Development of Diagnosis & Repair Methodology for long life of Coke Oven

Battery

Team:-SudhanshuB.D.PandeyAsim BiswasAvijit MukherjeeAsis Kumar SarkarPrakhar Mishra

TATA GROUP OF INDUSTRIES

Mr. J N TataChairmanship :1868- 1904

• The foundation of what would be called the ‘Tata Group’ over centuries was laid in 1868 by Jamsetji Nusserwanji Tata – then a 29 yr old who had learned the ropes of business while working in his father’s banking firm – when he established a trading Company in Bombay.

• A visionary entrepreneur, an avowed nationalist & a committed philanthropist, Jamsetji Tata helped pave the path to industrialization in India by seeding Empress Mills, a textile venture in the year 1877 in Nagpur which was the 1st of the big industrial projects undertaken by him. In 1892 J N Tata Endowment Scholarship started.

• In 1903 the most dazzling of the Tata enterprises that came into being during the Jamsetji Tata’s lifetime was the Taj Mahal Hotel in Bombay.

• Following Jamsetji Tata’s death, in Germany in 1904, the Chairman of the Tata Group passed to the elder of his two sons, Sir Dorab Tata, who accomplished the daunting task of turning his father’s extraordinary ideas into reality.

• Sir Dorab was the force behind the setting up in 1905, of the Tata Iron & Steel Company. In 1910 Tata Power near Bombay.

• In 1911, 7 yrs after his death, Jamsetji Tata’s long cherished dream of establishing an institution where Indians could cultivate their scientific temper was realized. It was then that the Indian Institute of Science brought into existence, which later nurtured some of the brightest minds in India.

Sir Dorab TataChairmanship : 1904-1932

1912 Labor Welfare practices and 8 Hours week1920 Tata Provident Fund ( Govt. 1952)

• By the time of Sir Dorab Tata’s death in 1932, the Tata group had consolidated in business while also getting in new areas, notably insurance & the production of soaps, detergents & cooking oils.

• Sir Dorab was succeeded as Chairman of the Group by Sir Nowroji Saklatwala. In1938, following Sir Nowroji’s demise, 34 yr old, JRD Tata was appointed as the new chairman. He would lead the Tata Group for the next 53 yrs – with wisdom & foresight.

Sir Nowroji Saklatwala Chairmanship : 1932 - 1938

• When JRD Tata was at the helm, the Tata group expanded regularly into new spheres, more prominent were Tata Chemicals(1939), Tata Motors (1945), Voltas(1954), Tata Tea(1962), Tata Consultancy Services(1968) & Titan Industries(1984).

• The beginning of the 1990s ushered in plenty of change in Indian business. Economic reforms opened up many sectors, signaling increased competition & arrival of foreign cos.

• With more than sixty years of experience in top management, he developed his own philosophy and method where leadership was concerned. JRD Tata’s death, in 1993, symbolized the end of an era in more ways than one.

Mr J R D TataChairmanship : 1938 - 1991

“What comes from the people must go back to the people many times over “

• Ratan Tata, who took over as chairman, would guide the Tata Group as it faced a host of challenges in the fast changing business environment. •The Tata Group has, over the past decade and a half, changed more than ever before in its long & illustrious history. Rejuvenating existing business, entering new ones.• In 1996, Tata Teleservices was set up to tap into India’s burgeoing telecom market; in 1998, the Indica came to the markets. Tata Sons successfully acquired Corus Group, Jaguar & Land Rover. •Ratan Tata's dream was to manufacture a car costing Rs 100,000 -the dream which has also come true after many controversies with the launch of NANO very recently.

Mr Ratan N TataChairmanship : 1991-2012

• Acquisitions-•2000 Tata Tetley•2004 Tata Daewoo•2005 Natsteel, Brunner Mond Group (UK)•2007 Tata Corus•2008 JLRs

Some Interesting facts-• Tata’s Equity participation in Tata Steel 7% to 27.5% ( Equity participation of Birla has been more ). Corus is thrice the size of Tata Steel.•In 1991 Rs 14,000 cr Today 130,000 cr•In 2000 22 Companies around the globe now 54 Companies across 6 continents , Exports to 120 countries.

Tata Goes Global -- 2000 and beyond

Metamorphosis of the Tata Group

•Mr. Cyrus P. Mistry is the Chairman of Tata Sons. He is a graduate of Civil Engineering from Imperial College, UK, and has a M.Sc. in Management from London Business School. A Director of Tata Sons since 2006, Mr. Mistry was appointed as Deputy Chairman in November 2011.

Mr Cyrus .P.Mistry Chairmanship : 2012 onwards

The TATA Group - 7 business sectors – 98 Companies

Engineering Materials / Steel Energy Chemicals

Communications & IT Consumer Products Services

Commercial VehiclesPassenger Cars

MetalsComposites

PowerChemicalsPigments

TelecommunicationsInformation TechnologyControl systems

Consumer goods

HotelsFinancial ServicesInternational operationsOther Services

The TATA Group

A business built on a foundation of

“No success or achievement in material terms is worthwhile unless it

serves the needs or interests of the country and its people and is

achieved by fair and honest means.”

