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B Equipment Manual
Projekt / Project Datum / Date Index / Index Seite / Page
J711 2100 / JSW-SMP 2010-08-06 01 1/1 ©2010 by SMS Siemag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
175t BOF Converter
Projekt / Project Datum / Date Index / Index Seite / Page J711 2100 / JSW-SMP 2010-08-06 01 1/1 ©2010 by SMS Siemag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
MANUAL J711 2100 / JSW-SMP
175t BOF Converter
JSW STEEL LIMITED Toranagallu, India
Year of Supply 2010
A - Operating Manual
B - Equipment Manual
C - Subsuppliers’ Components Manual
D - Erection Manual
E - Electrical Equipment Manual
T - Technology Manual
B0 Contents
Table of contents B-Equipment Manual
1 Lubrication Instructions………………………………………… B1 / Register 1.0
2 Plant Equipment………………………………………………….. B2 / Register 2.0
Description
Sub-register
Oxygen Lance Installation 2 / 1
Projekt / Project Datum / Date Index / Index Seite / Page
J711 2100 JSW-SMP 2010-08-06 01 1 / 1 2009 by SMS Siemag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Auft.-Nr. / Order No. Stand / Revision Index Blatt / Sheet
J711 / JSW-SMP 09/08/2010 - - 1 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher.
Lubrication instructions
1.1 General instructions
1.1.1 Grease lubrication
1.1.2 Oil lubrication system
1.1.3 Other parts to be lubricated
1.2 Lubricant recommendations for grease and oil SN 180 Parts 1 and 2
1.3 Terms used in the lubrication instructions SN 181
1.4 Lubrication instructions
B1 Lubrication instructions
Auft.-Nr. / Order No. Stand / Revision Index Blatt / Sheet
J711 / JSW-SMP 09/08/2010 - - 2 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher.
1.1 General instructions
1.1.1 Grease lubrication
The grease types and lubrication cycles specified in the lubrication instructions must be
followed.
Mixing
Greases with different types of saponification must not be mixed.
Adjustment of the centralised grease lubrication system
For economical lubricant consumption, the centralised grease lubrication system has to be
adjusted during commissioning of the plant by the commissioning staff of the seller to suit the
plant operating conditions.
This setting refers to the following activities:
The lubrication intervals for the individual grease lubrication systems shall be checked via
the relays of the pump controls.
The grease volume per lubricating point shall be set at the respective lubricant metering
block.
Initial grease fills
For nipple and central lubrication, the initial fill must be made in such a way that grease
escapes from the bearing points.
Danger of contamination
Cleanliness is of prime importance when handling greases, for instance during
storage (always keep container sealed)
decanting.
Cleaning of bearings
Cleaned all bearing parts with petroleum ether, acid-free kerosene or another suitable cleaning
agent, followed by immediate protection against corrosion by thoroughly covering them with oil
or grease. If compressed air is used for drying the bearing, it must be free from water.
B1 Lubrication instructions
Auft.-Nr. / Order No. Stand / Revision Index Blatt / Sheet
J711 / JSW-SMP 09/08/2010 - - 3 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher.
1.1.2 Oil lubrication system
Use of the oil grades specified in the lubrication instructions is mandatory.
The specified quantities must be checked and adjusted as necessary during operation.
Oil change
Used oil is to be drained at operating temperature. Closed gear boxes must be cleaned by
flushing them.
High-viscosity oils
High-viscosity oils must be heated before use.
Doped oils
Doped oils must be flushed with the oil grade provided for operation. This does not cause any
problems during re-filling.
1.1.3 Other parts to be lubricated
If necessary, the chains must be cleaned before relubrication.
The lubricant should be applied in the relieved area on the inner side of the chain, if possible.
1.2 Lubricant recommendations for grease and oil Refer to the following pages: SN 180 Parts 1 and 2
B1 Lubrication instructions
Auft.-Nr. / Order No. Stand / Revision Index Blatt / Sheet
J711 / JSW-SMP 09/08/2010 - - 4 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher.
Betriebsmittel Operating media
Schmierstoffempfehlungen FETT Lubricant recommendations GREASE
SN 180 Teil / Part 1
Fettarten gemäß Types of grease as per
Vorschläge der Lieferanten / Recommendations by grease supplier
Sch
mie
rsto
ff N
r.
No.
of l
ubric
ant
DIN 51502
MOBIL SHELL ESSO TEXACO( DEA ) BP ELF Klüber Tribol
Typischer Anwendungsfall
Typical
application
1 KPOK-20 KPOOK-20 oder ähnlich or similar
Mobilplex 44 Tivela- Compound A Spezial-Getriebefett H
Grease S 3655
FIBRAX EP 370 EP Grease 350
Fließfett S 420
Fluidized grease S 420
Multifac EPO ( GlissandoEPO )
EnergreaseHT-EP 00
Epexelf 00
Klübersynth GE 46-1200*) Grafloscon C-SG 0-Plus
Tribol 5000
Molub-Alloy Fett 0/00 Tribol 9020
Zahn- kupplungen Gear couplings
2 KP2K-20 Mobilux EP2
Alvania EP2
BEACON EP2
Multifac EP2
( GlissandoEP2 )
EnergreaseLS-EP2
Epexelf 2 Centoplex 2 EP
Centoplex GLP 402
Tribol 4020/220-2
Molub-Alloy 860/220-2
Wälz- und Gleitlager
Antifriction andplain bearings
3 K2N-30 _
_
_
Texando FO20
( Spectron FO20 )
_
_
Stabutherm GH 461
Barrierta 1) L 55/2
Molub-Alloy 894
Tribol 9020
Molub-Alloy 2115-2 1)
Wälz- und Gleitlager max. 250°C. Bei häufiger automatischerNachschmierung
Antifriction andplain bearingsmax. 250°C for frequent automatic regreasing
4
NEVER SEEZ NS Never Seez compound corporation Broadview, Illinoise 60153 USA
Wolfracoat C Molub-Alloy 298
Gleitflächen, Zahnstangen
Sliding faces,racks
5 KTC2K _
_
-
_
_
_
Isoflex Topas L 32
_
Exzenter- buchsen für CL-Gerüste
Eccentric sleeve for CL-stands
Außer den genannten Schmierstoff- Lieferanten können weitere nach Rücksprache verwendet werden, z.B.: Apart from the makes of lubricant indicated, other makes may be used, e.g.:
ADDINOL Mineralöl GmbH Lützkendorf 06242 Krumpa / Geiseltal
*) Synthetischer Schmierstoff, nicht mit Mineralöl mischen Synthetic lubricant, do not mix with mineral oil
1) Diese Fett ist abhängig von der Betriebstemperatur für Lebensdauer-geschmierte Lager sowie als Abdichtfett bei „Einmalschmierung“ oder für lange Schmierintervalle geeignet Depending on the operating temperature, this grease is suitable for bearings with service-life lubrication and as sealing grease for service-life lubrication or for long lubrication intervals.
Please observe the lubricant qualities specified in the lubrication instructions!
B1 Lubrication instructions
Auft.-Nr. / Order No. Stand / Revision Index Blatt / Sheet
J711 / JSW-SMP 09/08/2010 - - 5 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher.
Betriebsmittel Operating media
Schmierstoffempfehlungen ÖL Lubricant recommendations OIL
SN 180 Teil / Part 2
Ölarten gemäß Types of oil per
Vorschläge der Lieferanten / Recommendations by grease supplier
Sch
mie
rsto
ff N
r.
