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Steel Melting Shop Procedures..: Prepared By: M G Sunil, Sse /TTC

The document provides procedures for steel melting shop operations including preparation of charges, furnace maintenance, sample taking, tapping metal from the furnace, and crane operation. It also outlines critical stations in the moulding room such as closing down moulds, pouring, splitting wheels, and hub cutting. Procedures are provided for operations like normalizing, rim quenching, annealing, hub quenching, drag and cope spraying, and stopper pipe setting. Safety is emphasized for crane operation and proper techniques are outlined for various casting and heat treatment steps.

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abhimanyutiwari1234
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334 views50 pages

Steel Melting Shop Procedures..: Prepared By: M G Sunil, Sse /TTC

The document provides procedures for steel melting shop operations including preparation of charges, furnace maintenance, sample taking, tapping metal from the furnace, and crane operation. It also outlines critical stations in the moulding room such as closing down moulds, pouring, splitting wheels, and hub cutting. Procedures are provided for operations like normalizing, rim quenching, annealing, hub quenching, drag and cope spraying, and stopper pipe setting. Safety is emphasized for crane operation and proper techniques are outlined for various casting and heat treatment steps.

Uploaded by

abhimanyutiwari1234
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Download as PPT, PDF, TXT or read online on Scribd
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STEEL MELTING SHOP

PROCEDURES..

Prepared
by:
M G Sunil,
SSE /TTC

CONTENTS
Preparation of Charge Preparation of New Laddle

Preparation of Bucket Charge Laddle Pre Heating


Charging the Furnace Electrode Addition
Melting of Scrap in Furnace
Sample Taking ,Cutting and Polishing
Removal of Initial Slag Operation

Spectro Analysis Furnace Lining

Recarburising Furnace maintenance

Decarburising Watercooled PANEL


Taking Pre Tap Sampling Tap Hole
Preparation of Laddle Back Charging
Tapping of Metal from Furnace
Crane Operation
Removal of Slag from Laddle
Wet Ramming Mass
Spectro Analysis
Preparation of Laddle
CRANE OPERATION
Follow the set procedure and siren when heavy loads are lowered
or raised.

Only one person should give the instructions to the crane operator.

Use horn when heavy loads are transferred from one place to other.

Operates crane slowly when hot metal is transported.

Do not operate the crane when the hoist are slipping.

Do not keep the crane idle.

As and when the crane is free, unload the scrap from the wagons.

Whenever the crane goes under the breakdown, park it at the


extreme end.

Do not unload slag pot on dirt floor where water has accumulated.
MOULDING RoOM
CRITICAL STATIONS!!
Prepared
by:
M G Sunil,
SSE /TTC
CLOSE DOWN STATION

MAKING MOULD
SET, FOR
POURING , BY
CLOSING DOWN
COPE OVER
DRAG.

INSPECT THE
POURING STATION
CASTING OF WHEELS WITH BOTTOM INGATE
CONTROLLED AIR PRESSURE POURING
TECHNIQUE TRANSFERRED FROM M/S GRIFFIN
USA. BE

IMMERSION OF POURING TUBE TO BE DONE


CAREFULLY WITHOUT GOING SLAG/INCLUSION
INSIDE TUBE AND WITH IN THE RANGE OF INTIAL
Fb login METAL TEMPRATURE AND WITH PROPER ADDITION
OF LADLE INSULATION MATERIAL.

PUTTING SINGLE ASBETOS GASKET WITH


PREHEATED CONDITION &REMOVAL OF ASBETOS
GASKET CAREFULLY WITHOUT FALLING IN
POURING TUBE BY SPRAYING FUSED

SILICA POWDER SOLUTION INTERMITTANTLY.

ADDING RICE HULL TO THE OPTIMUM LEVEL SO


THAT SUFFICIENT THERMAL INSULATION & EXO
THERMIC ACTION TO BE TAKEN PLACE BY
BURNING THE SAME.

PROPER CHECKING OF THE LEVEL OF METAL AND


JUDGING THE LAST WHEEL SO THAT SLAG
POURING STATION
CASTING OF WHEELS WITH BOTTOM INGATE
CONTROLLED AIR PRESSURE POURING
TECHNIQUE TRANSFERRED FROM M/S GRIFFIN
USA. BE

IMMERSION OF POURING TUBE TO BE DONE


CAREFULLY WITHOUT GOING SLAG/INCLUSION
INSIDE TUBE AND WITH IN THE RANGE OF INTIAL
METAL TEMPRATURE AND WITH PROPER ADDITION
OF LADLE INSULATION MATERIAL.