– J.R.D. Tata

Trust and Ethics

These values, which have been part of the Group’s beliefs and convictions from its earliest days, continue to guide and drive the business decisions of Tata Companies.

4th

The Tata Group is the world’s 6th most reputed company

Company RankToyota 1Google 2

Ikea 3Ferrero 4

Johnson & Johnson 5Tata Group 6

Infosys 14Source: 'Global 200: The World's Best Corporate Reputations' list, compiled by US-based Reputation Institute.

- Japan

- U S A

- Sweden

- Italy

- U S A

- India

- India

7.13 Mtpa Fy’12

Time

Cap

aci

ty

1911 0.05Mtpa

1935 1Mtpa

1958 2Mtpa

1980 3Mtpa

2004 4Mtpa2005 5Mtpa

2009 5.9Mtpa

Crude Steel Production: Tata Steel India

Major developments in the steelmaking and casting area include the following:

Switchover from open hearth steelmaking to BOF. Adopting optimum LD vessel configuration (to accommodate the high slag volume as a result of high silicon and phosphorus in hot metal) and use of bottom inert gas agitation. Strategy to make low phosphorus Steel. Adoption of continuous casting of billet and slab

8.13 Mtpa FY’13

Evolution and Improvement of Steel Production in Tata Steel

1907 1911 1924-29 1955-58 1960-83 1993-97 2010-2013

Start Up

1st SMS

2nd SMS

3rd SMS

LD#1 &Blt Caster

Closure of 2nd SMS

LD#2 &SCClosure of 3rd

SMS

LD#3 & TSCR

8 Open hearth50-130tons

Duplex process(3 nos 25T Acid Bessemer+3 nos Tilting Basic Hearth)

3 nos 32 T Acid Bessemer+ 7 Open Hearth (up to 200T)

2 nos 130T LD16-strand billet caster

100-130mm2

3 nos 130T LDsingle-strand slab caster

2 nos 160T LD and

two-strand thin slab caster

Evo

luti

on

Life History of Coke Oven Battery #3

Coke Oven Battery #3 First Light up 1940 On 11 th June .Rebuilt [ cold repair on 1958 ]Ist Campaign – 18 years 2ND Rebuilt on 1975 2nd Campaign Life – 18 Years 3RD Campaign Life – 1975 to 2014 Life – 40 Years .

Battery Specification

• Number of Ovens – 27x2 = 54 Nos

• Length of oven sole – 13,760 mm

• Width R/S - 370 MM

• Width C/S - 430 MM

• Height 4570 mm

• Oven c to c dis - 1100 mm

• Streacher Thickness 90 mm

Preventative Maintenance Plan

• Regular Oven Inspection .

• Arresting of Cross Leakage .

• Ceramic Welding on Regular basis after 30 Years of Operation .

• Lance Scope Inspection Inspection/ Welding .

• End Flue Repair

• Full wall repair .

Preventative Maintenance Plan

• Conventional dusting

• Liquid Phase Dusting

• Anchorage Maintenance

• Buck stays Bending Tendency study.

• Back to Back distance measurement .

• Door /Door frame Inspection

• Spring load/Length Measurement .

DIAGONOSIS OF DEFECTS IN OVEN AND FOR REPAIR PLAN OF COKE OVENS

A. Inspection of Ovens

The present status of Battery of TATA STEEL Jamshedpur are as follows .

Battery No Year of Commissioning Nos of Ovens Capasity [MTPA] Type Avg Width/Taper Height 3 1975 27x2 0.3 top charge 400/60 45005 1995 30x1 0.2 stamp charge 460/20 45506 1993 30x2 0.4 stamp charge 460/20 45507 1989 27x2 0.4 stamp charge 460/20 45508 1998 70x1 0.5 stamp charge 460/20 45709 2000 70x1 0.5 stamp charge 460/20 457010 2012 44x2 0.7 stamp charge 564/40 500011 2014 44x2 0.7 stamp charge 564/40 5000

DIAGONOSIS OF DEFECTS IN OVEN AND FOR REPAIR PLAN OF COKE OVENS

A. Inspection of Ovens

Chimney emission

Battery # 5 Pusher side & Coke side Buckstay deflection & Vertical plumb of buckstay.

Spring Changing Report

Battery #3 Ceramic Welding

Battery #3 Ceramic Welding

Reduction in Stack Emission(Battery#3) Year - 2008

Actions:

Heating flues having cross leakages were identified.

Heating walls – cross leakages were rectified by ceramic welding & ABT

Root causes of Stack emisssion:---

Cross leakages in heating walls.

Improper combustion in heating flues.