No.
of l
ubric
ant
DIN 51502
MOBIL SHELL ESSOTEXACO( DEA ) BP ELF Klüber Tribol
Typischer Anwendungsfall
Typical
application
10 CLP 100 Mobilgear 627
Omala 100 Spartan EP 100
Meropa 100( Falcon CLP 100 )
Energol GR-XP 100
ReductelfSP 100
Klüberoil GEM 1-100
Tribol 1100/100 Molub-Alloy 80/100
11 CLP 150 Mobilgear 629
Omala 150 Spartan EP 150
Meropa 150( Falcon CLP 150 )
Energol GR-XP 150
ReductelfSP 150
Klüberoil GEM 1-150
Tribol 1100/150 Molub-Alloy 814/150
Getriebe Gear units
12 CLP 220 Mobilgear 630
Omala 220 Spartan EP 220
Meropa 220( Falcon CLP 220 )
Energol GR-XP 220
ReductelfSP 220
Klüberoil GEM 1-220
Tribol 1100/220 Molub-Alloy 90/220
Zentrale Öl- schmieranlagenCL-Gerüste, Getriebe, Kaltscheren
Central oil lubric. system CL-Mill stands, gear units, cold shears
13 CLP 320 Mobilgear 632
Omala 320 Spartan EP 320
Meropa 320( Falcon CLP 320 )
Energol GR-XP 320
ReductelfSP 320
Klüberoil GEM 1-320
Tribol 1100/320 Molub-Alloy 690/320
Zentrale Öl- schmieranlagenCL-Gerüste, Getriebe
Central oil lubric. system CL-Mill stands, gear units
14 CLP 460 Mobilgear 634
Omala 460 Spartan EP 460
Meropa 460( Falcon CLP 460 )
Energol GR-XP 460
ReductelfSP 460
Klüberoil GEM 1-460
Tribol 1100/460 Molub-Alloy 140/460
Zentrale Öl- schmieranlagenCL-Gerüste, Getriebe, Zahnkupplungen
Central oil lubric. system, CL-Mill stands, gear units gear couplings
15 CLP 680 Mobilgear 636
Omala 680 Spartan EP 680
Meropa 680( Falcon CLP 680 )
Energol GR-XP 680
ReductelfSP 680
Klüberoil GEM 1-680
Tribol 1100/680 Molub-Alloy 190/680
Schnecken- getriebe, Zahnkupplungen,Hauptantriebe
Worm gear units,gear couplings, main drives
16
17 VDL 100 DIN 51506
Rarus 427 Corena Oil H 100 D Corena Oil P 100
Verdichter Öl 3021 NCompress Oil 3021 N
Compr. Oil EP VDL 100( Actro VDL 100 )
Energol RC 100
Elf DacnisP 100
_
Tribol 890/100 Tribol 1750/100
Hochdruck- Kompressoren High pressure compressors
18 SE Solvac 1535 GD
Dromus B Kutwell 40 Texsol D ( Targon D )
Fedaro M _
_
_
5% Öl-in WasserEmulsion 5% oil-in water emulsion
B1 Lubrication instructions
Auft.-Nr. / Order No. Stand / Revision Index Blatt / Sheet
J711 / JSW-SMP 09/08/2010 - - 6 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher.
Please observe the lubricant qualities specified in the lubrication instructions!
Ölarten gemäß Types of oil as per
Vorschläge der Lieferanten / Recommendations by grease supplier
Sch
mie
rsto
ff N
r.
No.
of l
ubric
ant
DIN 51502
MOBIL SHELL ESSO TEXAC
O (DEA)
BP ELF Klüber Tribol
Typischer Anwendungsfall
Typical
application
19 HLP 46 DIN 51524/2
DTE 25 Tellus 46 Nuto H 46 Rando Oil HDB 46 ( Astron HLP 46 )
Energol HLP 46
Elfolna 46Elfolna DS 46
Lamora HLP 46
Tribol 943 AW 46
HydrauliksystemeHydraulic systems
20 ISO VG 100 Vacuoline 525
_
_
_
_
_
_
_
Zentrale Öl- schmieranlagen,Draht- Fertigblöcke Centralised oil lubrication systems, wire finishing blocks
21 ELPF 100 ( Molub-Alloy Ölfarn 892 XCL ) Hinweis: siehe Tribol Note: see Tribol
_
_
_
_
Synthesco Hotemp OY 95
Molub-Alloy 892 XCL Tribol 1430
Stelmor- Transportketten Stelmor conveyor chains
22 Synthetic Oil PGLP 150/ 220
Glygoyle 30 Tivela Öl WA
Umlauföl S 220
Synlube CLP 150 ( Polydea GLP 150 )
Energol SG-XP 220
Elf- syntherma P 270
Klübersynth GH 6-150/220 *)
Tribol 800/150 800/220
Stehlager Plummer blocks
23 _
MOS 2 Spray
Fa. DOW Corning GmbH D- 8000 München
Unimoly PA-Spray
Molub-Alloy 369
Ketten Chains
24 BC-V _
Cardium Fluid C
Surett Fluid 4K _
Energol WRL _
Grafloscon C-SG O-Plus
Molub-Alloy 936 SF
Zahnstangen racks
25 HL / HLP 22,32
CL / CLP 22,32
Mobil DTE 22 Mobil DTE Oil light Velocite oil No. 10
Tellus 22/32 Tellus C22/32
Nuto H 22/32 Spinesso 22 Teresso 46
Rando Oil- HDA 22/32 Aries 32 ( Astron HLP 22/32 Arkas DLP 32 )
Energol HLP 22/32HLP D22/32 HL 32
Elf Poly- telis 22, 32Elfolna 22,32 Elfolna DS 22, 32
Airpress 15/32
Tribol 943 AW 22 943 AW 32 Tribol 771
Luftwartungs- einheiten compr. air treatment units
26 CL 46 Mobil DTE 25
Tellus C46 Nuto 46 Teresso 46
Rando Oil 46 ( Astron HL 46 )
Energol HL 46
Elf Polytelis 46
Crucolan 46 Tribol 772 Spülöl für Zentral-ÖlschmieranlagenFlushing oil for Central oil lubrication stations
27 HFC 46 Hydrofluid HFC 46
Hydraulik Fluid HFC 46
_
_
_
Pyrelf HFC 46
_
_
Hydraulik-Systeme Wasser-Glykol Basis Hydraulic systems water-glycol basis
Außer den genannten Schmierstoff- Lieferanten können weitere nach Rücksprache verwendet werden, z.B.: Apart from the makes of lubricant indicated, other makes may be used, e.g.: ADDINOL Mineralöl GmbH Lützkendorf 06242 Krumpa / Geiseltal *) Synthetischer Schmierstoff, nicht mit Mineralöl mischen Synthetic lubricant, do not mix with mineral oil Please observe lubricant qualities specified in lubrication instructions!
