INCIDENCE OF 7 OCT ’19 AT BF-

Tape Hole-1 Main Runner got through.

Hot metal fallen on Circuit-2 LP supply water line

& damaged it.

Heavy leakage from damaged pipe line.

Subsequent CRISIS Management.

 CLOSED LOOP COOLING SYSTEM OF BLAST FURNACE

Hot Water Hot Return Water

Furnace
‘‘‘‘ ‘‘‘‘
‘‘‘‘ ‘‘‘‘
‘‘‘‘ ‘‘‘‘
‘ ‘ ‘Cooling
‘ ‘‘‘‘
Tower Heat

Exchanger
SECONDARY PRIMARY
CIRCUIT CIRCUIT

Industrial Water Soft Water

Cold Water Cold Supply Water

SCHEMATIC DIAGRAM OF FURNACE COOLING

 NORMAL WORKING OF COOLING CIRCUIT
Engine also Failed N2
Exp Tank
SOV Opens
Power Failed
Supply from EOHT EOHT Empties EOHT
EXP. TK
Diesel Engine Starts H=48m & DP-21 Starts 1800 m3
SOV Ht= 60 m

Strainer
Emergenc
STAVES / y Circuit

Flow under
Plate Heat Primary
Secondary

TUYERES

Gravity
Exchanger Circuit
TK-21 DP-21
Ckt.

CP 1800 m3

Make SOV
Up
DP
COOLING CIRCUITS FOR BF # 8
COOLING
SYSTEM

CIRCUIT CIRCUIT CIRCUIT CIRCUIT

NO. 1 NO. 2 NO. 3 NO. 4

FIXED
PROFILOMETER
CAST IRON STAVES
(H1÷H4) BURDEN CAMERA

SECONDARY SIDE STAVES CAST IRON STAVES

BLT HEAT (TZ-S5) (R1-R3)
EXCHANGER
TAP HOLE STAVES
MUD GUNS

TUYERE NOSE
UNDER HEARTH
COOLING TUYERE BODY

TUYERE COOLER

HOT BLAST VALVE

BACK DRAFT VALVE

 12/5
COOLIN 12/6 FIXED
PROFILOMETER
N₂ purging
G 2/6 BURDEN CAMERA
2/5

CIRCUIT 25/6 SECONDARY SIDE BLT 25/5

TK 02
No. 2 HEAT EXCHANGER 20m³
EXPANSION TANK
16/10 4 MUD GUNS 16/9 - ---- - - - -
@ 4m³/h --------
972/9. 36 TUYER NOSE 972/6.
--------
2 @ 27m³/h 8 ------- + 47 m
-
900/5. 36 TUYER BODY
900/5.
9 @ 25m³/h
3
HP Circuit
1027/1

LP Circuit
900/5.6 36 TUYER COOLER 900/5.
@ 25m³/h 2
2

370 325/ 3 HBV and HBIV 325/6 370/6

3197/4.4/45
6.9 @ 65m³/h GROUND
2170/8

STORAGE
TK 21
45/ 45/6
BACK DRAFT VALVE
6.9 STR 02
CPB02 A-C
3197/6.5/40 HE02 A-C
EMERGENCY SOFT
WATER (1500m3) CP02 A-D MAKE UP SOFT WATER
FROM TK 21.2 & 21.3 DP02
COOLING CIRCUIT NO. 2 P & I TK02
DIAGRAMBLT COOLING SYSTEM IN BURDEN CAMERA Ø45
20 m³
HE 0

Ø500
Ø80
Ø50 FIX
M
PROFILOMETER TO HEAT EXCHANGER
Ø80 Ø800

Ø600
M
Ø450
Tuyer
Ø80

e Ø200
testin
g
point
TUYERE NOSE M

Ø300
M
Ø450
TUYERE TUYERE
COOLER BODY
Ø25
DISCHARGE
MUD MUD MUD MUD RING HBV,
TUYERE TUYERE
GUN GUN GUN GUN COOLER BODY HBIV and
1 2 3 4 BDV
T T
P P P P FEEDING RING
E E
Ø25 I I I I

Ø50
HP Ø600
LP
FROM PUMP HOUSE Ø300
 EMERGENCY TANK FLOW DIAGRAM
71 TO GCP RECIRCULATION
PUMPS GLAND SEALING
m
TK21.3 (Ckt
TK21.2 (Ckt

V=800 m³
TK1, TK2,
3) TK3 & TK4
V=700 m³ DRAIN &
2)

OVERFLO
W MAKE UP BLT

MAKE UP WATER COOLING

CIRCUIT 1,2,3 & 4

55.8 m FROM DRINKING

TK21-B (Ckt 1) WATER
51 m V= 300 m³ DISTRIBUTION

47.35 m SOFT WATER

TK11.1(Industri CP20 PRODUCTION
al water A-C PLANT
40 distribution) CP21 A/B
m DP21 A/B 2 (1+1) LINES
V= 500 m³ X 35 m³/h
28.5 m
HOT
each
TK06 WELL (TK21)
(Backwashing) GROUND TANK
HOT STOVE SOFT
25 m V= 200 m³ SERVICES V=1800m³
WATER
HOT STOVE HEAT TANK
RECOVERY TK11 (TK20)
SYSTEM & V=500 m³
CP11 A-E V=200m³
DEMISTER
CLEANING
 Incident
Conditions before the incident :
• 2 pumps of LP working
• 1 pump of HP working
• EOHT TK 21.1, 21.2 and 21.3 were full.
• Hot well TK 21 was 55% full as usual.

