Inductortherm furnaces
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About This Presentation
the article treat about of induction furnace that inductortherm offer
Slide Content
INDUCTOTHERM
The Induction Heating and Melting Safety
Fundamentals Guide That Might Save Your Life
The Induction Heating and Melting Safety
Fundamentals Guide That Might Save Your Life
Melting Safety Fundamentals Guide
Molten metal is inherently dangerous. The infor-
mation provided in this guide must be followed.
Failure to do so could result in injury or death.
Equipment should only be operated by or maintained
by properly trained personnel who have read and
understand all equipment manuals, company
procedures and applicable safety information.
Molten metal is inherently dangerous. The infor-
mation provided in this guide must be followed.
Failure to do so could result in injury or death.
Equipment should only be operated by or maintained
by properly trained personnel who have read and
understand all equipment manuals, company
procedures and applicable safety information.
Induction Heating & Meling Safety Fundamentals Guide
About This Guide 1
Equipment Manuals Must Be Your Primary Safety Source 1
Safety Must Be a Key Corporate Value 1
Hazard Intensity Levels 1
2
2
Consult Your Governing Agencies & industry Organizations
Inductotherm Heating & Melting Safety Kt
Induction Heating & Meting _ 3
Induction Electrical System Configurations — 3
Safely Implications. 3
Induction Furnaces Come In Many Varieties 4
4
4
4
Coreless Furnaces,
Channel Furnaces
Induction Heating ——
Be Aware of Induction Hazards
Personal Protective Equipment (PPE)
Personal Protective Equipment (PPE) Can Save Your Li
Primary Protective Equipment,
Secondary Protective Equipment
Lower Temperature, Higher Risk of Metal Splash
Masks & Resprators — o
Three Keys to Personal Saety
Furnace Equipment Operation & Safety Precautions
Molten Metal Splash: The Most Visible Foundry Hazard 10
Eliminating Wet Scrap = = ==
Sealed Containers 10
"
11
Other Haar _
Centritugaly-Cast Sera
Furnace Cooling — 2
Open Water Systems Require Careful Maintenance. 12
Bridging Situations Require Immediate Emergency Action 13
Warning Signs of Bridging 5
Inthe Event of Bridge 48
Spil Pts May Keep You from Being Knee-Deep in Molten Metal 4
Ground & Leak Detection Systems. 15
Ground Leak Probe Key to Protection a “15
Ground Detector Module Turns OH Power 16
System Maintenance 7
Independent Moten Metal Leak Detector 7
About This Guide 1
Equipment Manuals Must Be Your Primary Safety Source 1
Safety Must Be a Key Corporate Value 1
Hazard Intensity Levels 1
2
2
Consult Your Governing Agencies & industry Organizations
Inductotherm Heating & Melting Safety Kt
Induction Heating & Meting _ 3
Induction Electrical System Configurations — 3
Safely Implications. 3
Induction Furnaces Come In Many Varieties 4
4
4
4
Coreless Furnaces,
Channel Furnaces
Induction Heating ——
Be Aware of Induction Hazards
Personal Protective Equipment (PPE)
Personal Protective Equipment (PPE) Can Save Your Li
Primary Protective Equipment,
Secondary Protective Equipment
Lower Temperature, Higher Risk of Metal Splash
Masks & Resprators — o
Three Keys to Personal Saety
Furnace Equipment Operation & Safety Precautions
Molten Metal Splash: The Most Visible Foundry Hazard 10
Eliminating Wet Scrap = = ==
Sealed Containers 10
"
11
Other Haar _
Centritugaly-Cast Sera
Furnace Cooling — 2
Open Water Systems Require Careful Maintenance. 12
Bridging Situations Require Immediate Emergency Action 13
Warning Signs of Bridging 5
Inthe Event of Bridge 48
Spil Pts May Keep You from Being Knee-Deep in Molten Metal 4
Ground & Leak Detection Systems. 15
Ground Leak Probe Key to Protection a “15
Ground Detector Module Turns OH Power 16
System Maintenance 7
Independent Moten Metal Leak Detector 7
Induction Heating & Melting Saety Fundamentals Guide
‘Charging & Preheating Systems
Charging & Preheating Systems Help Fight Molten Metal Spas 18
Drying & Preheating Systems _ 18
Charging Systems _ Se 8
Moving Equipment Presents Trapping Hazard — 19
Refractory Lining
Maintaining Your Refractory Lining _ : — 2
Choosing the Right Refractory = 2
a
2
Proper Installation of à Furnace Lining
Automated Sintering Control Systems,
Monitoring Normal Lining Wear 2
Physical Shock & Mechanical Stress — 2
Excessive Temperatures & Thermal Shook 2
Managing Slag or Dross 3
2
2
Slag Removal Automation
Inductive Sting _____
Met Automation Technology Helps an
Electrical Monitoring of Lining Wear 25
Electrical Operation & Safty Precautions
Induction Electrical System Satey_— u 25
Safety Recommendations for Foundry Supervisors & Managers — Ss
Safely Lockouts ar Key Systems. ar
Induction Power Units Include Some or Al E
For Trained Electricians On 28
Common Regulatry Electrical Notices & Requirements 2
Other Hazards
Hydraulic System Say _ »
Do Not Use “Subsitute/Unauihorized” Parts 30
VITON Seal Safety Advisory. 30
Furnace cing —_—_ 30
Melt Shop “Confined Spaces El
Furnace Lids 31
Launders El
Mechanical Component Inspection — = = E
Safely ls Shared Value
Making Melt Shop Safety a Shared Value 33
‘Who Needs Melt Shop Safety Training? 33
Safety Stats on Day One E
Melt Shop Supervisors Play Key Role =
Preparing for Accidents
Specity Sater Equipment —
‘Charging & Preheating Systems
Charging & Preheating Systems Help Fight Molten Metal Spas 18
Drying & Preheating Systems _ 18
Charging Systems _ Se 8
Moving Equipment Presents Trapping Hazard — 19
Refractory Lining
Maintaining Your Refractory Lining _ : — 2
Choosing the Right Refractory = 2
a
2
Proper Installation of à Furnace Lining
Automated Sintering Control Systems,
Monitoring Normal Lining Wear 2
Physical Shock & Mechanical Stress — 2
Excessive Temperatures & Thermal Shook 2
Managing Slag or Dross 3
2
2
Slag Removal Automation
Inductive Sting _____
Met Automation Technology Helps an
Electrical Monitoring of Lining Wear 25
Electrical Operation & Safty Precautions
Induction Electrical System Satey_— u 25
Safety Recommendations for Foundry Supervisors & Managers — Ss
Safely Lockouts ar Key Systems. ar
Induction Power Units Include Some or Al E
For Trained Electricians On 28
Common Regulatry Electrical Notices & Requirements 2
Other Hazards
Hydraulic System Say _ »
Do Not Use “Subsitute/Unauihorized” Parts 30
VITON Seal Safety Advisory. 30
Furnace cing —_—_ 30
Melt Shop “Confined Spaces El
Furnace Lids 31
Launders El
Mechanical Component Inspection — = = E
Safely ls Shared Value
Making Melt Shop Safety a Shared Value 33
‘Who Needs Melt Shop Safety Training? 33
Safety Stats on Day One E
Melt Shop Supervisors Play Key Role =
Preparing for Accidents
Specity Sater Equipment —
Induction Heat
8 Meting Saety Fundament
‘About This Guide
This guide describes general safety information. Some, but
‘otal ars of this brochure wl apply to your equipment. All
information contained in this brochure isthe atest informa»
tion avalabl a the time of printing. Inducotherm Cor. re
serve the right to make changes at any time without notice.
inductothem Corp. makes no warranty of any kind with
‘gard to ths material and assumes no responsibilty fr any
(errors that may occur in this brochure.
Equipment Manuals Must Be Your Primary Safety Source
We really care about you and your workers. This is why we
have taken the time fo compile this “Heating and Melting
Safety Fundamentals Guide” to bring to your attention some
‘major safety hazards.