B1 Lubrication instructions
1.3 Terms used in the lubrication instructions
See following pages SN 181
Explanation of the item numbers on the lubrication list drawings
Manual lubricating point
Centralized grease lubrication system
Lubrication point hidden behind component, not visible
Marking not used
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 7 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 8 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
Begriffe zur Schmieranweisung / Terms used in the lubrication instructions SN 181
1. Art der Schmierung / Type of lubrication
Spalte 5 Column 5
Art der Schmierung Type of Lubrication
E Hydraulik- Emulsion Hydraulic emulsion F Öl- bzw. Fettfüllungen Oil or grease fillings
Fe Festschmierstoff Solid lubricant
Hy Hydrauliköl Hydraulic oil
Hp Handschmierpumpe Hand-operated lubricating pump
Hs Hydrostatisch Hydrostatic lubrication
K Korrosionsschutz Protection against corrosion
M Morgoil Schmiersystem Morgoil lubrication system
O Oberflächenschmierung Surface lubrication
OL Öl- Luft- Schmierung Oil- in- air lubrication
On Ölnebel- Schmierung Oil mist lubrication
OV Öl- Verlustschmierung Lost oil lubrication
S Schmiernippel Grease nipple
Sd Sprühdosenschmierung Spraying can lubrication
Sg Schmierstoffgeber Metering block
Sp Sprühschmierung Spray lubrication
U Ölumlaufschmierung Recirculated oil lubrication
Wf wartungsfreie Schmierstelle Maintenances- free lubrication point
Z Zentral- Fettschmierpumpe Centralized grease pump
ZHp Zentral- Fettschmierpumpe, Hand Centralized grease pump, hand- operated
B1 Lubrication instructions
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 9 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
2. Schmierintervalle / Lubrication interval
Spalte 6 Column 6
Schmierintervall ( im 3- schichtigen Betrieb )
Lubrication interval ( on base of 3- shift operation )
ED Einschaltdauer- Schmierung Lubrication system duty cycle GW bei Gerüst- / Segmentwechsel When changing stand / segment
H stündlich Every hour
J jährlich Every year
L Lebensdauer- Schmierung Greased for life
M monatlich Every month
3M 3- monatlich Every 3 months
6M 6- monatlich Every 6 months
S je Schicht ( 8 Stunden ) Every shift ( 8 hours )
T täglich ( 24 Stunden ) Every day ( 24 hours )
W wöchentlich Every week
WW bei Walzen- / Rollenwechsel When changing rolls
Spalte 6 Column 6
Schmierintervall ( im 3- schichtigen Betrieb )
Lubrication interval ( on base of 3- shift operation )
B1 nach Angaben des Lieferanten siehe Zulieferkomponenten-Handbuch C
According to supplier see Bought-out Components Manual C
B2 überprüfen Check
B3 alle 6 Monate überprüfen bzw. nachfüllen Check and / or refill every 6 months
B4 nach 3.000 Betriebsstunden wechseln, maximal nach 18 Monaten
Change after 3,000 operating hours, after 18 months maximum
B5 Ölwechsel nach je 10.000 Betriebsstunden Oil change after every 10,000 operating hours
B6 1. Ölwechsel mit Reinigung nach 500 Betriebsstunden, dann alle 2.500 Betriebsstunden
1st oil change with cleaning after 500 operating hours then every 2,500 operating hours
B7 1. Ölwechsell nach 500 Betriebsstunden,2. Ölwechsel nach 2.000 Betriebsstunden,weitere Ölwechsel nach 4.000 Betriebsstunden,mindestens 1 mal jährlich
1st oil change after 500 operating hours2nd oil change after 2,000 operating hoursfurther oil changes after 4,000 operating hours,at least once a year
B8 1. Ölwechsell nach 200 Betriebsstunden,2. Ölwechsel nach 1.500 Betriebsstunden,weitere Ölwechsel nach 4.000 - 5.000 Betriebsstunden
1st oil change after 200 operating hours2nd oil change after 1.500 operating hoursfurther oil change after 4,000 – 5,000 operating hours
B9 wöchentliche Prüfung, Ölmessstabanzeige beachten
1 check per week, observe gauge stick indication
B10 Kettengelenke bei Bedarf schmieren Lubricate chain links if required
B11 20 Doppelhübe 20 double shots
B12 Schmierintervalle: alle 30 Minuten Lubrication interval: every 30 minutes
B13 Schmierintervalle: alle 4 Stunden Lubrication interval: every 4 hours
B14 Schmierintervalle: alle 1 Minute Lubrication interval: every 1 minute
B15 Schmierintervalle: alle 1,5 Minuten Lubrication interval: every 1.5 minutes
B16 Schmierintervalle: alle 20 Minuten Lubrication interval: every 20 minutes
B1 Lubrication instructions
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 10 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
3. Mengeneinheiten / Quantitative units
Spalte 7 und 8 Angaben der Mengeneinheiten
Columns 7 and 8 statement of quantitative units
FA bis fett austritt until grease flows out
cm3 mit Angabe indicated
dm3 mit Angabe indicated
m3 mit Angabe indicated
4. Füllmengen, Definition / Fill volumes, Definition
Die Erstfüllmenge ist die gesamthaft erforderliche Menge des zu schmierenden Teiles und aller Nebenräume. Sie ist vor dem ersten Anlauf einzufüllen.
The initial fill is the total required volume of the part to be lubricated and of all ancillary cavities. It is to be filled in prior to initial start.
B1 Lubrication instructions
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 11 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
1.4 Lubrication Instructions - - -
Erzeugnisbenennung:
Equipment unit designation:
O2-Lanze
O2-Lance LD3/ LD4
Item Nr.:
Item No.:
6.1.4.12
Lubricant no. according to SN 180
Initial filling volume according to SN 181-4 for each lube point
Quantity for one lube point and interval according to SN 181-3 Lubrication interval according to SN 181-2
Type of lubrication according to SN 181-1 No. of lube points per component
Components per equipment unit
Sch
mie
rste
llen
Nr.
Lube
poi
nt n
o.
Designation of part to be lubricated Drawing-No. 0 1 2 3 4 5 6 7 8 9
1 Lance Trolley travel Wheels 21500503
21500504 4 2 S 3M FA 200cm3 2
2 Lance Trolley Guide Roller 21500506 4 1 S 3M FA 80cm3 2
3 Lance Trolley Geared Motors (Supplier - IC
Bauer) 21500500 2 1 F
B5
*
11.4
dm3 *
11.4
dm3 *
12
*
4 Lance Guide Interlock Assembly 21500409 1 1 S W FA 50cm3 2
5 Lance Guide Running Rollers 21500431 6 1 S 3M FA 70cm3 2
6 Latch pin at Lance Guide 21500390 2 1 S M FA 40cm3 2
7 Carriage Lubrication Left 21500438 8 1 S 3M FA 85 cm3 2
8 Carriage Lubrication Right 21500386 8 1 S 3M FA 85 cm3 2
9 Rope Pulley Assembly 21500558 2 2 S 3M FA 60 cm3 2
10 Hoist drum LH / RH pedestal bearing 21500556 /
21500557 1/1 1/1 S 6M FA
750
cm3 2
11 Hoist drum LH / RH coupling (Supplier – M.A.T.
Malmedie Antriebstechnik GmbH)
21500610 /
21500611 1/1 1/1 S J * FA *
750
cm3 * 2 *
12 Main Hoist Gearbox LH / RH (Supplier – Shanthi
Gears Ltd.)
21500560/
21500561 1/1 1/1 F
6M
* 255 L 255 L
14
*
13 Emergency Hoist Gearbox LH / RH (Supplier –
Shanthi Gears Ltd.)
21500562 /
21500563 1/1 1/1 F
6M
* 1.3 L 1.3 L
13
*
14 Lance Hoist Air Motor ( Supplier – Duesterloh
Fluidtechnik 21500566 2 1 F M * 1.4L * 1.4L *
19
*
15 Lance Hoist Air motor ( Supplier – Duesterloh
Fluidtechnik 21500566 2 4 S M * FA FA
K3
K*
16 EUBA Electric Actuator 21500492 1 2 S * * * 2
17 All Lubricators of pneumatic piping systems 1 F * * * *
* Please also see section C – Sub Supplier Components Manual
B1 Lubrication instructions
Lube point for Drawing No. 21500503 / 21500504
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 12 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500506
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 13 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500500
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 14 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500409
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 15 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500431
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 16 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500390
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 17 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500438
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 18 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500386
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 19 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500558
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 20 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500556 / 21500557
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 21 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500610 / 21500611
Projekt / Project Datum / Date Index / Index Seite / Page
J711 JSW-SMP 09/08/2010 01 22 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500560 / 21500561
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J711 JSW-SMP 09/08/2010 01 23 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500562 / 21500563
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J711 JSW-SMP 09/08/2010 01 24 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500566
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J711 JSW-SMP 09/08/2010 01 25 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B1 Lubrication instructions
Lube point for Drawing No. 21500492
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J711 JSW-SMP 09/08/2010 01 26 / 26 2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 Plant equipment
Table of contents for the Operating and Maintenance Instructions for the following equipment
General instructions and regulations for
Maintenance and safety see A-Operating Manual
Lubrication see B-Equipment Manual, B 1, Register 1.0
Item Nr. Project No.
