Safety Operating Procedures for Induction Furnace Melting

 The safety operating procedures for induction furnace melting are of paramount importance. They safeguard personnel safety by preventing accidents like electric shocks and burns, ensure the stable operation of equipment and minimize malfunctions, enhance production efficiency and quality, comply with regulatory requirements, and contribute to the steady development of enterprises.

1. Operators must receive training to gain an understanding of the equipment's structure, principles, and performance. They should be well-acquainted with the melting process, competent in operating the equipment, and must pass the safety education examination.

2. Operators are required to don heat-insulating workwear, work shoes, heat-resistant gloves, and protective goggles.

3. Prior to starting up the furnace, a comprehensive inspection should be conducted to verify that the following requirements are satisfied:

① The furnace body and refractory lining are in good condition and intact.

② The electrical control system and inductor are functioning properly, with normal voltage levels.

③ The cooling water pressure and flow rate are within the normal range. There is no leakage, the water quality is satisfactory, and the water temperature does not exceed the specified limit.

④ Safety protection devices are fully equipped and reliable, and the grounding is in excellent condition.

⑤ All tools are complete, in good working order, and dry.

⑥ The site is clean and well-organized, with unobstructed passageways and no flammable or explosive materials present.

⑦ The materials to be melted are of qualified quality. Their size, moisture content, and cleanliness meet the specified requirements. They are free from enclosed containers with trapped substances as well as flammable or explosive items.

⑧ The site must be equipped with effective ventilation and cooling facilities.

4. When multiple operators are working together, the team leader must issue unified commands. Each operator should diligently carry out their assigned tasks and pay close attention to coordinating with their colleagues. The furnace should be started up following the specified procedures, and the melting process should be conducted in accordance with the technology tailored to the specific type of metal being melted, so as to ensure both safety and high - quality products. Operators must take measures to prevent electric shocks, burns, and injuries caused by falling objects.

5. The maximum melting temperature and melting capacity must not exceed the furnace's specified limits. During the melting process, if a furnace leakage is detected, the power supply should be cut off immediately, and the melting operation should be halted.

6. In the event of a short - term power outage during the melting process, insulation measures should be implemented. If the power outage lasts for a relatively long period, the molten metal in the furnace should be poured out.

7. The ladle should be preheated beforehand. When pouring the molten metal from the furnace into the ladle, operators must closely collaborate to prevent injuries resulting from splashing or overflowing.

8. After the melting work is finished, cut off the power supply and shut down the furnace. Once the cooling requirements are satisfied, stop the flow of cooling water. Maintain the equipment, organize the tools and return them to their designated locations, stack and arrange the remaining iron ingots and other materials properly, and clean and tidy up the work site.

9. When repairing the refractory linings of the furnace and the ladle, refractory materials with properties such as refractory rating and strength that meet the specified requirements must be used. It is strictly forbidden to add any metals into the mixture. The repair work must be carried out with a focus on ensuring high quality.

10. Regularly clean the cooling water system and replace the contaminated water to maintain good water quality. If a significant amount of scale builds up inside the induction - heating copper tubes of the furnace, it should be promptly removed to ensure an effective cooling effect.