E&i Delay Analysis Report - Feb'15

PRESENTATION ON
MILL ELECTRICAL
PERFORMANCE
Monthly Report
PAGE: 1
FROM 1st FEB15 TO 28th FEB15
PAGE: 2
Data Summary : BRM

Electrical
Till date summary data
From : 1/02/15 to 28/02/15
Total Delay
2673 minutes
Acceptable Delay
1034 minutes
Total frequency of delay in Electrical
96 numbers
Mean time to Restore (MTTR)
11 minutes
PAGE 3
Copyright 2010 Jindal Steel & Power Ltd.
PLANNED VS ACTUAL
PRODUCTION
ACTUAL DELAY
(min)
DATE
01.02.2015
68
02.02.2015
22
03.02.2015
04.02.2015
27
05.02.2015
35
06.02.2015
12
07.02.2015
16
08.02.2015
09.02.2015
26
10.02.2015
126
11.02.2015
17
12.02.2015
13
13.02.2015
68
14.02.2015
PLAN QTY. (MT)
EQUIVELANT LOSS OF
EQUIVELANT LOSS OF PRODUCTION CUMULATIVE ACC. TO
PRODUCTION ACC. To PLAN
PLAN (MT)
(MT)
1792.85
84.66
84.66
1792.85
27.39
112.05
1792.85
6.23
118.28
1792.85
33.62
151.89
1792.85
43.58
195.47
1792.85
14.94
210.41
1792.85
19.92
230.33
1792.85
3.74
234.06
1792.85
32.37
266.44
1792.85
156.87
423.31
1792.85
21.17
444.48
1792.85
16.19
460.66
1792.85
84.66
545.32
1792.85
0.00
545.32
PAGE: 4
PLANNED VS ACTUAL
PRODUCTION
DATE
ACTUAL DELAY (min)
15.02.2015
20
16.02.2015
55
17.02.2015
37
18.02.2015
17
19.02.2015
20
20.02.2015
21
21.02.2015
15
22.02.2015
54
23.02.2015
149
24.02.2015
25.02.2015
101
26.02.2015
27.02.2015
47
28.02.2015
57
PLAN QTY. (MT)
EQUIVELANT LOSS OF PRODUCTION

EQUIVELANT LOSS OF
PRODUCTION ACC. To PLAN (MT)
CUMULATIVE ACC. TO PLAN (MT)
1792.85
24.90
570.22
1792.85
68.48
638.70
1792.85
46.07
684.77
1792.85
21.17
705.93
1792.85
24.90
730.83
1792.85
26.15
756.98
1792.85
18.68
775.65
1792.85
67.23
842.89
1792.85
185.51
1028.40
1792.85
3.74
1032.13
1792.85
125.75
1157.88
1792.85
7.47
1165.35
1792.85
58.52
1223.87
1792.85
70.97
1294.83
PAGE: 4
Electrical Total Acceptable Delay Overview Area wise
Area
Delay(in hr)
Frequency
Furnace
2.33
26
Mill
7.78
31
Cooling Bed
4.73
22
Media
0.26
Stacker
2.21
16
PAGE: 7
DELAY SUMMARY
PAGE: 7
DELAY SUMMARY
PAGE: 7
PAGE: 7
Total Electrical Acceptable Delay

Details
DELA
DELAY TIME Y (IN
MIN)
AREA
01.02.2015
12:44 13:00
16
MILL
01.02.2015
17:58 18:01
01.02.2015
18:31 18:51
20
MILL
Delay due to auto chopped generated in line-A ,

RES-1A trip due to encoder fault.
RES-1A tripped on F07453 fault. Encoder cover

was found loose. Tightness done and made ok.
01.02.2015
22:26 22:31
MILL
Optimization reset due to variation of length in

line-A.
01.02.2015
0:41
1:04
24
02.02.2015
13:52 14:00
DATE
02.02.2015
15:14 15:28
14
03.02.2015
19:41 19:51
10
REASON
Delay due to Std#14 trip.
REMARKS
In drive panel for stand-14, MCB for blower(drive

side) was off, due to this stand-14 motor got
tripped on over temp. fault. (F30004)
FURNACE Delay due to kick-off-1 finger not moving forward.
Delay due to relay got latched of kick-off-1 for up

FURNACE position and due to this the kick-off-1 not
operating properly.
Relay for Kick off-1 got latched. Relay changed

from RIO & made ok.
Delay due to RES-1B rotation was not proper ,

brake pressure adjusted.
Delay due to both CBCT-2 & CBCT-3 comes

COOLING forward at a time and due to this tray transfer
BED
system taken blank cycle in auto mode & layer
stuck at chain transfer.
MILL
MILL
Delay due to RES line-B rotation fault as the metal
entering RES while RES in rotating.

