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AFETYCON IDERATIONFOR OPERATINGCORELE
INDUCTIONMELTINGFURNACEBY
JACK MCMILLIN
AJAX TOCCO MAGNETHERMIC
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AFELY MELTING WITHCORELE INDUCTIONFURNACE BEGINWITHOPERATORTRAINING
The following program
o!line" #on"i$era!ion" for!ha! !raining%%
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THE FOUNDRYENVIRONMENT
The
foundry can
look
ominous,but it need
not be
intimidating.
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THE FOUNDRYENVIRONMENT
With proper
training and
understanding
the foundry
can be a safeworkplace.
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afety Throuh O!erator Tra"#"#$% E&!'oyer Re(!o#(")"'"ty
&n$er"!an$ing
!ha! !herea"on for afon$r' !o (ein ("ine"" i"
!o ma)e aprofi! an$grow%
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afety Throuh O!erator Tra"#"#$% E&!'oyer Re(!o#(")"'"ty
*ar! of goo$("ine"" i" !o p!program" in pla#e
!o minimi+ea##i$en!", in-rie",
an$ lo"! !imein#i$en!" !ha! areharmfl an$#o"!l'%
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afety Throuh O!erator Tra"#"#$% E&!'oyer Re(!o#(")"'"ty
lo'er re"pon"i(ili!' ... *ro/i$e a "afe wor)ing en/ironmen! wi!h !he !raining an$ !ool" !o perform !he
re0ire$ !a")" in a "afe manner%
The 12 C3R 4e#!ion 5256%571 8Co$e of 3e$eral Regla!ion9 re0ire" !he emplo'er
!o $o ha+ar$ a""e""men! an$ !o !hereaf!er pro/i$e an$ re0ire
#onformi!' !o !ha! a""e""men! (' ha/ing emplo'ee" wear proper **E
8*er"onal *ro!e#!i/e E0ipmen!9
*ro/i$e "afe frna#e e0ipmen! wi!h proper gron$ing an$ empha"i+e !he
impor!an#e for opera!ing "afel'%
Main!ain !he e0ipmen! 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!'%
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afety Throuh O!erator Tra"#"#$% E&!'oyer Re(!o#(")"'"ty
:efine primar'
pro!e#!i/e #lo!hing"!an$ar$"%
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afety Throuh O!erator Tra"#"#$% E&!'oyer Re(!o#(")"'"ty
:efine an$ orpro/i$e "e#on$ar'pro!e#!i/e #lo!hing"!an$ar$"%
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afety Throuh O!erator Tra"#"#* % Def"#e Wor+ !a,e
ine opera!or wor) "pa#e an$ e0ipmen! !o (e "e$ an$ main!aine$% :efine pro#e$re"% Be
#er!ain !he' )now !he e0ipmen!%
:efine !he proper **E 8*er"onal *ro!e#!i/e E0ipmen!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 rn 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$er"!an$ fme #olle#!or opera!ion" for /ario" frna#e "!age", mel!,
hol$ing, "in!ering, an$ #harging
Protect against mechanical equipment hazards, pinch points, open pits, moving
equipment.
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afety Throuh O!erator Tra"#"#* % Def"#e Wor+ Pro,e-ure(
Ele#!ri#al e0ipmen! ha+ar$"%
Bri$ging an$ Rn o!"%
ha! !o $o when 'o ge! a gron$ !rip%
Han$ling power "ppl' "h!.$own" /"% frna#e mel! #on$i!ion" an$ !he
impa#! on refra#!or'%
ain!ain hea! log "hee!" for proper re#ommen$e$ $o#men!a!ion
)eeping=f!re referral%
ron$ !e"! !o en"re proper gron$ing for opera!or=e0ipmen! "afe!'%
e of frna#e energ' moni!or" #omp!eri+e$ wi!h loa$ #ell" on frna#e%
e of frna#e energ' moni!or", "#h a" )
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afety Throuh O!erator Tra"#"#* % Def"#e E&ere#,yPro,e-ure(
Bri$ging o##r" when a
>#ap? form" o/er !he !op of!he frna#e, allowing a(il$p of "perhea!e$ga"e" in !he /oi$ (elow%
The /oi$ "epara!ing mol!enme!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$l'%
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afety Throuh O!erator Tra"#"#* % Def"#e Wor+ Pro,e-ure(
rna#e gron$ing an$ impor!an#e for opera!ing "afe!'%
rna#e energ' mel! #al#la!ion" for effi#ien! mel!ing%
l#la!ing a "per hea! !ime on /ario" mel! "'"!em #om(ina!ion"%
e of "lag #oaglan!" for op!imm "lag remo/al%
1%16
