Compliance Status of Consolidated Consent & Authorization for Blast Furnace vide consent order no.AWH -37455 Date of issue: 12.05.10

Condition No.

Description Compliance Status

1. Consent order no. AWH -37455 Date of issue : 12.05.10

2. The Consent shall be valid up to 12.01.2010 for use of outlet for the discharge of trade effluent and emission due to operation of industrial plant for manufacture of the following items / products at Survey No. / Plot no: 169 /P -3, VILLAGE: DHRUB – MUNDRA TA: MUNDRA DIST: KUT CH

Sr. No. Product Quantity (

MT/MONTH)

1. PIG IRON 20835

2. BY PRODUCTS

1.Granulated Slag

2.BF Gas

8000

84000

Complied

3. Condition Under the Water Act. 1974:

3.1 The generation and disposal of the industrial effluent from the manufacturing process and other ancillary industrial operations shall be NIL

Complied

3.2 The quantity of the sewage effluent from the factory shall not exceed 12 KL/ Day

Complied

3.1 TRADE EFFLUENT

3.3.1 Domestic effluent shall e treated in common STP of 500 KLPD capacity situated in the township and utilized for plantation / green belt development.

Complied

4 CONDITIONS UNDER THE AIR ACT:

4.1 The following shall be used as flue boiler / furnace/heater respectively.

Sr. No. Fuel Quantity

1. Furnace Oil 88320 Lit / Day

2. HSD 16992 Lit / Day

3. Diesel 1925 Lit / Day

4. Oil 17 KL/ Day

5. Blast Furnace Gas

1258 GCAL / Day

Complied

4.2 The flue gas emission through stack attached to boiler / furnace / heater shall conform to the following standards.

Stack

No.

Stack

attached

to

Stack

height

in

meter

Air

Pollution

control

system

Parameter Permissible

Limit

1. DG Set

6000

KVA – 02

Nos

40

Each

--------- PM

SO2

NOx

150 mg/ NM3

100 ppm

50 ppm

2. DG Set

3240

KVA – 02

Nos

35

Each

---------- PM

SO2

NOx

150 mg/ NM3

100 ppm

50 ppm

3. DG Set

1180

KVA – 03

Nos

35

Each

PM

SO2

NOx

150 mg/ NM3

100 ppm

50 ppm

4.3 The process emission through various stacks / vent of reactors , process vessel shall conform to the following standards:

Stack

No.

Stack

attached

to

Stack

height

in

meter

Air

Pollution

control

system

Parameter Permissible

Limit

1. Dedusting

System

35 Dust

extraction

system /

Bag Filter

PM

SO2

NOx

150 mg/ NM3

100 ppm

50 ppm

2. Boiler-I 45

3. Boiler-II 45

4. Stove

Stack

50 -----

5. Flare

Stack

50 ------

Complied

4.4 The concentration of the following parameters in the ambient air within the premises of the industry shall not exceed the limits specified hereunder.

Sr.

No.

Pollutant Time weighted

Average

Concentration

in ambient air

1. Sulphur Dioxide

(SO2),µg/ M3

Annual

24 hours

50

80

2. Nitrogen Dioxide (NO2),

µg/ M3

Annual

24 hours

40

80

3. Particulate Matter

( Size less than 10 µm)

OR PM10 µg/ M3

Annual

24 hours

60

100

4. Particulate Matter

( Size less than 2.5 mm)

OR PM2.5 µg/ M3

Annual

24 hours

40

60

Complied

4.5 The applicant shall provide portholes, ladders, platforms etc. at chimney(s) for monitoring the air emissions and the same shall be open for inspection to / and for use of Board’s staff. The chimney(s) vent attached to various sources of emission shall be designed by numbers such as S-1, S-2 Etc. and these shall be painted / displayed to facilitate identification.

Complied

4.6 The industry shall take adequate measures for control of noise levels from its own sources within the premises so as to maintain ambient air quality standards in respect of noise to less than 75 dB (a) during day time and 70 dB (A) during night time . Day time is reckoned in between 6:00 am and 10 pm and night time is reckoned between 10:0 pm and 6:00 am.

Complied

5. Authorisation For The [Management, Handling & Transboundary Movement] Of Hazardous Wastes Form-2 (See rule 5 (4) Form for grant of authorization for occupier or operator handling hazardous waste rule, 2008.

