Application of Wireless Technology to Enhance Safety and Productivity in Steel Plant

Indigenously developed innovative scheme for transmission of signals, to remotely control mudgun and drill machine at Blast furnace in Rourkela Steel Plant (RSP), has been designed and commissioned. Control cable and switchgear based conventional automation scheme resulted in breakdowns, amounting to loss of production. In hazardous steel plant locations, cable laying or on-line fault rectification is extremely difficult at times. It also sometimes creates life threatening situations for the operators due to proximity of hot liquid iron coming out of tap holes of a Blast Furnace. Industrial Wireless Controls have rapidly replaced wired automation systems. Industrial Wireless Controls send signals through radio waves of varying frequencies. These electromagnetic waves are received by radio receivers at other ends. This hassle-free means of data transfer has made Industrial Wireless Controls popular across in different walks of life. This developmental activity was taken up with objectives firstly to improve safety parameters for operator by providing flexibility to operate from safe distance secondly to reduce production loss due control cable and associated switchgear related breakdowns and consequently to improve availability of cast house equipment like mudgun and drill machine. The system comprises of radio remote control (RRC), valve stand, Programmable Logic Controllers (PLC) and special panels suiting the harsh ambiance. PLC software has been developed with in –house expertise. The system is in continuous operation at RSP, Blast Furnace since 2015.