SAFETY CONSIDERATIONS FOR OPERATING CORELESS INDUCTION MELTING FURNACES

BY JACK MCMILLIN
AJAX TOCCO MAGNETHERMIC

SAFELY MELTING WITH CORELESS INDUCTION FURNACES BEGINS WITH OPERATOR TRAINING
The following program o !line" #on"i$era!ion" for !ha! !raining%%

THE FOUNDRY ENVIRONMEN T

The foundry can look ominous, but it need not be intimidating.

THE FOUNDRY ENVIRONMENT

With proper training and understanding the foundry can be a safe workplace.

Safety Throu h O!erator Tra"#"#

$% E&!'oyer Re(!o#(")"'"ty

&n$er"!an$ing !ha! !he rea"on for a fo n$r' !o (e in ( "ine"" i" !o ma)e a profi! an$ grow%

Safety Throu h O!erator Tra"#"#

$% E&!'oyer Re(!o#(")"'"ty *ar! of goo$ ( "ine"" i" !o p ! program" in pla#e !o minimi+e a##i$en!", in- rie", an$ lo"! !ime in#i$en!" !ha! are harmf l an$ #o"!l'%

Safety Throu h O!erator Tra"#"# $% E&!'oyer Re(!o#(")"'"ty

plo'er re"pon"i(ili!' ... *ro/i$e a "afe wor)ing en/ironmen! wi!h !he !raining an$ !ool" !o perform !he re0 ire$ !a")" in a "afe manner% The 12 C3R 4e#!ion 5256%571 8Co$e of 3e$eral Reg la!ion9 re0 ire" !he emplo'er !o $o ha+ar$ a""e""men! an$ !o !hereaf!er pro/i$e an$ re0 ire #onformi!' !o !ha! a""e""men! (' ha/ing emplo'ee" wear proper **E 8*er"onal *ro!e#!i/e E0 ipmen!9 *ro/i$e "afe f rna#e e0 ipmen! wi!h proper gro n$ing an$ empha"i+e !he impor!an#e for opera!ing "afel'% Main!ain !he e0 ipmen! an$ en" re i! opera!e" a" in!en$e$%

:e/elop an$ main!ain repor!ing "'"!em" !o en" re #on"i"!en! opera!ional effi#ien#ie" an$ "afe!'%

Safety Throu h O!erator Tra"#"# $% E&!'oyer Re(!o#(")"'"ty

:efine primar' pro!e#!i/e #lo!hing "!an$ar$"%

Safety Throu h O!erator Tra"#"# $% E&!'oyer Re(!o#(")"'"ty

:efine an$ or pro/i$e "e#on$ar' pro!e#!i/e #lo!hing "!an$ar$"%

Safety Throu h O!erator Tra"#"#

* % Def"#e Wor+ S!a,e

ine opera!or wor) "pa#e an$ e0 ipmen! !o (e "e$ an$ main!aine$% :efine pro#e$ re"% Be #er!ain !he' )now !he e0 ipmen!% :efine !he proper **E 8*er"onal *ro!e#!i/e E0 ipmen!9 an$ in"!r #! i!;" proper "e% :efine mel! $e#) area an$ opera!or;" re"pon"i(ili!' :efine mel! $e#) organi+a!ion an$ wh' !o lo#a!e i!em" in !heir (e"! $e"ire$ po"i!ion :efine "e of r n o ! pi!" an$ !he impor!an#e of )eeping !hem $r' :i"# "" an$ n$er"!an$ "#rap $r'ing, pre.hea!ing or (a!#h mel!ing /er" " !ap an$ #harge mel!ing% &n$er"!an$ f me #olle#!or opera!ion" for /ario " f rna#e "!age", mel!, hol$ing, "in!ering, an$ #harging Protect against mechanical equipment hazards, pinch points, open pits, moving equipment.

Safety Throu h O!erator Tra"#"#

* % Def"#e Wor+ Pro,e-ure(

Ele#!ri#al e0 ipmen! ha+ar$"% Bri$ging an$ R n o !"%

<ha! !o $o when 'o ge! a gro n$ !rip% Han$ling power " ppl' "h !.$own" /"% f rna#e mel! #on$i!ion" an$ !he impa#! on refra#!or'%

Main!ain hea! log "hee!" for proper re#ommen$e$ $o# men!a!ion )eeping=f ! re referral%

ro n$ !e"! !o en" re proper gro n$ing for opera!or=e0 ipmen! "afe!'%

"e of f rna#e energ' moni!or" #omp !eri+e$ wi!h loa$ #ell" on f rna#e%

"e of f rna#e energ' moni!or", " #h a" )<h #o n!er"%

Safety Throu h O!erator Tra"#"#

* % Def"#e E&er e#,y Pro,e-ure(

Bri$ging o## r" when a >#ap? form" o/er !he !op of !he f rna#e, allowing a ( il$ p of " perhea!e$ ga"e" in !he /oi$ (elow% The /oi$ "epara!ing mol!en me!al from !he (ri$ge of "oli$ #harge ma!erial a#!" a" an in" la!or% The mol!en me!al will " perhea! an$ !he !empera! re will ri"e rapi$l'%

Safety Throu h O!erator Tra"#"#

* % Def"#e Wor+ Pro,e-ure(

rna#e gro n$ing an$ impor!an#e for opera!ing "afe!'%

rna#e energ' mel! #al# la!ion" for effi#ien! mel!ing%

al# la!ing a " per hea! !ime on /ario " mel! "'"!em #om(ina!ion"%

"e of "lag #oag lan!" for op!im m "lag remo/al%

1%16

Safety Throu h O!erator Tra"#"#

. / Fur#a,e Char "# Pro,e-ure(

<e $o no! wan! !o lea/e an'!hing !o #han#e% Know wha! i" (eing #harge$ in!o !he f rna#e%

