11.

6 WORK INSTRUCTION FOR START UP CHECKS AND ACTIVITIES FOR

ARGON OXYGEN DECARBURIZATION CONVERTOR

4. Method :-
4.1. Material Stocking:-

4.1.1. Check of Raw Materials at Day Bins.

4.1.1.1. Check the level sensors indicating the presence of Raw Material-Green
Indication.
4.1.1.2. If indication is not Green- inform Shift in-Charge of RMHS Department for
Physical stock check and day bin filling.

4.1.2. Stocking of Material for addition by EOT crane.

4.1.2.1. Raw Materials whose addition could not be completed through MHS are
received from store and arranged in the vicinity of AOD work area for timely
addition. The material received must be written in the AOD operation register
4.2. Process Gas Line Pressure:-

Sl. No. Unit O2 N2 Ar

Max. Bar 22 22 22
Min. Bar 13 13 13

4.3. Acceptable length of tuyeres:-

Minimum length of tuyeres is 600 mm or as the visual inspection of the vessel.

4.4. Slag Pot Centering:-

4.4.1. Check if slag pot is present in the De-slagging area of AOD.

4.4.2. Check if the slag pot is filled with slag or not.
4.4.3. If full contact the slag yard supervisor, for replacing the full slag pot with empty
slag pot.
4.4.4. Ensure the slag pot is dry and has lime dust/slag at the bottom, if not it is
required to be replaced by a dry one.
4.4.5. Ensure centering of Slag pot below the AOD convertor by visual inspection.

4.5. Work instruction for newly lined AOD vessel

4.5.1. Mechanical (AOD) is informed to install newly lined AOD vessel.

4.5.2. After completion of installation by mechanical department following parameters
are checked :-
4.5.2.1. Hose pipe of tuyeres for any kind of leakage
4.5.2.2. Tilting drive status is checked (should be in “drive selected” mode).
4.5.2.3. AOD is tilted to cooling position
4.5.2.4. AOD is taken in process mode and pressure of process gas. Line pressure of
16 bars (min.).
4.5.2.5. All supply valves for shroud gas and tuyere gas should be in auto mode.
4.5.2.6. Heat is started if all start of heat condition in HMI is satisfied.
 4.6. Work instruction for AOD kept in online preheating mode

4.6.1. Mechanical / Electrical department is notified to switch off and move back the
preheating burner.
4.6.2. AOD is tilted to cooling position.
4.6.3. AOD is taken in process mode and pressure of process gas is checked. Line
Pressure should be 16 Bar min.
4.6.4. All supply valves for shroud gas and tuyere gas should be in auto mode.
4.6.5. Heat is started if all Start of Heat condition in HMI is satisfied refer to Sl. No.
4.7 Temperature lance check:
4.7.1 Calibration of temperature lance done using a check mate
Process Setting Parameter Range Possible effect of parameter
Convertor lubrication system Indicative Green Required for tilting of AOD.
Central hydraulic system Indicative Green Required for normal operation of all
pressure relive valve
Blocking System Indicative Green Necessary for blow start
Tilting system Indicative Green Runs in both auto and manual mode and
is necessary for AOD gas flow in AUTO
mode
Tuyere Process gas Indicative Green All valve should be in auto mode
Tuyere Shroud gas Indicative Green All valve should be in auto mode
AOD de-dusting System Indicative Green All flow switch should be in auto mode,
if not than it is manually acknowledged
and process is started
AOD dust Transport system Indicative Green All the pressure switch should running
OK
AOD cooling stack system Indicative Green Water flow must be more 3300 NM3/hr
Start of Heat – Lance conditions
Lance hoist system Indicative Green Should be released electrically
Lance blowing system Indicative Green Process line lance Oxygen ready, feeder
Argon and Nitrogen line ready
Lance cooling system Indicative Green
START OF HEAT – GENERAL READY CONDITION
Material handling Indicative Green Pull cord/pull rope/safety switches
should be in ON position
4.7.2 Actual and resultant temperatures noted down and duly signed

