Report BM2 Water System

Water System Specification Report
Duration: Week 14(3/4/2017) Week 16(22/4/2017)
Contents Page no
2
1.0 INTRODUCTION
1.1 Water used in Steel Plant and its Types 2
1.2 Water Function in Steel Plant 2
1.3 Source of Water
2
2.0 BAR MILL 2 WATER SYSTEM
2.1 Direct Water System
2.2 Indirect Water System
2.3 Torsid (Quenching Process) Water System
Source of Water
1.0
2.0
5.0
1
1.0 INTRODUCTION
1.1 Importance of Water Steel Plant
Water is used in every steel plant and for practically all the functions of water. A steel plant
cannot function without water. Because of this steel plants are normally built near to ample
sources of fresh water to ensure the availability and quality of water needed by the steel
plant. However, these days, greater attention is given to the management of available water
resources in the steel plant environment, particularly in terms of water quality, quantity, and
how it is used.
A steel plant uses large quantity of water for steam generation, cooling, waste transfer, and
dust control etc. The processes of the plant cannot take place without the availability of
water. Enormous quantity of water is needed at every stage of production. Less than 10 % of
this water is actually consumed and balance water is usually being returned to the system.
Several factors make water a versatile material. It is normally easy to handle, readily
available, and inexpensive. It can carry large amounts of heat per unit volume (high specific
heat). It neither expands nor compresses significantly within ambient temperature ranges. It
does not decompose. It can dissolve, entrain, suspend, and subsequently transport other
materials.
1.2 Water Function in Steel Plant
Water is used for direct contact cooling and cleaning of the steel in process, for cooling the
process off-gases, for product rinsing, and for process solution make-up etc. A large quantity
of water is used for indirect non-contact cooling of processing equipment. Water is also used
for steam and power generation, potable uses, and dust and moisture control. In fact, in a
steel plant, water carries out a number of functions. Major functions of water in a steel plant
are given below:
Most of the water used in a steel plant is for cooling. Examples are coke quenching,
cooling of blast furnace shell, oxygen lance in converter, cooling in continuous casting
machines and hot rolling mills. Virtually any hot spot is cooled mainly by using water,
one way or another.
Water is used for descaling in continuous casting and in hot rolling operations. It is
also used as conveying media for transporting scales to the scale pit.
Water is used for on line heat treatment (thermos mechanical treatment) in the hot
rolling mills.
Water serves as a resource to produce steam.
2
Water is also used as part of chemical treatments, such as solvent in acidic pickling,
matrix for generation of emulsions for rolling, cleaning, degreasing or rinsing steel
sheet surface, etc.
Water is used for electrochemical treatments, such as electro-galvanizing or tin
plating etc.
Water is used for dust suppression
1.3 Source of Water
Raw water is that water which is available in the natural sources such as:
1. Surface or ground water sources (river, lake, reservoir, and sea etc.)
2. Underground water sources. Sea water is having high salinity and need treatment like
reverse osmosis etc. for its use in the steel plant. Ground water is also required to be
tested since it may be brackish. Raw water collected from sources other than sea also
needs treatment before it can be used in the steel plant as shown in Figure 1.1
below. The extent of treatment required to be given to the particular water depends
upon the characteristics and quality of the available water. Water after treatment is
called treated water.
Figure 1.1: Underground Water Tube Well as One of the Water Resource at BM2.
Rain water of the steel plant is harvested these days and pumped to the treatment plant.
This helps in the reduction of the intake water and in turn helps in the conservation of the
natural resources. The overall layout of the BM2 plant is shown in the FIGURE 2.0 on the
next page.
2.0 BAR MILL 2 WATER SYSTEM
3
2.1 Direct Water System
After continuous casting process, the cast steel product or in this plant it called as billet is
transferred to a reheating furnace to bring the semi-finished steel to a uniform temperature.
Whether the reheating furnace is of skid, walking beam, or tunnel design. Indirect cooling
water is typically used to provide the cooling for doors, internally cooled rolls, skid pipes,
beams, bearings, and miscellaneous equipment.
In the hot rolling mill, the mill stand work rolls are cooled by a direct water cooling system to
maintain roll contour, to prevent surface cracking of the steel rolls due to sudden
temperature changes, to minimize fire checking, and to extend roll life. Water is also used in
descale in the form of high pressure jets to remove scale from the reheated steel before
rolling to maintain surface quality. It is also used between certain roll stands to maintain
surface cleanliness of the steel in process. In addition, water is used as flume flushing to
transport the scale to the scale pits for removal.
The rolling mill water system typically incorporates scale pits, oil skimmers, straining devices,
solids removal with clarifiers and/or deep bed filtration equipment (when low suspended
solids levels are to be maintained), and cooling towers. Waste water treatment usually
includes facilities for likely contamination from fine mill scale, grease, hydraulic fluids, and
lubrication oil which gets collected in this system.
All piping layout with equipment that used direct cooling system in BM2 can be summarize
in the Figure 2.1.1 in next page.
4
In the Table 2.1.1, 2.1.2 & 2.1.3 below is the technical and operation specification detail for
all the sub-component in the direct cooling system start from Scale Pit Pump, Direct Cooling
Tower, and Direct Pump:
Table 2.1.1: Scale Pit Pump Technical and Operation Specification.
Detail Component Specification

