Manual B - Equipment Manual

B
Equipment Manual
175t BOF Converter
J711 2100 / JSW-SMP
Projekt / Project
2010-08-06
Datum / Date
Index / Index
01
Seite / Page
1/1
2010 by SMS Siemag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
MANUAL
J711 2100 / JSW-SMP 175t BOF Converter JSW STEEL LIMITED Toranagallu, India
Year of Supply 2010
ABCDE T -
Operating Manual Equipment Manual Subsuppliers Components Manual Erection Manual Electrical Equipment Manual Technology Manual
Projekt / Project J711 2100 / JSW-SMP
Datum / Date 2010-08-06
Index / Index 01
Seite / Page 1/1
B0
Contents
Table of contents B-Equipment Manual
Lubrication Instructions B1 / Register 1.0
Plant Equipment.. B2 / Register 2.0
Description Oxygen Lance Installation
Subregister 2/1
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B1 Lubrication instructions
Lubrication instructions
1.1 1.1.1 1.1.2 1.1.3 1.2 1.3 1.4 General instructions Grease lubrication Oil lubrication system Other parts to be lubricated Lubricant recommendations for grease and oil Terms used in the lubrication instructions Lubrication instructions SN 180 Parts 1 and 2 SN 181
Auft.-Nr. / Order No.
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2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher.
1.1
General instructions
1.1.1 Grease lubrication

The grease types and lubrication cycles specified in the lubrication instructions must be followed. Mixing Greases with different types of saponification must not be mixed. Adjustment of the centralised grease lubrication system For economical lubricant consumption, the centralised grease lubrication system has to be adjusted during commissioning of the plant by the commissioning staff of the seller to suit the plant operating conditions. This setting refers to the following activities: The lubrication intervals for the individual grease lubrication systems shall be checked via the relays of the pump controls. The grease volume per lubricating point shall be set at the respective lubricant metering block.
Initial grease fills For nipple and central lubrication, the initial fill must be made in such a way that grease escapes from the bearing points. Danger of contamination Cleanliness is of prime importance when handling greases, for instance during storage (always keep container sealed) decanting.
Cleaning of bearings Cleaned all bearing parts with petroleum ether, acid-free kerosene or another suitable cleaning agent, followed by immediate protection against corrosion by thoroughly covering them with oil or grease. If compressed air is used for drying the bearing, it must be free from water.
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1.1.2 Oil lubrication system

Use of the oil grades specified in the lubrication instructions is mandatory. The specified quantities must be checked and adjusted as necessary during operation. Oil change Used oil is to be drained at operating temperature. Closed gear boxes must be cleaned by flushing them. High-viscosity oils High-viscosity oils must be heated before use. Doped oils Doped oils must be flushed with the oil grade provided for operation. This does not cause any problems during re-filling.
1.1.3 Other parts to be lubricated

If necessary, the chains must be cleaned before relubrication. The lubricant should be applied in the relieved area on the inner side of the chain, if possible.
1.2
Lubricant recommendations for grease and oil

Refer to the following pages: SN 180 Parts 1 and 2
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Betriebsmittel Operating media

Schmierstoffempfehlungen FETT Lubricant recommendations GREASE
Schmierstoff Nr. No. of lubricant
SN 180
Teil / Part 1
Fettarten gem Types of grease as per Vorschlge der Lieferanten / Recommendations by grease supplier DIN 51502 MOBIL SHELL
TivelaCompound A SpezialGetriebefet tH Grease S 3655
Typischer Anwendungsfall Typical application
ESSO
FIBRAX EP 370
TEXACO
( DEA )
BP
Energrease HT-EP 00
ELF
Epexelf 00
Klber
Tribol
Mobilplex 44 KPOK-20 KPOOK-20 oder hnlich or similar
Multifac EPO ( Glissando EP Grease EPO ) 350 Fliefett S 420 Fluidized grease S 420
Klbersynth Tribol 5000 GE 461200*) Grafloscon C-SG 0Plus MolubAlloy Fett 0/00
Zahnkupplungen Gear couplings
Tribol 9020 Multifac EP2 ( Glissando EP2 ) Energrease LS-EP2 Epexelf 2 Centoplex 2 EP Centoplex GLP 402 Stabuther m GH 461 Tribol Wlz- und 4020/220-2 Gleitlager MolubAlloy 860/220-2 MolubAlloy 894 Antifriction and plain bearings Wlz- und Gleitlager max. 250C. Bei hufiger automatischer Nachschmieru ng Antifriction and plain bearings max. 250C for frequent automatic regreasing Gleitflchen, Zahnstangen Sliding faces, racks Exzenterbuchsen fr CL-Gerste Eccentric sleeve for CL-stands
KP2K-20
Mobilux EP2
Alvania EP2
BEACON EP2
K2N-30 _ _ _
Texando FO20 ( Spectron FO20 )
Barrierta L 55/2
1)
Tribol 9020
MolubAlloy 1) 2115-2
4
NEVER SEEZ NS Never Seez compound corporation Broadview, Illinoise 60153 USA
Wolfracoat C MolubAlloy 298 Isoflex Topas L 32
KTC2K _ _ _ _ _
Auer den genannten Schmierstoff- Lieferanten knnen weitere nach Rcksprache verwendet werden, z.B.: Apart from the makes of lubricant indicated, other makes may be used, e.g.: ADDINOL Minerall GmbH Ltzkendorf 06242 Krumpa / Geiseltal *) 1) Synthetischer Schmierstoff, nicht mit Minerall mischen Synthetic lubricant, do not mix with mineral oil Diese Fett ist abhngig von der Betriebstemperatur fr Lebensdauer-geschmierte Lager sowie als Abdichtfett bei Einmalschmierung oder fr lange Schmierintervalle geeignet Depending on the operating temperature, this grease is suitable for bearings with service-life lubrication and as sealing grease for service-life lubrication or for long lubrication intervals.
Please observe the lubricant qualities specified in the lubrication instructions!

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Betriebsmittel Operating media

Schmierstoffempfehlungen L Lubricant recommendations OIL
SN 180
Teil / Part 2
larten gem Types of oil per Vorschlge der Lieferanten / Recommendations by grease supplier DIN MOBIL 51502
CLP 100 Mobilgear 627
SHELL
ESSO
TEXACO
( DEA )
Meropa 100 ( Falcon CLP 100 ) Meropa 150 ( Falcon CLP 150 ) Meropa 220 ( Falcon CLP 220 )
BP
ELF
Klber
Tribol
10
Omala 100 Spartan EP 100
11
CLP 150
Mobilgear 629
12
CLP 220
Mobilgear 630
Energol Reductelf Klberoil Tribol GR-XP 100 SP 100 GEM 1-100 1100/100 Molub-Alloy 80/100 Energol Reductelf Klberoil Tribol GR-XP 150 SP 150 GEM 1-150 1100/150 Molub-Alloy 814/150 Energol Reductelf Klberoil Tribol GR-XP 220 SP 220 GEM 1-220 1100/220
Getriebe Gear units
Zentrale lschmieranlagen CL-Gerste, Molub-Alloy Getriebe, 90/220 Kaltscheren Central oil lubric. system CL-Mill stands, gear units, cold shears
13
CLP 320
Mobilgear 632
Meropa 320 ( Falcon CLP 320 )
Energol Reductelf GR-XP 320 SP 320
Klberoil Tribol GEM 1-320 1100/320
Zentrale lschmieranlagen CL-Gerste, Molub-Alloy Getriebe 690/320 Central oil lubric. system CL-Mill stands, gear units
14
CLP 460
Mobilgear 634
Zentrale lschmieranlagen CL-Gerste, Molub-Alloy Getriebe, 140/460 Zahnkupplungen Central oil lubric. system, CL-Mill stands, gear units gear couplings
15
CLP 680
Mobilgear 636
Schneckengetriebe, Zahnkupplungen, Molub-Alloy Hauptantriebe 190/680 Worm gear units, gear couplings, main drives
16 17
VDL 100 DIN 51506 SE Rarus 427 Corena Oil H 100 D Corena Oil P 100 Solvac 1535 GD Dromus B Verdichter l 3021 N Compress Oil 3021 N Kutwell 40 Compr. Oil Energol EP VDL 100 RC 100 ( Actro VDL 100 ) Texsol D Fedaro M ( Targon D ) Elf Dacnis P 100 _ Tribol 890/100 Tribol 1750/100 _ HochdruckKompressoren High pressure compressors 5% l-in Wasser Emulsion 5% oil-in water emulsion
18
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Please observe the lubricant qualities specified in the lubrication instructions! larten gem Types of oil as per Vorschlge der Lieferanten / Recommendations by grease supplier DIN 51502
HLP 46 DIN 51524/2
MOBIL SHELL ESSO