Ladle transfer car Indicative Green Drive and cable drum should be ready
Slag pot transfer car Indicative Green Drive and cable drum should be ready
4.8Start of Heat Condition in Human Machine Interface (HMI)
 4.9 SAFE WORKING INSTRUCTIONS:-
4.9.1 All Shift I/c s and melters responsible for the activities defined in this work
instruction are hereby instructed to ensure provision and utilization of Personal
Protective Gears to and by the people respectively as mentioned in Sl. No. 3.
Helmets must be worn with chin straps on
4.9.2 All AOD melters are hereby instructed to ensure that no personnel are present under
the hook of the EOT crane while transporting material.
4.9.3 For testing for AOD tilting all shift in-charges (Maintenance & Operation) must
ensure sure that all personnel previously working are evacuated and taken to safe
distance before taking trial.
4.9.4 All shift In-charges are hereby instructed to maintain and ensure proper
communication between the machine operating personnel and the person who is
checking the machine in the field.
4.9.5 All AOD melters are herby instructed to sign the work permit of the respective
maintenance department, before accepting the machine/instrument for operation.
4.9.6 All EOT Crane operators are hereby instructed to sound hooters while transporting
material and Shift I/c s are hereby instructed to ensure the same.
5.0 ENVIRONEMTAL IMPACT CONTROL PROCEDURE
5.1 All melters and section I/c s are hereby instructed to carryout Housekeeping of the area on
regularly basis, this will ensure optimal resource utilization.

6.0 OPERATION CONTROL PROCEDURE:-

6.1 Spillage of Raw Material while transferring by EOT Crane: - All melters are hereby
instructed to use proper transfer bags (not worn)/chutes in case of transferring material to
and fro furnace as to reduce spillage of material and thus resource waste. The spilled over
material so generated shall be re-bagged and re-used.
6.2 Generation of Dust: - The above procedure must be complied, as generation of dust is
initiated from the spillage of material while transporting.
 11.7 WORK INSTRUCTION FOR PROCESSING OF HEAT IN ARGON OXYGEN
DECARBURIZATION CONVERTOR

1. Method :-
1.1. De Slagging
1.1.1. De slagging of Liquid metal tapped from EAF is done with the help of Slag
Skimmer.
1.1.2. Slag removal is carried out on the basis of visual inspection.
1.1.3. Major portion of slag is removed; ladle is ready to be lifted with crane to charge
liquid metal in convertor
1.2. Sample analysis report check
1.2.1. Reception of Sample Analysis report from QC Laboratory
1.2.2. Noting down the analysis report in AOD Log Sheet.
1.2.3. Checking of received sample chemistry with that mentioned below:
Grade Opening LM C% Si% Cr% Mn% Ni% Mo% P%
430 RF3 134-136 1.8-2.0 16.5-18.0 - - - .035 max
410 DB 134-136 1.8-2.0 10-13.0 - - - .040 max
430 Mint 134-136 1.8-2.0 14-16 - - - .030 max
441 134-136 1.8-2.0 16-19 - - - .035 max
439 134-136 1.8-2.0 16-18 - - - .035 max
446 134-136 1.8-2.0 21-25 0.7-0.9 - - .035 max
410S 134-136 1.8-2.0 10-10.5 - - - .030 max
IRSM/EN 1.4003 134-136 1.8-2.0 0.2- 10-11.5 - - - .035 max
409L 134-136 1.8-2.0 0.40 10-11.5 - - - .026 max
EN 1.4301 132-134 1.9-2.1 19-21 <=1.5 7.3-7.5 - .040 max
EN 1.4307 132-134 1.8-2.0 19-21 <=1.5 7.3-7.5 - .040 max
EN 1.4404 132-134 1.9-2.1 15-17 <=1.5 9.5-10.5 1.8-2 .040 max
316L/316Ti 132-134 1.8-2.0 17-19 <=1.5 9.0-9.5 1.5-1.6 .040 max
301 132-134 1.9-2.1 15-17 <=1.6 6.5-7.5 - .038 max
310S 132-134 1.9-2.1 23-27 <=1.6 18-20 - .030 max
321 132-134 1.9-2.1 19.5-20 <=1.5 9.2 - .040 max
AUS/ EN 1.4372 130-132 1.7-2.0 17.5-18.8 <=1.5 3.6-4.2 - .060 max
204Cu 130-132 1.9-2.1 17-19 <=1.5 1.5-1.8 - .040 max
J4 130-132 1.8-2.0 16-17.5 <=1.5 1.1-1.2 - .060 max
JT 130-132 1.8-2.0 15.5-16.5 <=1.5 0.2-0.25 - .080 max
U SD 130-132 1.8-2.0 15.5-17 <=1.5 0.4-0.45 - .080 max
U DD 130-132 1.8-2.0 16-17.5 <=1.5 0.55-0.6 - .080 max
U KP 130-132 1.8-2.0 14-16 <=1.5 0.4-0.6 - .080 max
1.3. Weighment:
Weight mentioned in Electronic display board of EOT crane is noted down
in AOD Log Sheet.
1.4. Transfer of Liquid Metal to AOD:
1.4.1. Liquid metal is poured in AOD under the supervision of melter.
1.4.2. Continuous communication between crane operator and Melter
1.5. AOD is taken in cooling position with charged liquid metal.
1.6. Sample is taken
1.7. Addition Calculation and Planning
1.7.1. Addition Calculation
1.7.1.1. Aim Chemistry of Grades received from Quality Plan of the respective
grade.(Refer to Table No.1 for Quality Plan)
1.7.1.2. Weight of Liquid Metal from EAF calculated as specified in clause 4.3.
1.7.1.3. Opening Chemistry from lab as specified in clause 4.2.
1.7.1.4. Formula to Calculate Ferro-Alloy/Pure Metal Addition.
%of Alloy* Liquid Metal
Addition of Ferro-Alloy /Pure Metal (PM) = ----------------------------------------
(In KG) Efficiency of Ferro-Alloy/PM * Recovery
1.7.1.5. Addition of Lime as per requirement for maintaining proper Basicity
between 1.7-1.9
1.7.1.6. All the addition to noted in AOD Log Sheet.
Σ (CaO + MgO)
BASICITY = -----------------------------------------
SiO2
1.7.2. PLANNING
1.7.2.1. Decision taken for addition of fluxes or raw material through MHS or by
EOT Crane as per their feasibility of addition.

