Jindal Steel Sohar (JSS), the largest privately owned integrated steel producer in the Persian Gulf, has completed a major modernization project at its Sohar facility by replacing outdated protection relays with ABB’s advanced Relion® technology. The upgrade enhances reliability, reduces downtime, and strengthens the company’s commitment to sustainable industrial growth aligned with Oman’s Vision 2040.

With an annual production capacity of 2.4 million tons and over USD 1.5 billion in regional investments driving expansion, JSS needed to modernize its infrastructure without interrupting ongoing operations. Its aging protection relays — vital for the continuous operation of the steel plant — had become a potential risk due to declining reliability and spare parts availability, posing challenges for cost control and production continuity across the Gulf Cooperation Council (GCC), Europe, and other key markets.

Continuous production is essential for steelmaking, and even minor electrical protection failures can have significant consequences. To avoid the expense and disruption of replacing entire switchgear systems, ABB designed a retrofit solution using Relion® REX615 and REX640 relays. These modern protection and control devices ensure reliable, efficient operation of 33kV and 6.6kV systems while preserving much of the existing infrastructure.

“ABB’s retrofit solution played a key role in maintaining seamless operations at our Sohar facility,” said Srinivasan Sankaran, Head DR at Jindal Steel Sohar. “The modernization strengthened our protection systems, improved reliability, and minimized downtime — all while aligning with our sustainability and Vision 2040 goals.”

The project successfully replaced 12 protection units while retaining over 90% of the existing switchgear components, including metal cabinets, steel plates, and busbars. This approach not only reduced capital expenditure but also cut carbon emissions associated with new manufacturing and installation.

ABB’s coordinated international approach was instrumental in achieving the rapid upgrade. ABB’s Electrification Service center in Finland supplied pre-configured and pre-programmed relays, simplifying installation and avoiding the need for time-consuming on-site programming. Meanwhile, ABB’s Oman team provided hands-on demonstrations and technical support to JSS engineers, ensuring a smooth transition to the new system.

“This project is a great example of ABB’s global expertise combined with strong local delivery,” said Amarish Tiwari, Electrification Service Manager at ABB Oman. “With JSS’s planned March shutdown, we ensured delivery within six weeks of the February order, with all materials arriving ahead of schedule.”

Beyond replacing aging systems, ABB’s Relion® REX615 and REX640 relays introduce advanced digital functionality that enhances operational insight and responsiveness. With real-time graphical displays and improved communication interfaces, JSS technicians now have instant visibility into system performance, enabling faster maintenance decisions and improved network resilience.

“This retrofit is a perfect example of how modernization and sustainability can go hand in hand,” said Vivekananthan Sabesan, Site Lead Engineer, Electrification Service at ABB Oman. “We replaced 12 protection relays across six feeders within a narrow maintenance window, ensuring the plant’s protection systems are ready for future challenges.”

With modernized protection systems now in place, Jindal Steel Sohar is better equipped to support its expansion and maintain its reputation for operational excellence. The collaboration with ABB demonstrates how targeted technological upgrades can extend asset life, enhance performance, and contribute to long-term sustainability — reinforcing JSS’s leadership in the region’s industrial growth story.

Source: themachinemaker.com