Safety Throu h O!erator Tra"#"#

. / Char "#

Fur#a,e 4afe!' an$ "e# ri!' are of primar' impor!an#e% *er"onnel "afe!' $epen$" on )nowing wha! goe" in!o !he f rna#e% @ ali!' pro$ #!ion $epen$" on #on"i"!en#' in opera!ion"%

Safety Throu h O!erator Tra"#"#

. / Char "#

Fur#a,e

Safety Throu h O!erator Tra"#"#

. / Char "#

Fur#a,e

Safety Throu h O!erator Tra"#"#

. / Char "#

Fur#a,e

*o ring or ino# la!ing #an (e - "! a" $angero " an$ "ho l$ (e performe$ wi!h proper #a !ion%

Safety Throu h O!erator Tra"#"#

. / Char "#

Fur#a,e

)e p, #harging "afe!', #harge pro#e$ re", #harge "e0 en#e% 4#rap "!orage% Charging a f rna#e, ma!erial "e0 en#e% Charge ma!erial ma)e. p an$ !'pe%

ge ma!erial an$ !he effe#!" on opera!ion, refra#!or', energ' an$ "afe!'A #hip", oil' "#rap, effe#!" of none me!alli#;", #harging large pie#e", e!#% 4afe!' pre#a !ion" !o follow when #harging a f rna#e, #harge "e0 en#e, weighe$ #harge"% *roper !ime !o a$$ allo' an$ !he effe#!" on refra#!or' lining an$ #hemi"!r'

Safety Throu h O!erator Tra"#"#

0 / Fur#a,e Re'"#"#
Lining mea" remen! "hee! for proper lining $imen"ional in"!alla!ion a" well a" lining moni!oring when i! wear" A/aila(le lining pene!ra!ion "en"ing, " #h a" >4afewa'?, e!#%

ining. moni!oring !he f rna#e lining, $e!ermining when !o reline, !earing o ! a "pen! lining%

Ele#!roni# "'"!em" #o/ering lining wear #har!ing=in$i#a!ion

Refra#!or' ma!erial" an$ !he $e"ire$ opera!ing !empera! re"

*a!#hing refra#!or' . B:o no! pa!#h o/er !he gro n$ pro(e"B

Safety Throu h O!erator Tra"#"#

0 / Fur#a,e Re'"#"#
Lining remo/al pro#e$ re an$ !he impor!an#e of re"!oring !he f rna#e for !he neC! reline, gro ! repair, "e of "lip plane ma!erial"%

Coil #oa! ma!erial "ele#!ion, in"!alla!ion, pa!#hing an$ $r'ing

3 rna#e refra#!or' "ele#!ion for !he allo'" (eing mel!e$

Lining in"!alla!ion "'"!em", " #h a" Gra$ma!i#

Safety Throu h O!erator Tra"#"# 1 / S"#ter"# L"#"# the Fur#a,e

ining "in!ering pra#!i#e" an$ pro#e$ re"% 4in!ering refra#!or' lining"

er "in!er #harge ma!erial, "!a#)ing, "!ar!er (lo#)", an$ following !he re#ommen$e$ !empera! re ramp. p"A )eeping re#or$"% 4in!ering an$ proper moni!oring wi!h !hermo#o ple in"!alla!ion%

D%E D%D

*roper "in!er power le/el for gi/en f rna#e "i+e% Con"i"!en#' i" impor!an!%

Safety Throu h O!erator Tra"#"# 1 / S"#ter"# L"#"# the Fur#a,e

The " ##e"" or fail re of a lining #ampaign "!ar!" wi!h !he "in!ering%

Safety Throu h O!erator Tra"#"# 2 / Fur#a,e Shut Do3# a#Co'- Start"#

*roper f rna#e "h ! $own an$ #ol$ "!ar! pro#e$ re"% Col$ "!ar! p" an$ #ool $own" 3an #ooling Tor#h prehea! pro#e$ re"% *ower prehea! pro#e$ re" O/ernigh! hol$ing% A !o re"!ar!%

Safety Throu h O!erator Tra"#"#

4 / Fur#a,e Ma"#te#a#,e

in!enan#e *ro#e$ re" an$ Con"i$era!ion"

4afe!' pre#a !ion" for Main!enan#e per"onnel

Ele#!ri#al e0 ipmen! ha+ar$"

Me#hani#al e0 ipmen! ha+ar$"

ing af!er main!enan#e people, a" !he' ma' (e le"" familiar wi!h f rna#e an$ power " ppl' !han 'o a" !he opera!or

Safety Throu h O!erator Tra"#"#

4 / Fur#a,e Ma"#te#a#,e
Hea! log "hee!" for proper re#ommen$e$ $o# men!a!ion )eeping=referral

GL: gro n$ lea) $e!e#!or opera!ion

3 rna#e gro n$ing an$ impor!an#e for opera!ing "afe!'

<a!er flow" an$ !empera! re"

*ower lea$ polari+a!ion for maCim m effi#ien#'=minim m lo"" an$ proCimi!' hea!ing

Safety Throu h O!erator Tra"#"#

5 / Other ,o#("-erat"o#( for (!e,"f", "#(ta''at"o#( or !ro,e((e(6

Thi" i" a wor) in progre""%

7ue(t"o#( Co&&e#t( 8 8
Opinion" F 4 gge"!ion" F A""i"!an#e F
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