This guide provides safety information of a general nature
and isnot intended to bea substitute for the more detailed
and specie operational and safety information provided in
Inductotermis equipment manuals. These equipment man-
uals must always be your primary source of information on
the proper and safe operation of Inductotherm equipment
Salety Must Bea Key Corporate Value
Please read this guide thoroughly and have al of the ap
propriate personne in your organization read and follow the
instructions carefully. tis our fm bei that management,
‘uers and supervisor play a kay role in assuring safe op-
eration of melting, holding, pouring and heating equipment.
In most me shops, they bear frontine responsibilty for
implementing and monitoring established safety procedures
and new worker training, as well as equipment inspection
and maintenance,
Vinil ts impossible to remove the risk from heating and
‘melting metal it's possible to make the met shop an aci
entres workplace. To accomplish this goal require a true
partnership between mel shop managers, he suppliers who
equip the mel shop and the met shop workers who operate
their equipment.
I requires management to make safety key corporate value
and then to communicate that othe melt shop workers both
by selecting the safest avaiable equipment and by extending
every possible effort to assure that personnel are instructed
ints proper use
Hazard Intensity Levels
A al times you must refer to your equipment manual for
comprehensive information and defntions. You must follow
these warnings careful o avoid injury and possible death
Throughout this “Heating and Melting Safety Fundamentals
Guide,” you wil see both safety and operational warnings
set apart from the regular informative text. These special
boxes have been inserted to call your attention to matters
that you cannot afford to overiook. They are often referring
to incidents tat ignored or overlooked can lead to serious
Injury or death
There are tree general accepted signal words defining
thre levels of hazard intensity, and a fourth hat should lso
be read carefully The types of warnings, what they look tke
and how they are used in this “Heating and Meling Safety
Fundamentals Guide are described here for you to familiar-
ize yourself with and to use to educate other personne in
your mel shop.
ro
Danger tags advise ofan immediate hazard that presents
that of death o serious bodily injury.
Warning tags advise of a hazard that presents some
probability of death or severe injury.
Caution tags advise of potential hazards orto caution
against unsafe practices
A vonce
Notice tags advise of policies that relate directly or
indirectly to personal safety or property protection
8 Meting Saety Fundament
‘About This Guide
This guide describes general safety information. Some, but
‘otal ars of this brochure wl apply to your equipment. All
information contained in this brochure isthe atest informa»
tion avalabl a the time of printing. Inducotherm Cor. re
serve the right to make changes at any time without notice.
inductothem Corp. makes no warranty of any kind with
‘gard to ths material and assumes no responsibilty fr any
(errors that may occur in this brochure.
Equipment Manuals Must Be Your Primary Safety Source
We really care about you and your workers. This is why we
have taken the time fo compile this “Heating and Melting
Safety Fundamentals Guide” to bring to your attention some
‘major safety hazards.
This guide provides safety information of a general nature
and isnot intended to bea substitute for the more detailed
and specie operational and safety information provided in
Inductotermis equipment manuals. These equipment man-
uals must always be your primary source of information on
the proper and safe operation of Inductotherm equipment
Salety Must Bea Key Corporate Value
Please read this guide thoroughly and have al of the ap
propriate personne in your organization read and follow the
instructions carefully. tis our fm bei that management,
‘uers and supervisor play a kay role in assuring safe op-
eration of melting, holding, pouring and heating equipment.
In most me shops, they bear frontine responsibilty for
implementing and monitoring established safety procedures
and new worker training, as well as equipment inspection
and maintenance,
Vinil ts impossible to remove the risk from heating and
‘melting metal it's possible to make the met shop an aci
entres workplace. To accomplish this goal require a true
partnership between mel shop managers, he suppliers who
equip the mel shop and the met shop workers who operate
their equipment.
I requires management to make safety key corporate value
and then to communicate that othe melt shop workers both
by selecting the safest avaiable equipment and by extending
every possible effort to assure that personnel are instructed
ints proper use
Hazard Intensity Levels
A al times you must refer to your equipment manual for
comprehensive information and defntions. You must follow
these warnings careful o avoid injury and possible death
Throughout this “Heating and Melting Safety Fundamentals
Guide,” you wil see both safety and operational warnings
set apart from the regular informative text. These special
boxes have been inserted to call your attention to matters
that you cannot afford to overiook. They are often referring
to incidents tat ignored or overlooked can lead to serious
Injury or death
There are tree general accepted signal words defining
thre levels of hazard intensity, and a fourth hat should lso
be read carefully The types of warnings, what they look tke
and how they are used in this “Heating and Meling Safety
Fundamentals Guide are described here for you to familiar-
ize yourself with and to use to educate other personne in
your mel shop.
ro
Danger tags advise ofan immediate hazard that presents
that of death o serious bodily injury.
Warning tags advise of a hazard that presents some
probability of death or severe injury.
Caution tags advise of potential hazards orto caution
against unsafe practices
A vonce
Notice tags advise of policies that relate directly or
indirectly to personal safety or property protection
The following provides a description of the universal
symbols that wil be placed inside the appropriate hazard
AN
At Elson
A
N noe à
À LB ak ot £tcocution
AN attention
nis is
A ri te à,
À AW espiato Required
A Hor sure Hard A
FEN comasve Materia
(Consult Your Governing Agencios & Industry Organizations
Wile we at Inductotherm are aware of many safety hazards
and want to help create a safer melt shop, we cannot be your
sole source of safety. Please consult with both your national
and local goveming agencies and industry organizations for
addtional safety information and refer to national and local
sat codes
Occupational Saety &
Health Administration (OSHA)
‘wovu.0sha.gov
National Fire
Protection Agency (NFPA)
nu nfpa org
“American Foundry Society (AFS)
afin org
American National
Standards Insitute (ANS!)
aan org
ASTM Intemational
un astm 010
Induction Heating & Meting Si
ty Fundamentals Guide
Inductotherm Heating & Melting Saety Training Kit
Working wth molten metal always ha been a dangerous job
Inthe past, the heat, noise and fumes produced by combus
tion funaces constantly reminded melt shop workers of melt
shop hazards. But today’ high-efciency induction furnaces
have improved working conditions by making melt shops
codler, cleaner and generally less hostle workplaces. They
have nat, however, eliminated the dangers inherent in work
ing close to molten metal.
‘The goal of this guide and
the Inductotherm Heating
and Meting Safety Training
Kit described below is to
make al mel shop workers
aware ofthe lifesaving pre-
cautions that must always
betaken whenever metal is
mete,
Induction fumaces make
today's melt shops safer
and more productive than
a any time in history. Sad
ly, many ofthe deaths and. IA
injuries that have occurred could have bean prevented by
observing common-sense safety precautions,
For ths reason, we have created the Inductotherm Heating
and Melting Safety Training K and have made it avalable
for re to all mel shops, whether they have Inducttherm
equipment o not
The Inductotherm Heating and Melting Safety Training Kit
consists ofthe following parts:
+ This “Heating and Metting Safety Fundamentals Guide”
+ Safety related bulletins and articles
A Inductotherm, we want every met shop employee, owner
and supervisor fo become knowledgeable about the safety
hazards associate with meting metal This kts one way we
are working to achieve ths goal
Meting Sat Training Kit
This safety training guide provides safety information ofa general nature. ti not intended to bea substitute fr the more
detalle and specific operational and safety information provided in Inductotherm’s equipment manuals. These equipment
‘manuals must be your primary source of Information on the proper and safe operation of Inductotherm equipment
{Under OSHA's "Employer Responsibites and Rights” section, all employers must establish or update operating proce-
dures and communicate them so that employees follow safety and heath requirements.
symbols that wil be placed inside the appropriate hazard
AN
At Elson
A
N noe à
À LB ak ot £tcocution
AN attention
nis is
A ri te à,
À AW espiato Required
A Hor sure Hard A
FEN comasve Materia
(Consult Your Governing Agencios & Industry Organizations
Wile we at Inductotherm are aware of many safety hazards
and want to help create a safer melt shop, we cannot be your
sole source of safety. Please consult with both your national
and local goveming agencies and industry organizations for
addtional safety information and refer to national and local
sat codes
Occupational Saety &
Health Administration (OSHA)
‘wovu.0sha.gov
National Fire
Protection Agency (NFPA)
nu nfpa org
“American Foundry Society (AFS)
afin org
American National
Standards Insitute (ANS!)
aan org
ASTM Intemational
un astm 010
Induction Heating & Meting Si
ty Fundamentals Guide
Inductotherm Heating & Melting Saety Training Kit
Working wth molten metal always ha been a dangerous job
Inthe past, the heat, noise and fumes produced by combus
tion funaces constantly reminded melt shop workers of melt
shop hazards. But today’ high-efciency induction furnaces
have improved working conditions by making melt shops
codler, cleaner and generally less hostle workplaces. They
have nat, however, eliminated the dangers inherent in work
ing close to molten metal.
