At Alloy Steel Plant of SAIL, due to the bath level of the furnace being slightly high, liquid metal would touch the bottom part of the side wall panel, resulting in water leakage in the furnace. Moreover, hot metal coming in contact with water is a major safety hazard. The solution was to either deepen the bottom of the furnace or increase the height of the water header from the furnace bottom. Since the first would make the vessel unsafe, the only option left was to modify the side wall water cooled panels and water header. Accordingly all water-cooled panels were removed, wall panel height was shortened by about 300 mm and the main water supply header was raised by about the same measure.