5.1 M/S JINDAL SAW LTD.( IPU) is hereby granted an authorization to operate facility for following hazardous wastes on the premises situated at Survey No.: / Plot No. 294/1,324,286,287,336/1,294/2,293,325/1,288/1, Village: SAMAGHOGHA, Mundra Ta: Mundra Dist: Kutch .

Sr. No. Waste Quantity/Year Schedule/I Facility

1. Used Oil/ Spent Oil

27 KL 1,5.1 Collection, storage, Transportation, Disposal by utilized for lubrications of machines & remaining selling out to registered recyclers / reprocessor.

5.2 The authorization is granted to operate a facility for collection, storage, within factory premises, transportation and ultimate disposal of Hazardous wastes by selling out to registered recyclers.

Complied

5.3 The authorization is subject to the conditions stated below and such other conditions as may be specified in the rules from time to time under the Environment ( Protection ) Act -1986

Complied

5.5 TERMS AND CONDITIONS OF AUTHORISTION

a) The applicant shall comply with the provision of the Environment (Protection) Act-1986 and the rules made there under.

To be Followed

b) The authorization shall be produced for inspection at the request of an officer authorized by the Gujarat Pollution Control Board.

To be Followed

c) The person authorized shall not rent, lend, sell, and transfer of otherwise transport the hazardous wastes without obtaining prior permission of the Gujarat Pollution Control Board.

To be Followed

d) Any unauthorized change in personnel, equipment or working conditions as mentioned in the authorization order by the persons authorized shall constitute breach of this authorization.

Complied

e) It is the duty of the authorized person to take prior permission of the Gujarat Pollution Control Board.

To be Followed

f) An application for the renewal of an authorization shall be made as laid down in rule 7.

To be Followed

g) Industry shall submit annual report within 15 days and sub sequent by 31st January every year.

To be Followed

h) Hazardous waste shall be disposed off in accordance with the Haz. Waste (Management, Handling & Transboundary Movement) rules,2008 and unit shall have to obtain Authorisation of this Board for all applicable categories of Waste.

To be Followed

6 General Conditions :-

6.1 Any change in personnel, equipment or working conditions as mentioned in the consents form/ order should immediately be intimated to this Board.

To be Followed

6.2 Applicant shall also comply with the general conditions given in annexure1 To be Followed

6.3 The waste generator shall be totally responsible for (i.e. Collection, storage, transportation and ultimate disposal) of the wastes generated.

6.4 Records of wastes generation, its management and annual return shall be submitted to Gujarat Pollution Control Board in form -4 by 31st January of every year

To be Followed

6.5 In case of any accident, details of the same shall be submitted in form-5 to Gujarat Pollution Control Board.

To be Followed

6.6 As per “public Liability Insurance Act-91” company shall get Insurance policy, if applicable.

6.7 Empty drums and containers of toxic and hazards materials shall be treated as per guideline published for “management & handling eg. discarded containers”. Records of the same shall be maintained and forwarded to Gujarat Pollution Control Board regularly.

To be Followed

6.8 In no case any kind of Hazardous waste shall be imported without prior approval of appropriate authority

To be Followed

6.9 In case of transport of hazardous waste to a facility ( i.e. Treatment, storage and disposal) existing in a state other the the state where hazardous waste are generated ,the occupier shall obtain “ No Objection Certificate” from the State pollution control board, the committee of the concerned state or Union territory Administrative where the facility exists.

To be Followed

6.10 Unit shall take all concrete measures to show tangible results in waste generation, reduction, voidance, reuse and recycle. Action taken in this regards shall be submitted within 03 months and also along with Form 4.

To be Followed

6.11 Industry shall have to display the relevant information with regard to hazardous waste as indicated in the Hon Supreme court’s order in W.P. No. 657 of 1995 dated 14th October 2003.

Complied

6.12 Industry shall have to display on line data outside the main factory gate with regard to quantity and nature of hazardous chemicals being handled in the plant, including waste water and air emissions and solid hazardous waste generated within the factory premises.

Complied

NO: PC /CCA- KUTCH – 223 (2) / GPCB ID: 18037/ 51985

Compliance Status of Consolidated Consent & Authorization for Pipe Plants vide consent order no.AWH -37730 Date of issue: 07.06.10

Condition No.