1.8. CALCULATION OF MAIN BLOW METALLURGICAL OXYGEN

1.8.1. For calculation of main blow metallurgical oxygen
1.8.1.1. Carbon and silicon from opening chemistry (clause 4.3) is taken.
1.8.1.2. Carbon and silicon from calculated alloy addition (clause 4.6.1.4) is
taken.
1.8.2. Oxygen amount for main blow is calculated using formula :
[(%C X Calculated Alloy Addition) + (OC % X ILM)] x 0.933
Oxygen = -------------------------------------------------------------------------------
CRE
Where ,CRE – Carbon Removal Efficiency
OC - Opening Carbon
ILM – Initial Liquid Metal
 4.8.3 CRE for various blow duration is calculated from the table given below :

SL NO. BLOW CRE

1. MAIN BLOW 65% - 70%
2. DB 1 50% - 60%
3. DB 2 20% - 40%
4.8.4 Mention the calculated amount in AOD Log Sheet.
4.8. START OF BLOW
4.8.1. Before start of blow following pre conditions must be checked

Sl. PROCESS SETTING RANGE

No. PARAMETER
1. Tuyere blowing system Ready/Released
2. Cooling stack system Ready/Released
3. De-dusting system Ready/Released
4. Material handling system Ready/Released
5. Convertor tilting system Ready/Released
6. Central lubrication system Ready/Released
7. Central hydraulic system. Ready/Released
8. Convertor blocking system Ready/Released
ADDITIONAL READY FOR BLOW/ TREATMENT
9. Convertor upper position Ready/Released
10. Convertor is blocked Ready/Released
11. N2 sealing valve for cooling stack Ready/Released
open
LANCE SYSTEM
12. Lance needed for blow Ready/Released
13. Lance hoist system Ready/Released
14. Lance blowing system Ready/Released
15. Lance cooling system Ready/Released
4.9. O2 BLOW START
4.9.1. Vessel is taken in cooling position.
4.9.2. For starting blow tilting drive is taken in automatic mode by selecting “AUTO
ENABLE”.
4.10.4 “START BLOW” button is pressed.
4.10. BATCHING & CONVEYING
4.10.1. The amount Ferro-Alloy/Pure Metal / flux calculated in Clause 4.6 are being fed
in to Batch Table which collects the material from the Day Bins, convey the material
to Weighing Hopper with the help of conveyor for weighing, which further
been conveyed to Charging Chute and finally discharged to AOD.
4.10.2. Material Added are reported in the AOD Log Sheet.
4.10.3. Other materials are fed into the AOD through a chute with the help of the EOT
crane
4.11. O2 BLOW STOP
4.11.1. “BLOW STOP” button is pressed on function AOD function column in HMI.
4.11.2. AOD will automatically get tilted to cooling position.
4.12. REDUCTION
4.12.1. Reduction mixture is added when the carbon in the bath reaches the desired level,
as per clause no.4.16.
 4.13. PRE TAPPING CHECKS
4.13.1. Both the tilting drives should be in selected mode.
4.13.2. Slag pot should be centered.
4.13.3. Make sure that pre heated ladle is placed on the ladle car and hydraulic &
Purging is On.
4.14. SLAG OFF
4.14.1. Slag from AOD is poured into slag pot.
4.14.2. Distinction between slag and metal depends solely on the expertise and
experience of the melter.
4.15. TAPPING
4.15.1. Ladle car along with ladle is taken into position
4.15.2. Liquid metal from AOD is poured into teeming ladle.
4.15.3. After tapping complete, LTC hydraulic to be switched off
4.15.4. After LTC taken out to EOT crane position for lift up, purging to be switched
off, and purging line to be disconnected
4.15.5. Tapped liquid metal is sent to LRF for further processing.
4.16. STIRRING
