#ARCTIC. #SIBERIA. THIS IS TAIMYR. The Nadezhda metallurgical plant has begun repairing the second production line – this is the most extensive work this year. The modernization includes the replacement of the flash smelting furnace (FSF) and repairs of peripheral equipment. All this will increase production reliability and increase plant capacity.
“11 large blocks are planned. This is the replacement of the FSF-2 furnace, capitalized repair of depletion electric furnace No. 3, replacement of the steam removal shaft, repair of the slag granulation pool plus peripheral equipment. That is the modernization or reconstruction of the second production line”, said Vitaly Dovgal, general director of Norilsknickelremont (NNR) repair enterprise.
Currently, old equipment is being dismantled at the facility. The work is proceeding according to a strict schedule. For example, 14 days are allotted for the FSF-2 disassembly, and 13 days – for the electric furnace. The level of dismantling work mechanization changes while maintaining the technology.
“If previously we used jackhammers, today we are increasingly using demolition robots. There are currently 15 units of such equipment at the site. The main advantage of this robot is that it can be sent to a dangerous zone – to a place where people are not allowed to work, where the temperature is high, and there is a danger of structures collapsing. The robot is equipped with remote control and video surveillance, so people remain in a safe zone. The operator may be within radio range depending on the situation. It can be 100 meters or 150. And he can observe the work both through direct visibility and through video cameras that are installed on the machine”, said Vitaly Dovgal.
The power of the robot’s hydraulic hammer is 1500 joules, which is 30 times more than that of a jackhammer. One robot replaces 30 people. The car’s body kits can be changed.
The plant prepared for large-scale modernization in advance – they developed a concept and purchased equipment.
“We’ve purchased a lot of lifting mechanisms, so-called spider cranes. This is a crawler crane that can travel and get installed in places where stationary cranes cannot help us. The carrying capacity of the ‘spiders’ is different: three tons, five tons, the maximum is about 17 tons. We’ve also bought a lot of welding equipment. For example, if earlier we traditionally used kerosene cutters to cut metal structures, today we use plasma cutters for most of the work, especially where the metal is thick. They can cut steel up to 150–200 millimeters thick more efficiently without the use of oxygen”, said the Norilsknickelremont’s head.
At the preparatory stage, about 2800 NNR employees were involved at the site, but as work progresses, their number is increasing. At peak, 3200 people will work, half of them are constantly on shift.
“For now, the plant employs mainly installers, cutters, and welders, but the need for specialists will continue to grow. There are about 180 different professions in our organization. 40 of them are basic. These are just installers of steel reinforced concrete structures, welders of various profiles, and electricians. At the finish line, specialists in refractory masonry – acid-resistant specialists – will come to the site”, explained Vitaly Dovgal.
The main task is to complete large-scale repairs without a single injury and on time. 60 days are allotted for the modernization of the second production line. The absolute record for work on replacing FSF is 68 days. At Nadezhda they hope to beat it.
It’s possible to monitor the repairs online using cameras – the video flows onto monitors at the headquarters.
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Text: Angelika Stepanova, Photo: Nornickel Polar Branch’s press service
