PROTOCOL FOR BLOWING DOWN OF BLAST FURNACE-II Date: 10.04.

2011 Time: 10:00 AM ** Blowing Down of BF II will be followed by gunning of stack ** 01.01. PRECONDITIONS / PREPARATORY JOBS S.No. Activity On Responsibility 01 Clean all the platforms on BF, DC and stoves and dust and debris from al l structural. On 1st April11 till 9th April11 Ritesh Mishra/Mech Maint. 02 Check steam lines and N2 for steam / N2 supply to dust catcher and gas n etwork. Steam and N2 should be above 6 bar pressure. On 3rd April11 Ritesh M ishra /Mech. Maint. 03 Top water spray to be checked as per following points. a. Installed spiral nozzles to be removed out and to be checked for their proper functioning (proper automization). b. Water @ +80 m3/hr should be available for top spray. c. Each spray line should have a cut off valve in working condition. In shut down on 4th Apr11 Manoj Kumar Rai /Mech Maint. 04 Tuyere no. 10 & 11 to be opened up and burnt tuyeres to be changed. In shut down on 4th Apr11 Ritesh Mishra /Mech. Maint. 05 Provision of Steam purging at the top of the furnace has to be as per fo llowing. a. All four steam nozzles will remain as it is and will supply steam as per the normal procedure. b. Each line should have a cut off valve in working condition. In shut down on 4th Apr11 Manoj Kumar Rai /Mech Maint. 06 Repair any shell crack or opening as far as possible to avoid any air in filtration during blowing down. In shut down on 4th Apr11 B.K.Pandit 07 Check the working of furnace bleeder, dust catcher bleeder and GCP cut o ff valve. In shut down on 4th Apr11 Ritesh Mishra/Mech Maint. 08 Carefully check the whole BF cooling system. In case of any leakage in t he coolers of bosh and shaft close the water of the suspected cooler. In case of tuyeres / TC change the leaking member immediately. In shut down on 4th Apr11 Manoj Kumar Rai /Mech Maint. 09 To check all the instruments especially Blast volume, pressure, temperature, Top temperature and pressure gauges. On 5th April11 Manoj Kumar Rai/ E&I/Mech Maint 10 Arrange 4-5 sets of tools & tackles for changing tuyeres and blowpipes i ncluding 10 numbers of rammers (Dali) for blanking tuyeres and 10 steel crow bars (Poking rods). On 8th April11 Ashish Pandey/Mech Maint. 11 Store sufficient wood and 50-60 torches and HSD on furnace top for gas b urning, if required. On 8th April11 Ritesh Mishra 12 All concerned agencies like SMS, Power Plant, Gas safety, Coke oven, Qua lity control, O2 plant, Sinter plant, RMHS etc are to be informed two days prior to Blow out. Inform them about exact date and time. On 8th April11 Manoj Ku mar Rai 13 A separate screen in HMI to be made available showing the Blow down para meters. On 8th April11 E&I/Manoj Kumar Rai 14 Stove heating arrangement to be checked in advance. On 8th April11 Janardan Patel 15 Both the drill machines are to be thoroughly checked and prepared to dri ll with big (60-80mm) drill bits. There should be sufficient stock of 55, 60, 75 and 80 mm drill bits with rods. On 8th April11 Ashish Pandey/Mech Maint . 16 To ensure proper Furnace drainage and wall cleaning. a. Furnace to be operated preferentially with wall working. Heat load ~ 60 GJ.