DTE 25 Tellus 46 Nuto H 46
TEXAC O (DEA)
Rando Oil HDB 46 ( Astron HLP 46 ) _
BP
Energol HLP 46
ELF
Klber
Tribol
19
Elfolna 46 Lamora HLP 46 Elfolna DS 46
Tribol Hydrauliksysteme 943 AW 46 Hydraulic systems Zentrale lschmieranlagen, DrahtFertigblcke Centralised oil lubrication systems, wire finishing blocks
20
ISO VG 100 Vacuoline 525
21
ELPF 100
( Molub-Alloy lfarn 892 XCL ) Hinweis: siehe Tribol Note: see Tribol Glygoyle 30 Tivela l WA
Synthesco Hotemp OY 95
Molub-Alloy StelmorTransportketten 892 XCL Tribol 1430 Stelmor conveyor chains Stehlager Plummer blocks
22
Synthetic Oil PGLP 150/ 220 _
Umlaufl S 220
Synlube CLP 150 ( Polydea GLP 150 )
Energol SG-XP 220
ElfKlbersynth Tribol syntherma GH 800/150 *) P 270 6-150/220 800/220 Unimoly PA-Spray
23 24 25
BC-V _ HL / HLP 22,32 CL / CLP 22,32
MOS 2 Spray
Cardium Fluid C Tellus 22/32
Fa. DOW Corning GmbH D- 8000 Mnchen Surett Fluid 4K Nuto H 22/32 Spinesso 22 Teresso 46 _ Rando OilHDA 22/32 Aries 32 ( Astron HLP 22/32 Arkas DLP 32 ) Energol WRL Energol HLP 22/32 HLP D22/32 HL 32 _
Molub-Alloy Ketten 369 Chains Molub-Alloy Zahnstangen 936 SF racks LuftwartungsTribol 943 AW 22 einheiten 943 AW 32 compr. air treatment units Tribol 771
Grafloscon C-SG O-Plus
Mobil DTE 22 Mobil DTE Oil light Velocite oil No. 10 Mobil DTE 25
Tellus C22/32
Elf PolyAirpress telis 22, 32 15/32 Elfolna 22,32 Elfolna DS 22, 32
26
CL 46
Tellus C46 Nuto 46 Rando Oil Teresso 46 46 ( Astron HL 46 )
Energol HL 46
Elf Crucolan 46 Tribol 772 Polytelis 46
Spll fr Zentrallschmieranlagen Flushing oil for Central oil lubrication stations HydraulikSysteme Wasser-Glykol Basis Hydraulic systems water-glycol basis
27
HFC 46
Hydrofluid Hydraulik HFC 46 Fluid HFC 46
Pyrelf HFC 46
Auer den genannten Schmierstoff- Lieferanten knnen weitere nach Rcksprache verwendet werden, z.B.: Apart from the makes of lubricant indicated, other makes may be used, e.g.: ADDINOL Minerall GmbH Ltzkendorf 06242 Krumpa / Geiseltal Synthetischer Schmierstoff, nicht mit Minerall mischen Synthetic lubricant, do not mix with mineral oil Please observe lubricant qualities specified in lubrication instructions! *)
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1.3
Terms used in the lubrication instructions

See following pages SN 181
Explanation of the item numbers on the lubrication list drawings
Manual lubricating point
Centralized grease lubrication system
Lubrication point hidden behind component, not visible
Marking not used
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2010 by SMS India Pvt. Ltd. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
Begriffe zur Schmieranweisung / Terms used in the lubrication instructions 1. Art der Schmierung / Type of lubrication Spalte 5 Column 5 E F Fe Hy Hp Hs K M O OL On OV S Sd Sg Sp U Wf Z ZHp Art der Schmierung Hydraulik- Emulsion l- bzw. Fettfllungen Festschmierstoff Hydraulikl Handschmierpumpe Hydrostatisch Korrosionsschutz Morgoil Schmiersystem Oberflchenschmierung l- Luft- Schmierung lnebel- Schmierung l- Verlustschmierung Schmiernippel Sprhdosenschmierung Schmierstoffgeber Sprhschmierung lumlaufschmierung wartungsfreie Schmierstelle Zentral- Fettschmierpumpe Zentral- Fettschmierpumpe, Hand Type of Lubrication
SN 181
Hydraulic emulsion Oil or grease fillings Solid lubricant Hydraulic oil Hand-operated lubricating pump Hydrostatic lubrication Protection against corrosion Morgoil lubrication system Surface lubrication Oil- in- air lubrication Oil mist lubrication Lost oil lubrication Grease nipple Spraying can lubrication Metering block Spray lubrication Recirculated oil lubrication Maintenances- free lubrication point Centralized grease pump Centralized grease pump, handoperated
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2. Schmierintervalle / Lubrication interval Spalte 6 Schmierintervall Column 6 ( im 3- schichtigen Betrieb ) ED GW H J L M 3M 6M S T W WW Einschaltdauer- Schmierung bei Gerst- / Segmentwechsel stndlich jhrlich Lebensdauer- Schmierung monatlich 3- monatlich 6- monatlich je Schicht ( 8 Stunden ) tglich ( 24 Stunden ) wchentlich bei Walzen- / Rollenwechsel Lubrication interval ( on base of 3- shift operation ) Lubrication system duty cycle When changing stand / segment Every hour Every year Greased for life Every month Every 3 months Every 6 months Every shift ( 8 hours ) Every day ( 24 hours ) Every week When changing rolls Lubrication interval ( on base of 3- shift operation )
Spalte 6 Schmierintervall Column 6 ( im 3- schichtigen Betrieb )