‘The goal of this guide and
the Inductotherm Heating
and Meting Safety Training
Kit described below is to
make al mel shop workers
aware ofthe lifesaving pre-
cautions that must always
betaken whenever metal is
mete,
Induction fumaces make
today's melt shops safer
and more productive than
a any time in history. Sad
ly, many ofthe deaths and. IA
injuries that have occurred could have bean prevented by
observing common-sense safety precautions,
For ths reason, we have created the Inductotherm Heating
and Melting Safety Training K and have made it avalable
for re to all mel shops, whether they have Inducttherm
equipment o not
The Inductotherm Heating and Melting Safety Training Kit
consists ofthe following parts:
+ This “Heating and Metting Safety Fundamentals Guide”
+ Safety related bulletins and articles
A Inductotherm, we want every met shop employee, owner
and supervisor fo become knowledgeable about the safety
hazards associate with meting metal This kts one way we
are working to achieve ths goal
Meting Sat Training Kit
This safety training guide provides safety information ofa general nature. ti not intended to bea substitute fr the more
detalle and specific operational and safety information provided in Inductotherm’s equipment manuals. These equipment
‘manuals must be your primary source of Information on the proper and safe operation of Inductotherm equipment
{Under OSHA's "Employer Responsibites and Rights” section, all employers must establish or update operating proce-
dures and communicate them so that employees follow safety and heath requirements.
Induction Heating & Meling Safety Fundamentals Guide
Induction Heating & Melting
Combustion furnaces and induction furnaces produce eatin
‘wo entirely diferent ways
In a combustion furnace, bat is created by burning a fuel
Such as coke, oll or natural gas. The During fuel brings
the interior temperature ofthe furnace above the set point
temperature ofthe charge material placed inside. This heats
the surface of the charge mater, causing i to heat or met
depending on the application.
Induction fumaces produce their heat cleanly, without com
bustin, Aerating electric current from an induction power
unitfiousintafumace andthrougha collmade afholow cp-
per tubing, This creates an electromagnetic field that passes
through the refractory material and couples with conductive
‘metal charge inside the furnace. This induces electric current
to flow inside the metal charge isl, producing heat that
rapidly causes the metal to reach the set point temperature
‘though some
furnace surfaces
may become hot
enough to present
burn hazard, with
induction, you heat
the charge drecty,
not the furnace.
Induction
Coil
Furnace
Refractory Lining
‘Current flowing in one drecton in the induction col in-
‘duces a current flow in the opposite direction in the metal
(charge. This current heals the metal and causes ito rapid
reach se point temperature.
Induction Electrical System Configurations
Induction furnaces require two separate electrical systems:
one forthe cooling system, fumace ting and instrument
tion, and the oher fr the induction col power.
Aline tothe plants power distribution pane typically furnish
Power for the pumps inthe induction col cooling system,
the hydraulic furnace tting mechanism, and instrumentation
and control systems,
Electric fr he induction cols is fumished from a three-
phase, high voltage, high amperage uty lin. The complex
iy ofthe power supply connected t te induction cols var-
Tes with the typeof furnace and its use
‘A channel fumace that holds and pours liquefied metal can
operate efficiently using mains frequency provided by the lo-
cal utility. By contrast, most coreess furnaces for melting
require a medium to high frequency power supply. Silay
power supplies used for heating applications il operate at
medium to high frequency.
Raising the frequency of the alternating current flowing
through the induction cols increases the amount of power
that can be applied toa given size furnace. This, in tun,
means faster meli.
A 10 on coreless fumace operating at 60 Hz can malt is
capacity in two hours At 275 Hz, he same furnace can melt
‘the fll 10 ton charge in 26 minutes, or four times faster.
An added advantage of higher frequency operation is that
furnaces can be started using less bully scrap and can be
‘emptied completely between heats.
‘The transformers, inverters and capacitors needed to “tune”
the frequency required for high-efficiency induction furnaces
can pose a serious electrical hazard.
For ths reason, fumace power supplies are housed in eye
locked steel enclosures, equipped with safety interlocks,
Salety implications
‘Typically, the induction col power supply and the other ur-
nace systems are energized from multiple electric services.
This means that melt shop workers cannot assume thatthe
power tothe furnace coll has stopped because service has
been interrupted tothe furnace's cooling system or hydraulic
pump. Review the lckouttagout section provide inthis
safely guide.
Induction Heating & Melting
Combustion furnaces and induction furnaces produce eatin
‘wo entirely diferent ways
In a combustion furnace, bat is created by burning a fuel
Such as coke, oll or natural gas. The During fuel brings
the interior temperature ofthe furnace above the set point
temperature ofthe charge material placed inside. This heats
the surface of the charge mater, causing i to heat or met
depending on the application.
Induction fumaces produce their heat cleanly, without com
bustin, Aerating electric current from an induction power
unitfiousintafumace andthrougha collmade afholow cp-
per tubing, This creates an electromagnetic field that passes
through the refractory material and couples with conductive
‘metal charge inside the furnace. This induces electric current
to flow inside the metal charge isl, producing heat that
rapidly causes the metal to reach the set point temperature
‘though some
furnace surfaces
may become hot
enough to present
burn hazard, with
induction, you heat
the charge drecty,
not the furnace.
Induction
Coil
Furnace
Refractory Lining
‘Current flowing in one drecton in the induction col in-
‘duces a current flow in the opposite direction in the metal
(charge. This current heals the metal and causes ito rapid
reach se point temperature.
Induction Electrical System Configurations
Induction furnaces require two separate electrical systems:
one forthe cooling system, fumace ting and instrument
tion, and the oher fr the induction col power.
Aline tothe plants power distribution pane typically furnish
Power for the pumps inthe induction col cooling system,
the hydraulic furnace tting mechanism, and instrumentation
and control systems,
Electric fr he induction cols is fumished from a three-
phase, high voltage, high amperage uty lin. The complex
iy ofthe power supply connected t te induction cols var-
Tes with the typeof furnace and its use
‘A channel fumace that holds and pours liquefied metal can
operate efficiently using mains frequency provided by the lo-
cal utility. By contrast, most coreess furnaces for melting
require a medium to high frequency power supply. Silay
power supplies used for heating applications il operate at
medium to high frequency.
Raising the frequency of the alternating current flowing
through the induction cols increases the amount of power
that can be applied toa given size furnace. This, in tun,
means faster meli.
A 10 on coreless fumace operating at 60 Hz can malt is
capacity in two hours At 275 Hz, he same furnace can melt
‘the fll 10 ton charge in 26 minutes, or four times faster.
An added advantage of higher frequency operation is that
furnaces can be started using less bully scrap and can be
‘emptied completely between heats.
‘The transformers, inverters and capacitors needed to “tune”
the frequency required for high-efficiency induction furnaces
can pose a serious electrical hazard.
For ths reason, fumace power supplies are housed in eye
locked steel enclosures, equipped with safety interlocks,
Salety implications
‘Typically, the induction col power supply and the other ur-
nace systems are energized from multiple electric services.