Details
DATE
DELA
DELAY TIME Y (IN
MIN)
AREA
REASON
REMARKS
The block which store the time to reach stand-01

from HMD-01 was malfunctioning, due to this billet
came in small gap. Block resetting done and made
ok.
04.02.2015
11:16 11:27
11
MILL
Half billet chopped due to tracking fault, as

looper-1,3 & both line repeater persuder arm
in down position.
04.02.2015
16:40 17:00
10
MILL
Delay due to cobble in line-A due to material

break. Water pressure adjustment done,exact
reason not found.
04.02.2015
4:24
4:27
04.02.2015
5:37
5:40
05.02.2015
15:15 15:25
10
05.02.2015
19:45 19:50
MILL
Delay due to adjusting sensitivity of HMD-15B.
05.02.2015
20:45 21:05
20
MILL
Delay due to RES-2A tripped due to encoder

fault and its causes cobble in mill.
RES tripped on F7453 (LR preprocessing error).

Encoder tightness done and made ok.
MILL
Delay due to billet stuck at discalar due to

billet positioning was not proper in furnace at
discharging roller.
06.02.2015
6:53
6:57
06.02.2015
12:38 12:46
06.02.2015
13:29 13:31
11
COOLING
CBCT-3 trip.
BED
MILL
Charging of billet not possible as billet length

not sensing.
COOLING Cooling bed full due to improper laying of bars
BED
and the cut length.
COOLING
Delay due to CBCT-1 tripped.
BED
MILL
Delay due to billet slow during charging.

Details
DATE
07.02.2015
DELA
DELAY TIME Y (IN
MIN)
6:56
AREA
REASON
6:58
07.02.2015 13:36 13:38
07.02.2015 17:29 17:34
07.02.2015 18:03 18:10
Stacker
Auto cycle is not coming for LTF of both the Stacker ,MCB
tripped of both stackers.
MCB for DI-XA04 of RIO-11 got

tripped, resetting done and made ok.
08.02.2015 23:37 23:40
Stacker
Delay due to weighing machine tripped of stacker-2.
09.02.2015
9:22
10
Media
Delay due to high tank temperatuure fault occurred for lubeC1.
09.02.2015 10:30 10:35
MILL
Delay due to slight undershoot in line-C.
MILL
Delay due to undershoot as there was no gap in RIT HMD in

one piece (Reason not found).
N/A as head of 4th bar found bent,

due to to this bar hitted and got
undershoot. Everything was checked
and found ok from electrical side.
9:12
09.02.2015 23:55
0:15
09.02.2015
0:49
12
0:44
FURNACE Delay due to charging due to billet slow during charging.
REMARKS
Stacker
MCB tripped of LTD of both the stacker.
COOLING Layer got stuck at tray transfer while transfer time from chain
BED
to tray.
COOLING
Delay due to CBCT-1 trip so layer got stuck in chain.
BED
CBCT-1 got tripped on fault F07490.

Resetting done & made ok.

Details
DATE
10.02.2015
DELAY TIME
0:54
DELAY (IN
MIN)
AREA
REASON
Due to malfunctioning of block, AUR of

Cobble in line-C due to divide shear not taken divide shear got missing & speed
cut as its reference speed stop.
reference got down & divide shear did
not taken cut & went to overshoot.
3:00
126
MILL
11.02.2015 Cumulative Delay
14
FURNACE
Delay due to furnace walking beam up cycle

was slow operated.
11.02.2015
19:25
19:28
FURNACE
Walking beam cycle was slow due to this billet
discharge was done manually.
12.02.2015
15:05
15:08
Stacker
Delay due to short bar cleaning from stacker

area , As laying positions (To & Fro) ,
optimization adjusted.
12.02.2015
16:40
16:42
Stacker
Delay due to short bar cleaning from stacker

area , As laying was not proper from PR-8B ,
parting closed to 0.2m.
12.02.2015
20:22
20:24
Stacker
Delay due to stacker-2 , 12m PED

continuously sensing.
12.02.2015
23:34
23:38
COOLING Delay due to PED-2 continuous sense at

BED
gauge beam.
13.02.2015 Cumulative Delay
41
Stacker
Stacker-1 was not in operation due to cable of

LTD of stacker-1 got damaged and cable
replaced by electrical & slow operation of CP4 due to stacker-1 is not working.
13.02.2015
MEDIA
Mill stop due to Air-oil-1 pressure switch fault
occurred for Std#9.
13
9:38
9:50
REMARKS
LTD-1 was tripping continously on

fault F31117. encoder cable was
found loose & opened. Tightness done
and made ok.