B1 B2 B3 B4 B5 B6
According to supplier nach Angaben des Lieferanten siehe Zulieferkomponenten-Handbuch C see Bought-out Components Manual C berprfen alle 6 Monate berprfen bzw. nachfllen nach 3.000 Betriebsstunden wechseln, maximal nach 18 Monaten lwechsel nach je 10.000 Betriebsstunden 1. lwechsel mit Reinigung nach 500 Betriebsstunden, dann alle 2.500 Betriebsstunden 1. lwechsell nach 500 Betriebsstunden, 2. lwechsel nach 2.000 Betriebsstunden, weitere lwechsel nach 4.000 Betriebsstunden, mindestens 1 mal jhrlich 1. lwechsell nach 200 Betriebsstunden, 2. lwechsel nach 1.500 Betriebsstunden, weitere lwechsel nach 4.000 - 5.000 Betriebsstunden wchentliche Prfung, lmessstabanzeige beachten Kettengelenke bei Bedarf schmieren 20 Doppelhbe Schmierintervalle: alle 30 Minuten Schmierintervalle: alle Schmierintervalle: alle 4 Stunden 1 Minute Check Check and / or refill every 6 months Change after 3,000 operating hours, after 18 months maximum Oil change after every 10,000 operating hours 1st oil change with cleaning after 500 operating hours then every 2,500 operating hours after 500 operating hours 1st oil change after 2,000 operating hours 2nd oil change further oil changes after 4,000 operating hours, at least once a year after 200 operating hours 1st oil change after 1.500 operating hours 2nd oil change further oil change after 4,000 5,000 operating hours 1 check per week, observe gauge stick indication Lubricate chain links if required 20 double shots Lubrication interval: every 30 minutes Lubrication interval: every Lubrication interval: every 4 hours 1 minute
B7
B8
B9 B10 B11 B12 B13 B14 B15 B16
Schmierintervalle: alle 1,5 Minuten Schmierintervalle: alle 20 Minuten
Lubrication interval: every 1.5 minutes Lubrication interval: every 20 minutes

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3. Mengeneinheiten / Quantitative units
Spalte 7 und 8 Angaben der Mengeneinheiten FA cm3 dm3 m

3
Columns 7 and 8 statement of quantitative units until grease flows out indicated indicated indicated
bis fett austritt mit Angabe mit Angabe mit Angabe
4. Fllmengen, Definition / Fill volumes, Definition Die Erstfllmenge ist die gesamthaft erforderliche The initial fill is the total required volume of Menge des zu schmierenden Teiles und aller the part to be lubricated and of all ancillary cavities. Nebenrume. It is to be filled in prior to initial start. Sie ist vor dem ersten Anlauf einzufllen.
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1.4 Lubrication Instructions Erzeugnisbenennung: Equipment unit designation:
--O2-Lanze O2-Lance LD3/ LD4 Item Nr.: Item No.: 6.1.4.12
Lubricant no. according to SN 180 Initial filling volume according to SN 181-4 for each lube point Schmierstellen Nr. Lube point no. Quantity for one lube point and interval according to SN 181-3 Lubrication interval according to SN 181-2 Type of lubrication according to SN 181-1 No. of lube points per component Components per equipment unit Designation of part to be lubricated 1 Lance Trolley travel Wheels Lance Trolley Guide Roller Lance Trolley Geared Motors (Supplier - IC Bauer) Lance Guide Interlock Assembly Lance Guide Running Rollers Latch pin at Lance Guide Carriage Lubrication Left Carriage Lubrication Right Rope Pulley Assembly Hoist drum LH / RH pedestal bearing Hoist drum LH / RH coupling (Supplier M.A.T. Malmedie Antriebstechnik GmbH) Main Hoist Gearbox LH / RH (Supplier Shanthi Gears Ltd.) Emergency Hoist Gearbox LH / RH (Supplier Shanthi Gears Ltd.) Lance Hoist Air Motor ( Supplier Duesterloh Fluidtechnik Lance Hoist Air motor ( Supplier Duesterloh Fluidtechnik EUBA Electric Actuator All Lubricators of pneumatic piping systems Drawing-No. 2 3 4 4 2 1 6 2 8 8 2 4 2 1 1 1 1 1 1 1 2 5 6 7 FA FA 11.4 3 dm * FA FA FA FA FA FA FA FA * 255 L 1.3 L 1.4L * FA * * 8 200cm 80cm 11.4 3 dm * 50cm 70cm
3 3
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
9 2 2 12 * 2 2 2 2 2 2 2 2* 14 * 13 * 19 * K3 K* 2 *
21500503 21500504 21500506 21500500 21500409 21500431 21500390 21500438 21500386 21500558 21500556 / 21500557 21500610 / 21500611 21500560/ 21500561 21500562 / 21500563 21500566 21500566 21500492
S 3M S 3M F S B5 * W
S 3M S M
40cm
S 3M S 3M S 3M
85 cm 85 cm 60 cm 750 3 cm 750 3 cm *
1/1 1/1 S 6M 1/1 1/1 S J * 1/1 1/1 F 1/1 1/1 F 2 2 1 1 4 2 1 6M * 6M *
255 L 1.3 L 1.4L * FA * *
F M* S M* S F * *
* Please also see section C Sub Supplier Components Manual
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Lube point for Drawing No. 21500503 / 21500504
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Lube point for Drawing No. 21500506
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B2
Plant equipment
Table of contents
for the Operating and Maintenance Instructions for the following equipment General instructions and regulations for Maintenance and safety Lubrication see A-Operating Manual see B-Equipment Manual, B 1, Register 1.0
Item Nr.
6.1.4.12
Project No. Designation J711 2165 Oxygen Lance Installation
B2/ Subregister 2/1
Pages Index
31
01
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Datum / Date
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B2
O2 Lance
O2 Lance
Z:\Indian\JSW-SMP\J711\002 Engineering\001 Mechanical\007 Operation & Maintenance Manual\BOF\Manual B\PDF\JSW_B2_Oxygen-Lance.doc
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2008 by SMS Demag AG, Germany. All rights reserved. No part of this book may be reproduced, in any form or by any means, without permission in writing from the publisher
B2
O2 Lance
Table of contents
Page 1 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1
List of drawings ........................................................................................................................... 3 Technical data.............................................................................................................................. 8 Mechanics....................................................................................................................... 8 Electrics ........................................................................................................................ 10 Hydraulics ..................................................................................................................... 10 Pneumatics ................................................................................................................... 10 Utility systems............................................................................................................... 11 Lubrication systems ...................................................................................................... 11 Function...................................................................................................................................... 12 Overall function (Lance system) ................................................................................... 12 Single functions ............................................................................................................ 15 Maintenance instructions.......................................................................................................... 16 Preventive maintenance ............................................................................................... 16 Maintenance procedure ................................................................................................ 17 Lubrication instructions ................................................................................................. 20 Special safety regulations/Residual risks ..................................................................... 20 Installation/Dismantling of Equipment........................................................................... 21 Installation / Dismantling............................................................................................... 21
3.2 4 4.1 4.1.1 4.1.2 4.2 4.3 4.3.1
4.3.2.1 Removal of Lance Carriage .......................................................................................... 21 4.3.2.2 Change of wire ropes of Lance Carriage ...................................................................... 23 4.3.2 4.3.3 4.3.4 4.4 4.4.1 4.4.2 4.4.3 4.5 4.6 Setting work, setting values and tolerances ................................................................. 23 Transport ...................................................................................................................... 24 Special Tools ................................................................................................................ 24 Shutting down/Restarting.............................................................................................. 25 Shutting down ............................................................................................................... 25 Restarting ..................................................................................................................... 26 Function test ................................................................................................................. 27 Suppliers' instructions for assembly/installation, commissioning and maintenance ..... 31 Records ........................................................................................................................ 31
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B2
O2 Lance
List of drawings for Oxygen Lance Installation (Item No.6.1.4.12)

