An enterprising effort of ‘Tejas’ Quality Circle (QC) team of New Plate Mill (NPM) has helped accrue huge savings for SAIL, Rourkela Steel Plant (RSP). They have successfully implemented a project Modification of Cooling Line System to improve the heat capacity of Reheating Furnace’ which has led to significant cost savings and enhanced production efficiency. The enterprising team comprises Mr. Gopabandhu Behera (OCT), Mr. Shirshananda Das (SOST), Mr. Deepak Sahu (Assistant Roller), Mr. Asit Behera (SOST), and Mr. Deepak Kumar Sahoo (OCT), with Mr. Abhijit Patnayak, Manager (NPM), serving as the team’s facilitator.
It is noteworthy that the Reheating Furnace of NPM was facing intermittent issues such as maintain efficiency and prevent damage, water is circulated through horizontal beams to keep the temperature within safe limits. However, over time, the horizontal beams and skid posts experience oxidation, leading to gradual thinning and frequent replacements. In recent years, the frequency of punctures in the skid posts has become an alarming issue, causing interruptions in production and damage to vital components such as pipe support beams, refractory materials, and recuperators in the reheating furnaces. These malfunctions, operating at extreme temperatures, can result in significant production losses.
The Tejas QC took up the challenge to address the problem. The team after detailed study and brainstorming added an extra cooling line, sourced from the main water supply, to regulate temperatures at the skid posts that were exceeding safe limits. This additional cooling line helped to keep the skid posts within the permissible temperature range, converting potential breakdowns into scheduled maintenance shutdowns.
The QC team bagged the prestigious J K Das Memorial Trophy in the recently organised Chapter Level Quality Circle Competitions held at Rourkela securing highest grade amongst the 140 participating teams from various big corporate houses.