4.16.1. Stirring phase can be started any time during the heat by selecting “STIRRING”
tab in HMI.
4.17. Retreatment:
4.17.1 Re Treatment can be started by selecting “RE TREATMENT” tab in HMI
4.18. END OF HEAT
4.18.1. After tapping process is completed process data for the heat is frozen by pressing
“END OF HEAT” in the function AOD dialogue box in HMI
4.19. LADLE DEPARTURE
4.18.1 After “END OF HEAT” is selected in the AOD dialogue box, and if retreatment
is not done, then “LADLE DEPART” button in pressed in AOD dialogue box, to send the
information to Level-2 for increment of heat number in Level-2 display screen.
4.20 AOD mouth jam cleaning:
4.20.1 AOD mouth jam cleaning to be done before taking liquid metal from EAF
4.20.2 AOD mouth jam cutting by lancing:
4.20.2.1 AOD to be tilted between 70 to 90 deg
4.20.2.2 Lancing pipes connected to oxygen line in 9.8m
4.20.2.3 By varying the outlet valve condition (switch handle parallel to pipe meaning full
open, switch handle perpendicular to pipe meaning full close), varying the oxygen output
content
4.20.2.4 Use the gas to cut through the mouth jam
4.20.2.5 After jam is cut, switch of the oxygen valve at 9.8m
4.20.2.6 AOD to be tilted back to cooling position
4.20.3 AOD mouth jam cleaning by TML:
4.20.3.1 AOD to be tilted between 150 deg towards tapping side to -150 deg towards scrap
charging car side
4.20.3.2 TML to be used for dislodging jam from AOD mouth
4.20.2.3 AOD to be tilted back to cooling position

4.21 AOD pit cleaning

4.21.1 AOD pit cleaning by earth moving vehicles

4.21.1.1 This activity has to be carried in the supervision of the shift-in-charge/meltor
4.21.1.2 The pit has to be cleaned either when the AOD is in hold condition as in tilted at 70
deg position or when the AOD is in operation.
4.21.1.3 If pit cleaning is done when AOD is in 70 deg position, no lancing/maintenance jobs
can be carried out on AOD.
4.21.1.4 If pit cleaning carried out when AOD in operation, communication to be maintained
between operator in control room and shift-in-charge/meltor near pit so that the earth moving
vehicles can be shifted back before AOD tilting for pouring/tapping/addition of charge from
outside.
4.21.1.5 During any such activity it is to be ensured that no water is sprayed in the pit for
reduction of dust emission.
4.21.2 AOD pit cleaning by lancing
4.21.2.1 Compressed air to be used for removal of dust/slag from the metallic jam present in pit.
4.21.2.2 Lancing pipes connected to oxygen line at 0m
4.21.2.3 By varying the outlet valve condition (switch handle parallel to pipe meaning full
open, switch handle perpendicular to pipe meaning full close), varying the oxygen output
content
4.21.2.4 Use the gas to cut through the mouth jam
4.21.2.5 After jam is cut, switch of the oxygen valve at 0m
4.21.2.6 Jam to be removed from AOD pit either with the help of earth moving vehicles or by
using a sling.
4.21.2.7 Refer to WI 11.27 for full activity.
4.22 AMOUNT OF CARBON ACHIEVED TILL OXIDATION SAMPLE
SERIES GRADE % OF CARBON
J4 0.12-0.25
JT 0.15-0.25
JSL AUS 0.06-0.15
200 SERIES

204 Cu 0.12-0.22
JSL – U 0.12-0.25
304(O) 0.06-0.20
304 L .03-0.10
316 L .03-0.10
300 SERIES 316Ti .03-0.10
310S 0.06-0.10
301 .03-0.10
321 .03-0.10
430 .03-0.10
IRSM .03-0.10
409 L .008-.015
446 .07-.15
400 SERIES
441 .008-.017
410DB 0.08-0.15
410 S 0.08-.15
439 .008-.015

