ROURKELA STEEL PLANT

STEEL AUTHORITY OF INDIA LTD.

PRESENTS A PAPER FOR THE AUGUST PLATFORM OF
DTSM’21 ON

USE CASES OF DIGITAL

TRANSFORMATION IN THE
BOF SHOP OF STEEL
MELTING SHOP-II OF
ROURKELA STEEL PLANT.

Presented By
Rohit Ranjan
Manager, SMS II(E)
SAIL, RSP
Mob no.8895504211

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ABSTRACT
Steel Melting Shop-II has undergone numerous technological upgradations since its inception. It has
set numerous records for RSP and SAIL in the production process breaking all notions of limitations
that was comprehended erstwhile. A major chunk of the credit for these achievements goes to the
robust automation system and our steadfast efforts to upgrade it in sync with technological
developments around the world. The exponential growth in innovations in the field of Information &
Communications Technology and Power Electronics has made it absolutely imperative to catch up
with its pace to remain significant in this extremely competitive market of the contemporary world.
This paper describes some examples of our dedicated effort in the BOF area to show that we are on
the right path of digital transformation and ready to embrace the next era of Industrial revolution,
i.e.,4.0. Our PLC communication network for Conv 1 and 2 has been upgraded to the latest TCP/IP
protocol-based communication. Drastic efforts have been made to convert the existing system of huge
control desk to user friendly, compact HMI based process control. Continuous efforts have been made
to make the steel making process free of human intervention, automated pattern-based blowing and
setpoint based flux addition being prime example of that. More and more data are being added at both
Level 1 and Level II for precise monitoring of KPIs, equipment health and improved data analysis.
The development of ring network of CCTV cameras has enhanced the level of process monitoring and
enable us to reap huge benefits from safety point of view.
Keywords-BOF, network, communication, Industry 4.0, technology.
INTRODUCTION
Steel Melting Shop is the first stage in the Steel manufacturing value chain where product
differentiation and customization start. Our Steel Melting Shop -II, with state-of-the-art
technology adheres to ISO-9001-2015 norms and focussed on meeting the demands for our
customer in terms of High productivity with highest Quality based on strong foundation of
Environment and Safety Standards.
On 7th November 2021, SMS II completed its 25 years of inception. It was commissioned in
1996 with the latest technologies of Industry 3.0 comprising of 2 Converters of 150T capacity
and 2 single strand Continuous Casting machines. The automation system consisted of a
number of PLCs, DCS, SCR based drives all integrated with coaxial cable networking using
repeaters.
Converter C came along in 2014 with the new modernisation programme with its new
innovations of the time consisting of Fibre optic network integrated with RS485 protocol,
HMI based process control, IGBT controlled AC drives and motors.
Our leaders in automation had realised this fast pace of technological revolution. They
chalked out a plan to upgrade the existing networks, equipment and process control of
Converter 1 and 2 and decided to bring it at par with Converter 3 and beyond. Thus, began a
phase wise implementation of series of AMR projects and inhouse modification to begin our
preparedness for Industry 4.0.
The result of these efforts has helped our department achieve a series of records surpassing
all previous milestones.
1. Highest Blow on a Single day -81 on 27th March 2021
2. Highest Blow with 2 Converters i.e., B and C-73 on 19th August,2020.
3. Highest Number of Blow in Single converter in a day- 48 in Conv C on 2nd
July,2020.
4. Best ever Half yearly Crude steel production since inception-1731272 T(April-
September,2021).
The following section describes a number of examples of our ceaseless efforts that has
instilled our confidence in abilities of our robust automation system that led to achieving
these milestones.
 Exhibit 1. Layout of Steel melting Shop -II

THE STEEL MAKING PROCESS

Steel making involves the following treatment done in various sections of Steel Melting
Shop:
1. Hot Metal (HM) Pre-treatment / Hot Metal Desulphurization.
2. Primary Steel Making (BOF Vessel / LD Converter).
3. Secondary Steel Making (LHF / RH degasser).
4. Continuous Casting.