Description Compliance Status

1. Consent order no. AWH -37730 Date of issue : 07.06.10

2. The Consent shall be valid up to 31.01.15 for use of outlet for the discharge of trade effluent and emission due to operation of industrial plant for manufacture of the following items / products at Survey No. / Plot no: 294/1, 324,286,287,336/1,294/2,293,325/1,288/1 VILLAGE: SAMAGHOGHA , MANDVI- PRAGPAR ROAD , TA: MUNDRA DIST: KUTCH

Sr. No. Product Quantity ( MT/MONTH)

1. Ductile Iron Pipes 25,000

2. L Saw Steel Pipes 16,667

3. H Saw ( Spiral) Steel Pipes 12,500

4. Sand for Re-use 750

5. PE / Epoxy Coating 50,000

Complied

3. Condition Under the Water Act. 1974:

3.1 The generation and disposal of the industrial effluent from the manufacturing process and other ancillary industrial operations shall be NIL

Complied

3.2 The quantity of the sewage effluent from the factory shall not exceed 100 KL/ Day

Complied

3.3 TRADE EFFLUENT :

3.3.1 Domestic effluent shall be treated and to conform to the following standards and shall discharge on land for plantation and gardening purpose within the premises.

BOD ( 5 DAYS AT200 C ) Less than 20 mg /L

Suspended Solids Less than 30 mg /L

Residual Chlorine Minimum 0.5 mg /L

Complied

4 CONDITIONS UNDER THE AIR ACT:

4.1 The following shall be used as flue in boiler / furnace/heater respectively.

Sr. No. Fuel Quantity

1. LPG 800 Kg / Day

2. HSD/ LDO 1700 Lit / Day

3. Blast Furnace Gas

12,000 M3 /Day

Complied

4.2 The flue gas emission through stack attached to boiler / furnace / heater shall conform to the following standards.

Stack

No.

Stack

attached

to

Stack

height

in

meter

Air

Pollution

control

system

Parameter Permissible

Limit

1. Bitumen

Drying

Oven

32 --------- PM

SO2

NOx

150 mg/ NM3

100 ppm

50 ppm

2. Bitumen

Drying

Oven

32 ----------

3. Annealing

Furnace

32 ----------

4. Annealing

Furnace

32 ----------

Complied

5. DG Set

750 KVA

– 04 Nos

15

Each

PM

SO2

NOx

150 mg/ NM3

100 ppm

50 ppm

4.3 The process emission through various stacks / vent of reactors , process vessel shall conform to the following standards:

Stack

No.

Stack

attached to

Stack

height

in

meter

Air

Pollution

control

system

Parameter Permissible

Limit

1. MG

Converter I

& II

30 Bag Filter PM

SO2

NOx

150 mg/ NM3

100 ppm

50 ppm

2. Core

cleaning &

Dusting

30 Bag Filter

3. Shot

Blasting

30 Bag Filter

4. Barrel

Grinding &

Dusting

30 Bag Filter

5. Barrel

Grinding &

Dusting

30 Bag Filter

6. Core shop (

I & II)

50 Bag Filter

7. Sand

Reclamation

Unit

32 Bag Filter

8. Zinc Coating

I & II

30 Bag

Filter/

Cyclone

separator

Zinc 20 mg/ NM3

Complied

4.4 The concentration of the following parameters in the ambient air within the premises of the industry shall not exceed the limits specified hereunder.

Sr.

No.

Pollutant Time weighted

Average

Concentration

in ambient air

1. Sulphur Dioxide

(SO2),µg/ M3

Annual

24 hours

50

80

2. Nitrogen Dioxide (NO2),

µg/ M3

Annual

24 hours

40

80

3. Particulate Matter

( Size less than 10 µm)

OR PM10 µg/ M3

Annual

24 hours

60

100

4. Particulate Matter

( Size less than 2.5 mm)

OR PM2.5 µg/ M3

Annual

24 hours

40

60

Complied

4.5 The applicant shall provide portholes, ladders, platforms etc. at chimney(s) for monitoring the air emissions and the same shall be open for inspection to / and for use of Board’s staff. The chimney(s) vent attached to various sources of emission shall be designed by numbers such as S-1, S-2 Etc. and these shall be painted / displayed to facilitate identification.