Description G.A. Oxygen Lance System Arrangement Lance Body Assembly Lance Body Spherical Disc Lance Dome Cap 6-Loch-Lanzenkopf Oxygen Hose DN200 Water Hose DN150 SMS Siemag Drawing No. 21500330 21500331 21500332 21500336 21500347 21119451 21500348 21500349 HW-1-1545-00 309235-02-00 309235-03-00
Saar Metall * Rattay * Rattay *
SMS Siemag Order No. J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165
Subsupplier Drawing No.
Subsupplier name
J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165
Carriage Assembly Left Carriage Assembly Right Rope Arm Assembly Bolt Spherical Seat Guide Roller Assembly Eccentric Shaft Track Roller Spring Assembly Track Roller Assembly Carriage Lubrication Left Carriage Lubrication Right Guide Track Arrangement Latch Assembly Latch
21500351 21500382 21500354 21500463 21500359 21500365 21500366 21500370 21500377 21500438 21500386 21500387 21500390 21500391
Track Roller supplier Eich - do Track Roller supplier Eich
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B2
O2 Lance
SMS Siemag Order No. J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165 J 711 2165
Description
SMS Siemag Drawing No. 21500393 21500397 21500431 21500409 21500492 21500410 21500413 21500412 21500418 21500419 21500425 21500430 21500465 21500466
Subsupplier name
Compression spring 3.2 Running Rollers Assembly Lubrication For Running Roller Interlock Assembly Electric Actuator Center Bracket Center Piece Bolt Bush Buffer Guide Track Support Bearing Assembly Guide Track Fixing Arrangement Limit Switch Arrangement Limit Switch for Trolley movement
Track Roller supplier P&N *
E/X-B4-001
Euba *
Buffer supplier Insutech Corporation *
Limit supplier Balaji # -do-
switch Jai
Limit Switch for Latch
21500471
Proximity switch supplier Pepperl+Fuchs # 3/2 way roller lever oprtd. Valve supplier IMI Norgren *
Pneumatic Limit Switch
21500481
Trolley Assembly Idle wheel Assembly Wheel Axle Drive Unit Assembly Drive Wheel Assembly Axle Geared Motor Geared Coupling
21500500 21500503 21500509 21500514 21500502 21500504 21500513 430199/GM/2 21500525

International Combustion (I) * Wellman *
Projekt / Project
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SMS Siemag Order No.
Description Drive Unit Assembly - II Geared Motor Encoder Bonded Buffer TG-0315 Guide Roller Assembly Eccentric Axle Hoist Assembly LH Main Hoist Gear Box LH Emergency Hoist Gear Box LH Rotary cam limit switch
SMS Siemag Drawing No. 21500505
Subsupplier name
430199/GM/1 21500524 21500517 21500506 21500530 21500556 21500560 21500562 21500564 21500566 21500567 21500568 21500571 21500610 21500559 21500607 21500572 21500558 21500565 21500598 21500557 21500560 21500563 21500611 21500440
31026872-REV-1, DD2 31026798 31026872-REV-1, DD1 31026799
International Combustion (I) * TR Electronics # Resistoflex * Track Roller supplier Eich *
Shanthi Gears * Shanthi Gears * Leonard, Germany #
Air Motor Brake Air Clutch Brake Drum Coupling Rope Drum Assembly LH Rope LH lay lift. winch Rope RH Lay lift. winch Drum Coupling Pulley Assembly Load Transducer Pin Rope Pulley Hoist Assembly RH Main Hoist Gear Box RH Emergency Hoist Gear Box RH Rope Drum Assembly RH Maintenance Platform Assembly
02.5352.00 U903903115D
0521-015-39151000
Dsterloh Fluidtechnik * Siegerland Bremsen * Ortlinghaus * Rathi Transpower *
Malmedie *
1601108XXXX
Hirschmann
Shanthi Gears * Shanthi Gears *
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SMS Siemag Order No.
Description Platform - II Support Roller Assembly Pneumatic Cylinder Support Roller Assembly Fixed Support of Hoses GA Nitrogen Tank 7m3 Pneumatic Diagram Converter 3 Pneumatic Diagram Converter 4 Pn. Emerg. Lance Lifting Conv. 3 Pn. Emerg. Lance Lifting Conv. 4 Lance Cooling Water System Valve Station Left
SMS Siemag Drawing No. 21500442 21500453 21500496 21500454 21500554 21850412 21500499 21500555 21850410 21850411 21850425 21850426 21850456 21850416 21850417 21850453 21850419 21850421 21850423
Subsupplier name
NIPL-C112671
Nucon *
Valve Station Right Oxygen Piping for Lance Oxygen Valve Stand-1 Oxygen Valve Stand-2 Nitrogen Valve Station-1 Nitrogen Valve Station-2 Burn Out Copper Piece
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The listed drawings will be submitted with the drawing documentation! These Operating and Maintenance Instructions cover the major equipment functions and working instructions only and illustrate them in simplified images. It is assumed that the installation is operated and maintained solely by trained and qualified personnel.
# For more details refer separate Electrical Documentation * For more details refer Manual C Subsuppliers Components Manual
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2
2.1
Technical data
Mechanics
Lance facility Number of converters Heat size Oxygen blowing rate Nominal / max. Oxygen pressure (inlet of valve rack) Number of oxygen lances (connected) Cooling water flow rate (max.) Cooling water pressure (at valve rack inlet)
2 nom. 175 t (min. 165 t, max. 175 t) 575 / 600 Nm/min
1.7 MPa(g) 4 (2 per converter) 200 m3/hr 10 bar
Lance hoist Quantity Safe Working Load (SWL) Rope drum root diameter (at bottom of groove) Rope details 2 98 kN 1250 mm
36 mm, Steel Core, 6x37 construction,

1770 Tensile Class, Breaking Strength (Min.) = 730 kN, Galvanized
Number of load-bearing ropes Load Transducer pins in deflection pulleys Nominal load Overload preset value Slack rope load preset value Mechanism group Traversing distance of lance carriage
2 (1 no. RH Lay and 1 no. LH Lay)
76 kN 61 kN (per pin) 16 kN (per pin) M6 acc. to IS 13834-1, working. 14,300 mm For lance exchange, 14820 mm Pneumatic emergency lifting, 15820 mm
Lifting speed Pneumatic Emergency lifting speed

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0 - 31 m/min 6.13 m/min

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Main drive Rated output power Full load speed Reduction gear ratio (between electric motor and rope drum) Brake
Electric motor 75 KW 1,475 rpm 192.4:1
Fail safe type external spring applied double shoe drum brake, Brake release gear electro hydraulic Thruster for operation with electricity and Pneumatic cylinder for operation without Electricity
Brake torque setting
530 Nm (refer Subsupplier component Manual C SIBRE, for setting up the Brake torque)
Emergency drive
pneumatic geared motor 26 kW at 5 bar(g) 1500 rpm 5 bar(g) 989.4:1
Drive power Motor speed Nitrogen pressure at the motor Reduction gear ratio (between pneumatic gear motor and rope drum) Oxygen lance Quantity Operating lance Standby lance Outside diameter of lance Lance length to lance support Overall lance length
2 (per converter) 1 1 (connected ready for operation) 298,5 mm 16,535 mm 20,875 mm
Hoses Number of oxygen hoses Hose diameter Hose length Number of cooling water hoses Hose diameter Hose length
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1 per lance DN 200 18,000 mm 2 per lance DN 150 18,000 mm