Details
DATE
DELA
DELAY TIME Y (IN
MIN)
AREA
REASON
13.02.2015 12:53 13:08
Stacker
Delay due to LTD not working in auto mode of stacker-2.
13.02.2015 14:36 14:51
11
Stacker
Delay due to stacker-2 weight machine misaligned.
13.02.2015
2:08
2:12
MILL
Delay in discharging due to billet tracking fault in furnace.
15.02.2015
8:02
8:07
COOLING
BED
15.02.2015 14:00 14:07
COOLING
BED
15.02.2015 14:09 14:14
COOLING
BED
15.02.2015 00:49 00:52
MILL
16.02.2015
8:12
8:22
10
16.02.2015
Cumulative
Delay
10
16.02.2015
14
0:52
1:27
35
REMARKS
Forcefully disabled the network

connection than enabled & made
ok.
Delay due to CP-3 camera was not working.
ok.
Delay due to cooling bed camera was not working & CBCT-2
tripped.
ok.
Slow operation of CP-3 due to camera of CP-3 was not
working.
Dealy due to short length billet charging slow.
FURNACE Furnace charging door id not working in auto mode.
MILL
Walking beam not taking cycle properly.
MILL
RES-1B drive fault occur in running mill condition due to

encoder wire found loose,during this delay Std #15 pass
changed done.
RES-1B got tripped on faultF07453. during check +VE supply

core of encoder found broken.
Reconnection done and made ok.

Details
DATE
DELA
DELAY TIME Y (IN
MIN)
AREA
REASON
REMARKS
COOLING
BED
Tray Transfer taken blank cycle.
17.02.2015 13:27 13:48
21
COOLING
BED
HMD-14A sensed late, head of

Overshoot in line-A as HMD-14A sensed late and autochop metal (did not sensed). Due to this
generated so, small piece gets overshoot.
false autochop generated & billet
got cobble.
17.02.2015 18:21 18:23
Stacker
17.02.2015
4:01
4:13
12
18.02.2015
8:05
8:08
17.02.2015
7:51
7:53
Stacker-1,PED continous sensing.
MILL
Delay due to line-B entry switch pipe not ready,so

synchronized by electrical.
Synchronization done & made ok.
Stacker
Delay due to stacker-1 LTD start cycle not coming.
18.02.2015 13:05 13:10
Stacker
Delay due to stacker-1 both up-down proxy not functioning.
Cumulative
Delay
MILL
18.02.2015 18:33 18:35
FURNACE
18.02.2015 20:17 20:19
FURNACE Delay due to kick-off pick up billet not properly.
18.02.2015
15
Delay in charging due to discharging stopper not working

properly.
In furnace 2 cycle gap due to discharging stopper not

working properly.

Details
DATE
DELA
DELAY TIME Y (IN
MIN)
AREA
REASON
19.02.2015 15:47 15:51
19.02.2015
1:42
1:47
19.02.2015
1:58
2:13
15
COOLING
Delay due to chain transfer was tripped at finishing area.
BED
20.02.2015
7:37
7:45
COOLING Delay due to long length billet comes at charging area as its
BED
length was not sensed.
20.02.2015
Cumulative
Delay
MILL
20.02.2015 21:40 21:46
Stacker
21.02.2015 18:37 18:39
FURNACE
21.02.2015 19:45 19:47
FURNACE Delay in furnace due to billet tracking fault.
21.02.2015 19:56 19:58
FURNACE Delay due to kick-off pick up two billet.
Cumulative
Delay
FURNACE Walking beam strake was not proper.
21.02.2015
16
FURNACE In furnace 3 cycle gap due to RT-1 tripped.
MILL
Delay due to optimization length was not proper.
CBTT-2 tripped on F7900.

resetting done and made ok.
Delay due to billet stuck in roller table-1 and billet skid

continue taken cycle.
Delay due to layer mixes in stacker due to tracking fault.
Delay in charging due to discard arm pick up two billet due

to PED-1 not sense.
REMARKS

Details
DATE
DELA
DELAY TIME Y (IN
MIN)
AREA
REASON
Delay in charging due to 2 billet comes in RT-1 and stuck in
its guide plate.
Cumulative
Delay
FURNACE
22.02.2015 16:17 16:26
FURNACE Delay in charging due to charging was manual.
Cumulative
Delay
10
FURNACE Delay in charging due to charging was not in auto mode.
22.02.2015 18:09 18:13
MILL
Delay due to billet skid tripped.
22.02.2015 18:52 18:54
MILL
Delay due to billet skid synchronization was failed.
22.02.2015 20:15 20:17
22.02.2015
22.02.2015
22.02.2015 21:42 22:03
23.02.2015 13:49 14:20
17
FURNACE In furnace 2 blank cycle due to charging was manual.
21
MILL
Delay due to Std#14 & Std#16 gear box lub fault as cable
was damaged.
31
COOLING
BED
Delay due to overshoot in line-A as HMD-12A continuously