b. Slag Basicity to be kept lower around 0.85, to remove the alkalis. c. Metal temperature to be kept at higher side, around 1480-1500 deg C to ensure full drainage of liquids. d. Put Non CDI burden and put ~620Kg Coke rate in last 24 hrs. e. Aim Si in Hot Metal 1.0% and Al2O3 in Slag 15% for last 12 hrs. From 8th April11 onwards Ritesh Mishra/Mech Maint. 17 There should be sufficient lighting at cast house, tuyere platform, all furnace platforms and across the furnace area. From 8th April11 onwards E&I / As hish Pandey 18 The lift must be in working condition. From 8th April11 continuous. E&I/ Manoj Kumar Rai 19 Provision of immediate Gas analysis to be made. a. Orset from QC lab to be shifted to BF control room. b. Two sampling lines to be provided at tuyere plat form. c. Top gas analyzer to be cleaned and calibrated and it has to be in working condition. d. Top gas analyzer to be calibrated to measure up to 15% H2. On 9th April11 M.S. Raghuwanshi/ Manoj Kumar Rai 20 Blast Furnace profile to be printed on paper and distances are to be mar ked to check burden position with respect to measured level during Blow out. On 9th April11 Saurabh Makhariya 21 Firefighting lines with hoses and nozzles should be ready at cast house, tuyere platform and furnace top. On 9th April11 Ritesh Mishra/Mech Maint . 22 Preparation of cast house for Metal and slag handling a. Both the dry pits have to be totally clean and covered with a 300 500 mm thic k sand layer. b. Cast House B should be ready to handle at least 3-4 casts of high Si metal, c ontinuously. c. During Blow down only 4 ladles will be in circulation. On 8th April11 Ashish Pandey 23 Before preparatory shut down cast opening should be planned in such a ma nner that it should be closed at 6:00 am. In preparatory shut down on 10th April11 Ashish Pandey 24 Provision of Nitrogen purging through stack pressure probes has to be as per following. a. Total six (three each at 90 and 270 deg) pressure probes are to be removed an d converted to supply N2 during the Blowing down. b. The probes provided at 19.9m, 23.6m & 26.4 m elevation are to be converted to supply N2. c. Total +4000 Nm3/hr N2 flow for purging during Blowing down should be availabl e. d. Measurement of N2 flow & pressure (in new header) should be available and dis played in control room. e. Each line should have a cut off valve in working condition. In preparatory s hut down on 10th April11 Manoj Kumar Rai /Mech Maint./ E&I 25 Provision of accurate burden level measurement to be done as follows. a. The rope of SLI to be replaced with a longer and stronger rope and it is to b e calibrated to measures 30 m level. b. There should be physical marking on the rope to count the distance traveled. c. Both the radars are to be cleaned and calibrated to measure 30 m level. In preparatory shut down on 10th April11 Ritesh Mishra/Mech Maint./ E&I 26 Ensure that all the peep holes are provided with blue glass and keep thr ee sets as reserve on tuyere platform. In preparatory shut down on 10th April11 Ashish Pandey/Mech Maint. 27 Two hrs before blowing out, the required amount of raw material must be there in the bunkers as per the calculation, such that after giving the blank ch arge all the bunkers / weigh hoppers must be empty (except Sinter) In prepa ratory shut down on 10th April11 Manoj Kumar Rai/ Sanjay Gautam 28 Before taking preparatory shut down a total of 20 mt coke blank will be

charged in the furnace in ring 4 and 5. After dumping the coke blank charging in furnace will be stopped. In preparatory shut down on 10th April11 Manoj Ku mar Rai 29 Ambulance and Fire brigade should be available at BF II ramp. From 8 a m on 10th April11 onwards Deepesh Chandra/ SN Srivastava 30 Safety officers and Gas safety men must be present round the clock durin g the whole period of blowing out, gunning and blowing in. From 8 am on 10th April11 till 16th April11 Dr. PC Nipaney / PK jain / SN Srivastava 31 Drill angle of Drill machine B to be reduced to facilitate oxy lance ins ertion On 14th April11 Ashish Pandey/Mech Maint. 32 Preparation of cast house for Metal and slag handling a. Both the dry pits have to be totally clean and covered with a 300 500 mm thic k sand layer. b. Cast house B to be drained, the main trough is to be cleaned and bypass to be closed. c. Cast House B should be ready to handle at least 3-4 casts of high Si metal, c ontinuously. d. During Blow down only 4 ladles will be in circulation. On 14th April11 Ashish Pandey 33 One flux bunker to be spared for DRI and to be filled in with same. On 14th April11 Sanjay Gautam

01.02. BLOWING DOWN S. No. Activity Responsibility 01 After the preparatory shut down the connection of water spray lines, ste am lines and Nitrogen line at top and Nitrogen in the stack points to be checked and its readiness to be ensured. Manoj Kumar Rai/ Mech. Maint. 02 During the Blow out the position of different valves must be as follows. a. b. c. d. Equalization valve -closed Relief Valve -closed LSV and LMG -closed USV and UMG -closed Ritesh Mishra 03 Nitrogen to stack pressure lines to be opened by 50% of valve position. Ritesh Mishra 04 After shutdown furnace is to be started as per the normal procedure. Manoj Kumar Rai 05 Blast volume, pressure, temperature and other operating parameters are t o be maintained on normal operation level. Manoj Kumar Rai 06 Steam at the top will remain in open condition. N2 in dust catcher and G CP will be stopped. Ritesh Mishra 07 The purging medium in PCI lances will be changed to Nitrogen and purging with N2 will continue through out the Blow down period. Ritesh Mishra 08 Receiving and transfer hopper will remain empty and main charging convey or will run through out the Blow down period. Manoj Kumar Rai / Sanjay Gautam / Ritesh Srivastava