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Nitrogen Tank Number of tanks Internal Volume Outside Diameter Height Total height from support platform Working Pressure Safety valve set at Pressure regulator set at 2 7 m3 1,794 mm 3,500 mm 3,950 mm 18 bar(g) 20 bar(g) 6 bar(g)
The unit/machine must be operated only within the limits specified in the technical data. Use of the unit/machine outside the specified limits is considered as not in line with the intended purpose. This includes, among others: Increase of the oxygen blowing rates specified in the technical data. Increase of the converter capacities specified in the technical data.
2.2
Electrics (see E-Electrical Equipment Manual)
2.3 2.4
Hydraulics Pneumatics N2 Pneumatic diagram N2 tank N2 Pressure N2 working temperature N2 Purity : : : : :
not applicable
21500499 & 21500555 21850412 18 bar(g) Ambient temperature 99.99 %
For trouble shooting of all pneumatic components, panels and loose items that are fitted on the nitrogen pipeline between the tank and the panels refer sub supplier Manual C
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Ross Controls. A brief description of the pneumatic system for Lance emergency lifting is given in section 3 of this manual
2.5
Utility Systems Oxygen Piping including valve station Lance Cooling water System O2 Pressure O2 Quality Water pressure Water Quality : : : : : : 21850416 21850425 1,7 Mpa(g) 99.5 % 10 bar Soft Water
For trouble shooting of all components of the valve stations and line mounted valves please refer the corresponding manuals of the suppliers.
2.6
Lubrication systems
See manual B1-Lubrication Instructions
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3
3.1
Function
Overall function (Lance system)
2 oxygen lances, one in operation and another standby, are available for each converter. The oxygen lance is suspended in the support bracket of the travel carriage. In the upper part of the lance carriage the lance is secured by a lance clamping device. The lance with the hoses (oxygen hose, cooling water supply and return hose) is attached to the corresponding valve stations ready for operation via pipe bends and swing bolt flanges. The lance hoists, one for each lance, serve to lower the lance carriage with the oxygen lance fastened to it into the converter or to lift it out of the converter. The lance hoists mounted on top of the lance trolley mainly consist of the electric motor, the gear box, the rope drum, the corresponding couplings and the double shoe brake as well as a pneumatic emergency drive unit. The rope drum is connected by two ropes to the lance carriage via a rope equalizer. The ropes are each designed with a safety factor of 7.4 to prevent rope breakage at maximum load, i.e., each rope is capable of carrying the maximum load. The equalizer on the lance carriage compensates the different rope lengths. A load transducer pin arranged in the deflection pulley acts an overload guard or slack rope protection, respectively. The overload protection is set at 61 kN, the slack rope protection at approx. 16 kN. The lance hoists are shut down automatically when the overload protection is actuated. The lance hoists can then only be electrically raised at low speed by operating the master switch (joystick). As the slack rope protection is activated, the lance is raised at low speed up to the STANDBY POSITION (see Arrangement Drawing No 21500614). The electrical function of the lance hoists is described in detail in the electrical equipment manual. Work on the lance hoist equipment must be performed only if the lance is in the latch position. For work on the lance hoist equipment or on the ropes, the unit has to be shut down electrically via the emergency off push-button in the local control desk and the supply of nitrogen to the emergency drive unit has to be shut off and the nitrogen line after the tank has to be completely depressurised. (see also functional description of electrical equipment).
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For operation of the oxygen lance certain requirements must be fulfilled. In the "Standby" position a check is made as to whether the following preconditions have been satisfied: Oxygen available Lance cooling water available Gas cleaning system ready Nitrogen available for emergency lifting
After all preconditions have been fulfilled, the oxygen lance may be started. It travels over the speed-change point at high speed and then slowly moves to the blowing position. The supply of oxygen is started after synchronisation. The elevation of the speed-change point and the oxygen blowing position are variable and depend on the bath level in the converter. After the preset oxygen flow rate has been blown, the oxygen lance automatically moves up to the synchronisation position. The lowermost blowing position of the lance tip is at approx. +9,485 When reaching the lower most buffer position, an alarm is given out and the lance is electrically raised up to the upper standby position. While raising the oxygen lance, the oxygen quick-action double shut off valves are closed in the upper area of the lance stroke and the lifting speed of the lance is reduced. The oxygen blowing procedure runs automatically. Operation of the lance hoist drive is tracked by the computer preset Blowing distance. Electrical control of the oxygen lance is summarized and described in the electrical equipment part.
Emergency lifting In addition to the main electric drive unit, the lance hoist is equipped with a pneumatically operated emergency drive unit which in case of a power failure or "Emergency off" automatically starts with a time delay and lifts the oxygen lance. For the power supply of the emergency drive unit including its control system, nitrogen is available from a standby nitrogen tank in which nitrogen is stored at 18 bar(g) pressure. The pressure in the line downstream of the tank is reduced to 6 bar(g) by a pressure regulator before feeding the valve panels and pneumatic geared motors of the emergency drive units. A pneumatic geared motor is connected to the input shaft of the main gear box via a pneumatic actuated clutch, a small single stage helical reduction gearbox and a flexible coupling. The valve and control panels of the emergency drive units (see C-Subsuppliers' components manual for Ross Controls and pneumatic diagram no. 21500499 and 21500555) are arranged at the top of the Lance trolley.
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The following description of the working of the emergency drive shall be read together with the Pneumatic Diagram Converter 3 21500499. During emergency lifting both working lance and standby lance are lifted up simultaneously. Working lance lifts up by 15.82 m and standby lance lifts up by 1.0 m. Nitrogen supply is already available up to the inlet of pilot operated 3/2 way shut off valves B3.21500499.11 located just before the inlet of pneumatic geared motor. In the event of power failure or Emergency open operation, the solenoid pilot operated 5/2 way valve B3.21500499.8 in the Control panel is de-energized and is switched to through passage. This causes nitrogen to flow through the pilot lines after a time delay through the 3/2 way time delay valves B3.21500499.18, through the 3/2 way roller lever actuated valves B3.21500499.6 and through flow control valves B3.21500499.3 to the control circuit of the pneumatic motor, brake and clutch. Owing to the time delay, a possibly lowering O2 lance can come to a halt before the pneumatic motor is actuated. When the pilot nitrogen enters the 3/2 way valves B3.21500499.11 and the direction control valves of air motors, main nitrogen supply is switched on to the air motors. At the same time pilot nitrogen actuates the 3/2 way valves B3.21500499.9 which causes nitrogen to flow to the pneumatic clutches and hence the clutches are engaged and becomes positive. As pressure builds up in the pneumatic motor chamber, the impulse line from the motor actuates the lock up valves B3.21500499.20. This causes pilot nitrogen to actuate 3/2 way valves B3.21500499.9 which pressurises the thruster brake releasing cylinders through a delay circuit (3/2 way valves B3.21500499.18 + B3.21500499.19) for both lances. Thus the holding brake is released last before the lances lift up and free fall of lance is avoided. The lances are lifted up by the pneumatic motors till the upwardly moving lance carriages actuate the roller lever actuated 3/2 way valves B3.21500499.6. The valves are closed, pilot nitrogen supply is stopped to the controls of the pneumatic motor, clutch and brake and the lines downstream of these valves are vented. The clutch disengages, the pneumatic motor shuts down and the holding brake is applied. The pneumatic limit switch valves B3.21500499.6 are arranged in such a way that the lance carriage always overrides the latch in case of emergency lifting. When the power is restored the previously mentioned 5/2 way solenoid actuated valve B3.21500499.8 is moved to closed position where it ventilates the pilot lines proceeding to the valve panels. The lance can be lowered again from the pneumatic limit switch position by electric power only. In this case, the latch must be operated manually.
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3.2
Single functions
not applicable
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Maintenance instructions
see A-Operating Manual, Chapter 8
General maintenance instructions
4.1
Preventive maintenance
Operating condition
Time interval = Every hour
COM = During commissioning H OPE = In operation PRO = During production SST = During standstill
Sch = After each heat S D W M 2M 3M 6M N Y 2Y = Every shift (8 hours) = Every day (24 hours) = Every week = Every month = Every 2 months = Every 3 months = Every 6 months = After each relining = Every year = Every 2 years
TOL = Time-on Lubrication LTL = Lifetime lubrication
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4.1.1
Maintenance procedure
The careful servicing of all parts is necessary for perfect functioning of the lance equipment. All functions, electrical, pneumatic and mechanical, need to be checked each day (see also ELECTRICAL manual).
Important: For all maintenance operations as well as for oxygen lance changes the guide carriage must be in the mechanically blocked latch position. The supply of nitrogen downstream of the tank must be shut off and the line downstream the nitrogen tank has to be vented to avoid accidental starting of the unit.
The carrying ropes must be checked every day for possible damage in accordance with IS:3973 Code of Practice for selection , installation and maintenance of wire ropes All flanged joints of the oxygen, nitrogen and cooling water lines must be checked for leaks.
The function of the pneumatic emergency drive unit has to be checked regularly by way of a "lance emergency lifting" running test. All screws/bolts must be regularly checked for firm seating. The torques indicated in the drawings must be complied with. The oxygen lance must be permanently checked for a possible escape of cooling water. In case of a leak the oxygen lance must be immediately replaced or the spare lance from the spare lance storage must be used.
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Equipment, device
Connections of complete gas supply system and pneumatic system oxygen blowing lance tip All screw fittings of the oxygen blowing lance system Lance Hoist brake drum wear, brake shoe lining wear, brake torque setting, reserve stroke of thrusters and pneumatic release cylinder, Lever adjustment tie rod bolt tightness Lance Hoist Main and emergency gear box, Lance Trolley Geared Motor oil level and leaks Elongation of one rope with respect to the other for lance carriage
Inspection, measure
for leaks Check for wear at the nozzles check for tight fit, retighten, if necessary
Operating Condition
Time interval
S
SST
S H *) / 3M
Check; adjust/ reset/ replace if required SST Check; arrest leaks and refill oil if necessary Check: Readjust rope equaliser rocker arm at carriage top. Check as per IS:3973; replace if necessary. Check for rust, dirt deposits and leaks Check; tighten if required Check for smooth operation and alignment; tighten all bolts check for proper function Check; tighten all bolts with the given tightening torque, realign coupling hub in axial direction as per supplier catalogue, replace if wear exceeds permissible limit check for tight fit, retighten, if necessary SST check for tight fit, retighten, if necessary SST SST
S/W/3M #
M M M 3M
Wire ropes of Lance hoist - deformation, stretching, corrosion, breakage of strands Pipe work , valves and fittings of complete utility supply system, pneumatic equipment Fastening of ropes on travel carriage and rope drum Guide Rollers /wheels of lance carriage, lance trolley and lance maintenance platform Clamping Device for lance on the carriage Drum Coupling between lance hoist rope drum and gear box- tightness of connecting bolts, disturbance in the axial location of the coupling, wear inside the coupling
3M 3M
6M @
Fastening of all drive motors and gear units Fastening of guide column
6M 6M
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Equipment, device
Inspection, measure
check for operating condition, leaks, tightness of flange / thread connections with pipe work Check filters for filter element clogging and that the lubricators are filled with oil; Clean filter elements or replace if necessary, top up lubricators with correct grade of oil Check, Replace seals if necessary Check for perfect function, Check for tightness in hose connection, clutch plates wear, check that clutch is decoupled from main gearbox when not pneumatically actuated; replace worn clutch plates, spring if necessary Check the filter at the main air inlet DN 50 on the body of air motor for clogging; clean air filter check for perfect function
Operating Condition
Time interval
Pressure hoses for utility supply, pneumatic equipment
6M
Lance emergency pneumatic drive In line filters and lubricators
SST 3M
Pneumatic cylinder of lance Maintenance platform Leakage Lance emergency pneumatic drive
6M W
Lance emergency pneumatic drive pneumatic actuated clutch
W SST
Lance emergency pneumatic drive Pneumatic geared motor Complete operating sequence Steel structure and welds Change of lubricating grease on the bearings
Y check Replace the entire old grease till fresh grease comes out from the seals Drain used oil at operating temperature. Fill flushing oil of same type and grade as the lubricating oil, run unit again with flushing oil for a short period and then drain. Finally top up to required level with fresh lubricating oil as given in manual B1 and again run the unit for a short period. Top up again if necessary. SST 6M
Change of lubricating oil of all gearboxes and geared motors
SST
6M
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*) # @
Only applies to the first 2 months after initial startup Refer Sub supplier component manual C SIBRE for more details Refer Sub supplier component manual C MALMEDIE for more details
4.1.2
Lubrication instructions (for the pertaining lubrication instructions, see B-Equipment Manual, Volume 1, Register 1.0)
4.2
Special safety regulations/Residual risks see A-Operating Manual, Chapter 2 see A-Operating Manual, Chapter 3.10 see A-Operating Manual, Chapter 8
Basic safety regulations Plant-related safety regulations