sensed.
REMARKS
Press switch signal for lube of Std14,16 was healthy. Cable founded
shorted in JB. Signal forced and
made ok.
Material got overshoot as freeze &
switch brake command went late.
HMD-12A sensed longer time than
usual.

Details
DATE
DELA
DELAY TIME Y (IN
MIN)
AREA
27
COOLING
BED
23.02.2015 19:26 20:51
85
COOLING
BED
23.02.2015
4:37
Stacker
24.02.2015 13:31 13:34
25.02.2015
9:17
25.02.2015 15:57 17:02
65
MILL
25.02.2015
25.02.2015
1:43
2:22
18
14
26.02.2015 23:00 23:06
Stacker
Stacker
COOLING
BED
23.02.2015 16:46 17:13
18
4:29
8:51
1:08
2:08
REASON
Delay due to CBCT-2 not going home position due to its

proxy straightner break.
REMARKS
During check, striker for home

position proxy found broken.
Welding of striker was done and
made ok.
RES-1A tripped on fault F7453

Overshoot in line-1A due to drive fault so encoder changed , (Encoder LR positioning fault).
In between Std#16 & NTM RE guide changed.
Encoder of RES-1A changed with
encoder of RES 2B & made ok.
6 mtr PED was not sension
Delay due to stacker-2 6m PED was continuous sensing.
properly. Signal forced and made
ok.
COOLING
Delay due to CBCT-2 not going in home position.
BED
FURNACE Delay due to walking beam taking extra cycle.
Stacker-1 LTD trip.

Stacker-1 LTD trip.
Changed the offset from 15

to 45. In previous rolling
section encoder of RES 2B
was used in RES2A. During
start of this rolling section
new encoder was mounted &
offset got changed .
Magnetic chain not gone to its home position.
Delay due to undershoot in line-B due to material

hitted in RES as it's off-set was not ok.
Total Electrical Not Acceptable Delay Details

DATE
DELAY
DELAY TIME (IN MIN)
01.02.201
14:27
5
14:32
AREA
REASON
REMARKS
COOLING Delay due to RES-2B pressure adjusted as its N/A as rotation was not ok due to
BED
rotation was not ok.
abnormal break pressure.
N/A as 11th pcs pf line-A hitted inside RES
Undershoot in line-A RES-2A as 2 pieces went & got stucked. Following pcs hitted & got
in same line.
undershoot. Everything was checked and
found ok from electrical side.
Cobble in line-B due to the RES-1B rotation
Rotation was not proper, due to uneven
was not proper meanwhile pass changed of
brake pressure, die to this head hitted at
Std#16 and all braking pinch rolls closed.
entry of RES.
Delay due to RES-1B & 2B rotation was not
N/A as rotation was not ok due to
proper , RES-1B & 2B synchronized and brake
abnormal break pressure.
pressure adjusted by electrical & mechanical.
01.02.201
16:55
5
17:17
22
MILL
01.02.201
22:51
5
23:26
35
MILL
01.02.201
5
2:44
2:52
MILL
02.02.201
5
6:52
7:30
38
MILL
Delay due to undershoot in line-A , last piece 'N/A as Everything was checked and
material stops after travelling 60m from RES. found ok from electrical side.
02.02.201
5
3:28
4:26
58
MILL
Delay due to metal hit at RES-2B duering this

'N/A as Everything was checked and
delay RES offset adjusted and also pass
change of Std#11 done.
03.02.201
5
7:12
7:30
18
MILL
Rolling stop due to RES-2B rotation was not

proper brake pressure adjusted.
N/A as problem initiated because of brake

pressure.
03.02.201
12:50
5
14:00
70
MILL
Cobble in line-A divide shear due to metal

carry forward ,divide shear arm got shifted of
upper blade meawhile Std #13 changed.

03.02.201
14:00
5
14:26
26
MILL
Delay continued from previous shift.