4.23 STANDARD AOD BLOW PRACTICES

 Sl. WORK INSTRUCTION MISCELLANEOUS FLOW (Nm3/Min)
No.
1.        TAPPING THE HEAT 0
AOD ANGLE : 80 - 135
0 N2/Ar-10
‘0’ BATCH CHARGING AOD ANGLE: 0 - (- 5.7 ) (addition of D N2/Ar-60
0 0

2.        Lime)
3.        POURING 0
AOD ANGLE: 30 - 65
0 N2/Ar-60
4.        COOLING POSITION AOD ANGLE: 70 -75
0 0 N2/Ar-10
MAIN BLOW (O2: N2/Ar)=(15.5:1) (Approx) O2 Flow =330
0 0
5.        ACHIEVED TEMP = 1690 - 1710 N2 /Ar = 20
DYNAMIC BLOW 1 (O2: N2/Ar)=(10:1) (Approx)
0 0
ACHIEVED TEMP = 1680 – 1720 O2 Flow =290
6.        N2 /Ar = 30
DYNAMIC BLOW 2 (O2: N2/Ar)=(4.5:1) O2 Flow =270
0
7.        ACHIEVED TEMP = ~1700 N2 /Ar = 60
DYNAMIC BLOW 3 (O2:N2/Ar)= (3.2:1) O2 Flow =250
8 N2 /Ar = 80
DYNAMIC BLOW 4 (O2:N2/Ar)= (1:1.7) O2 Flow =60
9 N2 /Ar = 100
REDUCTION PHASE MIXING TIME – 7 TO 9 MIN N2 (120-140)-Ar(120-140)
0 0
8.        ACHIEVING TEMP = 1670 - 1710 C
9.        SLAG OFF
10.    TAPPING THE HEAT

4.24 GENERAL INFORMATION

1. Approximate Receive transfer LM = 100 – 140 MT
2. Approximate AOD heat size = 145-165 MT
3. Approximate Build up to 15 – 40 % in AOD
4. Use Fe Si and MCSiMn in reduction phase for reduction.
5. Some special grade like – 409L, 321,316Ti; 40% Al and 60% Si is used as reduction
mixture.
6. 300 – 1000 Kg CaF2 is used in 200, 300 and 400 series.
7. During special grade processing, argon is used primarily as the inert gas. Thus the
nitrogen valve is manually shut off and the argon line is manually operated for this purpose
to prevent any chances of nitrogen leakage inside the tuyere pipes. The method for this
activity is as follows:
8. Check leakage in hose fitting, hose connection and hose condition.
9. Inspect the pressure inside the line
10. Ensure type of air inside the valve
11. Ensure the valve is suitable to the medium.
12. Check the outlet connections are suitable for the pressure.
13. Ensure no open body parts expose to medium during opening.
14. Valve to open slowly and required amount.
15. After completion the job supply valve must be turned off. This is to avoid possible gas
leakage between the ends of the working period and beginning of the next.
4.25 SAFE WORKING INSTRUCTIONS:-

1. All melters and personnel working in the area are hereby instructed to ensure proper centering
of re-filling ladle lip with AOD converter mouth while transferring liquid metal in AOD. Proper
communication with the EOT crane operator must also be maintained while carrying out this
activity.
2. Ensure Dog House is closed before AOD into operation.
3. All melters and hereby instructed to ensure provision of Personal Protective gears to all the
personnel working in the area and utilization of the same thereof. The list of PPE s are mentioned
in SL. No. 3 of this work instruction. Helmets must be worn with chin straps on.
4. All melters are hereby instructed to follow Operation Control Procedure for avoiding
Splashing of Liquid Metal while Tapping of heat from AOD mentioned below.
5. Unauthorized entry should be restricted in furnace floor.
6. Keep safe distance from AOD mouth while raw material charging by EOT Crane.
7. During any break down activity all melters are hereby instructed to ensure emergency button
of the respective area is pressed or that of the main control desk is pressed.
8. All melters are hereby instructed to carry out housekeeping of the adjoining area of AOD
converter to avoid any trip hazard.
9. All melters are hereby instructed to ensure AOD converter pit clean and dry.
10. All EOT Crane operators are hereby instructed to sound hooters while transporting material
and Shift I/c s are hereby instructed to ensure the same.
11. All melters and shift I/c s are hereby instructed to ensure that no inflammable material are
present by the side of the furnace so as to avoid fire hazard leading burn injury. Material such as
oil, plastic jumbo bags, card boards, paper bags are considered to be inflammable – These may
easily catch fire from a drop of liquid metal or slag which may fall into it during the process.
12. All melters are hereby instructed to maintain a careful flow of oxygen while mouth jam
cutting and also ensure that no personnel is present below