General maintenance instructions
as well as the safety regulations applicable in the country of the plant user.
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4.3 4.3.1
Installation/Dismantling Installation/Dismantling of the complete equipment unit not applicable
4.3.2
Installation/Dismantling of assemblies
4.3.2.1 Removal of Standby Lance carriage from the guide track for change of guide rollers. 1. Refer enclosed sketch below for approach to carriage. 2. First both lance carriages shall be lifted up to standby position (bottom of carriage at +40520). The lance trolley shall be further moved so that the standby lance is displaced from the normal standby position towards the trolley rail end stop (nearer to standby lance ) by about 500 mm.
3. The lance carriage of standby lance shall be brought to the latch position (bottom of carriage at + 41120 level) so that the carriage is mechanically locked against the latch and cannot move downwards. 4. After taking clearance from the blower and getting safety access key to the lance maintenance platform, the electric power to the lance trolley travel drive and lance hoist drive shall be disconnected. The oxygen and water lines to the lance shall be shut down at the respective valve racks. 5. The pressurised water remaining in the pipelines between the lance body and the hose has to be drained out 6. Using the lance maintenance platform, disconnect the water and oxygen hoses from the lance carriage and remove the disconnected hose ends by crane from the lance carriage. 7. Using the Lance maintenance platform disconnect the fixed oxygen and water pipes (item nos. 2 / 3 of drawing no. 21500331 Arrangement Lance Body) from the lance and then remove these pipes from the carriage by the Lance crane. 8. Using the Lance maintenance platform, open the lance clamp and remove the standby lance using the lance crane. Please follow the lance changing procedure that is described later. 9. Using the Lance Maintenance platform and the hose bracket for approach, disconnect the wire ropes (of lance hoist rope drum) from the rope equaliser bar of the lance carriage. Attach wire rope sling at the pins from where the wire ropes have been removed. Total assembled carriage weight for removal by crane is 2T. 10. Using the lance crane, lift up the carriage using the rope sling by about 200 mm.
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11. Depress (lower down) the hand lever of latch mechanism (accessible from +40.8 m level platform) so that it clears the carriage. Keeping the lever depressed lower the carriage by lance crane slowly until its top clears the guide track completely. Transport the carriage by crane to the location where the guide rollers can be changed. 12. For inserting the carriage into the guide track back after repair, follow the above steps in reverse order. 13. After completion of all fitting work for fixing the lance hoist wire ropes, the lance hoses and the standby lance to the carriage, the lance maintenance platform shall be retracted and locked, all personnel shall vacate the work area, oxygen and water connections to the lance shall be restored and the power supply started for the lance hoist and lance trolley drives. All systems shall be checked for proper operation. 14. Finally the safety access key of Lance Maintenance platform shall be returned to the Blower and clearance shall be given to him to resume Lance operations. APPROACH TO LANCE CARRIAGE FROM LANCE MAINTENANCE PLATFORM
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4.3.2.2 Change of wire ropes of Lance carriage (at the standby position) For changing the wire ropes of the lance carriage please follow the procedures for step numbers 3 to 9 of the above procedure for removing the lance carriage from the guide. The only difference is that for changing of wire rope of the carriage belonging to the standby lance, the lance trolley shall be at its normal end position and shall not be moved further by 500 mm towards the end stop. For winding on of a new wire rope to the rope drum take all care as given in IS:3973 so as to avoid any kinks in the new wire rope. Observe the tightening torques at the rope clamp of the rope drum and fit in locking wire at the heads of the locking screws of the rope clamps as given in drawing no. 21500610 Rope drum Assembly LH / 21500611 Rope drum Assembly RH.
4.3.3
Setting work, setting values and tolerances Lance Hoist
Torque setting of Lance Hoist Thruster Brakes Overload setting of Load Transducer pin at each pulley Slack Rope Load setting at load transducer pin Lance guide and Carriage Distance between centre lines of guide track and Lance Lance emergency lift pneumatic system Pressure setting at the pressure regulators (refer drawing nos. 21500499 and 21500555) tag no. B3.21500499.24 for Converter 3 and tag no. B4.21500555.24 for Converter 4 Lance Trolley Torque setting of travel drive brake (attached to geared motor) Trolley rail centre to centre distance Straightness of each rail in horizontal plane
530 Nm 61 kN 16 kN
560 mm + 8
6 bar(g)
16 Nm 2400 mm + 2
+ 1 mm for every 2 m of rail length, + 2 mm max.
Level at top of each rail
+ 44600 + 1mm
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4.3.4
Transport Observe Chapter 4.2 Special safety regulations/Residual risks
4.3.5
Special tools
not applicable
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4.4
Shutting down/Restarting
Operating requirements For hot commissioning of the oxygen lance certain requirements must be fulfilled: All mechanical and electrical equipment has been subjected to a cold-run test and performs its functions such as: - lowering of the oxygen lance into the converter and raising it again, - electrical emergency lifting, - pneumatic emergency lifting, - releasing the lance carriage from the latch (as explained before in section 4.3.2.1) - inspection of all electrical functions and measuring circuits (see Manual Electrical equipment) - All lubricating points and oil fillings are sufficiently supplied with grease and oil in accordance with the lubricating instructions. - The lance cooling water is ready for operation. - Oxygen and nitrogen are available in sufficient quantity and at sufficient pressure. - The converter and all pertinent equipment is ready for operation.
4.4.1 (1) (2) (3) (4)
Shutting down In case of a shutdown, e.g. during lance replacement, the lance carriage with the oxygen lance is electrically raised just above the latch position. The lance carriage can then be electrically lowered onto the latch to make sure that it is mechanically secured against further lowering. In the corresponding valve station oxygen and cooling water have to be safely shut off by closing the manual isolating or gate valves. Also the water remaining inside the pipeline between the lance body and the water hose has to be drained out. Danger
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4.4.1.1
Operational disturbances and their elimination
Disturbance Lack of water, leaks in cooling water system Lack of oxygen Lack of nitrogen Water breakout on the oxygen lance Excessively unequal rope lengths Rope breakage Power failure
Remedy
Find causes and repair
Lance replacement Equalize rope on rope drum Mount new ropes Emergency lifting of oxygen lance with pneumatic motor
Additional disturbances and remedies are included in the operating instructions of the units.
4.4.2
Restarting Before the oxygen lance can be lowered, certain parameters must be fulfilled (see functional description). Only then may the oxygen lance be started according to the converter process and the oxygen blowing process performed.
Danger
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4.4.3
Function test
Operation monitoring After the oxygen lance has been started, the oxygen blowing program runs automatically. After the oxygen flow rate preset by the computer has been blown onto the steel bath, the oxygen lance automatically moves out of the converter. The oxygen lance can also be operated manually, e.g. for repair purposes. Oxygen blowing merely needs to be monitored. Look out for irregularities. In case of any irregularities the oxygen lance must be electrically moved out of the converter. Before restarting the system, the causes must be eliminated. In case of a water breakout, e.g. on the oxygen lance, the closure valve in the cooling water valve station is automatically closed and the oxygen lance is raised. For further operation the stand-by lance is to be used. The damaged lance is to be replaced by the spare oxygen lance from the spare lance storage. For further operation the spare oxygen lance from the spare lance storage is used. First, the defective oxygen lance must be removed and transported to the lance repair shop or the spare lance storage. In case of a power failure the lance carriage is automatically raised by the pneumatic emergency drive unit via the latch position. The latch is equipped with two non-contact proximity switches. When the latch is overrun an alarm is transmitted to the main control pulpit by the 1st proximity switch, i.e., the latch is engaged and the lance carriage can no longer be lowered. From the latch position the lance carriage with the oxygen lance can only be electrically lowered again when the latch is manually released. When the latch is released the electrical interlock of the lance hoist drive is unlocked by the 2nd proximity switch and the oxygen lance is electrically lowered in jogging mode up to the upper end position. During lowering the latch must be pressed manually. To detect a water leak of the cooling system, a differential flow rate measuring unit (DMM) is installed. This compares the water flow rate in the supply and return line and blocks the supply of water in case of a leak. If the blowing lance is not needed for an extended period of time, the lance has to be moved to the mechanically blocked latch position.
Danger
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B2
O2 Lance
Lance replacement Oxygen lance dismantling and installation If the standby oxygen lance has to be replaced, the following procedure must be followed: Move travel carriage of standby lance onto the latch and set down onto the latch (bottom of carriage at + 41120 level ). From the platform +35.7m, +37.95m and 40.8m the shut off valves for oxygen, nitrogen and cooling water to the lance are well accessible. After taking clearance from the blower and getting safe access to the lance maintenance platform, the electric power to the lance trolley travel drives and the lance hoist drive of both lances shall be disconnected. For dismantling of the standby oxygen lance, supply of oxygen and nitrogen to both working and standby lance must be reliably shut off in the valve stations by closing the manual shut-off valves respectively. The cooling water supply to the standby lance shall also be shut off by closing the manual isolation valve at the cooling water valve station. The pressurised water remaining in the pipelines between the lance body and the hose has also to be drained out. The supply of nitrogen for the emergency drive unit for both working and standby lance have to be shut off downstream the nitrogen buffer tank by closing the valve at the outlet of the tank and the line downstream of the tank has also to be depressurised by operating the manual lever operated spring return close valve (B3.21500499.30 for Converter3 and B4.21500555.30 for Converter 4) downstream of the pressure regulators. The Lance maintenance platform for the lance to be changed has to be extended. Maintenance personnel can then go over to the extended lance maintenance platform. The swing-bolt flange connections of the oxygen and cooling water lines on the lance body must be opened and the hook of the lance EOT crane shall be gently engaged at the lifting pin provided at the top of the lance. The crane hook should be just holding the lance pin tightly so that the Lance does not move when the lance clamp is released. The lance shall be kept in clear view of the crane operator and good communication shall be maintained between the lance changing personnel and the crane operator.
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B2
O2 Lance
Next the lance clamping device on the travel carriage has to be swivelled away. The lance must be gently lifted up by about 800 mm by the lance crane, and then its inlet and outlet water connections shall be sealed with blind flanges to avoid that residual water escapes during transport. Take care to avoid contact with the water at the lance outlet as it may be hot. Next the maintenance personnel should vacate the extended lance maintenance platform . The extended lance maintenance platform shall be retracted. The oxygen lance may now be safely lifted out of the lance carriage by means of the lance changing crane and moved to lance deskulling and repair area. A spare lance is suspended in the lance carriage in reverse order. Then it is aligned, clamped and connected. For filling of the newly installed lance the vent screws on the lance and the hand-operated valve in the supply piping must be slowly opened. After water has escaped, close the vent screws and open the handoperated valve in the return line. The remaining ventilation takes place via the automatic bleeder valves.
Danger