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afety Throuh O!erator Tra"#"#. / Fur#a,e Char"#Pro,e-ure(
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afety Throuh 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 !hefrna#e%
@ali!' pro$#!ion$epen$" on #on"i"!en#'
in opera!ion"%
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afety Throuh O!erator Tra"#"#. / Char"# Fur#a,e
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afety Throuh O!erator Tra"#"#. / Char"# Fur#a,e
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afety Throuh O!erator Tra"#"#. / Char"# Fur#a,e
*oring or
ino#la!ing #an
(e -"! a"
$angero" an$
"hol$ (e
performe$ wi!hproper #a!ion%
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afety Throuh O!erator Tra"#"#. / Char"# Fur#a,e
e p, #harging "afe!', #harge pro#e$re", #harge "e0en#e%
4#rap "!orage%
Charging a frna#e, ma!erial "e0en#e%
Charge ma!erial ma)e.p an$ !'pe%
e ma!erial an$ !he effe#!" on opera!ion, refra#!or', energ' an$ "afe!' #hip", oil' "#rap, effe#!" of
none me!alli#;", #harging large pie#e", e!#%
4afe!' pre#a!ion" !o follow when #harging a frna#e, #harge "e0en#e,
weighe$ #harge"%
*roper !ime !o a$$ allo' an$ !he effe#!" on refra#!or' lining an$ #hemi"!r'
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afety Throuh O!erator Tra"#"#0 / Fur#a,e Re'"#"#
ning. moni!oring !he frna#e lining, $e!ermining when !o reline, !earing o! a "pen! lining%
Lining mea"remen! "hee! for proper lining $imen"ional in"!alla!ion a" well
a" lining moni!oring when i! wear"
A/aila(le lining pene!ra!ion "en"ing, "#h a" >4afewa'?, e!#%
Ele#!roni# "'"!em" #o/ering lining wear #har!ing=in$i#a!ion
Refra#!or' ma!erial" an$ !he $e"ire$ opera!ing !empera!re"
*a!#hing refra#!or' . :o no! pa!#h o/er !he gron$ pro(e"
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afety Throuh O!erator Tra"#"#0 / Fur#a,e Re'"#"#
Lining remo/al pro#e$re an$ !he impor!an#e of re"!oring !he frna#e for !he
ne! reline, gro! repair, "e of "lip plane ma!erial"%
Coil #oa! ma!erial "ele#!ion, in"!alla!ion, pa!#hing an$ $r'ing
3rna#e refra#!or' "ele#!ion for !he allo'" (eing mel!e$
Lining in"!alla!ion "'"!em", "#h a" Gra$ma!i#
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afety Throuh O!erator Tra"#"#1 / "#ter"# the Fur#a,eL"#"#
ning "in!ering pra#!i#e" an$ pro#e$re"%
4in!ering refra#!or' lining"
r "in!er #harge ma!erial, "!a#)ing, "!ar!er (lo#)", an$ following !he re#ommen$e$ !empera!re
ramp.p" )eeping re#or$"%
4in!ering an$ proper moni!oring wi!h !hermo#ople in"!alla!ion%
D%
D%D
*roper "in!er power le/el for gi/en frna#e "i+e%
Con"i"!en#' i" impor!an!%
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afety Throuh O!erator Tra"#"#1 / "#ter"# the Fur#a,eL"#"#
The "##e""or failre of a
lining
#ampaign"!ar!" wi!h !he
"in!ering%
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afety Throuh O!erator Tra"#"#2 / Fur#a,e hut Do3# a#-
Co'- tart"#*roper frna#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!%
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afety Throuh O!erator Tra"#"#
4 / Fur#a,e Ma"#te#a#,en!enan#e *ro#e$re" an$ Con"i$era!ion"
4afe!' pre#a!ion" for Main!enan#e per"onnel
Ele#!ri#al e0ipmen! ha+ar$"
Me#hani#al e0ipmen! ha+ar$"
ng af!er main!enan#e people, a" !he' ma' (e le"" familiar wi!h frna#e an$ power "ppl' !han 'o a"
!he opera!or
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afety Throuh O!erator Tra"#"#
4 / Fur#a,e Ma"#te#a#,eHea! log "hee!" for proper re#ommen$e$ $o#men!a!ion )eeping=referral
GL: gron$ lea) $e!e#!or opera!ion
3rna#e gron$ing an$ impor!an#e for opera!ing "afe!'
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afety Throuh 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""%
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7ue(t"o#(8 Co&&e#t(8
Opinion" F
4gge"!ion" F
A""i"!an#e F
Input ?
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