19

DATE
DELAY
DELAY TIME (IN MIN)
AREA
04.02.201
13:22
5
14:00
38
MILL
04.02.201
14:00
5
14:27
27
MILL
04.02.201
19:24
5
21:45
47
04.02.201
5
6:00
05.02.201
5
5:47
MILL
11:07
63
MILL
05.02.201
17:36
5
18:27
25
MILL
06.02.201
14:24
5
15:00
36
MILL
06.02.201
5
3:42
15
MILL
20
Cobble due to carry forward in line-A as two

pieces found at the entry of RES-1A.
Delay continued from previous shift due to
chopping shear cut piece carried forward in
line-A.
Delay due to undershoot in line-A(RES-2A)
due to material hitted in RES somewhere &
head got bend and material stop after
travelling 80m, during this cobble divide shear
arm got shifted in between PR-5A changed ,
and exact reason of cobble not found, in
between std #15 and Std #16 pass changed
done.(Pinch roll-9A bottom roll axial play is
more)
COOLING Overshoot in line-A as PR-9A did not drop in

BED
one piece.
8:18
3:27
REASON
REMARKS
N/A as material head hitted somewhere

inside RES. Rotation of RES trigger
command & HMD for respective HMD was
ok.
N/A as due to slippage. There was no

droppage in PR-9A. Due to this material
went to overshoot.
Delay due to undershoot in line-A (RES-2A)

due to last piece did drop from RES as its
head was got bend.
N/A as due to uneven speed of

intermediate & breaking pinch roll material
got stucked at entry of RES. After entering
60 mtr inside RES.Everything was
checked and found ok from electrical side.
Undershoot in line-A due to metal hit

somewhere in RES and also RES-2A offset
changed.
Overshoot in line-B due to movement of entry
switch pipe of line-B was late and due to this
the length of bar is too long and its caused
overshoot.
Cobble in looper-1 due to uneven loop in
looper-1
N/A as RES triggering command & timing

was ok. After changinf offset of RES
problem got resolved.
N/A as feedback was coming late due to
slow movement of entry switch pipe. Slow
movement was happened due to
machanical jam.
N/A as pusher out command timing,
calibration was ok.

DATE
07.02.2015
08.02.2015
09.02.2015
09.02.2015
10.02.2015
10.02.2015
21
DELAY TIME
17:02
0:26
11:44
21:00
21:11
22:24
17:18
1:12
12:46
21:44
21:28
23:36
DELAY
(IN
MIN)
AREA
REASON
REMARKS
MILL
N/A as a small chip of billet got

stucked infront of HMD-12A , Due to
HMD-12 A sensed continously so, auto chop
this HMD-12A sensed for longer
generated and a small piece got overshoot and a billet time. Due to this autochop was
chopped in mill.
generated and a small pc went to
overshoot. Passline cleaning done
and made ok.
MILL
Delay due to undershoot in RES-2A(line-A) due to bar

laying was not proper so tail piece stuck in RES (Exact
reason not found) , during this Std#15 pass change
and RE guide change of Std#15 , power slitter and
NTM A & B Std#20 & Std#22.
MILL
N/A as 'Material did not separated

properly, so head of bar hitted to tail
Undershoot in line-C due to metal hit in back end of the
of next bar & got undershoot. RIT
previous piece (Reason not Known).
HMD & brake slide checked & found
ok.
22
MILL
N/A as 'Material did not separated

properly, so head of bar hitted to tail
of next bar & got undershoot. RIT
HMD & brake slide checked & found
ok.
17
COOLING
BED
16
15
20
16
MILL
Delay due to undershoot as there was no gap in RIT

HMD-2 so the material not seperated.
N/A as tail of 5th pcs did not drop

from RES-2A, so next pcs hitted and
got undershoot. Everything was
checked and found ok from electrical
side.
N/A as Brake slide position

Overshoot due to laying was not proper it was approx command was 1.2 sec later than
25m with all parameter as previous.
normal position, so bar went to
overshoot.
Undershoot in 6th piece due to RIT HMD continue
sense.
N/A as as per RIT HMD, there was

no gap b/w 2 pcs, but brake slide
command was ok. The reason for
undershoot might be less gap b/w 2
pcs.
N/A as as per RIT HMD, there was

DATE
11.02.2015
DELAY TIME
7:27
11.02.2015 16:24
11.02.2015
11.02.2015
2:03
7:50
18:56
2:38
DELAY
(IN
MIN)
AREA
23
MILL
152
35
5:21
5:44
23
12.02.2015 15:16
15:36
20
12.02.2015 15:37
16:01
24
13.02.2015 23:14
0:11
16
14.02.2015 15:41
15:55
14
22
MILL
MILL
REASON
Cobble in looper-3 due to uneven loop
formation in looper-1 for which tension was
given in each billet.
Delay due to undershoot in line-C as there
was no seperation on the last two piece
during this Std#10 , Std#14 & Std#16 pass
change done.
Undershoot in line-C due to bar was not
separate in 5th & 6th piece.
REMARKS
N/A as looper calibration was checked and
found ok.
N/A as 2nd last pcs of billet hitted
somewhere in rake so coming pcs hitted and
got undershoot. Everything was checked
and found ok from electrical side.
N/A as 5th pcs of billet hitted somewhere in
rake so coming pcs hitted and got
undershoot. Everything was checked and
Overshoot in line-c due to divide shear cut