Primary Steel Making (LD Converter/BOF Vessel)

Process Features
Our BOF complex consists of the following subsections valid for all three converters as
shown in the Exhibit 2:
 Exhibit 2. Primary Steel Making equipment involved in LD process

BOF Shop automation is complex and huge. In BOF shop following are major areas.
1. Mixer, DS Plant and Hot metal car
2. Converter Tilting & Lance system, Lance trolley, Lance cooling, Steel Car,Slag car,
Ladle transfer car.
3. Gas Cleaning Plant with recovery system
4. Flux and Ferro alloy system
5. Belt conveyor system
6. Water system.
Besides this, Integrated Dedusting System for suction and removal of Dust during the entire
process from all three converters is presently working. Another system for Dedusting of
Mixer area, Conv A, B flux, ferroalloys also present.
All these subsystems are integrated by our robust automation system to ensure high quality,
safe and productive steelmaking.
Automation -Present Conditions
1. Converter A, B system is Level 1 system with ABB MP200(18 nodes, AC450 PLC (5
controllers) integrated with Tyrak Midi DC Drives for Converter (4 motors),2 Lance
Motors,4 steel car motors ,4 slag car motors, one Interbay Car. PLC and Drives are
communicating through Modems using Coaxial Cables. Individual Nodes were
communicating through Ethernet network using UTP converter with software and
hardware redundancy(Recently Modified ,originally coaxial cable network).
 2. Converter C is Siemens S7-400 based PLC with 5 main PLC namely BOF, GCP,
MHS, GRP, Common and Dedusting with their RIO units located at different remote
locations interconnected to each other using Profibus and Fibre Optic network.
3. Drives in Conv C are ACS 800 communicating with PLC using Profibus. Also we
have MCC protection systems called Simocode for monitoring and protecting our
MCC equipment.
4. The original system in Conv A, B also provided us with a GCOM Gateway to Level II
data servers (Matrikon). Some signals of Conv C have also been added to the same.
5. HMIs in now original systems (Conv A, B) have been upgraded to 800XA(ABB) in
server client system with Hot redundancy.
6. Conv C also has Server Client Configuration along with Emergency Server base on
WinCC. (Siemens) with Hot redundancy.
Important Modifications Successfully Implemented
Quality/Process Improvement based Modifications
1. The automated Blow pattern in Conv A, B was non-functional since long time.
Provision was made for auto adjustment of Lance height of blowing in coordination
with Oxygen flow. Manual override of the process has also been provided.
Advantage: Inconsistency in blow pattern is removed. The blower has now more
time to focus on controlling the additions of fluxes and thus, empowered with
more control over the process.
2. The project of converting Vibrofeeders, Sector gate to unbalanced motors in
Converter A, B for Flux Addition is in fast progress with conversion of 6 Weigh
Hoppers already done. (2 left).For bunkers ,6 of them have been converted from
Vibrofeeders to Unbalanced Motors.
Advantage: Faster and more controlled discharge of Flux leading to quality
heats as per specification.
3. Also, the calculation for discharge from each bunker for a particular heat has been
automated. Earlier, only the Weigh Hopper discharge weight was noted.
Advantage: Data keeping for each heat has been simplified and tracking of
discharge from each bunker for a heat will help keep track of actual inflow of
each raw material from CP-II.
4. Ferro Alloy addition has been categorised into different grades of steel and
automated. Earlier, it was manual start, stop control. The addition of Level II screens
at tapping desk helps the operator track record of each heat addition of Ferroalloys.
Advantage: Data keeping for each heat has been simplified and grade wise
addition has helped maintain consistency of grades.
5. Earlier, the operation of Conv A, B was 40% HMI and 60% control desk (Push button
based). Now, its 80% HMI based and 20% control desk based due to continuous
improvement and investment of huge efforts in the accumulating operation of almost
all process -based equipment through HMI. (Which was not a part of ABB 800XA
upgradation project).
Advantage: User friendliness of operation has increased manifolds with a huge 6-
metre-wide control desks now being converted into a 15-inch-wide screen with
keyboard and mouse. Now the main focus of the blower remains not somehow
managing the process but controlling its quality with superior confidence.
6. Ongoing modifications are going on to develop a .NET based information system for
eLogbook making of different parameters like Metal Analysis, Metal balance,
Torpedo position and Equipment Shutdown and breakdown History.
7. Already in pipeline is a project to integrate all three converters’ data through and
upgraded Level II Server and Gateways, finally getting connected to Plant status.

