Objective: To To standardize the melting process Roles and Responsibilities (Scope 1): Responsi
Shift Incharge/ Dy. Manager (Process)
ble Account
Manager (Process)
able Consulte
AGM / DGM - Production Production
d n!ormed
AGM / DGM - Production Production
"ocation: +$rna"e ,rea #re$re%uisites : 1. Furnace Furnace daiy chec!s are are carried out for safety ". A#aia$iity of re%uired ra& 'ateria
Sa!et& :
1. nsure usage of re%uired PPs
'resh Checs Furnace ne& ining
#rocedure: 1) Furn Furnace ace condit condition ion to $e chec!e chec!ed d $y the 'eter 'eter and rst hand hand
$efor $efore e
starting the furnace .*isua ins+ection is done to chec! foo&ing. ,here shoud shoud not $e any any cut in the furnace. furnace. hec! for the for'ation of furnace ring. hec! the ife of furnace fro' fro' the og og sheet hec! for any erosion $y +utting standard rod in the furnace and 'easuring the de+th. hec! fre%uency on the furnace +ane.
") After this 'eter cas the crane o+erator through signas &hich are as foo&ing.
1 ti'e $o&ing horn eectrica $/d " ti'es $o&ing horn 'echanic $/d ti'es $o&ing horn crane o+erator ca - charge 'i0 ti'es $o&ing horn side gate ade 2 ti'es $o&ing horn transfer ade rane o+erator then adds scra+ and PI as +er the daiy +an of charge 'i0 (3efer harge 'i0 re+ort Production re+ort). Meter con#eys the nu'$er of 'agnet of scra+ and PI to $e added through non #er$a co''unication. ) S&itch on the furnace 4 increase the +o&er +ot so&y u+to fu +o&er oad as foo&ing : 5) As +er ca+acity F 1 to 6 7 "268 9; F 7 5688 9; F 2 4 < 7 6888 9 4 F = 4 18 7 6688 9. 6) Mean&hie crane o+erator !ee+s accu'uating D3I near furnace. 6) hen i%uid +oo de#eo+ed then +ut s+onge Iron > +eet &hich is !e+t near furnace in furnace &ith the he+ of ?, crane. ) Furnace he+er then so&y starts 'ateria +oc!ing 4 after so'e ti'e sag re'o#a +rocess is started. 2) hen 'oten e#e in furnace reaches @ the e#e (esti'ation of 'eter) of 'oten 'eta then he+er e0tracts sa'+e through rod and sa'e is send to %uaity a$ &herein test is done as +er uaity chec!ist .,his chec!ist is then gi#en $ac! to he+er &ho gi#es to shift in charge. <) After recei#ing the a$ re+ort shift in charge instructs 'eter to initiate action $ased on car$on e#e.
If car$on is out of s+ecication.(refer %uaity chec!ist)7 o& car$on s+onge iron to $e used or 'i scae is added Met co!e is added in case car$on is o&. =) Meter !ee+s on adding D3I ti furnace is haf ed. Be+er ta!es another sa'+e and send it to a$ for car$on testing ( as +er chec! ist). 18) After recei#ing the a$ re+ort shift in charge instructs 'eter ta!e action as +er ste+ <. 11) Meter !ee+s adding D3I to increase the e#e of 'eta. Be+ers re+eatedy re'o#es sag. In this &ay the 'eter u+ the furnace u+ to C e#e of 'oten 'eta 4 then again ta!e one sa'+e 4 send to the a$ to chec! the of car$on ( as +er chec! ist). 1") After recei#ing the a$ re+ort shift in charge instructs 'eter to initiate action $ased on car$on e#e. If car$on is out of s+ecication.(refer %uaity chec!ist)7 o& car$on s+onge iron to $e used or &ater is s+rin!ed on s+onge or 'i scae is added E Met co!e is added in case car$on is o&.
1) After that De-sagging is done continuousy &ith the he+ of s+oon $y $ari'an. 15) After that of car$on &i $e set $y the 'eter as +er +roduct &hich is &ire 3od or ,M,. 16) Meter then instructs to the rst hand to increase the i%uid 'eta e#e according to the furnace ca+acity $y adding D3I 1) After that ceaning the sag <8 rest sag reduced &ith the he+ of 'et co!e 4 +ig iron.18 !g/,on Pig iron is added and 8.6 9g +er ,on of 'et co!e.
1<) ,e'+erature is then 'easure using te'+ ti+s. If te'+erature is ess than 18 degree cesius continue heating. ?nce te'+erature reaches 18 addition of the Ferro au'inu' 4 SiMn is done (ho& 'uch to add SiMn) 3e%uire'ent of SiMn as +er chart 7 8-''
12.68 !g/M,
Si 7 1 ; Mn 7 6"
-1" '' u'+s
(
'in
16.68 !g/M,
#aue) Si 7 1;Mn-
1.8 !g/M,
66 Si -15.6>/8.6;Mn 7 8 >/- 1
After addition of SiMn and Ferro Au'iniu' 'i0ing of i%uid 'eta is done &ith the he+ of $ari 1= ) Fina te'+erature is ta!en and in case te'+erature is in the range of 1<8 - 1288 shift In charge cas ade for ta++ing. "8) Shift in charge; SI instruct 'eter to +our the i%uid 'eta
into ade;
During ta++ing tea'er'an &i +ro#ide the +urging of nitrogen. 'inutes +urging at +ressure of 1.6!g/c'" "1) After co'+ete ta++ing rst hand ta!e na te'+erature in the ade. If te'+erature is in the range of 168-18 degree ; ade is sent to M for casting. ,hen ta!e one oy+o+ sa'+e 4 send to the a$ for testing. ") Finay ade send to the M for casting. "5) Meter u+dates the data in the +roduction sheet aong &ith re'ar! in case de#iation is there against the +an.