COOLING was not proper as in cooling bed found about N/A as Everything was checked and found
BED
5 mtr piece and both side divide shear cut
ok from electrical side.
marks.
MILL
Cobble in looper-1 due to uneven looping.
found ok.
Delay due to cobble in line-B NTM as looper
MILL
height was not proper in repeater , As looperfound ok.
2 was taken in line.
Cobble in line-B due to material break
N/A as material accumulated in NTM due to
MILL
between NTM and PR-4B (Exact reason was uneven pressure in water box-3, resulted
not found).
material got broken from PR4B & got cobble.
N/A as due to increase of 400 LPM water,
COOLING Overshoot in line-B as HMD-16 flicker so its temp got down by 120 & due to this there
BED
sensitivity.
was flickering in HMD-16B. Sensitivity
increased by 0.5.

DATE
DELAY TIME
DELAY
(IN
MIN)
15.02.2015 14:23
15:16
17
15.02.2015
1:43
21
15.02.2015
15.02.2015
16.02.2015
1:22
Cumulative
Delay
Cumulative
Delay
9:36
16.02.2015 18:35
16.02.2015 19:04
16.02.2015 19:30
19:02
19:29
20:12
13
16
27
25
42
REASON
21:05
30
REMARKS
N/A as first pcs of bar did not drop from

RES. Everything was checked and found ok
MILL
from electrical side. The head of all pcs was
bent.
COOLING Cobble due to carry forward in line-A short
N/A as Everything was checked and found
BED
pice of metal forward at PR-9A.
Billet to billet discharging gap was not proper N/A as the length of billet was not constant.
MILL
is was(20m to 25m)
Due to this gap was not proper.
N/A as the length of billet was not constant.
MILL
Billet to billet gap was not proper.
Due to this gap was not proper.
Billet request sent to furnace earlier then
MILL
specified time and due to this billet got bend N/A as billet call time was correct.
in furnace.
Delay due to undershoot in line-B(RES-2B)
due to metal did not drop from RES-2A in
frontend (Exact reason not found)
MILL
n/A as the dia of NTm of was different in

PLC than actual. In PLC previous dia did not
Cobble in line-A NTM and undershoot in linechanged while ring changed so there was
A.
difference in schedule speed & actual speed
of material.
MILL

Cobble in line-A,NTM due to speed was not
changed while ring changed so there was
ok in line-A.
of material.
MILL
Cobble in line-A NTM.
Cobble in line-A NTM and divide shear due

to carry forward.
Line-B entry switch cut line feedback come
18
2010 Jindal
2:56 Copyright
3:14
MILL Steel & Power Ltd.
late, due to it auto chop occur.
16.02.2015 20:35
23
16.02.2015
9:52
13
AREA
MILL

changed while ring changed so there was
of material.

DATE
DELAY TIME
DELAY
(IN
MIN)
AREA
17.02.2015 11:22
11:50
14
MILL
17.02.2015 12:12
12:52
40
MILL
17.02.2015 17:33
17:46
13
MILL
17.02.2015 21:07
21:22
15
MILL
17.02.2015 21:24
21:44
20
MILL
17.02.2015
1:11
1:57
15
MILL
18.02.2015
8:40
8:49
MILL
18.02.2015 23:25
24
23:53
29
REASON
REMARKS
Undershoot in line-B as last piece was 100m

as chopping shear goes late cut line also
optimization has been reset to MANUAL.
N/A as last pcs did not dropped from RES
Last piece undershoot in line-B as it did not
guide & coming bar for that slot of RES-1B
drop from RES-1B,PR-8B lying was not
hitted & got undershoot. Everything was
properly.
checked & found ok from electrical side.
N/A as billet length was varying, so one billet
Billet comes at very close gap so,metal stuck
call went from std-01 & next from HMD-02.
at looper-3.
Due to this billet came in close gap.
Delay due to last piece of bar could n't able to N/A as Everything was checked and found
drop from RES-1B its length was 90m.
Delay due to last piece of bar could n't able to N/A as Everything was checked and found
drop from RES-1B its length was 90m.
Delay due to undershoot in line-B(RESN/A as tail got stuck in entry of RES. So
1B)due to piece did not drop at back end
coming bar hitted & got
from RES(exact reason not found)(PR
undershoot.Everything was checked and
droppage & laying was ok).
N/A as roller table stopped because of
Delay due to roller table after descalar
prevent billet generated from mill due to auto
stopped after billet discharging.
interrupt roller table stopped.
N/A due to malfunctioning of block,

Metal carry forward in line-B due to
optimization changed from auto to manual &
COOLING
optimization mode was changed from auto to entry switch pipe was going into chopping.
BED
manual.
Regarding carry forward eveything was ok
from electrical side.