Exhibit 3: Proposed layout for Level II data exchange for three converters

Maintenance based Modifications

1. UPS system for PLC of Conv A, B 60KVA was upgraded to a newer version, shifted
to New Conv C MER (having excellent cooling system) with running and standby
mode using in-house manpower and skills.
Advantage: Led to savings of Lakhs of Rupees. Win-Win in terms of both
technology and price. Robustness and Reliability of system increased manifold.
2. ID Fan1, ID Fan2 have been upgraded to VVVF drive controlled system from Fluid
coupling based speed control.
Advantage: Mechanical maintenance of Fluid Coupling was a tedious and long
process. Spare availability was a serious concern. Energy consumption with
VVVF speed control has been reduced drastically by 25%.
3. Networking of all Controller Nodes for Conv A, B have been upgraded from Coaxial
cable to Ethernet based Switch network with addition of Server Client Configuration
for new 800XA HMIs in hot redundancy with communication speed of 10Mbps.
Advantage: Faster and reliable communication between process-based
commands, PLC, RIO units and field devices. Simpler and updated technology
of network configuration leading to quicker diagnostics.
4. 3 numbers of PLC were upgraded from ABB MP200 controllers to AC450 controllers
out of which one node for Converter tilting was upgraded totally by in house
resources and expertise.
 Advantage: Issues of PLC overloading, communication failure resolved with
faster communication speed and isolation of processor rack from field device
racks leading to better performance and reliability.
5. Secondary dedusting system PLC has been upgraded from S7 417-4H to S7417-5H
with inhouse skills and efforts.
Advantage: S7417-4H spares have started getting costlier with time. This will
have direct savings of around 50 lakhs rupees. With inhouse upgradation, now
we have the confidence of upgrading other 4 major controllers to their higher
version at an accelerated rate.

Electric Overhead Travelling (EOT) cranes

SMS-II has 15 numbers process cranes in BOF area. Cranes are lifeline of SMS-II in terms of
logistic. Optimum availability of Cranes is a major criterion for the lead time of our
production.

Process Features
BOF complex cranes consist of the following major types:
1. 250 T and 100 T cranes for liquid metal and slag handling.
2. 50 Ton cranes for lance transfer.
3. 20 Ton cranes for scrap loading.
4. 100 Ton Semi portal crane for scrap bucket handling.
Automation -Present Conditions
1. In BOF complex, 5 cranes have VFD system with Sq. cage motors and 2 no’s out of
them are PLC controlled.
2. Cranes are operated through master controllers at cabin with drive status indication
lamps. Slag yard cranes are operated through remote transmitters.
Modifications Successfully Implemented
1. Wi-Fi based Remote display of load cell data available at control room for 2 nos. Hot
metal cranes and 2 nos. Liquid steel cranes without auto data updating in SCADA.

New Era of CCTV camera network in SMS-II

Earlier we had analogue cameras mainly for thimble viewing of Converter 1 and Converter 2,
but in last two years entire SMS II has been covered with 36 digital cameras in an optical ring
network at all strategic locations with Wi-Fi based display for all metal handling cranes
ensuring highest level of process monitoring and safety. Converter C as its own network of
digital cameras. Day by day, the area covered under supervision is increasing with continuous
addition of cameras.
 Exhibit 4: Newly installed Optical ring network of CCTV

CONCLUSION
There are numerous AMR projects currently in execution mode and some in the pipeline. viz.
1. Conversion of DC motors of tilting drives to IGBT driven Squirrel cage induction
motors for both Converter 1 and 2.
2. Installation of IIOT devices for monitoring of temperature, humidity, current of
relevant equipment.
3. Conversion of Relay based B1, B2 old dedusting systems to PLC and HMI based
devices which will enable us to integrate the old and new Secondary Dedusting
systems with the Server of Environment Engg. department.
4. Conversion plan of ID fan 3 from fluid coupling drive to VVVF drive has also been
chalked out.
Thus, it can be concluded that we are fully committed to the path of Industry 4.0 which will
take our Data analytics to the next higher level, improve our KPIs, enhance our productivity
to meet the vision that SAIL and its pioneers, i.e.,
To be a respected world class corporation and the leader in Indian steel business in
quality, productivity, profitability and customer satisfaction.

ACKNOWLEDGEMENTS
I am thankful to Shri S. Palchowdhury sir, CGM(Instrumentation) and Sri P.Nath sir,GM (E)
SMS-II for guiding through the development of this paper.

REFERENCES
1.RSP panorama