SOP on BLOWER TRIP

a) single blower trip

BV PV DROPS BY MORE THAN 500 THAN THE SET VALUE .
BYPASS MODE IS ON . AG LOCKED AT CURRENT POSITION .

BV GOES TO 2900 NM3 . OGSV WILL CLOSE SO CLOSE THE OGCV .

OXYGEN SV TO 0.

CHANGE SV OF BLOWER AND TOP PRESSURE ACCORDINGLY TO PV.

PUT BYPASS TO OFF MODE AND UNLOCK THE AG.

REDUCE CDI TO 12 TPH .KEEP TOP PRESSURE TO MAINTAIN UG , VoT

ACCORDINGLY.
• ASK FOR SINGLE BLOWER VOLUME INCREASE
• 500 KG COKE RATE .
• MAINTAIN RAFT BY ADJUSTING STEAM .
• IF GETTING 3800 OR SO FROM SINGLE BLOWER
• START O2 ENRICHMENT TO 7000 AND INCREASE CDI BY 20TPH
 BOTH BLOWER TRIPPED
• SEMI CLEAN WILL OPEN IN AUTO MODE AS BP GOES BELOW 1.7 IF NOT OPENED
OPEN IT FROM DESK TO ACHIEVE TP 0.
• CLOSE IT ONCE LINE PRESSURE < 200 mm WATER COLUMN
• STEAM , CDI 0
• SAME WITH O2 AS MENTIONED ABOVE
• 2 STOVES ON GAS TO BOX UP .STOP CA & BOOSTER FAN
• START N2 & STEAM PURGING AT TOP

• OFF BLAST PROCESS – BP 0.5 CLOSE THE NETWORK BY DCIV OR DEMISTER GOOGLE
VALVE
• OPEN ALL THE BLEEDER
 OXYGEN PLANT TRIP

• In-case of one Oxygen Plant Trip:

• Make sure from oxygen plant that one oxygen plant is tripped.
• Reduce oxygen up to 9000 NM3/Min after informing oxygen plant. 
• Reduce Top Pressure to maintain UG within 2.4 to 2.5 m/s and TGS 0.85 to 0.95 m/s.
• Reduce CDI to maintain Constant fuel rate at tuyere after checking from heat balance sheet.
• Increase Blast volume up to 5900 Nm3/Min if Dp < 1.6 Kg/Cm2 and Tk < 3.0.
• increase Top Pressure to maintain UG within 2.4 to 2.5 m/s and TGS 0.85 to 0.95 m/s
• In-case of both Oxygen Plant Trip:
• Make sure from the oxygen plant that both the oxygen plant is tripped.
• Ensure Oxygen enrichment valve is closed and put it in manual mode.
• Inform CDI plant to stop CDI injection and put the lance in purging mode.
• Inform CDI Plant to ensure that all the valves in emergency nitrogen supply line is opened.
• Inform Oxygen plant to restore emergency nitrogen supply. 
• Apply Shut down Burden with Burden Calculation Done for 8hours of shutdown.
• Reduce blast volume to adjust fuel rate at tuyere after checking from heat balance sheet.
• Once Nitrogen supply is restored, start CDI at the rate of 20 TPH and gradually increase to maintain the
fuel rate at tuyere after checking from heat balance sheet.
• Increase Blast volume up to 5900 Nm3/Min if Dp < 1.6 Kg/Cm2 and Tk < 3.0.
• DO SHUTDOWN IMMEDIATELY
•
Power Failure Complications
• Blast Volume will become 0 nm3/min almost instantaneously
• Cooling Water pressure will drop
• Water Pressure in GCP will drop
• CA fan will trip
• Light may fluctuate, may become completely dark
• Charging will stop
• All hydraulic pumps, i.e., Stock House, Cast House, GCP, Stove and BLT will trip
• Semi-clean bleeder will open as the blast pressure goes below 1.7kg/cm2.
•

The jobs in the following areas need to be carried out parallelly:

