The document discusses several examples of reverse engineering and modification projects completed by Prowess for various steel plant clients. It provides details on modifications made to ladle furnace roofs, bottom shells, contact pads, wheels, lance designs, and fume extraction systems to address issues like increased production rates, operational ease, and changing charge mixes. The modifications were developed by studying existing designs and measurements and developing updated designs to meet new requirements.

2. JSPL FES REVERSE ENGINEERING AND MODIFICATION
BEFORE :
• Frequent Stoppage of Furnace to Remove Dust.
• Poor Life of Cooled & Uncooled Elements
• Increase of Hot Metal % in charge mix resulted in
high dust load and increase in temperature of
fume.

3. JSPL FES REVERSE ENGINEERING AND MODIFICATION
AFTER :
Prowess Studied the System and Modified the Same to
• Provide Sufficient Space For CO( Carbon Mono Oxide Burning)
• Access of Mobile Shovel to Remove the Dust in Shortest Possible Time.

4. EMIRATES STEEL BOTTOM SHELL R.E. AND MODIFICATION
Tapping weight increased by 20% by increasing Bottom shell diameter in such a way
that with replacement of bottom and top shell only keeping the tilting platform,
roof and all other elements same.

5. TATA STEEL L.D. # 1 LF #3 ROOF R.E. & MODIFICATION
NEW
OLD
BEFORE :
Tata steel was facing problems
• Excess stickers on the Roof
• Operational inconvenience due
to position and size of roof
openings.
• Metal jamming in Ladle bail
area.
AFTER :
Prowess Studied the System and
Modified the Same to
• Latest design conical roof
supplied.
• Changed the location of opening
and size for better operational
ease.
• Introduced a permanent opening
in the roof to accommodate the
bails and sticking free operation.

6. REVERSE ENGINEERING JOBS EXECUTED BY PROWESS
S.No. Client Area Scope of work
1
Tata
Steel
LD # 1 L.F. # 1 roof Prowess reverse engineered the LF roof assemblies on the basis of
available GA and modified, Flux addition, Top Lance and inspection
door openings as per the site requirement
2 LD # 1 L.F. # 2 roof
3 LD # 1 L.F. # 3 roof
Prowess reverse engineered the LF roof assemblies on the basis of
available GA and modified roof shape as per new roof (Conical type) of
LD # 3 Flux addition, Top Lance and inspection door openings as per the
site requirement
4 LD # 2 L.F. # 2 roof
Prowess reverse engineered the LF roof assemblies on the basis of
available GA, Flux addition, Top Lance and inspection door openings as
per the site requirement
5 LD # 1 Vessel # 1 Skirt
Prowess reverse engineered the Skirt Assembly on the basis of available
GA
6 LD # 1 Vessel # 2 Skirt
7 LD # 2 Vessel # 1 Skirt
8 LD # 2 Vessel # 2 Skirt
9 LD # 1 Flux Thimble
Prowess reverse engineered the Flux Thimble on the basis of available
GA
10 Ld # 2 Vessel # 3
Prowess took Site dimensions, done reverse engineering, manufactured
and supplied cooling stack upper part
11 LD # 1
Prowess reverse engineered the Radiation Hood for Vessel on the basis
of available GA
CONTD……

7. REVERSE ENGINEERING JOBS EXECUTED BY PROWESS
S.No. Client Area Scope of work
12
Emirates
Steel
Bottom Shell Emirates Steel wanted to increase the capacity of the furnace, but they
were not having detail drawing, Prowess Studied GA drawing developed
a Modified bottom shell and Split shell to achieve higher production
rate and supplied the same
13 Split Shell
14
Copper contact
Pad
Prowess detailed engineered the contact pas on the basis of Available
Ga and supplied the same
15
Kalyani
Gerdau
Ladle Furnace
Roof
Prowess reverse engineered the Ladle furnace roof assemblies on the
basis of available GA and modifies flux chute and door as per modified
site requirement
16
Salem Steel
Plant
Crane and
Transfer Car
Wheels
Prowess reverse engineered the Wheels assemblies on the basis of
available GA
17
Bhushan
Power &
Steel
KT Lance
Prowess developed new KT Lance indigenously, on the basis of GA
drawing and site measurement of the existing Lance
18
Electrode
Column
Prowess did reverse engineering of the available GA and modified
available electrode column to suit Arm No. # 2 as the same was shorter
than the available one
19 Copper Panel
Prowess reverse engineered the Steel/ copper panel on the basis of
available GA
20
Bhushan
Steel Ltd.
60 T EAF Roof Prowess Reverse engineered the new roof on the basis of available GA
CONTD……

8. REVERSE ENGINEERING JOBS EXECUTED BY PROWESS
S.No Client Area Scope of work
21
Neco jayaswal/
Deify
Delta Ring for 60 T
EAF
Prowess Reverse engineered the new Delta ring on the basis of available GA and
modified the same by converting the same in to sacrificial ring type.
22 Sunflag Steel
Electrode arm for 60
T LRF
Sunflag steel was facing the problem of arm getting red hot, Prowess designed an
improved arm similar to their existing LRF for better life and operation.
23
Jindal Steel
and Power
Development of
Fume Extraction
System
JSPL was facing problem in Fume extraction system, due to change in charge mix,
Prowess studied the system, modified, the design on the basis of available basic
drawings and design data and modified FES as per new practice
24
25
Jindal Stainless
Ltd
FES Ducts
Prowess developed detail engineering on the basis of available GA drawing,
Manufactured and supplied the ducts, Elbow and Panel26 Elbow and Panels

9. THANK YOU !!!