This means that melt shop workers cannot assume thatthe
power tothe furnace coll has stopped because service has
been interrupted tothe furnace's cooling system or hydraulic
pump. Review the lckouttagout section provide inthis
safely guide.
duction Heating & Ming S
ty Fundamentals Guide
Induction Furnaces Come In Many Varieties
Coreless Furnaces
‘Acoreless furnace has no inductor or cor, unlike the channel furnace
described below. Instead, the entire bath functions as the induction
heating area. Copper cols encircle a layer of refractory material ur- >
ounding the entre length ofthe furnace interior. Running a powerful
electric current through the cols creates a magnetic ll tht pen-
rates the refractory and quickly melts the metal charge material n-
side the furnace. The copper col is kept from meting by cooing water
flowing through it Coreless furnaces range in size from just a few
‘ounces to 120 tans of metal and more.
A diet electric heat furnace isa unique type of highly efficient air
Cooled careless furnace thatusesinductiontoheatacrucibleratherthan
the metal ie This furnace is used to melt most nonferous metals. Copper Coll
Channel Furnaces Inductor
In azine coating pot, induction heating takes place in the “channel
a relatively small and narrow area within the inductor. The channel
passes through a laminated steel core and around the col assembly.
‘The electric circuit formed by the core and cols completed when the
channel is filed with molten meta
(Once the channels file with malen meta, power can be applied to
the furnace col, This produces an intense electromagnetic feld which
causes electric current to flow through and further heat the molten
‘metal in the channel. Hotter metal leaving the channel circulates up-
wad, rasing the temperature of the entre bath
‘Typically, channel furnaces are sed to hold molten metal winenevr it
is needed. Channel furnaces are emptied only or rlining
Induction Heating
Induction also is widely used fora varity of heating
applications for metals as wells for non-metli mate
tials, or metals, induction heating applications include
heat treating, induction welding, semi-solid casting,
pats fing, annealing, galvanizing, galvanneaing, tin
flow, coatings, boosters, ar, bills, bloom, sib heat»
ingandin many other metal heat treatment applications
For non-metalc materials, induction heating is used to
produce ula-high temperature carbon composites and
{or making high-ualty optical glass
© 2006 Inductotherm Corp.
ty Fundamentals Guide
Induction Furnaces Come In Many Varieties
Coreless Furnaces
‘Acoreless furnace has no inductor or cor, unlike the channel furnace
described below. Instead, the entire bath functions as the induction
heating area. Copper cols encircle a layer of refractory material ur- >
ounding the entre length ofthe furnace interior. Running a powerful
electric current through the cols creates a magnetic ll tht pen-
rates the refractory and quickly melts the metal charge material n-
side the furnace. The copper col is kept from meting by cooing water
flowing through it Coreless furnaces range in size from just a few
‘ounces to 120 tans of metal and more.
A diet electric heat furnace isa unique type of highly efficient air
Cooled careless furnace thatusesinductiontoheatacrucibleratherthan
the metal ie This furnace is used to melt most nonferous metals. Copper Coll
Channel Furnaces Inductor
In azine coating pot, induction heating takes place in the “channel
a relatively small and narrow area within the inductor. The channel
passes through a laminated steel core and around the col assembly.
‘The electric circuit formed by the core and cols completed when the
channel is filed with molten meta
(Once the channels file with malen meta, power can be applied to
the furnace col, This produces an intense electromagnetic feld which
causes electric current to flow through and further heat the molten
‘metal in the channel. Hotter metal leaving the channel circulates up-
wad, rasing the temperature of the entre bath
‘Typically, channel furnaces are sed to hold molten metal winenevr it
is needed. Channel furnaces are emptied only or rlining
Induction Heating
Induction also is widely used fora varity of heating
applications for metals as wells for non-metli mate
tials, or metals, induction heating applications include
heat treating, induction welding, semi-solid casting,
pats fing, annealing, galvanizing, galvanneaing, tin
flow, coatings, boosters, ar, bills, bloom, sib heat»
ingandin many other metal heat treatment applications
For non-metalc materials, induction heating is used to
produce ula-high temperature carbon composites and
{or making high-ualty optical glass
© 2006 Inductotherm Corp.
Induction Heating & Meling Safety Fundamentals Guide
review of records of melt shops that use induction furnac
8 reves that, in almost every accident. injury and damage
could have been prevented by observing basic safety pre-
cautions. Most malt shop precaution, such as wearing eye
protection and nonfammabl clothing, are simple common
sense.
Other safety measures, such as knowing how to deal with
a bridging emergency, require specific knowledge of the
induction meting process.
This guide wil help you better understand and deal with both
day-to-day hazards present in al melt shops and many ofthe
emergency situation you may one day encounter.
Accident investigation report indicate that most melt shop
accidents happen due to one of the following reasons:
+The introduction of wet or damp metal into the met, caus-
ing a water/molten metal explosion
+ Lack of operator ski during temperature taking, sampling
or the addition of alloying compounds, causing metal splash
+ Dropping large pieces of charge material into a molten bath
causing meta splash
Working with molten metal alvays has been ar
occupation. Responsible mel shop workers acknowledge 1
sible managers minimize the risks by intiling among wor
of training and accident prevention
A
Personnel wit artifical organs, jin, plates or similar
Objects shoud keep avay rom any induction equipment
‘The magnetic fields from the equipment may induce
currents causing heating of metalic implants. Person
nol with cardiac pacemakers are particulary at risk and
sould stay well away rom any induction equipment
A
Do not operate the equipment it any safety devices are
Jumpered, bypassed, or non-operational,
A
Do nat attempt to use he equipment for anything other
than ts intended purpose.
+ Improper attention to charging,
causing abridging condition
+ Falure to stand behind safety
lines, causing a trapping station
+ Coming into contact with
electrical conductors, overriding
safely introck switches or coming
into contact with incompletely ds»
charged capacitors, causing elec
ttc shock or electrocution
+ Lack of operator traning
This guide wil focus on what you
can doo protect yourself and your
co-workers from. these hazards
and others. However, this is nat a
substitute for Ihe more detailed in
formation found in your equipment
‘manuals. The manuals must be your
primary Source of information,
review of records of melt shops that use induction furnac
8 reves that, in almost every accident. injury and damage
could have been prevented by observing basic safety pre-
cautions. Most malt shop precaution, such as wearing eye
protection and nonfammabl clothing, are simple common
sense.
Other safety measures, such as knowing how to deal with
a bridging emergency, require specific knowledge of the
induction meting process.
This guide wil help you better understand and deal with both
day-to-day hazards present in al melt shops and many ofthe
emergency situation you may one day encounter.
Accident investigation report indicate that most melt shop
accidents happen due to one of the following reasons:
+The introduction of wet or damp metal into the met, caus-
ing a water/molten metal explosion
+ Lack of operator ski during temperature taking, sampling
or the addition of alloying compounds, causing metal splash
+ Dropping large pieces of charge material into a molten bath
causing meta splash
Working with molten metal alvays has been ar
occupation. Responsible mel shop workers acknowledge 1
sible managers minimize the risks by intiling among wor
of training and accident prevention
A
Personnel wit artifical organs, jin, plates or similar
Objects shoud keep avay rom any induction equipment
‘The magnetic fields from the equipment may induce
currents causing heating of metalic implants. Person
nol with cardiac pacemakers are particulary at risk and
sould stay well away rom any induction equipment
A
Do not operate the equipment it any safety devices are
Jumpered, bypassed, or non-operational,
A
Do nat attempt to use he equipment for anything other
than ts intended purpose.
+ Improper attention to charging,
causing abridging condition
+ Falure to stand behind safety
lines, causing a trapping station
+ Coming into contact with
electrical conductors, overriding
safely introck switches or coming
into contact with incompletely ds»
charged capacitors, causing elec
ttc shock or electrocution
+ Lack of operator traning
This guide wil focus on what you
can doo protect yourself and your
co-workers from. these hazards
and others. However, this is nat a
substitute for Ihe more detailed in
formation found in your equipment
‘manuals. The manuals must be your
primary Source of information,
Le
Personnel working in proximity to molten metal must
‘wear primary protective clothing, Improper, fammable
clothing isthe number one cause of severe bums due to
‘molten metal, Personal Protective Equipment (PPE) may
prevent serious injury or death
OSHA's Personal Protective Equipment Part 29CFR
(1910.132) states, "The employer shal assess the work“
Place to determine if hazards are Ikely to be present,
hich necessitate the use of Personal Protective Equip
ment (PPE),
Respirators (not shown) may be needed pending he re-
sults of your ob hazard assessment.
