RMOC 2024

VISION, PURPOSE, DOLVI’s MISSION & VALUES

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Compact Strip Production Layout (HSM-
(HSM-1)

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 CSP MILL LAYOUT AND CONFIGURATION
CSP MILL SCHEMATIC
HEATING ZONE HOLDING ZONE
MILL

LINE B MEASURING LAMINAR COOLING

GAUGE

TOP PINCH ROLL

TOP PINCH ROLL
DESCALAR
RTB

LINE A

ERT
ROT BOTTOM PINCH
HEATING ZONE HOLDING ZONE BOTTOM PINCH
ROLL ROLL
EMERGENCY F1 F2 F3 F4 F5 F6 DOWN PARSYTEC
SHEAR

TUNNEL FURNACE

Tunnel Furnace Line A Line B Emergency Shear ( Toggle Lever ) ERT & Descaler Mill ROT ( Run Out roller Table ) Pinch Roll
No of Rolls 2 ( Top & Bottom )
Max. shear force 5500 kN No. of ERT Rolls 13 No. of 4 Hi stands 6 Length 80 m Diameter Top - 900/880 mm DOWNCOILER 1
Length of Furnace 185 m 182 m DOWNCOILER 2
Width of Furnace 1.96 m 1.96 m Top knife stroke 300 mm Roll Dia 300 mm Slab Thickness 55 mm to 65 mm No of Rollers 240 Bottom - 400/380
Height of Furnace 1.376 m 1.376 m Bottom knife stroke 194 mm Strip Thickness 1.2 mm to 25 mm Roll Diameter 260 mm mm
Average Temperature 1150 ± 7 deg C 1150 ± 7 deg C Top knife 5.2° V - Shaped Spray Headers 2 nos. Strip Width 900 - 1560 mm Drive 4.6 kW Motor 300 kW ( Both )
No. of Zones 6 5 Concave Entry - Low Press. 260 bar Max Speed 12.6 m/s Speed Range 0 - 15 m/s Speed 0-15 m/s ( Both )
No of Burners 111 105 Bottom knife Straight 2 nos. Steel Grade Cold Rolling/Structure/LPG/HSLA/API SHORT WALKING
Convex Exit - High Press 380 bar Gap Control Hydraulic Cylinder Laminar Cooling Breast Rollers BEAM
No of Photocell 24 21
Furnace Rolls 169 ( 49 Dry + Wet 120 ) 166 ( 46 Dry + 120 Wet ) Knife width 1800 mm Nozzle type 26° Flat- Stand Capacity 40 MN( F1-F4 )- 32 MN ( F5-F6 ) No of Rolls 4
jet LIFTING CAR
Diameter of Rolls 305 mm 305 mm Min Temp.at cut 600 °C Roll diameter 800/ 730 mm - 600/ 545 mm Length 38.7 m Roll diameter 300 mm
Roll Material Wet - Ni-Cr Alloy with refractory in between Min. cutting interval time 30 sec. Nozzle 18 l/min Roll Barrel length 1950 mm - 1950 mm Zones 1 no. Compact 10 bar Motor 4.6 kW ( 1100 rpm)
Dry - High Alloy Steel at Shaft & Mild Steel at shaft Top Knife Cylidner 200/110 x 440 100 bar Roll Material HiCr, HSS - ICDP 1 no. Spray 10 bar Speed 0-15 m/s
Roll Drive 2 HP Each roll 2 HP Each Roll mm Operating pressure 200 bar Number of the nozzles 40 per Mill Drive 7000 kW - 7000 kW 4 nos. Micro 0.7 bar Downcoiler 1 & 2
Drive Speed 4 - 60 m/min 4 - 60 m/min Bottom Knife Cylinder 480/340 x 435 header 1 no. Trim 0.7 bar Hold Down Roller
Scale Cleanout Doors 70 ( Pneumatic) 70 ( Pneumatic) mm Total water quantity 5160 Measuring Gauge Roll daimeter 300 mm Mandrel Design 4-segment wedge mandrel
Regenerative Chimney 2 ( 1 - Heating, 1- Holding) 2 ( 1 - Heating, 1- Holding) Operating pressure 200 bar l/min Parsytec Camera Motor 4.6 kW ( 1100rpm ) Diameter Collapsed 727 mm
Fuel Used COG OR RLNG COG OR RLNG Multifunction Gauge for Thicknes/Width/Profile/Flatness Measurement Top Parsytec is used to check top surface finish and Speed 0-15 m/s Expanded 762 mm
SAMPLING Pre Exp 745 mm
LONG WALKING STATION
Motor rating 800 kW
BEAM
Drive AC with Change Speed Gear
Speed 0- 200 / 600 rpm
CIRCUM
STRAPPING Wrapper Rolls 3
Arrangement Periphery of Mandrel
Daimeter 380 mm
Drive AC with universal shaft
EYE STRAPPING Motor Rating 0- 28.54 kW
Speed 0- 15 m/s
Gap Setting Hydraulic
Chute Plate Used for guide the Strip to
Mandrel for Wrapping