09 Before stopping the charging BF gas to all customers to be stopped and g as network to be water sealed. All the LPG pilot burners at flare stack to be fi red. BF gas to stoves will remain available. Manoj Kumar Rai & Ritesh Mishra 10 Blast Volume to be maintained at normal level (i.e. 2500-2600 Nm3/min). It may be reduced to prevent uncontrolled rise in top temperature. Manoj Ku mar Rai 11 The top pressure will be decreased to minimum, on instruction of I/c Blo w down. Manoj Kumar Rai 12 During lowering the burden top temperature to be maintained below 300 de g C and if it raises water at top to be opened and it should be closed when temp starts decreasing. Top temp should not decrease below 150 deg C. Manoj Ku mar Rai 13 Burden level to be measured by Mechanical SLI in every 30 minutes. Manoj Kumar Rai 14 Gas samples to be taken in every 30 minutes and analyzed in BF control r oom mainly for H2 and O2. M.S. Raghuwanshi 15 During lowering the burden level when H2 in top gas starts raising and r eaches at the level of 4% the N2 in stack pressure lines to be opened full and N 2 to PCI lances to be increased to maximum. Manoj Kumar Rai 16 The maximum allowable limit for H2 in top gas is 10% and the O2 should n ot cross the limit of 1% in top gas during Blow down. If the concentration of th ese gases increases above the said limit the blast volume to be reduced to contr ol the gas composition. Manoj Kumar Rai 17 Once the H2 in top gas crosses 8% level the gas to stoves to be stopped and the remaining two stoves will be boxed up. All gas will be flared. Manoj Ku mar Rai 18 Initially and during the maximum period of Blow down the CO in top gas w ill increase and CO2 will decrease but at the ending the CO2 will start increasi ng and CO will decrease. At this point of time the Blast volume is to be careful ly regulated around 1500-1600 Nm3/min and top temp to be maintained around 400 deg C. Top wat er spray at this point should be strictly controlled to prevent excessive water going in the hearth and evolution of more H2. Manoj Kumar Rai 19 Castings are to be opened normally and at regular intervals. Only four l adles will be in circulation. Ashish Pandey 20 Initially castings should be opened, normally, in cast house A taking all the metal in ladles and slag in SGP. 55 mm drill bits to be used. Ashish P andey 21 After 2 normal casts in cast house A main trough of cast house B to be fille d with sand and prepared to take all the metal slag in dry pit. Ashish P andey 22 When quality of Metal and Slag starts deteriorating, castings should be opened in cast house B with sand filled runners and all the metal and slag will go to dry pit. Ashish Pandey 23 The cast in Cast House B will be opened at a drill angle of 6 deg using 60 mm drill bit and second cast using 75 mm drill bit. The drill machine to be adj usted accordingly. Ashish Pandey 24 The last cast to be so adjusted that it should be closed simultaneously to the finishing of blow down. Ashish Pandey 25 When increase in O2% (more than 1 %) is observed reduce the blast volume , open furnace bleeders and disconnect the GCP from furnace by closing after dus t catcher goggle valve. Open N2 in dust catcher and GCP. Manoj Kumar Rai & Ritesh Mishra 26 Empty the dust catcher twice during the blow down Manoj Kumar Rai & Ritesh Mishra 27 Record all the process data in an interval of 30 minutes in a separate r egister. Ashish Pandey 28 When desired level (25.5 meter) is achieved reduce the blast pressure to

0.5 kg to facilitate the gas burning on the burden. Ensure that the gas is burn ing on burden, seeing through the peep holes. Manoj Kumar Rai & Ritesh Mishra 29 After ensuring flame on burden, Off Blast the furnace. Manoj Kumar Rai 30 Stop N2 in stack probes & PCI lances and after confirming safe working c ondition start opening charging hatch and draft holes, at furnace top. Manoj Ku mar Rai & Ritesh Mishra 31 Only after opening man holes at top start any job at tuyere platform Manoj Kumar Rai