Personal Protective Equipment (PPE) including an a
loves and ul hood helps protect his
uction Heating & M ety Fundamentals Guide
‘Aluminized coats, gloves and lego
workers from both metal splash and ra
founders boots
1 a met shop worker's fist line of defense against injury
or death is safe equipment and training that enables proper
‘operation under both routine and emergency conditions,
the final line of defense is the workers Personal Protective
Equipment (PPE)
‘Wearing the proper protective equipment can mean the dit
ference between walking away from a melt shop catastrophe
‘or being injured o ile
Various organizations that st national standards have estab
lished broad guidelines forthe use of protective equipment
in the metal casting Industry. These organizations tend to
agree onthe basic types of personal equipment which pro
vide workers with meaningful protection from molten metal
exposure
Many protective equipment manufacturers and distributors
refine Industry guidelines, Armed with knowledge of the
latest technological advances In protective materials and
products, they cantaor safety equipment programs to spe
Cite met shop needs
‘There ae two types of protective equipment worn in a melt
Shop: primary and secondary protective equipment
Personnel working in proximity to molten metal must
‘wear primary protective clothing, Improper, fammable
clothing isthe number one cause of severe bums due to
‘molten metal, Personal Protective Equipment (PPE) may
prevent serious injury or death
OSHA's Personal Protective Equipment Part 29CFR
(1910.132) states, "The employer shal assess the work“
Place to determine if hazards are Ikely to be present,
hich necessitate the use of Personal Protective Equip
ment (PPE),
Respirators (not shown) may be needed pending he re-
sults of your ob hazard assessment.
Personal Protective Equipment (PPE) including an a
loves and ul hood helps protect his
uction Heating & M ety Fundamentals Guide
‘Aluminized coats, gloves and lego
workers from both metal splash and ra
founders boots
1 a met shop worker's fist line of defense against injury
or death is safe equipment and training that enables proper
‘operation under both routine and emergency conditions,
the final line of defense is the workers Personal Protective
Equipment (PPE)
‘Wearing the proper protective equipment can mean the dit
ference between walking away from a melt shop catastrophe
‘or being injured o ile
Various organizations that st national standards have estab
lished broad guidelines forthe use of protective equipment
in the metal casting Industry. These organizations tend to
agree onthe basic types of personal equipment which pro
vide workers with meaningful protection from molten metal
exposure
Many protective equipment manufacturers and distributors
refine Industry guidelines, Armed with knowledge of the
latest technological advances In protective materials and
products, they cantaor safety equipment programs to spe
Cite met shop needs
‘There ae two types of protective equipment worn in a melt
Shop: primary and secondary protective equipment
Induction Heating & Meling Safety Fundamentals Guide
Primary Protective Equipment
Primary Protective Equipment is he gear which you wear
Over your Secondary Protective Equipment when there is
significant exposure to radiant heat, moten metal splash
and lame, Is designed to give you the greatest protection,
Primary Protective Equipment should be worn during work
activities Ike charging, sampling, temperature measuring,
sagging, tapping, pouting and casting operations, or when-
ver there is close proximity to molten metal. Primary Pro-
tectve Equipment includes safety glasses, a face shield, hard
at, jacket, apron love, leggings, spas, cape and sleeves,
and must be made of aluminized glass fabrics.
For eyeftace protection, safety glasses with side shields are
the minimum requirement. For moten metal exposure face
shield i needed in addition to safety glasses. Your eyes are
extremely susceptible 10 injury, and protection isso easy to
provide
For head protection from fyingtaling objects, shocks,
splashes, eo. a hard hat must be wor,
Working near places where there is heat, eat resistantlame
‘etardant gloves should be worn, In working near molten
‘metal, melt shop gloves which extend above the wists must
be worn,
For protection ofthe body, arms and legs, aluminized glass
‘outerwear has been recommended by the American Foundry
Society (AFS) for protection against radiant heat and mol-
en metal splash. Aluminized glass outerwear, similar to
that pictured here wil delet about 90% ofthe raiant heat
away from the body, while shedding malten metal splash and
sparks,
Use leggings to cover your les.
Pourer oracle safety boots are required for fot protec:
tion from molten substance exposure. They can be removed
Quick in case metal gets inside. Metaarsa-quard shoes
protect the op ofthe fo. lad boots are worn, they must
be covered with spats, especialy near the top where there is
‘danger ofthe molten metal entering
AS classes protective garments according to metal types.
‘When meting ferrous and other metals thigh temperatures,
they advise clothing whic hs undergone phosphorous-base
treatment, However, fr resistance to he clinging of molten
splash from lower temperature mets, such as aluminum,
gaalume, zinc ec, these vendors recommend apparel of
a non-phosphorous treatment,
Visitors must also be made to wear hard hats at all times
¡respective of their duration of stay or proximity to known
hazards and must aso adhere othe same safety guideline,
Typical Primary Protective Equipment
Safety Hood
Face Shield
Fame Resistant Matera
50" Aluminized Coat
14° Aluminized
Back Gloves
Leggings or
Spats
Laowess
Safely Boots
OSHA's Personal Protective Equipment Part 29CFR
(1910.192) states, “The employer shall assess the work
ace to determine if haar are likely to be present,
hich necessitate the use of Personal Protective Equip
ment (PPE).”
Respirators (nt shown) may be needed pending te re
Suis of your ob hazard assessment,
© 2006 Inductotherm Corp.
Primary Protective Equipment
Primary Protective Equipment is he gear which you wear
Over your Secondary Protective Equipment when there is
significant exposure to radiant heat, moten metal splash
and lame, Is designed to give you the greatest protection,
Primary Protective Equipment should be worn during work
activities Ike charging, sampling, temperature measuring,
sagging, tapping, pouting and casting operations, or when-
ver there is close proximity to molten metal. Primary Pro-
tectve Equipment includes safety glasses, a face shield, hard
at, jacket, apron love, leggings, spas, cape and sleeves,
and must be made of aluminized glass fabrics.
For eyeftace protection, safety glasses with side shields are
the minimum requirement. For moten metal exposure face
shield i needed in addition to safety glasses. Your eyes are
extremely susceptible 10 injury, and protection isso easy to
provide
For head protection from fyingtaling objects, shocks,
splashes, eo. a hard hat must be wor,
Working near places where there is heat, eat resistantlame
‘etardant gloves should be worn, In working near molten
‘metal, melt shop gloves which extend above the wists must
be worn,
For protection ofthe body, arms and legs, aluminized glass
‘outerwear has been recommended by the American Foundry
Society (AFS) for protection against radiant heat and mol-
en metal splash. Aluminized glass outerwear, similar to
that pictured here wil delet about 90% ofthe raiant heat
away from the body, while shedding malten metal splash and
sparks,
Use leggings to cover your les.
Pourer oracle safety boots are required for fot protec:
tion from molten substance exposure. They can be removed
Quick in case metal gets inside. Metaarsa-quard shoes
protect the op ofthe fo. lad boots are worn, they must
be covered with spats, especialy near the top where there is
‘danger ofthe molten metal entering
AS classes protective garments according to metal types.
‘When meting ferrous and other metals thigh temperatures,
they advise clothing whic hs undergone phosphorous-base
treatment, However, fr resistance to he clinging of molten
splash from lower temperature mets, such as aluminum,
gaalume, zinc ec, these vendors recommend apparel of
a non-phosphorous treatment,
Visitors must also be made to wear hard hats at all times
¡respective of their duration of stay or proximity to known
hazards and must aso adhere othe same safety guideline,
Typical Primary Protective Equipment
Safety Hood
Face Shield
Fame Resistant Matera
50" Aluminized Coat
14° Aluminized
Back Gloves
Leggings or
Spats
Laowess
Safely Boots
OSHA's Personal Protective Equipment Part 29CFR
(1910.192) states, “The employer shall assess the work
ace to determine if haar are likely to be present,
hich necessitate the use of Personal Protective Equip
ment (PPE).”
