Jindal Steel Sohar Boosts Operational Reliability and Sustainability with ABB Relion® Protection System Upgrade!

Jindal Steel Sohar (JSS), the largest privately owned integrated steel producer in the Persian Gulf, has completed a significant modernization initiative at its Sohar facility by upgrading its aging protection relays with ABB’s state-of-the-art Relion® technology. The strategic enhancement not only strengthens system reliability and minimizes downtime but also reinforces the company’s alignment with Oman’s Vision 2040 goals for sustainable and technologically advanced industrial development.

With a robust annual production capacity of 2.4 million tons, JSS has consistently invested in modernizing its infrastructure to support its expanding footprint across the GCC, Europe, and other international markets. As part of this commitment, the company sought to replace outdated protection relays that had become increasingly unreliable, costly to maintain, and difficult to source. These relays are critical for safeguarding continuous steelmaking operations, where even minor electrical faults can trigger costly interruptions.

To avoid the substantial expense and operational disruption associated with replacing entire switchgear systems, ABB delivered a tailored retrofit solution built around its Relion® REX615 and REX640 protection and control relays. These advanced devices integrate seamlessly into existing 33kV and 6.6kV systems, ensuring dependable performance while preserving over 90% of the original switchgear infrastructure — including cabinets, plates, and busbars. This approach significantly reduced capital expenditure and minimized environmental impact by avoiding unnecessary equipment disposal and manufacturing.

“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.”

A critical element of the project’s success was ABB’s efficient international coordination. ABB’s Electrification Service center in Finland supplied pre-configured and pre-programmed relays, simplifying commissioning and eliminating the need for prolonged on-site programming. Simultaneously, ABB’s local team in Oman provided hands-on demonstrations, technical training, and full support to JSS engineers, ensuring smooth integration with minimal operational disruption.

“This project is a great example of ABB’s global expertise combined with strong local delivery,” stated 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.”

The new Relion® REX615 and REX640 relays offer enhanced digital diagnostics, intuitive graphical displays, and improved communication capabilities, giving JSS maintenance teams deeper visibility into system performance. This real-time insight helps accelerate decision-making, reduce downtime, and strengthen long-term network resilience.

“This retrofit is a perfect example of how modernization and sustainability can go hand in hand,” added 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.”

By integrating ABB’s advanced Relion® technology, Jindal Steel Sohar has taken an important step toward future-proofing its operations, reducing environmental impact, and reinforcing its position as a technologically progressive leader in the regional steel industry.