J711 … Designation
B2/ Sub-
register Pages Index
6.1.4.12 2165 Oxygen Lance Installation 2 / 1 31 01
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J711 2100 JSW-SMP 2010-08-06 01 1 / 1 2009 by SMS Siemag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
O2 Lance
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J711/ JSW-SMP 2010-07-31 - - 1 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
Table of contents
Page
1 List of drawings ........................................................................................................................... 3
2 Technical data.............................................................................................................................. 8
2.1 Mechanics....................................................................................................................... 8
2.2 Electrics ........................................................................................................................ 10
2.3 Hydraulics ..................................................................................................................... 10
2.4 Pneumatics ................................................................................................................... 10
2.5 Utility systems............................................................................................................... 11
2.6 Lubrication systems ...................................................................................................... 11
3 Function...................................................................................................................................... 12
3.1 Overall function (Lance system) ................................................................................... 12
3.2 Single functions ............................................................................................................ 15
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4 Maintenance instructions.......................................................................................................... 16
4.1 Preventive maintenance ............................................................................................... 16
4.1.1 Maintenance procedure ................................................................................................ 17
4.1.2 Lubrication instructions ................................................................................................. 20
4.2 Special safety regulations/Residual risks ..................................................................... 20
4.3 Installation/Dismantling of Equipment........................................................................... 21
4.3.1 Installation / Dismantling............................................................................................... 21
4.3.2.1 Removal of Lance Carriage .......................................................................................... 21
4.3.2.2 Change of wire ropes of Lance Carriage ...................................................................... 23
4.3.2 Setting work, setting values and tolerances ................................................................. 23
4.3.3 Transport ...................................................................................................................... 24
4.3.4 Special Tools ................................................................................................................ 24
4.4 Shutting down/Restarting.............................................................................................. 25
4.4.1 Shutting down ............................................................................................................... 25
4.4.2 Restarting ..................................................................................................................... 26
4.4.3 Function test ................................................................................................................. 27
4.5 Suppliers' instructions for assembly/installation, commissioning and maintenance ..... 31
4.6 Records ........................................................................................................................ 31
Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 2 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
1 List of drawings for Oxygen Lance Installation (Item No.6.1.4.12)
SMS Siemag Order No.
Description SMS Siemag Drawing No.
Subsupplier Drawing No.
Subsupplier name
J 711 2165 G.A. Oxygen Lance System 21500330
J 711 2165 Arrangement Lance Body 21500331
J 711 2165 Assembly Lance Body 21500332
J 711 2165 Spherical Disc 21500336
J 711 2165 Lance Dome Cap 21500347
6-Loch-Lanzenkopf 21119451 HW-1-1545-00 Saar Metall *
Oxygen Hose DN200 21500348 309235-02-00 Rattay *
Water Hose DN150 21500349 309235-03-00 Rattay *
J 711 2165 Carriage Assembly Left 21500351
J 711 2165 Carriage Assembly Right 21500382
J 711 2165 Rope Arm Assembly 21500354
J 711 2165 Bolt 21500463
J 711 2165 Spherical Seat 21500359
J 711 2165 Guide Roller Assembly 21500365 Track Roller supplier Eich
J 711 2165 Eccentric Shaft 21500366
J 711 2165 Track Roller Spring Assembly 21500370 Track Roller supplier Eich
J 711 2165 Track Roller Assembly 21500377 - do -
J 711 2165 Carriage Lubrication Left 21500438
J 711 2165 Carriage Lubrication Right 21500386
J 711 2165 Guide Track Arrangement 21500387
J 711 2165 Latch Assembly 21500390
J 711 2165 Latch 21500391
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J711/ JSW-SMP 2010-07-31 - - 3 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
SMS Siemag Order No.
Description SMS Siemag Drawing No.
Subsupplier Drawing No.
Subsupplier name
J 711 2165 Compression spring ø 3.2 21500393
J 711 2165 Running Rollers Assembly 21500397 Track Roller supplier P&N *
J 711 2165 Lubrication For Running Roller 21500431
J 711 2165 Interlock Assembly 21500409
J 711 2165 Electric Actuator 21500492 E/X-B4-001 Euba *
J 711 2165 Center Bracket 21500410
J 711 2165 Center Piece 21500413
J 711 2165 Bolt 21500412
J 711 2165 Bush 21500418
J 711 2165 Buffer Guide Track 21500419
Buffer supplier Insutech Corporation *
J 711 2165 Support Bearing Assembly 21500425
Guide Track Fixing Arrangement 21500430
Limit Switch Arrangement 21500465 Limit switch supplier Jai Balaji #
Limit Switch for Trolley movement 21500466 -do-
Limit Switch for Latch 21500471
Proximity switch supplier Pepperl+Fuchs #
Pneumatic Limit Switch 21500481
3/2 way roller lever oprtd. Valve supplier IMI Norgren *
Trolley Assembly 21500500
Idle wheel Assembly 21500503
Wheel 21500509
Axle 21500514
Drive Unit Assembly 21500502
Drive Wheel Assembly 21500504
Axle 21500513
Geared Motor 430199/GM/2 International Combustion (I) *
Geared Coupling 21500525 Wellman *
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J711/ JSW-SMP 2010-07-31 - - 4 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
SMS Siemag Order No.
Description SMS Siemag Drawing No.
Subsupplier Drawing No.
Subsupplier name
Drive Unit Assembly - II 21500505
Geared Motor 430199/GM/1 International Combustion (I) *
Encoder 21500524 TR Electronics #
Bonded Buffer TG-0315 21500517 Resistoflex *
Guide Roller Assembly 21500506 Track Roller supplier Eich *
Eccentric Axle 21500530
Hoist Assembly LH 21500556
Main Hoist Gear Box LH 21500560 31026872-REV-1, DD1
Shanthi Gears *
Emergency Hoist Gear Box LH 21500562 31026799 Shanthi Gears *
Rotary cam limit switch 21500564 Leonard, Germany #
Air Motor 21500566 02.5352.00 Düsterloh Fluidtechnik *
Brake 21500567 U903903115D Siegerland Bremsen *
Air Clutch 21500568 0521-015-39-151000
Ortlinghaus *
Brake Drum Coupling 21500571 Rathi Transpower *
Rope Drum Assembly LH 21500610
Rope LH lay – lift. winch 21500559
Rope RH Lay – lift. winch 21500607
Drum Coupling 21500572 Malmedie *
Pulley Assembly 21500558
Load Transducer Pin 21500565 1601108XXXX Hirschmann
Rope Pulley 21500598
Hoist Assembly RH 21500557
Main Hoist Gear Box RH 21500560 31026872-REV-1, DD2
Shanthi Gears *
Emergency Hoist Gear Box RH 21500563 31026798 Shanthi Gears *
Rope Drum Assembly RH 21500611
Maintenance Platform Assembly 21500440
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J711/ JSW-SMP 2010-07-31 - - 5 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
SMS Siemag Order No.
Description SMS Siemag Drawing No.
Subsupplier Drawing No.
Subsupplier name
Platform - II 21500442
Support Roller Assembly 21500453
Pneumatic Cylinder 21500496 NIPL-C112671 Nucon *
Support Roller Assembly 21500454
Fixed Support of Hoses 21500554
GA Nitrogen Tank 7m3 21850412
Pneumatic Diagram Converter 3 21500499
Pneumatic Diagram Converter 4 21500555
Pn. Emerg. Lance Lifting Conv. 3 21850410
Pn. Emerg. Lance Lifting Conv. 4 21850411
Lance Cooling Water System 21850425
Valve Station Left 21850426
Valve Station Right 21850456
Oxygen Piping for Lance 21850416
Oxygen Valve Stand-1 21850417
Oxygen Valve Stand-2 21850453
Nitrogen Valve Station-1 21850419
Nitrogen Valve Station-2 21850421
Burn Out Copper Piece 21850423
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J711/ JSW-SMP 2010-07-31 - - 6 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
The listed drawings will be submitted with the drawing documentation!