Complied

4.6 The industry shall take adequate measures for control of noise levels from its own sources within the premises so as to maintain ambient air quality standards in respect of noise to less than 75 dB (a) during day time and 70 dB (A) during night time . Day time is reckoned in between 6:00 am and 10 pm and night time is reckoned between 10:0 pm and 6:00 am.

Complied

5. Authorisation For The [Management, Handling & Transboundary Movement] Of Hazardous Wastes Form-2 ( See rule 5 (4) Form for grant of authorization for occupier or operator handling hazardous waste rule,2008.

5.1 M/S JINDAL SAW LTD.( IPU) is hereby granted an authorization to operate facility for following hazardous wastes on the premises situated at Survey No.: / Plot No. 294/1,324,286,287,336/1,294/2,293,325/1,288/1, Village: SAMAGHOGHA, MANDVI-PRAGPAR Road Ta: Mundr a Dist: Kutch.

Sr. No.

Waste Quantity/Year Schedule/I Facility

1. Used Oil/ Spent Oil

0.50 KL 1,5.1 Collection, storage, Transportation, Disposal by utilized for lubrications of machines & remaining selling out to registered recyclers / reprocessor.

2. Zinc Dust 34 MT 1, 6.2 Collection, storage, Transportation, Disposal by utilized for lubrications of machines & remaining selling out to registered recyclers / reprocessor.

3. Discarded Drums

1090 Nos 1,33.3 Collection, storage, Transportation, Disposal at decontamination facility or send back to suppliers.

Complied

5.2 The authorization is granted to operate a facility for collection, storage, within factory premises, transportation and ultimate disposal of Hazardous wastes by selling out to registered recyclers.

Complied

5.3 The authorization is subject to the conditions stated below and such other conditions as may be specified in the rules from time to time under the Environment ( Protection ) Act -1986

To be followed

5.5 TERMS AND CONDITIONS OF AUTHORISTION

a) The applicant shall comply with the provision of the Environment (Protection) Act-1986 and the rules made there under.

To be followed

b) The authorization shall be produced for inspection at the request of an officer authorized by the Gujarat Pollution Control Board.

To be followed

c) The person authorized shall not rent, lend, sell, and transfer of otherwise transport the hazardous wastes without obtaining prior permission of the Gujarat Pollution Control Board.

To be followed

d) Any unauthorized change in personnel, equipment or working conditions as mentioned in the authorization order by the persons authorized shall constitute breach of this authorization.

To be followed

e) It is the duty of the authorized person to take prior permission of the Gujarat Pollution Control Board to close down the facility.

To be followed

f) An application for the renewal of an authorization shall be made as laid down in rule 7.

To be followed

g) Industry shall submit annual report within 15 days and sub sequent by 31st January every year.

To be followed

h) Hazardous waste shall be disposed off in accordance with the Haz. Waste (Management, Handling & Transboundary Movement) rules,2008 and unit shall have to obtain Authorisation of this Board for all applicable categories of Waste.

To be followed

6 General Conditions :-

6.1 Any change in personnel, equipment or working conditions as mentioned in the consents form/ order should immediately be intimated to this Board.

Complied

6.2 Applicant shall also comply with the general conditions given in annexure1 Complied

6.3 The waste generator shall be totally responsible for (i.e. Collection, storage, transportation and ultimate disposal) of the wastes generated.

Complied

6.4 Records of wastes generation, its management and annual return shall be submitted to Gujarat Pollution Control Board in form -4 by 31st January of every year

Complied

6.5 In case of any accident, details of the same shall be submitted in form-5 to Gujarat Pollution Control Board.

Complied

6.6 As per “public Liability Insurance Act-91” company shall get Insurance Complied

policy, if applicable.

6.7 Empty drums and containers of toxic and hazards materials shall be treated as per guideline published for “management & handling eg. discarded containers”. Records of the same shall be maintained and forwarded to Gujarat Pollution Control Board regularly.

Complied

6.8 In no case any kind of Hazardous waste shall be imported without prior approval of appropriate authority

To be followed

6.9 In case of transport of hazardous waste to a facility ( i.e. Treatment, storage and disposal) existing in a state other the the state where hazardous waste are generated ,the occupier shall obtain “ No Objection Certificate” from the State pollution control board, the committee of the concerned state or Union territory Administrative where the facility exists.