Conditions after the incident :

• Heavy leakage from LP supply line (of the order of 800-1000 m 3/h) started.
• Expansion Tank TK 02 got emptied within 1-2 minutes. CP 20 started for make up.
• Running pumps got starved, flow and pressure of line reduced.
• DP 02 started in auto. But flow and pressure could not increase due to starvation.
• SOV and NRV from EOHT opened to feed supply line.
• On decreasing EOHT level, DP 21 started to fill EOHT from hot well TK 21.
• Finally Hot well TK 21 got emptied and air was sucked by DP 21, because of no
return water from TK 02.
• Soft water make up to Circuit 2 was limited to 30-32 m 3/h through CP 20.
• These all happened within 1 hr.
 Crisis

• Emergency Over Head tanks TK 21.1, TK 21.2 and TK 21.3

emptied.

• Expansion tank TK 02 emptied.

• Hot well TK 21 (Ground level) emptied.

• Flow and pressure reduced in circuit-2, pumps on the verge of

starvation.

• ∆T increasing rapidly for tuyeres and stoves’ valves.

• Heavy leakage from LP supply line.

 Challenges

• To save stoves’ valves.

• To save tuyeres and tuyere coolers.

• Isolation of the punctured line.

• Restoration of normal supply.

• All works are to be carried out under strict supervision &

safely without any accident. (with limited resources)
 Actions taken
•Extra running pumps were stopped.
• Booster pump was stopped.
• One LP pump was stopped.

•CP 08 (Leakage compensation pump) started.

• Connection to stoves’ valves: soft water changed to industrial
water through hoses, one by one.
• Connection to tuyere body and tuyere cooler: soft water changed
to industrial water through hoses, one by one.

•Hot well TK 21(Ground level) filling.

• Industrial water from TK 11 to TK 21 by fire brigade pumps.
• Fire fighting booster pump was started and filling started with fire
hydrants.
• TK 09 overflow water pumped to TK 21 from channels by fire
brigade pumps.
 Actions taken
•CP 21 was started to fill EOH Tanks TK 21.2 and TK 21.3.

•Bypass of make up to circuit 2 was opened which increased flow from

30 m³/hr to 95 m³/hr, to keep circuit 2 pump running without
starvation.

•Filling of TK 20 started with drinking water to increase the flow into

TK 20 (softeners bypassed).

•LP incoming water line isolated by closing motorised valves at 3:45

P.M. The valves were closed manually also & ensured isolation.
Leakage reduced. Water was returning back from Exp. Tank.

•72 No. inlet valves of tuyere body and tuyere cooler closed for
isolation of return water by 7 P.M. Leakage further reduced to very
 Actions taken
•Fire Brigade pump was used to empty the trapped water in the
pipeline (around the point of puncture). Isolation was achieved
finally.

•Preparation for welding done, and again dewaterd.

•Welding / patching work was done (400 X 400 mm piece of Ø 600

mm pipe line.

• Restoration:
• 4 out of 72 closed valves opened and LP circuit main isolation
valve opened in steps ensuring the venting of the trapped air in
the circuit through expansion tank.
 Actions taken
•Tuyere body and tuyere cooler water was restored by removing the
leakage compensation hoses one by one.

•Hot Blast Valves’ soft water restored by removing leakage

compensation hoses one by one.

•All tuyeres were pressure tested.

•All pumps restored to automation.

•Expansion tank filling continued and monitored till stabilization.

 CIRCUIT NO. 02 HOT BLAST VALVE COOLING
FROM
CP -08
LEAKAGE COMPENSATION HEADER

Ø50
Ø40

Ø50
M

Ø50
Ø50

HOS
E
RIGID PIPE
Ø100

BALL VALVE

Ø100
BUTTER FLY VALVE

GATE VALVE

FEEDIN Ø300
G
Ø300
DISCHARGE
 TK 02

TUYERE
TUYERE BODY COOLER
TUYERE NOSE DRAIN
OUTLET OUTLET
OUTLET TROUGH
TUYERE
TUYERE NOSE TUYERE BODY
COOLER INLET
INLET INLET
FROM
PUMP
HOUSE
CIRCUIT-
2

LEAKAGE COMPENSATION HEADER (48

 Thank you

A Technical Cell - MAHAMAYA presentation