Layout Swivel Coil Conveyor

WEIGHING 22 Positions comprises Stripper Car, Lifting Car, Short Walking

MACHINE Beam, Lifting Table and Long Waking Beam. Online facilities
included are Sampling, Strapping and Weighment.

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 Journey of CSP

• CSP Commissioned • Capacity enhancement • Capacity enhancement 2.6 to 3.5 MTPA

• Capacity enhancement 2.4 to 2.6 MTPA • TF Fuel Converted from LDO to RLNG
1.2 to 2.4 MTPA • Dual Fuel Firing introduced (RLNG / COG )
• Revamping in Caster-1 to increase
Metallurgical Length to 9.4 Mtr & to • X Tek Pinch roll Introduced
equipped with LCR & EMBR facility • MMS Upgradation in Caster
• Caster 2 Level 1 Upgradation
2004- • 5th CNC Milling Machine
1998- 2008 Installation
2003 2009-
2016 2017- • Settling tank installation for
2021 water quality improvement

2022
• RGM 260 Revamping
• Introduction of Advanced
Tundish Outlet Modifier

2023

25 Years old
Facility
First CSP in
India
5
 Key Grades & Applications
Hot Rolled Steel
APPLICATIONS JSW GRADE EQUIVALENT
IS 5986 Fe 360
JISG3101 SS330
SG37AL/SG37AT
Fabrication of Agricultural, Industrial and Mining machinery DIN17100 St 37.2
parts like Bins, Hoppers, Chutes, Etc. EN10025 S235 JR G2
DIN17100 St 44.2
SG41AL/SG41AT
EN10025 S275 JR
Boiler & Pressure Vessel Parts MC26BQ ASTM 516 Gr.60, Gr.70

Machine parts, Panel SH41AM JISG3113 SAPH400

IS 2062 A, B, C
Machinery foundations, Base plates, Mining and Agricultural ASTM A570 D Gr. 45
ST41AL/ST41AT
machinery Parts
JISG3101 SS400 DIN17100 St 44.2,
EN100025 S275JR,S275JO
ASTM A570 Gr.50
ST46CL / CT
JISG3113 SAPH440
Mining & Industrial machinery Parts requiring higher strength
under static and dynamic loading DIN 17100 St 52.3
ST52AL / AM / AT
EN 10025 Fe 510 B

ST54AL/AM / AT IS 8500 Fe 540 B

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 Indian Machinery Industry
1.Power Equipments
HRS CRS GP CCS

 
Product Applicability

2 3
Power Transmission Machinery: 1
Transformer Tank

Power Distribution Machinery: 2

Switch Gear Parts
Electrical Panel Box 3

Power Generation Machinery: 4

Generator set

1 4

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 Indian Machinery Industry
2.Process Equipment
HRS CRS GP CCS


Product Applicability

3
Water Storage Tank 1

Boiler Tubing 2

Pressure Vessel 3 Pressure Vessel

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 Indian Machinery Industry
3. Construction Equipments
HRS CRS GP CCS
Product Applicability


Forklift 1 1

Loader 2

Tracked Excavators 3

2 9
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 Indian Machinery Industry
4.Industrial Equipments
HRS CRS GP CCS

 
Product Applicability

1
Overhead Crane 1

Belt Conveyor 2

Chain Conveyor 3

3
2

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 What is the Problem…?