DATE
18.02.2015
DELAY TIME
3:24
19.02.2015 14:08
20.02.2015 11:07
25.02.2015
26.02.2015
26.02.2015
25
14:19
11:44
33
11
37
AREA
MILL
MILL
MILL
REASON
REMARKS
N/A as tail of bar stucked into entry of Res.

Undershoot in line-B due to metal last piece There was possibility that it hitted at 78 mtr
was not transfer properly from RES.
inside RES. Everything was checked and
Delay in charging due to RT-1 roller was
tripped.
Cobble in line-B divide shear and NTM due
to small piece of chopping shear carries
forward , maximum cooling bed cut length
was 82 m but physically last piece was 76 m
and still it cuts the tail chopped.
Delay due to material break in line-B
when started 3rd waterbox taken on
line.
N/A as only one motor got tripped. Billet was

not straight so load was on only two roller
(during charging) instead of four roller. Due
to this motor got tripped. Resetting done &
made ok.
N/A as there was problem that it should not
chop but entry switch pipe chopped the
material. It should chop rest length
completely, which did not happened.
N/A 'Due to uneven pressure of WB-3B

material got fluctuatted & got
accumulated in NTM-B.
Delay due to one piece was in
17:58
18:18
11
MILL
material got fluctuatted & got
overshoot as it's laying was not proper.
Delay due to cobble in line-B due to
19:53
20:36
20
MILL
material break in line-B 3rd waterbox material got fluctuatted & got
when started.
N/A as loop height suddenly
Cobble in line-B due to material break decreased to 0mm & then after
14:47
15:00
13
MILL
from NTM in between Std #7 pass
sudden increased to 900mm,.
changed.
Everything checked from electrical
side & found ok.
N/A as material breaks b/w DS-4A &
Undershoot in line-A & B metal
exit switch pipe-A material undershoot
15:16
16:12
56
MILL
accumulated
in
RES.
in RES-1A. Everything checked &
25.02.2015 17:12
25.02.2015
4:30
DELAY
(IN
MIN)
17:39
13
MILL
SPARE CONSUMED DURING THE MONTH

SL.NO
Part No. / Model

No.
Make
Qty
DATE
Item
AREA
01.02.2015
MCB,32A,4P
Module shop
05.02.2015
Socket,15A
Roll shop
05.02.2015
Wooden board,6X4
Roll shop
04.02.2015
70W bulb
04.02.2015
Choke,70W
04.02.2015
Al lug,95 sqmm
welding m/c
06.02.2015
Plug,15A
Roll shop
07.02.2015
PVC board,8X10
CP-2
07.02.2015
16A socket
CP-2
07.02.2015
switch
cp-2
08.02.2015
Positioner,
DVC,6020
Line-A 2nd WB
10
Furnace
Furnace
1
2
3
4
5
6
7
8
9
10
11
12
13
26
09.02.2015
09.02.2015
Glass relay,24VDC
PVC
board,8X10X12

SL.NO
14
15
16
17
18
19
20
21
22
23
Qty
09.02.2015
Socket,20A,10A
1+1
Furnace
10.02.2015
Carbon brush
cp-2
10.02.2015
Starter
11.02.2015
Single core wire
40 mtr
Entry sw pipe
11.02.2015
Tube , 18W
ECR-2
11.02.2015
Pantry
Furnace
11.02.2015
Lamp,70W
Nut bolt,M8X100
mm
Industrial plug top,
30A, 3 pin
Furnace
13.02.2015
O2 analyser
1 set
Furnace
13.02.2015
nut bolt, M8X60mm
Furnace
MLDB-1
MLDB-1
MLDB-1
MLDB-1
11.02.2015
13.02.2015
25
13.02.2015
27
Make
Item
24
26
Part No. / Model

