The Captive Power Plant-1 (CPP-1) department of SAIL, Rourkela Steel Plant (RSP) played a key role in improving operational efficiency and workplace safety during the financial year 2024–25 through the successful execution of several innovative automation initiatives. In line with its commitment to continuous improvement and infrastructure excellence, CPP-1 carried out a series of renovation and upgradation projects, complemented by the integration of digital solutions, to enhance productivity and create a safer, more supportive work environment for plant personnel.
One of the key achievements was the enhancement of safety standards and the promotion of a safety-first culture through the integration of automation in High-Pressure (HP) Boilers. A major milestone was set with the successful automation of the Blast Furnace Gas (BFG) Drum Seal operation, allowing for reliable and safe remote control directly from the control room. This has significantly improved both operational safety and emergency response capabilities.
Besides, the Mixed Gas system for HP Boilers 1 and 2—previously managed manually—has now been brought under centralized control. This integration has enhanced operational efficiency and reduced response time during critical situations.
To further improve safety in gas handling, all boiler gas lines have been equipped with water seals for positive isolation. Beyond the U-seals, remotely operated butterfly valves have been installed, enabling safer and more efficient management of gas flows. These upgrades effectively reduce human exposure in gas-prone areas while optimizing control and monitoring processes.
The in-house development and deployment of the BFG Drum Seal remote operation system marks a significant advancement in safety, minimizing manual intervention and ensuring greater protection for personnel during both routine operations and emergencies.
This project was successfully executed in High-Pressure Boilers 3, 4, and 6, establishing safer working conditions and raising the overall safety standards within the department.