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B2
O2 Lance
Repair and testing of an oxygen lance The oxygen lance is repaired in the lance workshop. The most frequent repair work on an oxygen lance is the replacement of the lance nozzle. The oxygen lance design provides easy replacement of the lance nozzle after making a clean separating cut on the outer pipe. The oxygen lance to be repaired is moved to the lance deskulling stand by means of the lance changing crane and freed from adhering slag skull, steel splashes etc. Slag skull falls into a container positioned underneath the cleaning stand. After deskulling the lance is transferred to the lance tip cutting stand by crane and clamped at 2 places. The lance is drained through the leak that has occurred or through a hole which has been torch-cut or drilled into the outer pipe. The escaping cooling water is collected and directed into the sewage water pipe. The first separating cut is made at about 260 mm height from bottom of tip by the tip cutting device grinder (above the existing weld). The cut end is finished with a bevel suitable for welding in of the new tip. The bevelled end shall be clean, smooth and free of burrs. Then the oxygen lance is moved to the lance tilt down device by means of the lance changing crane. It is suspended in the lance tilt down device and clamped in the clamping device. Thereafter, the lance tilt down device is used to tilt the lance from the vertical to horizontal position. Then the lance is removed from the lance tilt down device and placed on the repair stand (roller brackets) by shop crane. Repair work must be performed according to the following operating sequences: - remove flange gaskets, - turn the lance, - slide new lance tip with new seals onto the inner tube, - align the lance tip, - tack-weld lance tip to outer pipe, align again and correct, if necessary - tack-weld lance tip at more points - weld lance tip to the lance outer pipe by turning the lance (suitable low hydrogen electrode compatible to steel material St52-3 shall be used) Danger
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O2 Lance
Make sure that the lance nozzle is slipped into the inner pipe with fresh seals and that the seals are properly seated and are neither jammed nor destroyed. The lance nozzle made of copper is provided with a welded-on steel pipe so that only one steel-to-steel weld is required when a lance nozzle is changed. For inspection purposes the oxygen lance is checked with water for leaks at a pressure of 13 bar. After the inspection the oxygen lance is suspended in the spare lance storage where it is ready for later use. For further lance nozzle changes each separating cut must be made above the existing weld and such that the existing weld and the new weld do not overlap. This ensures that clean raw material is available for the new lance/nozzle weld. The subsequent separating cuts for changing the lance tip may be performed at 30 mm above the existing weld. After every 2 tip changes a new outer pipe with a length of approx. 50 mm must be welded in to compensate the length. For all work performed on the oxygen lance it must always be ensured that all oxygen-carrying parts such as pipes, flanges, lance nozzle, etc., are free from oil and grease. Danger
4.5
Suppliers instructions for assembly/installation, commissioning and maintenance See manual C Subsuppliers component manuals
4.6
Records (observe the delivery and inspection instructions of the SN standard valid at the time)
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Manual B - Equipment Manual