Respirators (nt shown) may be needed pending te re
Suis of your ob hazard assessment,
© 2006 Inductotherm Corp.
‘Te American Foundry Society (AFS) publishes a “Guide
far Selection and Use of Personal Protective Equipment
(PPE) and Special Clothing for Foundry Operations.”
This guide can be obtained by contacting AFS at:
American Foundry Society
1695 North Penny Lane
Schaumburg IL 60173-4555 USA
Toll Free: 800/537-4287 Fax: 847/824-7848
Phone: 847/824-0181 Website: wwasine og
‘Along with Primary Protective Equipment, as dictated by
the working environment, .g. safety glasses, hard hat, ear
plus, had toe boos, ec, Secondary Protective Equipment
Is wor in areas where thre is less hazard and is used to
prevent ordinary clothing from igniting and burning. Flame
resistant coveralls would be an example of Secondary
Protective Equipment. Secondary Protective Equipment will
help to reduce burns significa.
In many cases, serious burns and fatalities have occurred
because ordinary clothing caught fre from a Sma spark or
splash, not because of burs caused direct by moten metal
‘Along with Secondary Protective Equipment you also must
‘wear natural fiber outer clothing, undergarments and socks.
‘Some synthei fabrics melt or cic ie and this can increase
the burn hazard, AFS recommends the use of washable, fre
resistant undergarments. Cetany, met shops are ht plac-
8510 work and Personal Protective Equipment (PPE) adds to
the problem of heat-elated stress, but it can save your if
alten aluminum I
is even more dangerous han higher temperature
‘metals and must be treated as such,
Induction Heating & Meting Safety Fundamentals Guide
When these ordinary work clothes were ignited by mote
aluminum, the worker suffered fatal bums, Fame resistant
clothing might have saved his ie
While some metals melt at a lower temperature than fer-
‘ous metas they, in some respects, presenta greater meta
splash hazard to the melt shop worker. Low temperature
‘metals and thee alloys, such as aluminum, galvalume, in,
lead, galan, zinc, copper and copper alloys, et, stick lo
bare sin, producing severe and possibly disfiguing bums. I
larger amounts of metal are involved, the burns can be fatal
Wearing Personal Protective Equipment (PPE), including
Safety glasses, face shield, head and body protection, and
foot and hand protection is crucial to safety when working
in proximity to molten metals, regardless of the melting
temperature.
Safely professionals advise that no all protective clothing
provides the same protection against all metals. For exam
le, they report that molten aluminum sticks to some fabrics.
and not others. lso, some types of aluminized fabric ignite
when splashed with molten aluminum while others do not.
They spect that splash tests be conducted to evaluate new
‘protective equipment before it put ito use
far Selection and Use of Personal Protective Equipment
(PPE) and Special Clothing for Foundry Operations.”
This guide can be obtained by contacting AFS at:
American Foundry Society
1695 North Penny Lane
Schaumburg IL 60173-4555 USA
Toll Free: 800/537-4287 Fax: 847/824-7848
Phone: 847/824-0181 Website: wwasine og
‘Along with Primary Protective Equipment, as dictated by
the working environment, .g. safety glasses, hard hat, ear
plus, had toe boos, ec, Secondary Protective Equipment
Is wor in areas where thre is less hazard and is used to
prevent ordinary clothing from igniting and burning. Flame
resistant coveralls would be an example of Secondary
Protective Equipment. Secondary Protective Equipment will
help to reduce burns significa.
In many cases, serious burns and fatalities have occurred
because ordinary clothing caught fre from a Sma spark or
splash, not because of burs caused direct by moten metal
‘Along with Secondary Protective Equipment you also must
‘wear natural fiber outer clothing, undergarments and socks.
‘Some synthei fabrics melt or cic ie and this can increase
the burn hazard, AFS recommends the use of washable, fre
resistant undergarments. Cetany, met shops are ht plac-
8510 work and Personal Protective Equipment (PPE) adds to
the problem of heat-elated stress, but it can save your if
alten aluminum I
is even more dangerous han higher temperature
‘metals and must be treated as such,
Induction Heating & Meting Safety Fundamentals Guide
When these ordinary work clothes were ignited by mote
aluminum, the worker suffered fatal bums, Fame resistant
clothing might have saved his ie
While some metals melt at a lower temperature than fer-
‘ous metas they, in some respects, presenta greater meta
splash hazard to the melt shop worker. Low temperature
‘metals and thee alloys, such as aluminum, galvalume, in,
lead, galan, zinc, copper and copper alloys, et, stick lo
bare sin, producing severe and possibly disfiguing bums. I
larger amounts of metal are involved, the burns can be fatal
Wearing Personal Protective Equipment (PPE), including
Safety glasses, face shield, head and body protection, and
foot and hand protection is crucial to safety when working
in proximity to molten metals, regardless of the melting
temperature.
Safely professionals advise that no all protective clothing
provides the same protection against all metals. For exam
le, they report that molten aluminum sticks to some fabrics.
and not others. lso, some types of aluminized fabric ignite
when splashed with molten aluminum while others do not.
They spect that splash tests be conducted to evaluate new
‘protective equipment before it put ito use
Induction Heat
& Mating Satty Fundamentals Guide
Where airborne hazards and noise polution pose a threat,
safety profesional also spect the use of respirators and
hearing protection devices. Silica dust particles are consid-
ered a health hazard when inaled ver tim.
Inhalation without protection may cause severe iriation of
the respiratory system, lading o silcoss or cancer. Please
refer to the manufacturer's warning,
EX
Ar fiers must be worn when mixing dry powders, in
ling refractories,
When insulating the col terminations or pass thus inside a
vacuum chamber, the materials used release fumes which
ate considered o be hazardous
Be sure to use the appropiate mask or a given situation
‘Most masks protect against only certain types of dust and
vapor. For example, respirators designed to ter out sultur
dioxide gas ae required in certain aplication.
Working with molten metalin amet shop i serious business
and involves many hazards. Injures ranging from minor to
fatal can occur, but by being avare ofthe dangers and taking
the appropriate steps to safeguard ourselves, we can reduce
the day-o-day risks associated with our work
EX
‘Dust respirators must be wor when removing and in
stalling furnace linings or where dust is prevalent. Check
with your refractory super to determine he correct fi
ter fr your aplication,
There ae three primary ways to help protect people from the
dangers of molten metal, These ae distance, protective bar
ries and Personal Protective Equipment (PPE),
Distance isa very staightforvard form of protection. The
further you are away from metal plas, the ster you are.
Thats why manufacturers promot features such as auto-
‘matic charging systems and computer controls. These sys
tems enable people working with the furnace to stay further
away and st do their obs. In all situations, people not di-
rectly involved in working wit the furnace must stay out of
the immediate area ofthe fumace during charging, meting
and pouring operations.
Protetve barres can provide protection against heat and
splash when distance ist practical, An example of a barrer
would bea screen around a pouring control station on the
met deck.
Wearing Personal Protective Equipment (PPE), however, is
the most important step you can take as an individual to pro
tect yourself from metal splash. Personal Protective Equip
ment (PPE) has tobe your last ine of defense
Control
a barrier.
oms protect te worker by al three Keys: ita
& Mating Satty Fundamentals Guide
Where airborne hazards and noise polution pose a threat,
safety profesional also spect the use of respirators and
hearing protection devices. Silica dust particles are consid-
ered a health hazard when inaled ver tim.
Inhalation without protection may cause severe iriation of
the respiratory system, lading o silcoss or cancer. Please
refer to the manufacturer's warning,
EX
Ar fiers must be worn when mixing dry powders, in
ling refractories,
When insulating the col terminations or pass thus inside a
vacuum chamber, the materials used release fumes which
ate considered o be hazardous
Be sure to use the appropiate mask or a given situation
‘Most masks protect against only certain types of dust and
vapor. For example, respirators designed to ter out sultur
dioxide gas ae required in certain aplication.
