The “Suraksha Setu” team from Sintering Plant-I of SAIL, Rourkela Steel Plant (RSP) addressed a critical challenge in Sinter Plant-I (SP-I), demonstrating technical acumen and innovative thinking.
Notably there are two sinter strands in SP-I. During maintenance shutdowns of one strand, it was found that the flue gases from the operating strand was infiltrating the idle strand—particularly around the grate bar area—posing serious safety risks. The presence of harmful gases in the gas created an unsafe environment, disrupted maintenance schedules, and affected overall plant reliability.
Additionally, when both strands operated together, a churning effect was observed at the chimney junction, causing excessive vibration, frequent motor tripping, loss of suction, and subsequent interruptions in sinter production. These operational anomalies had a direct impact on sinter output and the supply chain to the Blast Furnace.
A team from the department led by Leader Mr. Dilip Kumar Barik, Junior Engineer and Deputy Team Leader Mr. Ranjit Sethi, Technical Associate with key technical contributions from team members namely Mr. Soumya Ranjan Jena, Associate and Mr. Sachin Kumar Barik, ACT and facilitated by Mr. Prabhat Kumar Dash, AGM (Operations), undertook a detailed root cause analysis and implemented a cost-effective solution.
Two specially designed diversion plates were installed inside the chimney at the duct junction, which successfully redirected the flue gases straight upwards. This modification eliminated gas cross-flow and the churning effect, significantly improving suction stability and workplace safety.
The results were both immediate and impressive: the presence of harmful gas reduced significantly to safe level, workplace safety got enhanced, equipment vibrations were reduced, and sinter production resumed smoothly without disruption. The seamless supply of sinter to the Blast Furnace was restored, ensuring continued plant performance and reliability.
The entire job was done under the able leadership of Mr. Shubhransu Chakraborty, HOD, SP-I. The collective effort was lauded by Mr. Abakas Behera, GM and Safety Coordinator, RSP.
The team ‘Suraksha Setu’ presented the innovative project at the 16th Integrated Safety Circle Convention at SAIL, Bhilai Steel Plant and bagged the Gold medal for the project.
