer. Five (5) situations might occur, which set the available hold-up time, ie. Circuit Flow (m*/h) Hold-up time (min) Emergency cooling plate zone 1000 24 Emergency cooling tuyere zone 800 30 Emergency cooling hearth zone 120 200 Emergency cooling stoves 80 300 Emergency cooling for back-up 60 (max) 400 The values given are without make-up water supply from the softened water storage tank TK- 1001. Maximum make up water supply is 150 m3/h. sindal, Green Feld BIF Page 44 of 3 sly 28, 2004 Document No,: 28042261~1143-D001 Rev.:0© DANIEL! CORUS The emergency water volume will be set through a restriction orifice Circuit RO. Bore (mm) Emergency cooling plate zone FE-1301-RO By JSPL Emergency cooling tuyere zone LP FE-1501A-RO By JSPL Emergency cooling tuyere zone HP FE-15018-RO By JSPL Emergency cooling hearth zone FE-1901-RO By JSPL Emergency cooling stoves FE-1201-RO By JSPL Emergency cooling for back-up FE-1403-RO By JSPL The emergency situation (when occurs) that more than one (1) shut-off valves opens is likely to happen in the event of a total power outage. During a total power outage the diesel driven back-up pumps of the closed cooling water systems shall cut in. The probability that two (2) diesel driven back-up fails to cut-in is very low. Essential is that for the plate and tuyere cooling system the back-up pumps can be shared, which is realised by merging the two systems, because the hold-up time for either of these systems is limited (12-15 min). Merging is realised through remote operated isolation valves XV-1301C and XV-1301D. ‘Two case can be determined: 1. Pump P-1351D feeds plate cooling & tuyere cooling system Water flow to plate cooling system 1000 m°sh ‘Water flow to tuyere cooling system 800 m°/h 2. Pump P-1551D feeds tuyere & plate cooling system ‘Water flow to tuyere cooling system 800 m°/h ‘Water flow to plate cooling system 1000 m°/n Therefore the pumps P-1351D and P-1551D are identical Jindal, Green Field OF Page 45 of 9 sly 28, 2008 Document No: 28042261-J143.0001 Rev 0© DANIEL! CORUS ‘The water in emergency overhead tank TK-1003 is softened water. Any over flow returns to the softened water storage tank TK-1001 The level in the emergency overhead tank is regulated with a float LV-1003. Table for TK-1003 Level (mm) % Working Nozzle Remark Volume m? a 0 0 Outlet | NDEOO 5100 700 400 Normal level 5400 96.5 424 ‘Over Flow | ND150 5490 98 431 LT-1603 | LAHH-1003 5400 96.5 424 LT-1003 | LAH-1003 4870 87 382 LT-1003__| LAL-1003 “4480 80, 362, LT-1003___[ LAL-1003 414. WATER BALANCE As there are two sources of water supply to balance the losses for the various systems below a break down is given for the softened water consumers and industrial water in-takers: Softened Make-up Water _ RENE ‘System ‘System Tank Make-up Make-up Duty Cycle Flow | Capacity | Norm Max % mh mth Plate Cooling System | 2462 16 051 90 0.57 Tuyere Cooling Syotom 1500 18 0.31 135, 0.23 Hot Blast Stove Cooling System 411 5 0.023 20 0.115, Bell Less Charging Cooling System 25 25 0.0051 10 0.051 Total 4098 0.848 255 - Industrial Make-up Water— Base Case _ RBiH0 System System | Tank | Make-up | Make-up | Duty Cycle Flow | Capacity | Norm Max % mth min Hearth Spray Cooling ‘System 226 100 22 25 16 ‘Secondary Cooling ; Syste 37a0 | 300 306 | (@7) 100") 30.6 Jindal, Green Fe BF Page 45 of 49 July 28,2004 Document No: 280422G1-1143-001 Rev 0@ DANIELI CORUS Gas Cleaning Plant : : 18 | 040 45 ‘Slag Granulation z 7 ‘ Plant 56.3 | (317) 33072) 7 Plant Wash Down - - 05 : - Moisturising of DC : Aue : 0.25 0.4 - Gas Seal Flush : 18 38 - Slag Abortion : : - 25 : Total 4008 L_ 1087 400 : The base case lists the industrial water users when the softened water system is able to meet the water demand. The extended case is valid when the softened water system cannot balance the make-up water requirement. The make-up capacity of the softened water pump set P-1051A/B is 140 m*/h. RBM One operating pump can meet the normal demand and topping up two systems simultaneously is achieved by cutting in the second pump. (total 290 m*/h) Rei. For the industrial water system the same scheme applies. High slag quantities require two (2) make-up water pumps running. Adequate back-up is available in case a pump failure occurs, through lining up the emergency water tank as a buffer. In the extended case is enumerated the industrial water requirement in the event no softened water is available. The extended case is may lead to ‘extremes, i.e. high slag volumes and cooling water system make-up at regular intervals, which cannot be absorbed by both pumps P-1052A/B running (400 m3/h). Industrial Make-up Water ~ Extended Case System System | Tank | Make-up | Make-up | Duty Cycle Flow Capacity Norm Max % mth mth of norm flow Plate Cooling System | 2462 16 0st 90 0.57 Tuyere Cooling Syatem 1500 16 0.31 135 0.23 Hot Blast Stove Gooling System 114 5 0.023 20 0.115, Bell Less Charging Gooling Syston 25 25 0.0051 10 0.051 Hearth Spray Cooling Syeten 234 100 22 25 18 ‘Secondary Cooling i ‘System 3780 300 30.6 (87) 100") 30.8 Gas Cleaning Plant : : 18 26 7 Jindal, Green Feld BF Page a7 of a9 July 28, 2004 ‘Document No,: 2804226 1-1143-D001 Rev.:0© DANIELI CORUS Slag eet e 56.3 | (317) 330*2) 17 Slag Abortion 7 - 25 : Plant Wash Down 08 - : Waisurang 106 ae oe Gas Seal Flush 18 36 Total 8007 110.5, 400 - Notes: *1) The number between brackets denotes maximum water demand based on a maximum heat load rundown of 8 ton/min singel, Green Fela BF Document No: 28042261~J143-001 Page 48 of 49 *2) The number between brackets denotes maximum water demand based on a maximum slag July 28, 2008 Rev: 0© DANIELI CORUS 15. ATTACHMENT SPRAY NOZZLE FOR HSC Unifet™ spray nozzie TP FLAT SPRAY (STANDARD TYPE) ‘Steuonermcons seratres Surges sy sos PRESSE sma ne “ionv+ TP 11010 -SS Feanac OAH “rater We Jindal, Green Field B/F Page 49 of 49 sly 28, 2004 Document No.: 28042261.J143-0001 ne