These Operating and Maintenance Instructions cover the major equipment functions and working instructions only and illustrate them in simplified images. It is assumed that the installation is operated and maintained solely by trained and qualified personnel.
# For more details refer separate Electrical Documentation
* For more details refer Manual C – Subsuppliers’ Components Manual
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J711/ JSW-SMP 2010-07-31 - - 7 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
2 Technical data
2.1 Mechanics
Lance facility
Number of converters 2
Heat size nom. 175 t (min. 165 t, max. 175 t)
Oxygen blowing rate Nominal / max. 575 / 600 Nm³/min
Oxygen pressure (inlet of valve rack) 1.7 MPa(g)
Number of oxygen lances (connected) 4 (2 per converter)
Cooling water flow rate (max.) 200 m3/hr
Cooling water pressure (at valve rack inlet) 10 bar
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Lance hoist
Quantity 2
Safe Working Load (SWL) 98 kN
Rope drum root diameter (at bottom of groove) 1250 mm Rope details ø36 mm, Steel Core, 6x37 construction, 1770 Tensile Class, Breaking Strength (Min.) = 730 kN, Galvanized
Number of load-bearing ropes 2 (1 no. RH Lay and 1 no. LH Lay)
Load Transducer pins in deflection pulleys
Nominal load 76 kN
Overload preset value 61 kN (per pin)
Slack rope load preset value 16 kN (per pin)
Mechanism group M6 acc. to IS 13834-1,
Traversing distance of lance carriage working. 14,300 mm
For lance exchange, 14820 mm
Pneumatic emergency lifting, 15820 mm
Lifting speed 0 - 31 m/min
Pneumatic Emergency lifting speed 6.13 m/min
Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 8 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
Main drive Electric motor
Rated output power 75 KW
Full load speed 1,475 rpm
Reduction gear ratio (between electric motor and rope drum) 192.4:1
Brake Fail safe type external spring applied
double shoe drum brake,
Brake release gear – electro hydraulic
Thruster for operation with electricity and
Pneumatic cylinder for operation without
Electricity
Brake torque setting 530 Nm (refer Subsupplier component
Manual C – SIBRE, for setting up the
Brake torque)
Emergency drive pneumatic geared motor
Drive power 26 kW at 5 bar(g)
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Motor speed 1500 rpm
Nitrogen pressure at the motor 5 bar(g)
Reduction gear ratio (between pneumatic gear motor and rope drum) 989.4:1
Oxygen lance
Quantity 2 (per converter)
Operating lance 1
Standby lance 1 (connected ready for operation)
Outside diameter of lance 298,5 mm
Lance length to lance support 16,535 mm
Overall lance length 20,875 mm
Hoses
Number of oxygen hoses 1 per lance
Hose diameter DN 200
Hose length 18,000 mm
Number of cooling water hoses 2 per lance
Hose diameter DN 150
Hose length 18,000 mm
Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 9 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
Nitrogen Tank
Number of tanks 2
Internal Volume 7 m3
Outside Diameter 1,794 mm
Height 3,500 mm
Total height from support platform 3,950 mm
Working Pressure 18 bar(g)
Safety valve set at 20 bar(g)
Pressure regulator set at 6 bar(g)
The unit/machine must be operated only within the limits specified in the technical data.
Use of the unit/machine outside the specified limits is considered as not in line with the intended purpose. This includes, among others:
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La
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Increase of the oxygen blowing rates specified in the technical data.
_O
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Increase of the converter capacities specified in the technical data.
2.2 Electrics
(see E-Electrical Equipment Manual)
2.3 Hydraulics not applicable
2.4 Pneumatics
N2 Pneumatic diagram : 21500499 & 21500555 N2 tank : 21850412 N2 Pressure : 18 bar(g) N2 working temperature : Ambient temperature N2 Purity : 99.99 % For trouble shooting of all pneumatic components, panels and loose items that are fitted on the nitrogen pipeline between the tank and the panels refer sub supplier Manual C –
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J711/ JSW-SMP 2010-07-31 - - 10 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
Ross Controls. A brief description of the pneumatic system for Lance emergency lifting is given in section 3 of this manual
2.5 Utility Systems
Oxygen Piping including valve station : 21850416 Lance Cooling water System : 21850425 O2 Pressure : 1,7 Mpa(g) O2 Quality : 99.5 % Water pressure : 10 bar Water Quality : Soft Water For trouble shooting of all components of the valve stations and line mounted valves please refer the corresponding manuals of the suppliers.
2.6 Lubrication systems See manual B1-Lubrication Instructions
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J711/ JSW-SMP 2010-07-31 - - 11 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
3 Function
3.1 Overall function (Lance system)
2 oxygen lances, one in operation and another standby, are available for each converter. The oxygen lance is suspended in the support bracket of the travel carriage. In the upper part of the lance carriage the lance is secured by a lance clamping device.
The lance with the hoses (oxygen hose, cooling water supply and return hose) is attached to the corresponding valve stations ready for operation via pipe bends and swing bolt flanges.
The lance hoists, one for each lance, serve to lower the lance carriage with the oxygen lance fastened to it into the converter or to lift it out of the converter.
The lance hoists mounted on top of the lance trolley mainly consist of the electric motor, the gear box, the rope drum, the corresponding couplings and the double shoe brake as well as a pneumatic emergency drive unit. The rope drum is connected by two ropes to the lance carriage via a rope equalizer. The ropes are each designed with a safety factor of 7.4 to prevent rope breakage at maximum load, i.e., each rope is capable of carrying the maximum load. The equalizer on the lance carriage compensates the different rope lengths. A load transducer pin arranged in the deflection pulley acts an overload guard or slack rope protection, respectively. The overload protection is set at 61 kN, the slack rope protection at approx. 16 kN.
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The lance hoists are shut down automatically when the overload protection is actuated. The lance hoists can then only be electrically raised at low speed by operating the master switch (joystick).
As the slack rope protection is activated, the lance is raised at low speed up to the “STANDBY
POSITION” (see Arrangement Drawing No 21500614).
The electrical function of the lance hoists is described in detail in the electrical equipment manual.
Work on the lance hoist equipment must be performed only if the lance is in the latch position. For work on the lance hoist equipment or on the ropes, the unit has to be shut down electrically via the emergency off push-button in the local control desk and the supply of nitrogen to the emergency drive unit has to be shut off and the nitrogen line after the tank has to be completely depressurised. (see also functional description of electrical equipment).
Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 12 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
For operation of the oxygen lance certain requirements must be fulfilled.
In the "Standby" position a check is made as to whether the following preconditions have been satisfied:
Oxygen available
Lance cooling water available
Gas cleaning system ready
Nitrogen available for emergency lifting
After all preconditions have been fulfilled, the oxygen lance may be started. It travels over the speed-change point at high speed and then slowly moves to the blowing position.
The supply of oxygen is started after synchronisation.
The elevation of the speed-change point and the oxygen blowing position are variable and depend on the bath level in the converter. After the preset oxygen flow rate has been blown, the oxygen lance automatically moves up to the synchronisation position. The lowermost blowing position of the lance tip is at approx. +9,485
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When reaching the lower most buffer position, an alarm is given out and the lance is electrically raised up to the upper standby position.
While raising the oxygen lance, the oxygen quick-action double shut off valves are closed in the upper area of the lance stroke and the lifting speed of the lance is reduced.