To be followed

6.10 Unit shall take all concrete measures to show tangible results in waste generation, reduction, voidance, reuse and recycle. Action taken in this regards shall be submitted within 03 months and also along with Form 4.

Followed

6.11 Industry shall have to display the relevant information with regard to hazardous waste as indicated in the Hon Supreme Court’s order in W.P. No. 657 of 1995 dated 14th October 2003.

Followed

6.12 Industry shall have to display on line data outside the main factory gate with regard to quantity and nature of hazardous chemicals being handled in the plant, including waste water and air emissions and solid hazardous waste generated within the factory premises.

Followed

6.13 Industry shall have to carry out third party regular monitoring with respect to the efficiency of the air pollution control equipments through the credible institute and upgrade the EMS from time to time as required and furnish the reports in this regard to the Gujarat Pollution Control Board at regular interval of one month.

Followed

NO: PC /CCA- KUTCH – 620 / GPCB ID: 18036/ 53566

Point No 32: Details of Fatal/Non Fatal Accidents, loss of life or man hours, if any, occurred in

the existing unit in last three years and measures proposed to be taken for

avoiding re - occurrence of such accidents in future.

• One Road Incident

Measures taken for avoiding reoccurrence of such accident in future:

1. Appointed more safety officers (05 nos Safety Officers)

2. Introduced safety management system OHSAS/18001-2007.

3. Each hazards/non hazardous activity/risk identified and introduced measures to reduced

accidents. (HIRA Analysis).

4. Introduced safety induction training of contractual labour before joining.

5. Introduced shop floor training to workers by safety officers.

6. Constituted the Central Safety Committee & Departmental Safety Committee and co –

ordination committee on monthly basis.

7. Each & Every accident is investigated & suggested corrective and preventive measures

and ensures its compliances.

8. More focus on good quality PPEs and ensured the wearing of PPEs.

9. Introduced Night Vigilance Officer Duty to ensure the compliance of safety norms inside

plant during night hours also.

10. Observations of unsafe conditions/unsafe acts on daily basis and ensured its

compliance.

11. Introduced work permit systems.

12. Celebrated Safety week/safety day to increase safety awareness among the

employees.

13. Organized safety essay, Safety poster, Safety Slogan etc competition to increase safety

awareness among Employees and children of the surrounding areas.

14. Timely testing & certification of tools & tackles.

Type of

incidents

2008* 2009 2010

No of

incidents

Man Days

Lost

No of

incidents

Man Days

Lost

No of

incidents

Man Days

Lost

Reportable

Incidents 4 31 22 125 10 100

DESCRIPTION OF MANUFACTURING PROCESS WITH FLOW DIAGRAM

� DI Pipe Manufacturing

Ductile Iron spun pipe drawing process involves following steps:

• Treatment of hot pig iron in induction furnace for achieving desired composition • Superheating of hot metal up to 1500 c. • Spheroridizing treatment • Centrifugal casting of pipes • Heat treatment of pipes • Miscellaneous steps like grinding cleaning scouring of pipes hydraulic pressure testing of

pipes and antirust coating of pipes.

Treatment of hot pig iron for achieving desired composition:

The pre-treatment of hot metal is done in the induction furnace to reduce the sulphur and phosphorous content of the hot metal within the stipulated limits. The quality of hot metal required for ductile iron production is indicated below:

Element Stipulated Hot Metal Quality

C % 3.5 to 3.6

Si % 1.8 to 2.2

Mn % 0.3 (Max)

S % 0.03 (Max)

P % 0.05 (Max)

Super heating of hot metal and spheroridization. The temperature of the treated hot metal is increased to 15000 c in an induction furnace to melt significant amount of scrap containing low Si and/or Fe-Si as and when necessary in desired quantity.

The process of spheroridization treatment is done in the induction furnace to alter the chemical composition of and physical condition of the melt so that graphite precipitates in the spheroidal shape. To achieve this, in addition to carbon, the hot metal is mixed with appreciable proportion of silicon to accelerate the graphitization of Cementile. The presence of carbide forming elements such as manganese vanadium, titanium, chromium etc. is avoided for the process of

sphereoridization. The spheroidizing elements are mainly magnesium, cerium, calcium, zirconium alloys etc.

