Reverse Engineering

EXAMPLESOF

REVERSE ENGINEERING EXECUTED

BYPROWESS

JSPL FES REVERSE ENGINEERING AND MODIFICATIONBEFORE : • Frequent Stoppage of Furnace to Remove

Dust.• Poor Life of Cooled & Uncooled Elements• Increase of Hot Metal % in charge mix

resulted in high dust load and increase in temperature of fume.

JSPL FES REVERSE ENGINEERING AND MODIFICATION

AFTER :Prowess Studied the System and Modified the Same to

• Provide Sufficient Space For CO( Carbon Mono Oxide Burning)• Access of Mobile Shovel to Remove the Dust in Shortest Possible Time.

EMIRATES STEEL BOTTOM SHELL R.E. AND MODIFICATION

Tapping weight increased by 20% by increasing Bottom shell diameter in such a way that with replacement of bottom and top shell only keeping the tilting platform, roof and all other elements same.

TATA STEEL L.D. # 1 LF #3 ROOF R.E. & MODIFICATION

NEW

OLD

BEFORE :Tata steel was facing problems• Excess stickers on the Roof• Operational inconvenience

due to position and size of roof openings.

• Metal jamming in Ladle bail area.

AFTER :Prowess Studied the System and Modified the Same to• Latest design conical roof

supplied.• Changed the location of

opening and size for better operational ease.

• Introduced a permanent opening in the roof to accommodate the bails and sticking free operation.

REVERSE ENGINEERING JOBS EXECUTED BY PROWESS

S.No. Client Area Scope of work

1

Tata Steel

LD # 1 L.F. # 1 roof Prowess reverse engineered the LF roof assemblies on the basis of available GA and modified, Flux addition, Top Lance and inspection door openings as per the site requirement2 LD # 1 L.F. # 2 roof

3 LD # 1 L.F. # 3 roofProwess reverse engineered the LF roof assemblies on the basis of available GA and modified roof shape as per new roof (Conical type) of LD # 3 Flux addition, Top Lance and inspection door openings as per the site requirement

4 LD # 2 L.F. # 2 roofProwess reverse engineered the LF roof assemblies on the basis of available GA, Flux addition, Top Lance and inspection door openings as per the site requirement

5 LD # 1 Vessel # 1 Skirt

Prowess reverse engineered the Skirt Assembly on the basis of available GA




9 LD # 1 Flux Thimble Prowess reverse engineered the Flux Thimble on the basis of available GA

10 Ld # 2 Vessel # 3 Prowess took Site dimensions, done reverse engineering, manufactured and supplied cooling stack upper part

11 LD # 1 Prowess reverse engineered the Radiation Hood for Vessel on the basis of available GA

CONTD……

REVERSE ENGINEERING JOBS EXECUTED BY PROWESSS.No

. Client Area Scope of work

12

Emirates Steel

Bottom Shell Emirates Steel wanted to increase the capacity of the furnace, but they were not having detail drawing, Prowess Studied GA drawing developed a Modified bottom shell and Split shell to achieve higher production rate and supplied the same

13 Split Shell

14 Copper contact Pad

Prowess detailed engineered the contact pas on the basis of Available Ga and supplied the same

15 Kalyani Gerdau

Ladle Furnace Roof

Prowess reverse engineered the Ladle furnace roof assemblies on the basis of available GA and modifies flux chute and door as per modified site requirement

16 Salem Steel Plant

Crane and Transfer Car Wheels

Prowess reverse engineered the Wheels assemblies on the basis of available GA

17

Bhushan Power &

Steel

KT Lance Prowess developed new KT Lance indigenously, on the basis of GA drawing and site measurement of the existing Lance

18 Electrode Column

Prowess did reverse engineering of the available GA and modified available electrode column to suit Arm No. # 2 as the same was shorter than the available one

19 Copper Panel Prowess reverse engineered the Steel/ copper panel on the basis of available GA

20 Bhushan Steel Ltd. 60 T EAF Roof Prowess Reverse engineered the new roof on the basis of

available GA CONTD……

REVERSE ENGINEERING JOBS EXECUTED BY PROWESS

S.No Client Area Scope of work

21Neco

jayaswal/ Deify

Delta Ring for 60 T EAF

Prowess Reverse engineered the new Delta ring on the basis of available GA and modified the same by converting the same in to sacrificial ring type.

22 Sunflag Steel Electrode arm for 60 T LRF

Sunflag steel was facing the problem of arm getting red hot, Prowess designed an improved arm similar to their existing LRF for better life and operation.

23Jindal Steel and Power

Development of Fume Extraction System

JSPL was facing problem in Fume extraction system, due to change in charge mix, Prowess studied the system, modified, the design on the basis of available basic drawings and design data and modified FES as per new practice

24

25 Jindal Stainless Ltd

FES Ducts Prowess developed detail engineering on the basis of available GA drawing, Manufactured and supplied the ducts, Elbow and Panel26 Elbow and Panels

THANK YOU !!!