N Name Technical Specification No. Set
o
1 Moto Brand: TECO 4
r Type/Model No: AEVBCB
Phase: 3 Phase AC Induction
Volts: 415
Amps: 63
RPM: 1465
kW: 37
Hz: 50
Frame: 200L
2 Pump Brand: Vaughan Vertical Wet Well Pump 2
Model No: V6U8-300 X 2440mm
Pump Type: Centrifugal
Pump Flow Rate: 425 m/hour (4000 liters/min) @ AT 1.5 Bar
Speed Rating: 2100rpm
Brand: Pemo, Italy 2
Model No:
Pump Type: Centrifugal
Pump Flow Rate: 200 m/hour (4000 liters/min) @ AT 1.5 Bar
Operation Specification
Motor Running Amp : (Vaughan 67+/-5, Pemo 53 +/-3)
Pump Oil : HD 46
Water Pressure at Pump : 1.6 Bar
Water Outlet Temperature : 31-32 C
Table 2.1.2: Crossflow Induced Draft Cooling Tower-Direct Cooling System Scale Pit Pump
Technical and Operation Specification.

N Name Technical Specification No.
o Set
5
1 Motor Brand: TECO 2
Type/Model No: AEVBCB
Volts: 415
Amps: 63
RPM: 1465
kW: 37
Hz: 50
Frame: 200L
2 Gearbox Type: Right Angle Fan Drive 2
Brand: Amarillo
Model: F110
Service Rating: 60 HP
RPM Input: 1750
Service Factor: 2.0
Gearbox Reducing Ratio: 5:1
Gearbox Oil Type: ISO 220
Operating Temperature: -7C to 82C
Change Oil Every 2500 Hours or Every Six Month
3 Fan Blade Model No: PCI 3050-A8 2
No of Blade: 8
Fan Cylinder: Diameter-3050mm
Motor Running Amp : (Direct Motor AMP 28-32, Indirect Motor AMP 26)
Gearbox Oil : EP 220
Well Water Level :
Table 2.1.3: Direct Pump Cooling System Specification Scale Pit Pump Technical and
Operation Specification.

o
Type/Model No: AEEEBK M040L05 FM
Volts: 415
Amps: 63
RPM: 1762
HP: 250
Hz: 50
6
Frame: 280SC
2 Pump Type: Centrifugal-End Suction Pumps (Closed Impeller) 4

Brand: Allen Gwynnes Nimbus Pump
Pump Size: 200 x 150 x 315
Pressure: 5 Bar
Bearing End Float: 0.11-0.15 mm
Impeller Size:
Flow Rate : 370m3 / Hr @ 5.7 BAR
Motor HP : 75 KW
Motor Running AMP : Norm 75 +/-5
Water Pressure at Pump : 5.5 5.7 Bar
2.2 Indirect Water System
Indirect cooling application means the use of water for general purposes where water does
not contact the steel in process. Indirect water includes all the applications of water directly
used in the steel process which the main function is for heat exchanger, electric motor, and
roller bearing. All piping layout with equipment that used indirect cooling system in BM2 can
be summarize in the Figure 2.2.1 in next page.
In the Table 2.2.1, & 2.2.2 below is the technical specification detail for all the sub-
component in the indirect cooling system:
Table 2.2.1: Indirect Pump Scale Pit Pump Technical and Operation Specification.
7
o Set
Volts: 415
Amps: 63
RPM: 1762
HP: 250
Hz: 50
Frame: 280SC
Brand: TECO 2
Volts: 415
Amps: 63
RPM: 1762
HP: 250
Hz: 50
Frame: 280SC
Pump Size: 200 x 150 x 400
Pressure: 5 Bar
Impeller Size:
Type: Centrifugal-End Suction Pumps (Closed Impeller) 2
Pump Size: 200 x 150 x 315
Pressure: 5 Bar
Impeller Size:
Motor HP : 75 KW
Motor Running AMP : Norm 75 +/-5
8
Table 2.2.2: Crossflow Induced Draft Cooling Tower-Indirect Cooling System Scale Pit Pump