The oxygen blowing procedure runs automatically. Operation of the lance hoist drive is tracked by the computer preset “Blowing distance”. Electrical control of the oxygen lance is summarized and described in the electrical equipment part.
Emergency lifting
In addition to the main electric drive unit, the lance hoist is equipped with a pneumatically operated emergency drive unit which in case of a power failure or "Emergency off" automatically starts with a time delay and lifts the oxygen lance.
For the power supply of the emergency drive unit including its control system, nitrogen is available from a standby nitrogen tank in which nitrogen is stored at 18 bar(g) pressure. The pressure in the line downstream of the tank is reduced to 6 bar(g) by a pressure regulator before feeding the valve panels and pneumatic geared motors of the emergency drive units.
A pneumatic geared motor is connected to the input shaft of the main gear box via a pneumatic actuated clutch, a small single stage helical reduction gearbox and a flexible coupling.
The valve and control panels of the emergency drive units (see C-Subsuppliers' components manual for Ross Controls and pneumatic diagram no. 21500499 and 21500555) are arranged at the top of the Lance trolley.
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J711/ JSW-SMP 2010-07-31 - - 13 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
The following description of the working of the emergency drive shall be read together with the Pneumatic Diagram Converter 3– 21500499. During emergency lifting both working lance and standby lance are lifted up simultaneously. Working lance lifts up by 15.82 m and standby lance lifts up by 1.0 m.
Nitrogen supply is already available up to the inlet of pilot operated 3/2 way shut off valves B3.21500499.11 located just before the inlet of pneumatic geared motor.
In the event of power failure or “Emergency open” operation, the solenoid pilot operated 5/2 way valve B3.21500499.8 in the Control panel is de-energized and is switched to “through passage”. This causes nitrogen to flow through the pilot lines after a time delay through the 3/2 way time delay valves B3.21500499.18, through the 3/2 way roller lever actuated valves B3.21500499.6 and through flow control valves B3.21500499.3 to the control circuit of the pneumatic motor, brake and clutch.
Owing to the time delay, a possibly lowering O2 lance can come to a halt before the pneumatic motor is actuated. When the pilot nitrogen enters the 3/2 way valves B3.21500499.11 and the direction control valves of air motors, main nitrogen supply is switched on to the air motors. At the same time pilot nitrogen actuates the 3/2 way valves B3.21500499.9 which causes nitrogen to flow to the pneumatic clutches and hence the clutches are engaged and becomes positive. As pressure builds up in the pneumatic motor chamber, the impulse line from the motor actuates the lock up valves B3.21500499.20. This causes pilot nitrogen to actuate 3/2 way valves B3.21500499.9 which pressurises the thruster brake releasing cylinders through a delay circuit (3/2 way valves B3.21500499.18 + B3.21500499.19) for both lances. Thus the holding brake is released last before the lances lift up and free fall of lance is avoided. The lances are lifted up by the pneumatic motors till the upwardly moving lance carriages actuate the roller lever actuated 3/2 way valves B3.21500499.6. The valves are closed, pilot nitrogen supply is stopped to the controls of the pneumatic motor, clutch and brake and the lines downstream of these valves are vented. The clutch disengages, the pneumatic motor shuts down and the holding brake is applied.
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The pneumatic limit switch valves B3.21500499.6 are arranged in such a way that the lance carriage always overrides the latch in case of emergency lifting.
When the power is restored the previously mentioned 5/2 way solenoid actuated valve B3.21500499.8 is moved to closed position where it ventilates the pilot lines proceeding to the valve panels.
The lance can be lowered again from the pneumatic limit switch position by electric power only. In this case, the latch must be operated manually.
Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 14 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
3.2 Single functions not applicable
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Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 15 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
4 Maintenance instructions
General maintenance instructions see A-Operating Manual, Chapter 8
4.1 Preventive maintenance
Operating condition Time interval
COM = During commissioning H = Every hour
OPE = In operation Sch = After each heat
PRO = During production S = Every shift (8 hours)
SST = During standstill D = Every day (24 hours)
W = Every week
M = Every month
2M = Every 2 months
3M = Every 3 months
6M = Every 6 months
N = After each relining
Y = Every year
2Y = Every 2 years
TOL = Time-on Lubrication
LTL = Lifetime lubrication
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Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 16 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
4.1.1 Maintenance procedure
The careful servicing of all parts is necessary for perfect functioning of the lance equipment. All functions, electrical, pneumatic and mechanical, need to be checked each day (see also “ELECTRICAL” manual).
Important:
For all maintenance operations as well as for oxygen lance changes the guide carriage must be in the mechanically blocked latch position. The supply of nitrogen downstream of the tank must be shut off and the line downstream the nitrogen tank has to be vented to avoid accidental starting of the unit.
The carrying ropes must be checked every day for possible damage in accordance with IS:3973 – Code of Practice for selection , installation and maintenance of wire ropes
All flanged joints of the oxygen, nitrogen and cooling water lines must be checked for leaks.
The function of the pneumatic emergency drive unit has to be checked regularly by way of a "lance emergency lifting" running test.
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All screws/bolts must be regularly checked for firm seating. The torques indicated in the drawings must be complied with.
The oxygen lance must be permanently checked for a possible escape of cooling water. In case of a leak the oxygen lance must be immediately replaced or the spare lance from the spare lance storage must be used.
Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 17 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
Equipment, device Inspection, measure Operating Condition
Time interval
Connections of complete gas supply system and pneumatic system
for leaks S
oxygen blowing lance tip Check for wear at the nozzles S
All screw fittings of the oxygen blowing lance system
check for tight fit, retighten, if necessary
SST
H *) / 3M
Lance Hoist brake drum wear, brake shoe lining wear, brake torque setting, reserve stroke of thrusters and pneumatic release cylinder, Lever adjustment tie rod bolt tightness
Check; adjust/ reset/ replace if required
S/W/3M #
Lance Hoist Main and emergency gear box, Lance Trolley Geared Motor – oil level and leaks
Check; arrest leaks and refill oil if necessary
M
Elongation of one rope with respect to the other for lance carriage
Check: Readjust rope equaliser rocker arm at carriage top.
SST
M
Wire ropes of Lance hoist - deformation, stretching, corrosion, breakage of strands
Check as per IS:3973; replace if necessary.
M
Pipe work , valves and fittings of complete utility supply system, pneumatic equipment
Check for rust, dirt deposits and leaks
M
Fastening of ropes on travel carriage and rope drum
Check; tighten if required
SST
3M
Guide Rollers /wheels of lance carriage, lance trolley and lance maintenance platform
Check for smooth operation and alignment; tighten all bolts
3M
Clamping Device for lance on the carriage check for proper function 3M
Drum Coupling between lance hoist rope drum and gear box- tightness of connecting bolts, disturbance in the axial location of the coupling, wear inside the coupling
Check; tighten all bolts with the given tightening torque, realign coupling hub in axial direction as per supplier catalogue, replace if wear exceeds permissible limit
SST
6M @
Fastening of all drive motors and gear units check for tight fit, retighten, if necessary
6M
Fastening of guide column check for tight fit, retighten, if necessary
6M
SST
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Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 18 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
Equipment, device Inspection, measure Operating Condition
Time interval
Pressure hoses for utility supply, pneumatic equipment
check for operating condition, leaks, tightness of flange / thread connections with pipe work
6M
Lance emergency pneumatic drive – In line filters and lubricators
Check filters for filter element clogging and that the lubricators are filled with oil; Clean filter elements or replace if necessary, top up lubricators with correct grade of oil
3M
Pneumatic cylinder of lance Maintenance platform – Leakage
Check, Replace seals if necessary
SST
6M
Lance emergency pneumatic drive Check for perfect function, W
Lance emergency pneumatic drive pneumatic actuated clutch
Check for tightness in hose connection, clutch plates wear, check that clutch is decoupled from main gearbox when not pneumatically actuated; replace worn clutch plates, spring if necessary
W
Lance emergency pneumatic drive Pneumatic geared motor
Check the filter at the main air inlet DN 50 on the body of air motor for clogging; clean air filter
SST
M
Complete operating sequence check for perfect function
Steel structure and welds check Y
Change of lubricating grease on the bearings
Replace the entire old grease till fresh grease comes out from the seals
SST
6M
Change of lubricating oil of all gearboxes and geared motors
Drain used oil at operating temperature. Fill flushing oil of same type and grade as the lubricating oil, run unit again with flushing oil for a short period and then drain. Finally top up to required level with fresh lubricating oil as given in manual B1 and again run the unit for a short period. Top up again if necessary.
