Bhilai Steel Plant (BSP) has achieved a significant engineering milestone with the successful replacement of the 129-tonne, 52.5-metre-long hood assembly of Converter-1’s gas cooling system at Steel Melting Shop-3 (SMS-3). The first-of-its-kind replacement was executed under challenging operating conditions, with restricted workspace and no overhead travelling (EOT) crane available, highlighting the plant’s engineering capabilities, meticulous planning and effective interdepartmental coordination.

The replacement became necessary due to extensive wear and deterioration caused by prolonged exposure to high-temperature gases, abrasive particles and continuous thermal stress. The damage had resulted in thinning of tube walls, cracks and recurring water leakage, posing challenges to equipment reliability, operational safety and uninterrupted production. The complete replacement of the hood assembly is expected to enhance the reliability and availability of Converter-1’s gas cooling system, minimise leakage-related operational risks and reduce the likelihood of production disruptions.

The gas cooling system comprises a movable hood, two fixed hood sections and two deflection bend sections. The comprehensive replacement involved dismantling the existing assembly, erecting the new structure, precision alignment and welding. The entire operation was completed through systematic planning, round-the-clock deployment of manpower, continuous monitoring and close coordination among the concerned departments, while adhering to prescribed safety standards.

A felicitation ceremony was organised to recognise the employees and contractual workers whose contributions were instrumental in completing the challenging operation. Shri Vijay Kumar Behera, Chief General Manager-in-Charge (Materials and Utilities), and Shri Tribhuvan Baitha, Chief General Manager of Steel Melting Shop-3, appreciated the teams for their technical expertise, discipline, teamwork and unwavering commitment to safety. Contractual employees who made significant contributions to the project were presented with certificates and mementoes in recognition of their efforts.

The operation was carried out under the guidance of Shri Tribhuvan Baitha, with teams from the Mechanical, Electrical, Operations and Instrumentation departments working in close coordination. The contributions of Shri Ajit Narayan, General Manager (Mechanical), Steel Melting Shop-3, and Shri Rakesh Vrishnavanshi, Deputy General Manager (Mechanical), Basic Oxygen Furnace (BOF), along with their respective teams, were particularly noteworthy.

The successful completion of the replacement underscores Bhilai Steel Plant’s capability to execute complex engineering interventions under demanding operational constraints. The achievement also reinforces the plant’s emphasis on equipment reliability, production efficiency, coordinated teamwork and safe working practices.

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RDJ/BKT

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