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NewswireTODAY - /newswire/ -
Zurich, Switzerland, 2025/11/06 - Jindal Steel Sohar has modernized critical protection systems at its Sohar facility by upgrading its aging protection relays with ABB's advanced Relion®technology, enhancing operational reliability, minimizing downtime and supporting sustainable growth. ABBN: SIX Swiss Ex
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• Jindal Steel Sohar enhances production reliability and performance through strategic modernization program;
• ABB’s turnkey relay retrofit solution ready for direct installation, replacing aging infrastructure without costly switchgear replacement;
• Retrofit approach extends switchgear lifetime, bolsters reliability and avoids carbon emissions from manufacturing new systems.
As the largest privately-owned integrated steel producer in the Persian Gulf, Jindal Steel Sohar (JSS) (jindalsteel.om) operates at the forefront of Oman's industrial modernization and Vision 2040.
With a 2.4 million tons annual production capacity at its Sohar facility, and ambitious expansion plans supported by over USD 1.5 billion in regional investments, JSS was faced with a critical challenge. To support its growth ambitions, it needed to find a way to modernize its aging infrastructure without disrupting operational continuity. In particular, its aging protection relays which are essential to continuous steel production, were showing signs of wear and creating concerns about lead times and cost impacts for their critical systems, threatening the reliability required to serve their expanding client base across the Gulf Cooperation Council (GCC) region, Europe and beyond.
Engineered for performance and sustainability
The challenge was significant for a facility requiring continuous operations. JSS's aging protection relays raised concerns about spare parts availability and long-term viability for systems protecting critical 33kV and 6.6kV switchgear. For a steel processing plant serving clients across multiple continents, protection relay failures could trigger costly production disruptions and compromise operational continuity.
Rather than costly switchgear replacement, ABB (abb.com) proposed a targeted retrofit solution with Relion® REX615 and REX640 protection relays to minimize downtime, preserve existing infrastructure and increase equipment reliability and durability. These protection relays offer extensive protection and control functionality to ensure uninterrupted power supply.
Mr. Srinivasan Sankaran, Head DR at Jindal Steel Sohar, said: “ABB’s retrofit solution has been instrumental in ensuring business continuity at our Sohar facility. By modernizing our protection systems through an efficient and cost-effective upgrade, we were able to significantly enhance the reliability of our protection systems while ensuring seamless integration with our existing infrastructure and avoiding unnecessary downtime. This approach not only safeguarded uninterrupted steel production for our global customers, but also reflected our commitment to advancing Oman’s Vision 2040 through sustainable infrastructure investments.”
The solution replaced 12 protection units whilst retaining over 90% of the existing switchgear infrastructure, including metal cabinets, steel plates and busbars that can be used perpetually with proper upgrades. This avoided both the financial expenses and carbon emissions associated with manufacturing an entirely new switchgear.
Maximizing uptime with global-local expertise
ABB's cross-regional collaboration proved decisive. ABB’s Electrification Service center in Finland delivered fully programmed and configured relays based on existing system backup files, ready for direct installation. This approach eliminated the complexity of on-site programming and significantly reduced installation time. Locally, the Oman Electrification Service team leveraged their deep customer relationship and technical expertise to conduct on-site demonstrations with relay demo kits, enabling JSS engineers to experience the technology firsthand and build confidence in the solution.
"This project demonstrated the power of ABB's global service network," said Amarish Tiwari, Electrification Service Manager at ABB in Oman. "With JSS facing a scheduled March shutdown window, we committed to six-week delivery from February order placement, and our ABB colleagues in Finland ensured all materials arrived ahead of schedule."
Future-ready protection for continued growth
Beyond being a modern set of protection and control relays that help keep the power distribution operating at optimal conditions, ABB’s all-in-one Relion® REX615 and REX640 relays boost reliability, flexibility and digital integration.
At Jindal Steel Sohar, these relays have transformed operations with their intuitive graphic displays, giving technicians real-time visibility into equipment status and enabling smarter, faster maintenance decisions. With advanced communication capabilities, the team can now monitor the main relays and feeder performance more effectively, helping prevent costly downtime and ensuring a more resilient power network.
Vivekananthan Sabesan, Site Lead Engineer, Electrification Service at ABB in Oman, said: “This retrofit demonstrates targeted modernization at its best upgrading JSIS's protection capabilities with state-of-the-art technology while extending existing infrastructure life. Our team successfully replaced 12 protection relays across 6 feeders during a tight maintenance window through careful planning and coordinated execution. It's engineering that serves both performance and sustainability objectives.”
With enhanced protection systems now supporting their steel production operations, JSS is well-positioned to pursue their next phase of growth and modernization. The successful retrofit has strengthened their confidence in strategic infrastructure investments that balance operational excellence with sustainable development, setting the foundation for continued expansion of their market-leading position in the Persian Gulf.
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