No Name Technical Specification No. Set
Volts: 415
Amps: 63
RPM: 1465
kW: 37
Hz: 50
Frame: 200L
Brand: Amarillo
Model: F110
RPM Input: 1750
Service Factor: 2.0
No of Blade: 8
9
Motor Running Amp : Motor AMP 26 +/- 5
Well Water Level :
2.3 Torsid (Quenching Process) Water System
Quenching is the rapid cooling of a work piece to obtain certain material properties. In
metallurgy, quenching is most commonly used to harden steel by introducing martensite, in
which case the steel must be rapidly cooled through its eutectoid point, the temperature at
which austenite becomes unstable. A type of heat treating, quenching prevents undesired
low-temperature processes, such as phase transformations, from occurring. It does this by
reducing the window of time during which these undesired reactions are both
thermodynamically favourable, and kinetically accessible; for instance, quenching can
reduce the crystal grain size of both metallic and plastic materials, increasing their hardness.
In BM2 the HTD product usually require quenching process to achieve high tensile strength.
The most common quenchant used for hot rolling steel is water. The main advantage of
using a water quenchant is that water can provide the rapid quenching speeds necessary for
achieving high properties in many different mechanical properties. Water is also cheap and
readily available. In addition, water is reasonably flexible in that its quenching characteristics
can be changed somewhat by varying the temperature of the water.
All piping layout with equipment that used indirect cooling system in BM2 can be summarize
in the Figure 2.3.1 in next page.
In the Table 2.3.1, 2.3.2 & 2.3.3 below is the technical specification detail for all the sub-
component in the indirect cooling system:
Table 2.3.1: Torsid Injector Pump Scale Pit Pump Technical and Operation Specification.

o
10
Volts: 415
Amps: 100
RPM: 1480
HP: 250
Hz: 50
Frame: 280SC
2 Pump Brand: HICO 4
Type: Multistage 150/4
Model No: HTM 150/4
Pump Flow Rate: 240 m/hour (4000 liters/min)
Pump Pressure: 18 Bar
Table 2.3.2: Crossflow Induced Draft Cooling Tower-Torsid Injector Pump Scale Pit Pump

No Name Technical Specification No. Set
Volts: 415
Amps: 63
RPM: 1465
kW: 37
Hz: 50
Frame: 200L
Brand: Amarillo
Model: F110
RPM Input: 1750
Service Factor: 2.0
Change Oil Every 2500 Hours or Every Six Month
No of Blade: 8
11
Motor Running Amp : Motor AMP 26 +/- 5
Well Water Level :
Table 2.3.3: Torsid Return Cooling System Specification Scale Pit Pump Technical and
Operation Specification.

o Set
Volts: 415
Amps: 63
RPM: 1465
kW: 37
Hz: 50
Frame: 200L
12
Pump Size: 200 x 150 x 315
Pressure: 5 Bar
Impeller Size:
Motor HP : 75 KW
Motor Current : Normal 75 +/-5 Amp
2.3.1 Torsid Quenching Guideline
Torsid quenching box water inlet flowrate normally setting depend on the steel bar size
diameter. Below in the Table 2.3.4 is the all deformed bar size with the total water flow rate
require to perform quenching process and also in Table 2.3.5 below is the torsid box setup
configuration for BM 2 correspond with the size of steel bar.
Table 2.3.4: Torsid Return Cooling System Specification
Torsid Flow rate (m3) Cooling Bed Bar

Size R5 Pyrometer
Total Flow rate Temperature (C)
Min Max Min Max Min Max
12mm
920C 1040C 540 640 460C 540C
(S)
12mm
920C 1040C 550 650 460C 540C
(S)
16mm 920C 1040C 550 650 460C 540C
20mm 920C 1040C 550 650 460C 540C
22mm 920C 1040C 550 650 460C 540C
24mm 920C 1040C 550 650 460C 540C
25mm 920C 1040C 550 650 460C 540C
28mm 920C 1040C 550 650 460C 540C
32mm 920C 1040C 550 650 460C 540C
36mm 920C 1040C 550 650 460C 540C
40mm 920C 1040C 500 600 460C 540C
13
Table 2.3.5: Torsid Quenching Box Setup Configuration
Quenching Quenching Pipe