SST 6M
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Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 19 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
*) Only applies to the first 2 months after initial startup
# Refer Sub supplier component manual C – SIBRE for more details
@ Refer Sub supplier component manual C – MALMEDIE for more details
4.1.2 Lubrication instructions
(for the pertaining lubrication instructions, see B-Equipment Manual, Volume 1, Register 1.0)
4.2 Special safety regulations/Residual risks
Basic safety regulations see A-Operating Manual, Chapter 2
Plant-related safety regulations see A-Operating Manual, Chapter 3.10
General maintenance instructions see A-Operating Manual, Chapter 8
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as well as the safety regulations applicable in the country of the plant user.
Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 20 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
4.3 Installation/Dismantling
4.3.1 Installation/Dismantling of the complete equipment unit not applicable
4.3.2 Installation/Dismantling of assemblies
4.3.2.1 Removal of Standby Lance carriage from the guide track for change of guide rollers.
1. Refer enclosed sketch below for approach to carriage.
2. First both lance carriages shall be lifted up to standby position (bottom of carriage at +40520). The lance trolley shall be further moved so that the standby lance is displaced from the normal standby position towards the trolley rail end stop (nearer to standby lance ) by about 500 mm.
3. The lance carriage of standby lance shall be brought to the latch position (bottom of carriage at + 41120 level) so that the carriage is mechanically locked against the latch and cannot move downwards.
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4. After taking clearance from the blower and getting safety access key to the lance maintenance platform, the electric power to the lance trolley travel drive and lance hoist drive shall be disconnected. The oxygen and water lines to the lance shall be shut down at the respective valve racks.
5. The pressurised water remaining in the pipelines between the lance body and the hose has to be drained out
6. Using the lance maintenance platform, disconnect the water and oxygen hoses from the lance carriage and remove the disconnected hose ends by crane from the lance carriage.
7. Using the Lance maintenance platform disconnect the fixed oxygen and water pipes (item nos. 2 / 3 of drawing no. 21500331 – Arrangement Lance Body) from the lance and then remove these pipes from the carriage by the Lance crane.
8. Using the Lance maintenance platform, open the lance clamp and remove the standby lance using the lance crane. Please follow the lance changing procedure that is described later.
9. Using the Lance Maintenance platform and the hose bracket for approach, disconnect the wire ropes (of lance hoist rope drum) from the rope equaliser bar of the lance carriage. Attach wire rope sling at the pins from where the wire ropes have been removed. Total assembled carriage weight for removal by crane is 2T.
10. Using the lance crane, lift up the carriage using the rope sling by about 200 mm.
Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 21 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
11. Depress (lower down) the hand lever of latch mechanism (accessible from +40.8 m level platform) so that it clears the carriage. Keeping the lever depressed lower the carriage by lance crane slowly until its top clears the guide track completely. Transport the carriage by crane to the location where the guide rollers can be changed.
12. For inserting the carriage into the guide track back after repair, follow the above steps in reverse order.
13. After completion of all fitting work for fixing the lance hoist wire ropes, the lance hoses and the standby lance to the carriage, the lance maintenance platform shall be retracted and locked, all personnel shall vacate the work area, oxygen and water connections to the lance shall be restored and the power supply started for the lance hoist and lance trolley drives. All systems shall be checked for proper operation.
14. Finally the safety access key of Lance Maintenance platform shall be returned to the Blower and clearance shall be given to him to resume Lance operations.
APPROACH TO LANCE CARRIAGE FROM LANCE MAINTENANCE PLATFORM
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Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 22 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
4.3.2.2 Change of wire ropes of Lance carriage (at the standby position)
For changing the wire ropes of the lance carriage please follow the procedures for step numbers 3 to 9 of the above procedure for removing the lance carriage from the guide. The only difference is that for changing of wire rope of the carriage belonging to the standby lance, the lance trolley shall be at its normal end position and shall not be moved further by 500 mm towards the end stop. For winding on of a new wire rope to the rope drum take all care as given in IS:3973 so as to avoid any kinks in the new wire rope. Observe the tightening torques at the rope clamp of the rope drum and fit in locking wire at the heads of the locking screws of the rope clamps as given in drawing no. 21500610 – Rope drum Assembly LH / 21500611 – Rope drum Assembly RH.
4.3.3 Setting work, setting values and tolerances
Lance Hoist
Torque setting of Lance Hoist Thruster Brakes 530 Nm
Overload setting of Load Transducer pin at each pulley 61 kN
Slack Rope Load setting at load transducer pin 16 kN
Lance guide and Carriage
Distance between centre lines of guide track and Lance 560 mm + 8
Lance emergency lift pneumatic system
Pressure setting at the pressure regulators
(refer drawing nos. 21500499 and 21500555)
tag no. B3.21500499.24 for Converter 3 and
tag no. B4.21500555.24 for Converter 4 6 bar(g)
Lance Trolley
Torque setting of travel drive brake (attached to geared motor) 16 Nm
Trolley rail centre to centre distance 2400 mm + 2
Straightness of each rail in horizontal plane + 1 mm for every 2 m of rail length,
+ 2 mm max.
Level at top of each rail + 44600 + 1mm
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Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 23 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
4.3.4 Transport
Observe Chapter 4.2 Special safety regulations/Residual risks
4.3.5 Special tools not applicable
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Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 24 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
4.4 Shutting down/Restarting
Operating requirements
For hot commissioning of the oxygen lance certain requirements must be fulfilled:
All mechanical and electrical equipment has been subjected to a cold-run test and performs its functions such as:
- lowering of the oxygen lance into the converter and raising it again,
- electrical emergency lifting,
- pneumatic emergency lifting,
- releasing the lance carriage from the latch (as explained before in section 4.3.2.1)
- inspection of all electrical functions and measuring circuits (see Manual “Electrical equipment”)
- All lubricating points and oil fillings are sufficiently supplied with grease and oil in accordance with the lubricating instructions.
- The lance cooling water is ready for operation.
- Oxygen and nitrogen are available in sufficient quantity and at sufficient pressure.
- The converter and all pertinent equipment is ready for operation.
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4.4.1 Shutting down
(1) In case of a shutdown, e.g. during lance replacement, the lance carriage with the oxygen lance is electrically raised just above the latch position.
(2) The lance carriage can then be electrically lowered onto the latch to make sure that it is mechanically secured against further lowering.
(3) In the corresponding valve station oxygen and cooling water have to be safely shut off by closing the manual isolating or gate valves.
(4) Also the water remaining inside the pipeline between the lance body and the water hose has to be drained out.
Danger
Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 25 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
4.4.1.1 Operational disturbances and their elimination
Disturbance Remedy
Lack of water, leaks in cooling water system
Lack of oxygen
Lack of nitrogen
Find causes and repair
Water breakout on the oxygen lance Lance replacement
Excessively unequal rope lengths Equalize rope on rope drum
Rope breakage Mount new ropes
Power failure Emergency lifting of oxygen lance with pneumatic motor
Additional disturbances and remedies are included in the operating instructions of the units.