Before After

Battery # 7-A & B Pusher side & Coke side Buckstay deflection & Vertical plumb of buckstay.

Review of Key Performance Area [KPA]

KPI UOM PlanActual

Basis of Calculation

14-Oct

Inspection of ovens within 5 days from due date as per COMIT schedule % 100 100

(No. of ovens to be inspected within 5 days-No. of ovens could not be inspected within 5 days)/ No. of ovens to be inspected)*100(Total oven-357Delay-)

Attending priority ovens per month % 80 88(No. of priority ovens attended / No. of Non priority ovens)*100(Pri-22,Npri-3)

Submission of Priority report of battery#3, #567 & #89 every fortnightly with variation of +/- 2 days(date for submission of priority report is 1st & 16th of every month)

% 100 100

Compliance to report submission date

Machine availability (ceramic welding m/c, fosclean m/c, compressor, etc. % 100 100

(Total no. of job given - No. of interuption of job due to failure of machine) / Total no. of job given.

Preparation time for ceramic welding activity % <35 8.12 Record of delay sheet

Nos. of Diploma/ITI/Graduate % 10 34.28(Nos. of Diploma/ITI/ Graduate) / total no of man power(MP-35,IT/Gra/Dip-12)

Nos. of rework Nos. 0 0 No. of repeatation of job

Weekly Memo Submission % 100 100

(No. of weekly memo given in a month/ Total No. of memo generated in a month)*100

Monthly report submission by 10th of next month % 100 100Report submitted on (date)(before date-6.10.14)

Lance scope inspection within three days of demand % 100 NA Demand date - Execution date

Attending urgent welding requirement within 4hrs % 100 100

Emergency Job given time to Job execution time and no. of incidences in a month

PPE compliance % 100 100 Compliance to TSL safety audit

LTI/ First Aid cases Nos. 0 0 From your Monthly safety record

Severity Index Point <2.5   Score of TSL safety audit

Batt#3 GCMain Strengthening

Door burning from top has increased.Door burning from bottom and side of the door reduced.

158 Coke side Top 2 Middle 4 Bottom

6th Round - 19.10.2013 250 241 235 225 227

7th Round - 02.01.2014 250 218 194 172 180

8th Round - 04 04.2014 250 212 185 151 159

9th Round - 24.07.2014 250 198 165 136 142

10th Round - 04 11.2014 250 199 164 134 135158 Coke side

Out of such 11 buckstays, in each round of anchorage measurement significant movement were found in buckstay # 74, 76 and 158 Coke side (Detail analysis of cause are being

done).

Buckstay # 158 Coke side was changed.Coke side Buckstay # 74 and 76 are on close observation.

24 Coke side Top 2 Middle 4

Botto

m

6th Round -31.10.2013 250 188 164 148 157

7th Round -27.01.2014 250 185 161 146 156

8th Round - 12.05.2014 250 185 152 142 152

9th Round - 12.08.2014 250 183 146 124 14224 Coke side

25 - Pusher side Top 2 Middle 4 Bottom

6th Round -01.11.2013 250 195 173 150 152

7th Round -30.01.2014 250 198 174 153 155

8th Round - 29.05.2014 250 197 168 140 146

9th Round - 12.08.2014 250 194 164 136 14325 Pusher side

MEETING SCHEDULE

Monthly Meeting / Plant Visit Schedule of Technical Services

Schedule Time People require Agenda Venue Remarks1st week

1st Monday 9.30AM Contractor supervisor, TES Section, Batt. Maint. Sec.

Site visit Batt 8, 9  

1st Friday 3.00 PM All supervisor of TES and contractor

Sectional safety and job performance review

CP Conf. room

To be minuted

2nd week

2nd Monday 9.30AM Contractor supervisor, TES Section, Batt. Maint. Sec.

Site visit Batt 5,6 & 7  

2nd Tuesday

10.00AM Fosbel, BND, Uday, AKT, AB, AM, Sudhansu

Review of Anchorage and ceramic welding

CP Conf. room

 

2nd Friday 3.00 PM All rebuilding supervisor of TES, Uday, AKT, AB, AM, Sudhansu, Alok, Supervisor of supply executive office

Spares review Head TES room

Quarterly review

3rd week

3rd Monday 9.30AM Contractor supervisor, TES Section, Batt. Maint. Sec.

Site visit Batt 10,11  

3rd Friday 3.00 PM All supervisor of TES Sectional safety and job performance review

CP Conf. room

To be minuted

4th week

4th Tuesday 10.00AM Fosbel, BND, Uday, AKT, AB, AM, Sudhansu

Review of Anchorage and ceramic welding

CP Conf. room

 

4th Friday 3.30PM Meeting with Sr. Manager TES Major job planning Head TES room

 

Conclusion

The Health of Battery Once comes in operation its life fully dependents of Operational Discipline . Preventative Maintenance. Temperature Regime Hydraulic Regime Anchorage . Environmental Norms.