Working with molten metalin amet shop i serious business
and involves many hazards. Injures ranging from minor to
fatal can occur, but by being avare ofthe dangers and taking
the appropriate steps to safeguard ourselves, we can reduce
the day-o-day risks associated with our work
EX
‘Dust respirators must be wor when removing and in
stalling furnace linings or where dust is prevalent. Check
with your refractory super to determine he correct fi
ter fr your aplication,
There ae three primary ways to help protect people from the
dangers of molten metal, These ae distance, protective bar
ries and Personal Protective Equipment (PPE),
Distance isa very staightforvard form of protection. The
further you are away from metal plas, the ster you are.
Thats why manufacturers promot features such as auto-
‘matic charging systems and computer controls. These sys
tems enable people working with the furnace to stay further
away and st do their obs. In all situations, people not di-
rectly involved in working wit the furnace must stay out of
the immediate area ofthe fumace during charging, meting
and pouring operations.
Protetve barres can provide protection against heat and
splash when distance ist practical, An example of a barrer
would bea screen around a pouring control station on the
met deck.
Wearing Personal Protective Equipment (PPE), however, is
the most important step you can take as an individual to pro
tect yourself from metal splash. Personal Protective Equip
ment (PPE) has tobe your last ine of defense
Control
a barrier.
oms protect te worker by al three Keys: ita
Le
Molten metal splash area. Wear Personal Protec-
tive Equipment (PPE),
Wet charge materials are a serious safety hazard in all met
shops. When molten metal comes in contact with any var
ter, moisture or Iiui-bearing material, the water instant
‘neously tums to steam, expanding to 1600 times its original
volume and producing a catastrophic explosion. This occurs
‘without warning and throws molten metal and possibly high
temperature solids out ofthe fumace and puts workers, the
plant, fumace and related equipment at risk.
Awaterimolten metal explosion can ocur in any type of fur
‘nace, For an induction fumace, te aftereffects may be more
serious and include the possibilty of addtional explosions
caused by liquid in ruptured cooling System lines coming in
contact with molten metal, Molten metal need not be pres-
entin the furnace for an explosion to occur. Explosions also
can occur sealed drums or containers are charged into an
empty but hot fumace. In this case, he force ofthe explosion
can eject the newly charged material and quite key damage
the refractory lining as wel,
VA
The catastrophic and unpredictable nature of a water!
‘molten metal explosion makes the wearing of Personal
Protetive Equipment (PPE) by melt shop workers abso-
lutly imperative. Suc clothing may help prevent disig-
ing and incapacitating burns as well as fatal burs.
In met shops where most ofthe charge originals as scrap,
‘wet charge materials pose the greatest cause for concer,
Some melt shops reduce the possibilty of water/molten met
al explosions by string scrap undercover for atleast one
day and then careful inspecting the charge for any residual
‘moisture. A more reliable solution being used by an increas-
ing number of met shops today isto use remote charging
systems with charge dyers or preter.
Induction Hating & Melting Saety Fundamentals Guide
This image was taken from a video of areal furnace eruption,
probably caused by wet scrap dropped into te uma.
ES
Bundledorbaledscrap must be driedtoeliminaetrapped
moisture before adding to te met
Remote charging systems permit the operator to be away
from the furnace or behind protective screens during charg-
ing. Dryers and preheaters maximize the removal of water
and moisture before the scrap enters the bath
An easily overiooked danger is posed by sealed containers
and sections of tubing or piping that are sheared, closing
the ends. Containers holding combustible liquids or their
fumes wil explode long before Ihe scrap itself melts. Pre-
heating sealed materias will not prevent this hazard. Aero-
sol cans, oxygen cylinders, propane tanks, acetylene tanks
and shock absorbers must never be used as charge materia
In fact, tere isa risk that a sealed container wil explode
inside the preeating systems. Operator vgianceis the only
preventive measure,
Æ
Sealed material must never be permite into the furnace
or preheate, Sheared sections of scrap tube and pipe
and apparently empty Sealed containers may seem less
dangerous but can be equal hazardous.
Molten metal splash area. Wear Personal Protec-
tive Equipment (PPE),
Wet charge materials are a serious safety hazard in all met
shops. When molten metal comes in contact with any var
ter, moisture or Iiui-bearing material, the water instant
‘neously tums to steam, expanding to 1600 times its original
volume and producing a catastrophic explosion. This occurs
‘without warning and throws molten metal and possibly high
temperature solids out ofthe fumace and puts workers, the
plant, fumace and related equipment at risk.
Awaterimolten metal explosion can ocur in any type of fur
‘nace, For an induction fumace, te aftereffects may be more
serious and include the possibilty of addtional explosions
caused by liquid in ruptured cooling System lines coming in
contact with molten metal, Molten metal need not be pres-
entin the furnace for an explosion to occur. Explosions also
can occur sealed drums or containers are charged into an
empty but hot fumace. In this case, he force ofthe explosion
can eject the newly charged material and quite key damage
the refractory lining as wel,
VA
The catastrophic and unpredictable nature of a water!
‘molten metal explosion makes the wearing of Personal
Protetive Equipment (PPE) by melt shop workers abso-
lutly imperative. Suc clothing may help prevent disig-
ing and incapacitating burns as well as fatal burs.
In met shops where most ofthe charge originals as scrap,
‘wet charge materials pose the greatest cause for concer,
Some melt shops reduce the possibilty of water/molten met
al explosions by string scrap undercover for atleast one
day and then careful inspecting the charge for any residual
‘moisture. A more reliable solution being used by an increas-
ing number of met shops today isto use remote charging
systems with charge dyers or preter.
Induction Hating & Melting Saety Fundamentals Guide
This image was taken from a video of areal furnace eruption,
probably caused by wet scrap dropped into te uma.
ES
Bundledorbaledscrap must be driedtoeliminaetrapped
moisture before adding to te met
Remote charging systems permit the operator to be away
from the furnace or behind protective screens during charg-
ing. Dryers and preheaters maximize the removal of water
and moisture before the scrap enters the bath
An easily overiooked danger is posed by sealed containers
and sections of tubing or piping that are sheared, closing
the ends. Containers holding combustible liquids or their
fumes wil explode long before Ihe scrap itself melts. Pre-
heating sealed materias will not prevent this hazard. Aero-
sol cans, oxygen cylinders, propane tanks, acetylene tanks
and shock absorbers must never be used as charge materia
In fact, tere isa risk that a sealed container wil explode
inside the preeating systems. Operator vgianceis the only
preventive measure,
Æ
Sealed material must never be permite into the furnace
or preheate, Sheared sections of scrap tube and pipe
and apparently empty Sealed containers may seem less
dangerous but can be equal hazardous.
Induction Heating & Meting Safety Fundamentals Guide
Even though they do not contain combustible liquids, the ar
Inside them can rapily expand inthe heat. In extreme cases,
the pressure buildup vl esufcent to breach the container
wall or escape through a sheared-cosed end. I this occurs,
the forceful expulsion of gas can propel the hot scrap out
ofthe furnace or smash it into the furnace fining, causing
damage.
{old charges, tos cold aluminum “sow” molds and easily
fragmented materials pose a special hazard for induction fur
naces and their operating personnel because they may con-
tain a thin ayer of surface or absorbed moisture. On contact
withthe bath, the maisture turns to steam, causing Sting
or splashing. Proper protective clothing and face and eye
protection normally wil protect the operator. Prehating the
charge and tools helps prevent many splashing injures.
In ferrous metal mel shops the greatest splashing risk cœurs
toward the end ofthe mel, when a melt shop worker adds
ferroaloys or introduces tools into the melt, Ferro-alloy
During normal pours, sparks can ignite flammable clothing
causing serous injury if workers are not property protected.
1. Wet or damp charge material
2. Dropping heavy charge into a moten bath
3. Wet or damp toos or additives
4, Sealed scrap or centrfugaly-cast scrap rls,
1. Scrap ding and preheating systems
2. Remote charging systems.
3. Personal Protective Equipment (PPE)
4. Barns
materials can absorb moisture from ther surroundings.