PUTTING SINGLE ASBETOS GASKET WITH


PREHEATED CONDITION &REMOVAL OF ASBETOS
GASKET CAREFULLY WITHOUT FALLING IN
POURING TUBE BY SPRAYING FUSED

SILICA POWDER SOLUTION INTERMITTANTLY.

ADDING RICE HULL TO THE OPTIMUM LEVEL SO


THAT SUFFICIENT THERMAL INSULATION & EXO
THERMIC ACTION TO BE TAKEN PLACE BY
BURNING THE SAME.

PROPER CHECKING OF THE LEVEL OF METAL AND


JUDGING THE LAST WHEEL SO THAT SLAG
SPLITTING STATION

SPLITTING THE
WHEELS IN
RIGHT TIME SO
THAT DRIPPING
OF METAL/RISER
SHOULD NOT BE
IN WHEEL.
KEEP WHEEL S
GENTLY ON HW
KILN SLAT.
SPRUE WASH/ SPRUE
GRINDING
THE STUBS OF
FEEDERS FROM
RISER IS
WASHED WITH
THE HELP OF
COPPER
COATED 1INCH
GRAPHITE
ELECTRODE
WITH 1500
HOT STAMPING MACHINE

THE UNIQUE
NUMBER
SYSTEM IS
FOLLOWED
HERE BY
STAMPING THE
HEAT NUMBER
ON BACK HUB
AREA.
HUB CUTTING STATIONS

THE HUB
PORTION WHERE
THE AXLE IS
FITTING IS
ROUGHLY GAS
CUTTING DONE
AT THESE
STATION. TWO
CONVENTIONAL
& 2 CNC
NORMALISING

THE WHEELS
ARE BEING
NORMALISED IN
A ROTARY
HEARTH
FURNACE OF
FUEL HSD
WITH A ROTARY
HEARTH OF
CAPACITY 45*
RIM QUENCHING

TO INDUCE
HARDNESS AT
THE RIM
PORTION TO
WITH STAND THE
BRAKING
EFFECT &
DIFFERENT
TYPES OF
DYNAMIC LOADS
ANNEALING & HUB
QUENCHING
AFTER RIM
QUENCHING,
ANNEALING IS
DONE IN DRAW
FURNACE WITH
A CYCLE TIME
150 MIN.
LINEAR
FURNACE WITH
A VERTICAL
DRAG LINE

DRAG CLEANER :-
AFTER
SPLITTING
STATION DRAG
ARE CLEANED
BY SAND
BLASTING IN
DRAG CLEANER
WITH 105 AFS
SILICA SAND.
DRAG SPRAY STATION 1 & 2

DRAG ARE
SPRAYED WITH
FUSED SILICA
POWDER
SOLUTION WITH
TWO SPRAYING
GUN OF
QUANTITY 125-
175 ML FOR
DIFFERENT
COPE LINE

CTA 1 STATION :-
AFTER
SPLITTING THE
COPE CAN BE
INSPECTED IN
COPE TILTING
STATION (CTA1)
AND AFTER
CLEANING OLD
FUSED SAND IN
COPE SPRAY STATION 1 & 2
THE COPES ARE SPRAYED
FUSED SILICA SOLUTION WITH
DIFFERENT AREA LIKE HUB,
PLATE AND RIM WITH 03 GUNS
WITH QUANTITY OF 120 ML TO
200 ML WITH PROPER
OVERLAPING PATERN AND
PROPER ATOMISING
PRESSURE AND TRIGGER
PRESSURE AND TANK
PRESSURE AND GUN HEIGHT.

REJECTIONS ARE X10, X46, X47


STOPPER PIPE SETTING
THE STOPPER PIPE
STATION[CTC]
ASSEMBLY IS SETTING AT
THIS STATION,
ADDITIONALLY
INSPECTING THE WALL
THICKNESS AND PAD
THICKNESS OF COPE AND
SPRAY PATTERN AND
MORE WALL THICKNESS.

THE REJECTION ARE X61,


X10,X46,X48 & X62.

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