Innovative job by RSP team

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    OST Business Bureau
    Rourkela, Oct 24:

    The employees of Hot Strip Mill (Electrical) of Rourkela Steel Plant (RSP) have carried out an innovative job of converting the contractor logic based R0V0 Oil Lubrication system to PLC based control that has benefited the plant significantly, an RSP release said.

    Roughing Mill (R0) of Hot Strip Mill (HSM) is a 2 high reversing rougher and was installed and commissioned in 1997. The mill was fully automatic and was controlled by digital control system technology. The complex has different PLCs apart from the basic automation control system.

    However, the contactor logic based circuits were very congested and it was cumbersome to troubleshoot in case of any problem. The other systems were also creating frequent troubles because of years of wear and tear. The HSM (Electrical) team decided to take up the challenge of total dismantling of the existing circuits, rewire in line with PLC based system totally with in-house resources, the release said.

    According to the release, the job was taken up during the recent capital repair of Hot Strip Mill. A PLC system was therefore designed and engineered by HSM (Electrical) group and after necessary wiring, a program was developed in Siemens Step5 based system and subsequently commissioned during the stipulated period of Capital repair.

    “Since the pumps are now running in PLC based system, maintenance has become easier. The flow and pressure switches are now being monitored on line. The innovative job has saved quite a number of precious rolling hours thereby increasing mill availability and productivity. Since the PLC system has been commissioned using in-house resources, there is a direct cost saving of about Rs 5.2 lakhs. Cost saving due to reduction in delays due to lubrication system failure, is also immense,” the RSP release said.

    Successful implementation of this scheme is a clear demonstration of Frugal Engineering, which is the buzz word in today’s engineering world, the release stated.

    The innovative venture was conceptualized and implemented in house by RK Muduli, AGM, C Nayak, Senior Manager, PK Patnaik, Deputy Manager, Bholeswar Sahu, Senior Technician and SC Behera, Technician under the guidance of K Venkata Ramana, DGM In-charge of HSM (Electrical).