As part of his visit, Mr. Kumar made an extensive tour of the Plant to gain an overview of RSP’s operations, modernization initiatives and production facilities. The visit commenced with a briefing at the Model Room of the Learning & Development Centre, where Mr.  P. K. Sahoo, CGM (L&D), presented an overview of the Plant’s facilities, growth trajectory and future plans.

Subsequently, Mr. Kumar visited key operational units of the Plant, including the Raw Material Handling Plant (RMHP), Blast Furnace-5 (BF-5), Steel Melting Shop-II (SMS-II), and Hot Strip Mill-II (HSM-II). Mr. Biswaranjan Pallai, ED (Works), accompanied him during the Plant visit. During the tour, the CVO was received by respective CGMs and HODs of the Department. He interacted with senior officials and reviewed various operational and management practices being followed across the units.

Mr. Kumar also held discussions with the Chief General Managers of Blast Furnace and Hot Strip Mill-II at ‘Samagam’, Conference Hall of ED (Works) Secretariat, where issues related to operational excellence, system improvement and organizational effectiveness were deliberated upon.

During the day, the CVO interacted with officials from the Mines Department at Rourkela House and reviewed various aspects of mining operations and associated activities. He also held an interactive session with Young Managers, encouraging them to uphold the highest standards of integrity, transparency and professional excellence in their careers.

A special interaction programme with senior officers of the Plant, comprising Executive Directors and Chief General Managers was organized at the DIC Conference Hall, “Manthan”. ACVO, RSP and the team from Vigilance Deptt coordinated the entire visit.

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The remarkable enhancement in converter lining life was made possible through stringent process control, scientific refractory management practices, and consistent adherence to standard operating procedures during converter operations. The achievement highlights the operational excellence, technical competence, and dedicated teamwork of the entire SMS-II collective, including the operating crew, blowers, lance operators, and shift personnel.

Several key operational initiatives contributed significantly to this achievement, including optimized blowing practices, effective utilization of laser scanner technology, improved slag regime management, accurate end-point control, and timely gunning and patching of the refractory lining. Continuous monitoring of thermal load, bath agitation, and slag chemistry by the Area In-charge and Shift In-charges, along with disciplined control over hot metal and scrap quality, played a crucial role in minimizing localized wear and extending the converter campaign life.

The achievement also reflects the close coordination and collective efforts of the Refractory eng.dept and Operations,, Mechanical Maintenance, Electrical Maintenance of SMS-II and RCL teams, which ensured stable and consistent converter performance throughout the campaign period. The accomplishment was achieved under the overall guidance of Mr. S. S. Panda, CGM (Flux and Refractories) and Mr. M. G. Srikanth, CGM (SMS-II).

The converter lining life achieved significantly exceeded the guaranteed lining life of 6,000 heats, resulted in an estimated direct savings of approximately ₹1.5 crores. The extended campaign life of Converter ‘B’ has also contributed towards enhanced converter availability, higher productivity, and overall cost optimization of SMS-II.

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Reiterating its commitment to operational excellence, safety and reliability, the department delivered relentless services and executed major jobs ensuring uninterrupted production across the plant units.

Among the department’s notable achievements in the last fiscal year was the successful repair and refurbishment of Crane #2021 (03) in Steel Melting Shop-II (SMS-II) department. The team executed a complex and critical operation involving the repair of the main girder connection with the end carriage, as well as the replacement of Long Travel (LT) #4 and #1 main balancers of Crane #2021 (03) in SMS-2. This challenging task was accomplished after carefully jacking the main girder, showcasing the team’s technical expertise, precision planning and adherence to safety protocols.

Besides, the department efficiently addressed a significant issue with Crane #2011 (01). The damaged spreader beam of the mixer charging crane was meticulously repaired on-site, ensuring minimum downtime and avoiding potential delays in key production processes. Moreover end carriages of SMS-II scrap yard Crane #2014 (07) and slag yard Crane #2001 (04) were fabricated in-house and replaced successfully.

These achievements reflect the proactive maintenance culture and technical prowess of the Crane Maintenance team, contributing directly to the uninterrupted operations of the steel plant. Their relentless dedication and swift execution of critical maintenance jobs have set a benchmark in reliability and plant safety.

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On 18th October Mr. Alok Verma, ED (Mines) with additional charge of ED (Works) visited the site and congratulated the team. He was accompanied by Mr. R N Rajendran, CGM (Mechaniclal) and other senior officers.

It is worth mentioning here that during the routine maintenance, a structural issue was identified in the main girder of the crane, where cracks had formed at the connection between the main girder and the end tie. The damage, located near the main balancer bogie, presented a significant challenge due to its inaccessibility for repairs without removing the balancer.

Seizing the opportunity provided by a shutdown at Blast Furnace-5, the team scheduled a 12-shift crane shutdown starting 15^th October, 2024, to execute the repairs. One 26 Ton jacking structure comprising three parts made out of 400 dia pipe measuring 4500mm square and 26 metre high was erected underneath the Main Girder. After carefully jacking up the main girder, the team successfully removed the main balancer, gaining access to the damaged area. The cracked section was repaired, reinforced, and the balancer was replaced with a new unit.

This complex and critical repair was successfully completed safely as per schedule. It was possible due to the dedication and technical expertise of the Crane Maintenance team, under the supervision of Mr. S Panka, GM In-charge (Crane Maintenance) and guidance of Mr. R N Rajendran. The other supporting agencies which helped achieve this feat were, SMS-II, FM(M), RCM, and Safety Engineering departments.

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