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4.4.2 Restarting
Before the oxygen lance can be lowered, certain parameters must be fulfilled (see functional description). Only then may the oxygen lance be started according to the converter process and the oxygen blowing process performed.
Danger
B\P
D
Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 26 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
4.4.3 Function test
Operation monitoring
After the oxygen lance has been started, the oxygen blowing program runs automatically. After the oxygen flow rate preset by the computer has been blown onto the steel bath, the oxygen lance automatically moves out of the converter. The oxygen lance can also be operated manually, e.g. for repair purposes.
Oxygen blowing merely needs to be monitored. Look out for irregularities. In case of any irregularities the oxygen lance must be electrically moved out of the converter. Before restarting the system, the causes must be eliminated.
In case of a water breakout, e.g. on the oxygen lance, the closure valve in the cooling water valve station is automatically closed and the oxygen lance is raised. For further operation the stand-by lance is to be used. The damaged lance is to be replaced by the spare oxygen lance from the spare lance storage. For further operation the spare oxygen lance from the spare lance storage is used.
First, the defective oxygen lance must be removed and transported to the lance repair shop or the spare lance storage.
In case of a power failure the lance carriage is automatically raised by the pneumatic emergency drive unit via the latch position.
The latch is equipped with two non-contact proximity switches. When the latch is overrun an alarm is transmitted to the main control pulpit by the 1st proximity switch, i.e., the latch is engaged and the lance carriage can no longer be lowered.
From the latch position the lance carriage with the oxygen lance can only be electrically lowered again when the latch is manually released.
When the latch is released the electrical interlock of the lance hoist drive is unlocked by the 2nd proximity switch and the oxygen lance is electrically lowered in jogging mode up to the upper end position. During lowering the latch must be pressed manually.
To detect a water leak of the cooling system, a differential flow rate measuring unit (DMM) is installed. This compares the water flow rate in the supply and return line and blocks the supply of water in case of a leak.
If the blowing lance is not needed for an extended period of time, the lance has to be moved to the mechanically blocked latch position.
Danger
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Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 27 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
Lance replacement
Oxygen lance dismantling and installation
If the standby oxygen lance has to be replaced, the following procedure must be followed:
Move travel carriage of standby lance onto the latch and set down onto the latch (bottom of carriage at + 41120 level ). From the platform +35.7m, +37.95m and 40.8m the shut off valves for oxygen, nitrogen and cooling water to the lance are well accessible.
After taking clearance from the blower and getting safe access to the lance maintenance platform, the electric power to the lance trolley travel drives and the lance hoist drive of both lances shall be disconnected.
For dismantling of the standby oxygen lance, supply of oxygen and nitrogen to both working and standby lance must be reliably shut off in the valve stations by closing the manual shut-off valves respectively. The cooling water supply to the standby lance shall also be shut off by closing the manual isolation valve at the cooling water valve station. The pressurised water remaining in the pipelines between the lance body and the hose has also to be drained out.
The supply of nitrogen for the emergency drive unit for both working and standby lance have to be shut off downstream the nitrogen buffer tank by closing the valve at the outlet of the tank and the line downstream of the tank has also to be depressurised by operating the manual lever operated spring return close valve (B3.21500499.30 for Converter3 and B4.21500555.30 for Converter 4) downstream of the pressure regulators.
The Lance maintenance platform for the lance to be changed has to be extended.
Maintenance personnel can then go over to the extended lance maintenance platform.
The swing-bolt flange connections of the oxygen and cooling water lines on the lance body must be opened and the hook of the lance EOT crane shall be gently engaged at the lifting pin provided at the top of the lance. The crane hook should be just holding the lance pin tightly so that the Lance does not move when the lance clamp is released. The lance shall be kept in clear view of the crane operator and good communication shall be maintained between the lance changing personnel and the crane operator.
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Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 28 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
Next the lance clamping device on the travel carriage has to be swivelled away.
The lance must be gently lifted up by about 800 mm by the lance crane, and then its inlet and outlet water connections shall be sealed with blind flanges to avoid that residual water escapes during transport. Take care to avoid contact with the water at the lance outlet as it may be hot.
Next the maintenance personnel should vacate the extended lance maintenance platform .
The extended lance maintenance platform shall be retracted.
The oxygen lance may now be safely lifted out of the lance carriage by means of the lance changing crane and moved to lance deskulling and repair area.
A spare lance is suspended in the lance carriage in reverse order. Then it is aligned, clamped and connected.
For filling of the newly installed lance the vent screws on the lance and the hand-operated valve in the supply piping must be slowly opened.
After water has escaped, close the vent screws and open the hand-operated valve in the return line. The remaining ventilation takes place via the automatic bleeder valves.
Danger
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J711/ JSW-SMP 2010-07-31 - - 29 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
Repair and testing of an oxygen lance
The oxygen lance is repaired in the lance workshop. The most frequent repair work on an oxygen lance is the replacement of the lance nozzle.
The oxygen lance design provides easy replacement of the lance nozzle after making a clean separating cut on the outer pipe.
The oxygen lance to be repaired is moved to the lance deskulling stand by means of the lance changing crane and freed from adhering slag skull, steel splashes etc. Slag skull falls into a container positioned underneath the cleaning stand.
After deskulling the lance is transferred to the lance tip cutting stand by crane and clamped at 2 places. The lance is drained through the leak that has occurred or through a hole which has been torch-cut or drilled into the outer pipe. The escaping cooling water is collected and directed into the sewage water pipe.
The first separating cut is made at about 260 mm height from bottom of tip by the tip cutting device grinder (above the existing weld). The cut end is finished with a bevel suitable for welding in of the new tip. The bevelled end shall be clean, smooth and free of burrs.
Then the oxygen lance is moved to the lance tilt down device by means of the lance changing crane. It is suspended in the lance tilt down device and clamped in the clamping device. Thereafter, the lance tilt down device is used to tilt the lance from the vertical to horizontal position. Then the lance is removed from the lance tilt down device and placed on the repair stand (roller brackets) by shop crane.
Repair work must be performed according to the following operating sequences:
- remove flange gaskets,
- turn the lance,
- slide new lance tip with new seals onto the inner tube,
- align the lance tip,
- tack-weld lance tip to outer pipe, align again and correct, if necessary
- tack-weld lance tip at more points
- weld lance tip to the lance outer pipe by turning the lance (suitable low hydrogen electrode compatible to steel material St52-3 shall be used)
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Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 30 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2 O2 Lance
Projekt / Project Datum / Date Index / Index Seite / Page
J711/ JSW-SMP 2010-07-31 - - 31 / 31 2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
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Make sure that the lance nozzle is slipped into the inner pipe with fresh seals and that the seals are properly seated and are neither jammed nor destroyed.
The lance nozzle made of copper is provided with a welded-on steel pipe so that only one steel-to-steel weld is required when a lance nozzle is changed.
For inspection purposes the oxygen lance is checked with water for leaks at a pressure of 13 bar. After the inspection the oxygen lance is suspended in the spare lance storage where it is ready for later use.
For further lance nozzle changes each separating cut must be made above the existing weld and such that the existing weld and the new weld do not overlap. This ensures that clean raw material is available for the new lance/nozzle weld.
The subsequent separating cuts for changing the lance tip may be performed at 30 mm above the existing weld. After every 2 tip changes a new outer pipe with a length of approx. 50 mm must be welded in to compensate the length.
For all work performed on the oxygen lance it must always be ensured that all oxygen-carrying parts such as pipes, flanges, lance nozzle, etc., are free from oil and grease.
Danger
4.5 Suppliers’ instructions for assembly/installation, commissioning and maintenance
See manual C – Subsuppliers’ component manuals
4.6 Records
(observe the delivery and inspection instructions of the SN standard valid at the time)