� Centrifugal Casting of pipes :

The hot spheroids metal is discharged into pouring machines. The pouring machine are equipped with

• Different sized of pipes. • Mould coating machine • Inoculation feeding device.

The hot metal is transferred through ladles into the inoculation-feeding device, which rotates at angular velocity during pouring. The inoculation-feeding device inoculates the molten metal into the De-Lavoud type centrifuge-casting machine.

The De-Lavoud type centrifuge-casting machine is equipped with the following :

• Core setting system • Mould rotation system • Pipe extraction system • Pipe rolling equipment • Pipe weighing equipment • Pipe transport equipment

The hot metal is injected into the desired rotating mould, the pipes of desired geometry are extracted and will be set in the core setting zone. The heat treatment of the pipes is done in the horizontal continuous annealing furnace. The heat treatment process involves following steps:

Process description Duration

Heating from 350 to 960 c 6 – 15 minutes

Soaking at 960 c 15 – 20 minutes

Fast cool from 960 c to 780 c 7 – 10 minutes

Fast cool from 960 c to 780 c 18 – 22 minutes

The pipes are there after cleaned with water and then cut to desired size if required and rounded to meet the standard of ISO 2591 and BS 4772. Thereafter the pipes are sprayed with zinc as per

ISO 8179 and cement lined as per ISO 4179 and BS 4772. There after the pipes are cured in curing oven and coated.

� Longitudinally submerged Arc Welded (L SAW) Pipes

The raw material for manufacturing L Saw pipes is Steel sheet purchased from outside sources. The steel sheet is tested for uniformity and selected sheets are subjected to edge milling on milling machines and crimped. The crimped plates is given “J” bend on the power press followed by “C” bend and “O” bend join edges of the plates to give them a hollow pipe shape. The mechanically joined edges are continuously Track Welded followed by inner Longitudinal Seam Welding and outer Longitudinal Seam Welding under submerged arc to avoid any atmospheric contamination. The welded heads are controlled by guide rolls along the length of the seam and on going monitor scanning to avoid any possible defect. The configuration of the consumable is compatible to achieve desired quality result on the weld position.

The final dimensions of the pipe are obtained by mechanically expanding the original welded pipe through mechanical expanders of precision accuracy. The expansion of the pipes is done from in side in order to obtain uniform diameter. The dimension of the pipes varies from 18” outer diameter is 12” outer diameter and wall thickness up to 1.5”.

The pipes are hydro tested as per stipulated ISO standard. The passed pipes are then subjected to beveling at the ends to make it fit for field welding. The end-faced pipes are put ultrasonic test. Magnetic particle Inspection, final inspection and sent for coating.

� Spiral Steel Pipes

The spirally welded pipes are manufactured from Hot Rolled Steel Plate/Coils. The steel coils are first uncoiled, edges trimmed, passing through a trimmer. There after the un-coiled steel sheet is spirally recoiled on a continuous coil forming machine to impact the shape of a helical pipe. The mechanically spiraled pipes are seam welded automatically and continuously all along the spiral joint, first on the bottom of the rotating pipe from inside and then on the top from outside (cross seam and helical seam welding). The diameter of the pipes is vary from 20” to 80 “ and thickness up to 0.59”.

The pipes are cut into specific sizes and cleaned. There after the pipes are subjected to visual inspection and X-ray inspection for testing of welding quality and then put to hydro testing. The pipes ends are beveled for field welding. The beveled pipes are weighed, marked and put for customer inspection.

PROCESS FLOW CHART OF DI PIPES

Liquid Metal from Blast Furnace

Induction Furnace (Addition of MS Scrap and heating of Metal)

Magnesium Converter

Core Shooter (Core Marking) Spinning Machine Mould Shop

Annealing Furnace

External Zinc Coating

Grindings of Pipes

Hydro testing of Pipes

Inside Cement Mortar lining of Pipes

Cement mortar lining curing

Out Side Bitumen Coating of Pipes

Bitumen Coating Drying

Pipe for Dispatch

PROCESS FLOOW CHART OF LSAW PIPES Plate UT End Facer EDGE Planning MPI Crimping FUT JCO Press Radiography Mig Welding and Mig Repair Final Inspection Inside Welding Marking Outside Welding Pipe for Dispatch Wash Station Weld Repairs IUT Expander Hydro Tester