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Manual B - Equipment Manual

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B

175t BOF Converter

J711 2100 / JSW-SMP

Year of Supply 2010

Projekt / Project J711 2100 / JSW-SMP

Datum / Date 2010-08-06

Seite / Page 1/1

Table of contents B-Equipment Manual

Lubrication Instructions B1 / Register 1.0

Plant Equipment.. B2 / Register 2.0

Description Oxygen Lance Installation

J711 2100 JSW-SMP

Auft.-Nr. / Order No.

1.1.1 Grease lubrication

Auft.-Nr. / Order No.

1.1.2 Oil lubrication system

1.1.3 Other parts to be lubricated

Lubricant recommendations for grease and oil

Auft.-Nr. / Order No.

Betriebsmittel Operating media

Typischer Anwendungsfall Typical application

Mobilplex 44 KPOK-20 KPOOK-20 oder hnlich or similar

Zahnkupplungen Gear couplings

Texando FO20 ( Spectron FO20 )

Wolfracoat C MolubAlloy 298 Isoflex Topas L 32

Please observe the lubricant qualities specified in the lubrication instructions!

Betriebsmittel Operating media

Typischer Anwendungsfall Typical application

Omala 100 Spartan EP 100

Omala 150 Spartan EP 150

Omala 220 Spartan EP 220

Getriebe Gear units

Omala 320 Spartan EP 320

Meropa 320 ( Falcon CLP 320 )

Energol Reductelf GR-XP 320 SP 320

Klberoil Tribol GEM 1-320 1100/320

Omala 460 Spartan EP 460

Meropa 460 ( Falcon CLP 460 )

Energol Reductelf GR-XP 460 SP 460

Klberoil Tribol GEM 1-460 1100/460

Omala 680 Spartan EP 680

Meropa 680 ( Falcon CLP 680 )

Energol Reductelf GR-XP 680 SP 680

Klberoil Tribol GEM 1-680 1100/680

Auft.-Nr. / Order No.

Schmierstoff Nr. No. of lubricant

Typischer Anwendungsfall Typical application

MOBIL SHELL ESSO

Elfolna 46 Lamora HLP 46 Elfolna DS 46

ISO VG 100 Vacuoline 525

Synthetic Oil PGLP 150/ 220 _

Synlube CLP 150 ( Polydea GLP 150 )

Energol SG-XP 220

ElfKlbersynth Tribol syntherma GH 800/150 *) P 270 6-150/220 800/220 Unimoly PA-Spray

Grafloscon C-SG O-Plus

Elf PolyAirpress telis 22, 32 15/32 Elfolna 22,32 Elfolna DS 22, 32

Tellus C46 Nuto 46 Rando Oil Teresso 46 46 ( Astron HL 46 )

Elf Crucolan 46 Tribol 772 Polytelis 46

Hydrofluid Hydraulik HFC 46 Fluid HFC 46

Auft.-Nr. / Order No.

Terms used in the lubrication instructions

Explanation of the item numbers on the lubrication list drawings