CVC piston rod locknut looseness causing TCS

release which further leads to CSD, chopping
and profile variation, resulting production and
quality loss.

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 Monthly Trend – TCS release

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 Monthly Trend – CSD due to TCS release

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 ANALYSIS OF THE PROBLEM

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 Possible Root Causes-TCS Release

Sr.No. Brainstorming
1 Looseness of lock nut
2 Cable twisting
3 Malfunctioning In movement in CVC cylinder

4 Malfunction of Servo Valves

5 Design of locking mechanism

6 Axil Thrust due to lack of lubrication

7 Improper installation practise

8 Improper Locking of locknut

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 LIST OF POSSIBLE CAUSE AND THEIR VALIDATION
SN Potential Causes Observation Remark

1 Looseness of lock nut TCS release Servo current Valid

2
Cable twisting TCS release Servo current Valid

3 Malfunctioning In movement in CVC cylinder Process interruption Valid

4 Malfunction of Servo Valves Servo current Valid
5 Design of locking mechanism Repetition of issue Valid

Axil Thrust due to lack of lubrication

6 Movement of Cylinder Invalid

Improper installation practice Repetition of issue

7 Invalid

Improper Locking of locknut

8 Dismantling of CVC for correction Valid
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 LIST OF ROOT CAUSES (VALIDATED)

SN Root Causes Observation

1 Looseness of lock nut TCS release /Servo current

2 Cable twisting TCS release /Servo current

3 Design of locking mechanism Repetition of issue

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 LIST OF POSSIBLE SOLUTIONS

SN Root Causes Possible Solutions Validated (Y/N)

X1 Looseness of lock nut

1.1 Proper locking of locknut while installation Y
1.2 replacement of Backwasher Periodically Y
1.3 time based checking of CVC locknut loosening Y

X2
Cable twisting
2.1 Prevention rotation of cylinder rotation by ensuring non loosening of
Y
locknut

X3 Design of locking mechanism

3.1 Modification in Locknut mechanism Y
3.2 Change in design Y

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 SOLUTION IMPLEMENTATION

HOT STRIP MILL

LOCK NUT
CVC assembly
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 SOLUTION IMPLEMENTATION

CVC assembly
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 SOLUTION IMPLEMENTATION

Weak Locking
Loosened Locknut
Twisted Cable

Looseness of lock nut Cable Twisting Design Issue Weak locking

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 SOLUTION IMPLEMENTATION

OLD Design
Locknut

NEW DESGN –
SUPERNUT
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 SOLUTION IMPLEMENTATION

CVC PISTON OLD DESIGN CVC PISTON NEW DESIGN –Thread Length Extended
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 SOLUTION IMPLEMENTATION

CVC Flange OLD DESIGN CVC Flange New DESIGN

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 SOLUTION IMPLEMENTATION

Loosened Locknut old Design

Twisted Cable old Design

SUPER BOLT

Design Issue Weak locking

RMOC 2024 25 Installed Super Bolt
 SOLUTION IMPLEMENTATION

TOP VIEW OLD DESIGN TOP VIEW NEW DESIGN

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 CASTING SPEED DELAY AND TCS RELEASE / MONTH

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 ACTUAL SAVING CALCULATION

Data Collected from Jan 23 to Jun 23 and July 23- Nov 23

• Casting Speed Delay in minutes (Jan 23 to Jun 23) – Avg 17 minutes /month

• Cost of per min delay – Rs 80,000

• Target – 80% Reduction

• After Project implementation Casting Speed Delay in minutes (July 23- Nov 23) – 2.2 minutes /month

• Savings After Project implementation -11.84 lacs per Month

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 TANGIBLE AND INTANGIBLE BENEFITS

Intangible Benefits
Tangible Benefits

Reduction in casting speed delay Less human fatigue

Reduction In TCS release Safety of person

Increase in Production Employee Moral improved

Increase in MTBF Employee Knowledge Enhanced

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Thank You !
#BetterEveryday