In a remarkable display of innovation and engineering expertise, the Field Machinery Maintenance {FM(M)} department of SAIL, Rourkela Steel Plant (RSP), has extended critical support to major production units, significantly enhancing operational efficiency, optimizing resource utilization, and prolonging the service life of vital equipment. These initiatives, undertaken during the financial year 2024–25, have resulted in substantial cost savings for the plant.
A major achievement includes the development of a sludge pond measuring approximately 50 meters x 50 meters x 5 meters at Hot Strip Mill-2 (HSM-II). This infrastructure facilitates the safe, systematic, and environmentally responsible disposal of sludge, contributing to the sustainability and efficiency of mill operations.
Another highlight was the in-house renovation of an aging Chain Dozer. The FM(M) team replaced and modified the engine with one of equivalent horsepower, overhauled the undercarriage, and revamped the operator’s cabin and entire electrical wiring. This initiative not only extended the machine’s operational life by approximately five years but also resulted in a cost saving of around Rs. 40 lakhs. Considering that a new dozer of similar capacity costs approximately Rs. 299.50 lakhs, the department effectively helped the plant avoid significant capital expenditure.
Despite the unavailability of original spares for the now-obsolete 100T KH 500 crawler crane (TATA make), the team successfully refurbished the equipment using available in-house resources. Modifications were made to the engine and its cooling system, restoring the crane to full operational capacity. The crane plays a vital role in loading and unloading slabs at the facility.
Leveraging the refurbished KH 500 crawler crane, approximately 63,600 tonnes of rejected slabs have been efficiently unloaded and stacked in the CAT line area. This operational feat highlights the effective reuse of overhauled equipment and contributes to streamlined materials handling.
These accomplishments underline the commitment of FM (M) department to sustainable asset management, cost optimization, and operational excellence. By focusing on in-house capability development, the team continues to contribute significantly to RSP’s strategic goals of operational excellence and financial prudence.