No.
DATE
13.02.2015
13.02.2015
Lug ring, CU, 10

sqmm
Lug, ring,Cu,16
sqmm
Lug, ring,Cu,25
sqmm
Lug, ring,Cu,35
sqmm
AREA

SL.NO
30
31
32
33
34
35
36
37
38
39
Make
Qty
Item
14.02.2015
Lug, ring,Cu,0.5
sqmm
O2 analyser
17.02.2015
Battery, 12V
Roll shop UPS
17.02.2015
Battery, 6V
Emergency light
17.02.2015
MCB,10A
ECR-3
18.02.2015
Pulse amplifier
ECR-1
18.02.2015
MCB,32A,4P
ECR-1
18.02.2015
Industrial
socket,30A
Lube-A
18.02.2015
Industrial
socket,20A
Lube-A
18.02.2015
Screw
10
Lube-A
19.02.2015
PVC fan
Cooling bed
20.02.2015
Metal socket, 20A
Cooling bed
20.02.2015
4CX1.5 sqmm
cable
15 mtr
Module shop
28
29
Part No. / Model

No.
DATE
AREA

SL.NO
Part No. / Model

No.
Make
Qty
DATE
Item
AREA
20.02.2015
Screw
Module shop
20.02.2015
Hose pipe
1 roll
stand-15
21.02.2015
Industrial socket
20A
Furnace
21.02.2015
Indication
LED(RED) -220V
HYD-AA1
22.02.2015
H.F.O flow meter
Furnace
23.02.2015
6292Z bearing
ECR-1
24.02.2015
Encoder, 1024
RES
Furnace
Furnace
Central electrical
40
41
42
43
44
45
46
47
48
49
25.02.2015
Nut bolt,
M10X100mm
Welding
rod,3.15mm
26.02.2015
MCCb, 250A
25.02.2015
THANK
YOU

E&i Delay Analysis Report - Feb'15

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E&i Delay Analysis Report - Feb'15

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PRESENTATION ON

FROM 1st FEB15 TO 28th FEB15

Data Summary : BRM

From : 1/02/15 to 28/02/15

Total frequency of delay in Electrical

Mean time to Restore (MTTR)

Copyright 2010 Jindal Steel & Power Ltd.

PLAN QTY. (MT)

ACTUAL DELAY (min)

PLAN QTY. (MT)

EQUIVELANT LOSS OF PRODUCTION

Electrical Total Acceptable Delay Overview Area wise

Copyright 2010 Jindal Steel & Power Ltd.

Copyright 2010 Jindal Steel & Power Ltd.

Copyright 2010 Jindal Steel & Power Ltd.

Copyright 2010 Jindal Steel & Power Ltd.

Total Electrical Acceptable Delay

Delay due to auto chopped generated in line-A ,

RES-1A tripped on F07453 fault. Encoder cover

Optimization reset due to variation of length in

Delay due to Std#14 trip.

In drive panel for stand-14, MCB for blower(drive

FURNACE Delay due to kick-off-1 finger not moving forward.

Delay due to relay got latched of kick-off-1 for up

Relay for Kick off-1 got latched. Relay changed

Delay due to RES-1B rotation was not proper ,

Delay due to both CBCT-2 & CBCT-3 comes

Delay due to RES line-B rotation fault as the metal

entering RES while RES in rotating.

Copyright 2010 Jindal Steel & Power Ltd.

Total Electrical Acceptable Delay

The block which store the time to reach stand-01

Half billet chopped due to tracking fault, as

Delay due to cobble in line-A due to material

Delay due to adjusting sensitivity of HMD-15B.

Delay due to RES-2A tripped due to encoder

RES tripped on F7453 (LR preprocessing error).

Delay due to billet stuck at discalar due to

Charging of billet not possible as billet length

COOLING Cooling bed full due to improper laying of bars

Delay due to billet slow during charging.

Copyright 2010 Jindal Steel & Power Ltd.

Total Electrical Acceptable Delay

07.02.2015 13:36 13:38

07.02.2015 17:29 17:34

07.02.2015 18:03 18:10

MCB for DI-XA04 of RIO-11 got

08.02.2015 23:37 23:40

Delay due to weighing machine tripped of stacker-2.

Delay due to high tank temperatuure fault occurred for lubeC1.

09.02.2015 10:30 10:35

Delay due to slight undershoot in line-C.

Delay due to undershoot as there was no gap in RIT HMD in

N/A as head of 4th bar found bent,

FURNACE Delay due to charging due to billet slow during charging.

MCB tripped of LTD of both the stacker.

Copyright 2010 Jindal Steel & Power Ltd.

CBCT-1 got tripped on fault F07490.

Total Electrical Acceptable Delay

Due to malfunctioning of block, AUR of

11.02.2015 Cumulative Delay

Delay due to furnace walking beam up cycle

Walking beam cycle was slow due to this billet