Quenching Box
Product Size Nozzle (I.D) Internal Diameter
No.
mm (mm)
HTD 40 55 85
HTD 32 44 63
T-1, T-2, T-3, T-4
HTD 28 44 63
HTD 25 44 63
HTD 22 34 50
T-1, T-2, T-3
HTD 20 34 50
HTD 16 25 50
T-1, T-2
HTD 12 21 50
3.0 WATER TREATMENT

In order to maintain the quality of water in BM2, Nalco program administration manual
serves the purpose as treatment guide for plant personnel on the control and
troubleshooting with the respect to the water treatment.
3.1 Control Parameter and Ranges
a) The desired water parameter and control for indirect system are as given below:
No Water Parameter Control Limit

1 Turbidity <15 FAU
2 pH range 6.8-8.2
3 Conductivity Max 1000 micros
4 Ca Hardness 80-250 ppm
5 NaCl (Sodium Chloride) <250 ppm
6 Total Inorganic Phosphate (TIP) 8-12 ppm
7 Ortho Phosphate (OPO4) 8-17 ppm
8 Delta Phosphate <2 ppm
9 Total Iron (Fe) <2 ppm
10 Free CL2 0.2-0.5 ppm
11 Silica < 150 ppm
12 Active Polymer 8-12 ppm
b) The desired water parameter and control for indirect system are as given below:
No Water Parameter Control Limit

1 Turbidity <15 FAU
2 pH range 6.8-8.2
14
3 Conductivity Max 1000 micros
4 Ca Hardness 80-250 ppm
5 NaCl (Sodium Chloride) <250 ppm
6 Total Inorganic Phosphate (TIP) >4 ppm
7 Ortho Phosphate (OPO4) 8-12 ppm
8 Delta Phosphate <2 ppm
9 Total Iron (Fe) <2 ppm
10 Free CL2 0.2-0.5 ppm
11 Silica < 150 ppm
12 Active Polymer >4 ppm
3.1 Chemical used and function
There are four different types of chemical used at BM2 plant in order to achieve the required
parameter setting. All the chemical has different functions. The lists of chemical are in Table
3.2 below.
Table 3.2: All chemical list and it function
N Product Description
o
1 3DT288 3DT288 is a liquid multifunctional phosphate based corrosion and
scale inhibitor for open recirculating cooling water system. Its
contain an advanced cooling water treatment polymer and reliable
inhibitor to provide corrosion, fouling and scale protection
2 Nalco 7342 This also known as Actibrom. Use as Oxidising Bioxide
3 Nalco 3430 This is Cl based oxidizing biocide
4 Nalco 71630 It used at primary and secondary clarification, municipal and
industrial, lime softening, heavy water removal and oily emulsion
15
REFERENCE
Water used in Steel Plant and its Types. (n.d.). Retrieved June 14, 2017, from
http://ispatguru.com/water-used-in-steel-plant-and-its-types/
Direct or Indirect Cooling: Which Technology is More Efficient for Bulk Solids
Cooling? (n.d.). Retrieved June 14, 2017, from
https://www.solexthermal.com/resources/articles/direct-or-indirect-cooling-
which-technology-is-more-efficient-for-bulk-solids-cooling/
16

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Water System Specification Report

Duration: Week 14(3/4/2017) Week 16(22/4/2017)

1.1 Importance of Water Steel Plant

1.2 Water Function in Steel Plant

1.3 Source of Water

2.0 BAR MILL 2 WATER SYSTEM

Table 2.1.1: Scale Pit Pump Technical and Operation Specification.

Detail Component Specification

Detail Component Specification

Detail Component Specification

2 Pump Type: Centrifugal-End Suction Pumps (Closed Impeller) 4

2.2 Indirect Water System

Detail Component Specification

2.3 Torsid (Quenching Process) Water System

Detail Component Specification

Detail Component Specification

Detail Component Specification

2.3.1 Torsid Quenching Guideline

Table 2.3.4: Torsid Return Cooling System Specification

Torsid Flow rate (m3) Cooling Bed Bar

Quenching Quenching Pipe

3.0 WATER TREATMENT

3.1 Control Parameter and Ranges

No Water Parameter Control Limit

No Water Parameter Control Limit

3.1 Chemical used and function

Table 3.2: All chemical list and it function

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