•
COMMUNICATION
•
Inform PBS, EMD, PPC through Hot Line
• Inform Furnace In-charge
• Inform Electrical Shift In-charge
• Shift In-charge should direct the HMI operators for necessary action
• Ensure that CDI injection stops and Nitrogen purging starts in all the lances. No need to close hand valve in case of total power failure.
•

 
•          STOVE 
•
Diesel Generator (MCR Ground floor) should start
• If DG does not start inform Electrical Shift In-charge immediately
• When DG starts RESET the stove hydraulic pumps and START anyone
• Open SNORT 100 % to atmosphere
• BOX-UP the ON-GAS Stoves
• Select OFF Blast from Emergency Desk and BOX-UP the ON-Blast Stove
• Close MASV
• DO NOT open BDSV
•

GCP
•
Ensure ICW supply to pre-scrubber through XV5228. If not open it manually. 
• Open N2 in Dust Catcher. Open Steam and N2 in pre-scrubber. 
• Close Semi-clean bleeder when the blast pressure reaches 0.8kg/cm2.   
• Close DCIV or BGIV respectively.
• Open available furnace bleeders after DCIV or BGIV is closed.
• Open AGE to 65%
•
COOLING
•
Ensure 5 DG Pumps are running (1 HP, 1 LP, 1 Stave, 2 ICW)
• DG pump of LP circuit needs to be started first followed by DG pump of stave circuit and subsequently DG of HP circuit needs to be started. 
•

BLT & STOCK HOUSE

•
RESET the hydraulic pumps and start anyone
• Ensure all valves of BLT are closed
•

                   Cast House
•
Continue tapping irrespective of SGP is running or not
• Open 2nd tap hole if lap casting is not going on
• If lap tapping is going on open 3rd tap hole
• SUDDEN FALL IN THE BLOWER VOLUME RESULTING IN THE BLAST PRESSURE DROP .
• WHEN THERE IS FALL OF MORE THAN 500 NM3 OF VOLUME FROM THE SET VALUE BYPASS ON
COMMAND IS ACTIVE RESULTING IN THE QUICK FALL OF TOP PRESSURE IN ORDER TO MAINTAIN
DIFFERENTIAL PRESSURE (DELTA P) BY LOCKING THE AG AT THE PARTICULAR RUNNING CONDITION
.
• THIS WILL ALLOW THE TOP PRESSURE TO RELEASE IN ORDER TO MAINTAIN DP.
• If oxygen was running shut off valve (OGSV ) will close as the blast drops down to 3500 so close
the control valve ( OGCV ) set value should be changed to 0 .
• CDI should be reduced to 12 TPH if 3000 NM3 blast is available.

• WHEN THE CONDITION IS NORMAL . INCREASE THE VOLUME TO 3700 OR WHATEVER MAXIMUM
CAN BE GIVEN BY THE SINGLE BLOWER
• RESUME THE NORMAL OPERATION BY EQUALIZING THE TOP
PRESSURE WITH THAT OF RUNNING PROCESS VALUE AND THE BLAST
VOLUME SET VALUE TO THAT OF EQUAL TO THE CURRENT BLOWER
END VOLUME .
• GO FOR BYPASS OFF AND UNLOCK THE AG FOR NORMAL CONDITION
THEREAFTER GO NORMAL INCREASE OF VOLUME WHEN EVER 2ND
BLOWER COMES IN LINE
b) Both Blower Tripped.
• Incase of both blower trip , blast pressure falls drastically and below 1.7
kg of it semi clean will be opened to release the top pressure .
• Isolate the furnace in that condition from the stove side
• Put the on gas stoves to box up close the CA fan and booster fan to off
mode .
• Put the on blast stove to box up .
• In furnace side start purging at the furnace top by steam and nitrogen
• Cast house side open the tap hole as soon as possible . One should be
running other should be opened immediately to avoid chances of slag
back . If 3 are available open all within no time . .
• Close the bleeder at line pressure 200 mm water column to maintain
positive pressure.
• Look into the peep holes of tuyere to see any slag back into the
tuyere if it so take into note how many and in which particular tuyeres
it is.