Tata Steel’s wire rod line in Gamharia, located in Jamshedpur, India, has undergone a major modernization that promises to enhance both operational efficiency and product quality. The upgrade, executed in collaboration with Danieli Service, has significantly improved the overall performance of the mill, ensuring the production of high-quality wire rods with greater precision. The key elements of the upgrade were the installation of a new crank shear and a rotary shear, as well as an advanced electrical and automation package, all of which contribute to the mill’s more efficient operations.
The primary issue that Tata Steel sought to address with this upgrade was the suboptimal cutting quality, which had been a persistent problem at the Gamharia plant. Poor cuts, misalignments, and frequent operational issues like tail-cut carry forward, parking position errors, and both internal and external leakages were causing significant production losses. These challenges also led to frequent damage to the equipment, further hampering productivity. The new crank and rotary shears were designed to tackle these issues directly by improving the cutting precision and ensuring that the wire rods were produced to a much higher standard of quality.
The modernization project was an intensive task that required precise planning and execution. The shutdown of the wire rod line for installation was planned to last 20 days, during which time the new equipment would be installed and integrated into the mill’s operations. Despite the challenges of a tight timeline, Danieli Service's mechanical and automation experts worked diligently to ensure that the project was completed ahead of schedule. The team’s expertise in both the mechanical installation and the complex automation systems played a crucial role in achieving this goal.
One of the standout features of the modernization was the integration of the new crank and rotary shears into the existing mill infrastructure. These shears are crucial components of the wire rod line, responsible for cutting the wire rods into precise lengths. The new designs allow for faster, more accurate cutting, reducing the chances of errors and enhancing the overall throughput of the mill. Moreover, the shears are equipped with advanced technology that reduces wear and tear on the equipment, contributing to a longer operational lifespan and fewer maintenance issues.
The improved operational efficiency of the wire rod line also comes from the enhanced electrical and automation package supplied by Danieli Automation. This package helps streamline the control systems of the mill, providing real-time monitoring and precise control over the entire production process. The automation system allows for better coordination between the different components of the wire rod line, ensuring that all stages of production are aligned and functioning smoothly. By reducing manual intervention and increasing automation, Tata Steel is able to achieve higher productivity and reduce the risk of human error.
In addition to addressing the technical challenges, the modernization project also focused on improving the overall availability of the mill. Prior to the upgrade, Tata Steel Gamharia experienced significant downtime due to operational issues with the cutting systems. With the new shears and automation systems in place, these downtime events have been drastically reduced, leading to a more reliable production process. The timely startup of the new equipment and the successful integration into the mill’s workflow were key factors in achieving higher mill availability.
Tata Steel Long Products, which oversees the Gamharia facility, has expressed its appreciation for the work carried out by Danieli Service. The seamless execution of the upgrade project, including optimized procedures that allowed for the new equipment to be brought online quickly, has been highly praised. The improvements in cutting quality, operational efficiency, and product consistency have positioned the Gamharia wire rod line for continued success in the highly competitive steel industry. With these enhancements, Tata Steel is not only increasing its production capacity but also ensuring that it can meet the growing demand for high-quality wire rods used in various industries, including construction, automotive, and manufacturing.
This modernization is a part of Tata Steel's broader strategy to continuously innovate and improve its manufacturing processes. By leveraging cutting-edge technology and collaborating with experienced partners like Danieli, Tata Steel is ensuring that its plants remain competitive and capable of producing high-quality products while also increasing operational efficiency and reducing environmental impact. The successful completion of this project at the Gamharia plant is a testament to Tata Steel’s commitment to excellence and sustainability in steel production.