PROCESS FLOW CHART OF SPIRAL PIPES HR Coil Inspection Work Inspection Pope Forming Pipe Welding ID/OD Welding Customer Inspection Pipe Cleaning Radiography Visual Inspection Marking Cross Seam/Helical Seam Re-Welding Pipe for Dispatch Repair Station Hydro Tester End Facer FUT Radiography

DETAILS OF INDUCTION FURNACE

An induction furnace is an electrical furnace in which the heat is applied by induction

heating of metal). The advantage of the induction furnace is a clean, energy-efficient and well-

controllable melting process compared to most other means of metal melting. Most modern

foundries use this type of furnace and now also more iron foundries are replacing cupolas with

induction furnaces to melt cast iron, as the former emit lots of dust and other pollutants.

Induction furnace capacities range from less than one kilogram to one hundred tonnes capacity

and are used to melt iron and steel, copper, aluminium and precious metals. Since no arc or

combustion is used, the temperature of the material is no higher than required to melt it; this can

prevent loss of valuable alloying elements. Charge materials must be clean of oxidation products

and of a known composition and some alloying elements may be lost due to oxidation (and must

be re-added to the melt).

Operating frequencies range from utility frequency (50 or 60 Hz) to 400 kHz or higher,

usually depending on the material being melted, the capacity (volume) of the furnace and the

melting speed required. Generally, the smaller the volume of the melts, the higher the frequency

of the furnace used; this is due to the skin depth which is a measure of the distance an alternating

current can penetrate beneath the surface of a conductor. For the same conductivity, the higher

frequencies have a shallow skin depth - that is less penetration into the melt. Lower frequencies

can generate stirring or turbulence in the metal.

Superheating of metal is done electrically (Eddy current method). Water is circulated inside

the coil. Over head tank been provided to circulate water inside coil during power failure to

avoid damage to system, this emergency system will automatically switch over during power

failure or any failure in pumping system. All furnaces are covered with lids during operation &

sheds provided with roof ventilation & exhaust.

A preheated, 1-tonne furnace melting iron can melt cold charge to tapping readiness within

an hour. Power supplies range from 10 kW to 15 MW, with melt sizes of 20 kg to 30 tonne of

metal respectively.

ELECTRICAL SAFTEY CONTROLS IN INDUCTION

FURNACE

1) DOOR OPEN: This indicates either an open door or a failing capacitor. The circuit breaker

opens when one of these faults occurs.

2) SCR PROTECTION: The circuit breaker or The AC interrupter (ACI) or both will trip when

this type of fault occurs.

3) INTERNAL WATER SYSTEM HIGH TEMPERATURE: This indicates a trip on an internal

system temperature switch or sensor. This can be caused by high external water temperature, poor

cooling flow to the heat exchanger or operating above rated power.

4) INTERNAL WATER SYSTEM LOW PRESSURE: This indicates one or more of the

following reasons,

a) Pump is not operating.

b) Pump rating direction not proper

c) Setting of pressure switch not proper.

5) EXTERNAL WATER SYSTEM HIGH TEMPERATURE: This indicates one or more of the

following reasons,

a) High external water inlet temperature.

b) Over heating of a furnace drain line ( Coil out let water)

6) EXTERNAL WATER SYSTEM LOW PRESSURE: This indicates inadequate cooling water

supply. External pressure is less than required.

7) FURNACE SELECTOR SWITCH INTERLOCKS: This lamp indicates that a selector switch

is not properly closed or has been moved, or that there is no water flow to a furnace with a closed

selector switch.

8) FURNACE WATER VALVES: These valves turn on supply water to the furnace. Associated

with each valve is a position action flow switch, interlocked through the circuit monitor, to shut

down the power supply if there is no flow in an active furnace.

9) GROUND LEAK DETERCTOR: Used to detect low ground resistance in the electrical

system. It is also used to give an indication of a molten metal leak from the furnace to an

electrical conductor ( The coil )

10) EXCESS CHARGE (TOT): The turn off time light indicates that the inverter is not able to

produce the required power without operating at a repetition rate that would result in an SCR

TOT less than the design minimum of the device. This condition usually occurs with a dense

charge of cold magnetic material in the furnace.