‘Sampling spoons and slag rakes collect moisture as a thin
film of condensation, Following manufacturers instructions
for storing alloying materials and preheating tools minimizes.
moisture accumulation, reducing the is of splashing.
In a nonferrous melt shop, spitting or splashing can ac-
‘company the introduction of ingots into the mel, as surface
condensation comes in contact with molten metal tems
Such as ingos, pgs, sows, etc, must be placed in an empty
furnace or on top of melt shop returns. When added to an
ready molten pool, they must be preheated fist.
Incertainapplications, suchas inthe melting ofzinc cathodes
in channel furnaces, moisture is often trapped in the baled
cathodes. A special charging mechanism must be used to
introduce the cathode tales in the molten metal bath under à
protective cover which helps to contain hot metal splashes.
‘Since itis impossible to wring every bit of humidity from the
‘pen lr there is aay potential for moisture condensation
and splashing. Moisture condensation and absorption tend
‘increase with time between meli, Th greatest splashing
hazards, therefore, are likely o occur at te beginning ofthe
‘work week or workday, or aftr a furnace has been taken out
‘of service for maintenance. Allowing more time for he initial
mel during these start-up periods can help to reduce the
potential for splashing hazards.
‘Special steps need tobe taken when charging a furnace with
centfugalÿ-cat scrap rolls. This type of scrap should not
be meted in an induction furnace. The hazard stems from the
possibility a roll may contain a ductile inner core surrounded
by a bile outer layer. The diferent rates of expansion can
cause the surface material to explosively separate from the
ral, damaging equipment and injuring personnel. f scrap
roll ar to be mete, the fragmenting hazard can be mini
mized by breaking up the scrap before charging
Even though they do not contain combustible liquids, the ar
Inside them can rapily expand inthe heat. In extreme cases,
the pressure buildup vl esufcent to breach the container
wall or escape through a sheared-cosed end. I this occurs,
the forceful expulsion of gas can propel the hot scrap out
ofthe furnace or smash it into the furnace fining, causing
damage.
{old charges, tos cold aluminum “sow” molds and easily
fragmented materials pose a special hazard for induction fur
naces and their operating personnel because they may con-
tain a thin ayer of surface or absorbed moisture. On contact
withthe bath, the maisture turns to steam, causing Sting
or splashing. Proper protective clothing and face and eye
protection normally wil protect the operator. Prehating the
charge and tools helps prevent many splashing injures.
In ferrous metal mel shops the greatest splashing risk cœurs
toward the end ofthe mel, when a melt shop worker adds
ferroaloys or introduces tools into the melt, Ferro-alloy
During normal pours, sparks can ignite flammable clothing
causing serous injury if workers are not property protected.
1. Wet or damp charge material
2. Dropping heavy charge into a moten bath
3. Wet or damp toos or additives
4, Sealed scrap or centrfugaly-cast scrap rls,
1. Scrap ding and preheating systems
2. Remote charging systems.
3. Personal Protective Equipment (PPE)
4. Barns
materials can absorb moisture from ther surroundings.
‘Sampling spoons and slag rakes collect moisture as a thin
film of condensation, Following manufacturers instructions
for storing alloying materials and preheating tools minimizes.
moisture accumulation, reducing the is of splashing.
In a nonferrous melt shop, spitting or splashing can ac-
‘company the introduction of ingots into the mel, as surface
condensation comes in contact with molten metal tems
Such as ingos, pgs, sows, etc, must be placed in an empty
furnace or on top of melt shop returns. When added to an
ready molten pool, they must be preheated fist.
Incertainapplications, suchas inthe melting ofzinc cathodes
in channel furnaces, moisture is often trapped in the baled
cathodes. A special charging mechanism must be used to
introduce the cathode tales in the molten metal bath under à
protective cover which helps to contain hot metal splashes.
‘Since itis impossible to wring every bit of humidity from the
‘pen lr there is aay potential for moisture condensation
and splashing. Moisture condensation and absorption tend
‘increase with time between meli, Th greatest splashing
hazards, therefore, are likely o occur at te beginning ofthe
‘work week or workday, or aftr a furnace has been taken out
‘of service for maintenance. Allowing more time for he initial
mel during these start-up periods can help to reduce the
potential for splashing hazards.
‘Special steps need tobe taken when charging a furnace with
centfugalÿ-cat scrap rolls. This type of scrap should not
be meted in an induction furnace. The hazard stems from the
possibility a roll may contain a ductile inner core surrounded
by a bile outer layer. The diferent rates of expansion can
cause the surface material to explosively separate from the
ral, damaging equipment and injuring personnel. f scrap
roll ar to be mete, the fragmenting hazard can be mini
mized by breaking up the scrap before charging
For those unfamiliar with induction meling, it may seem
‘unusual fora high-temperature furnace to be equipped with
a cooling system that operates by circulating water inside
electrical conductors camping thousands of amps of electric
current. Yet without continuous cooling, induction furnaces
cannot operate.
‘The furnace col, which produces the electromagnetic fed
15 not designed to get ht. Although some heat is conducted
from the molten bath through the lining tothe col, most of
the heat oad onthe col is caused by current owing through
A This requires that tbe continually cooled, not only o in-
crease its electrical efficiency but to prevent it from meting,
‘Typically, the cooling system is buit into the cl tse which
5 made of hollow copper tubing in which the cooling water
flows. The water picks up the heat caused by the current as
vwellas heat conducted from the metal through the refractory
and cartes ito heat exchange or removal.
Man electrical or mechanical fare damages the pump that
circulates the water, a dangerous heat buildup could lead
to coll insulation damage, col arcing, steam buildup and
water leaks. These could then lead to a major explosion that
could occur within minutes. Therefore, induction furnaces
must havea backup cooling system, such asa battery-powe
ered or engine-powered water pump or a city water con-
‘nection that can be engaged if normal pump operation fal
Cooling Water
Thickwalled Copper Tubing
Induction furnaces must have a water cooling system bull
into the cil eh. The water picks up the heat caused by the
current as well s heat conducted from the metal through
the refractory and cares i toa heat exchanger for removal
Induction Hating & Melting Saety Fundamentals Guide
In erain low power channel meting applications and induc-
tively heated susceptor heating or melting application, iis
Possible to cool the inductor col with a forced air lw. The
same considerations apply to such a cooing system, and an
emergency cooling system must be installed to back up the
primary system in case of fare
Modern induction systems aretypicaly equipped with closed
water cooling systems. Toaly closed systems offer the best
protection against low water flow caused by scaling or the
accumulation of contaminants inthe water passages. Open
water systems, however, were common in systems bulk be
fore 1960.
For safe operation, open water systems require frequent
‘leaning, treatment and maintenance as specified in their op-
erating manual. Without careful maintenance, an accumula-
tion of mineral, dt, scale and other contaminants wil block
the cooling water passages, causing components within the
power supply andor furnace to overheat
In the power supply, this overeating could cause the de-
composition of insulating materials and produce flammable
hydrogen, methane and propane gases. Tis could produce
an explosion resulting in injury or death.
Im the furnace, los or restricted flow of cooing water
could lead to overheating the copper cl resulting in fare
of the tubing. This could produce water leaks leading to a
vater/molten metal explosion causing injury or death
Because water or ar cooing is crucial o tr safe operation of
induction furnaces and power supplies, no induction system
should be operated without functioning water temperature
and flow interlocks. These interlocks must nat be bypassed,
de
Any event trat interferes with normal furnace cooling
an quickly lead to col damage and may lad to a cat
stophic explosion hat can cause injury or death
EX
‘Never clean out water Ines wit compressed ai while
power is on. The ar wil dspace the cooing water and
{the system wil overheat rapidly, and may result ia cat-
astropic explosion that can cause injury or death
‘unusual fora high-temperature furnace to be equipped with
a cooling system that operates by circulating water inside
electrical conductors camping thousands of amps of electric
current. Yet without continuous cooling, induction furnaces
cannot operate.
‘The furnace col, which produces the electromagnetic fed
15 not designed to get ht. Although some heat is conducted
from the molten bath through the lining tothe col, most of
the heat oad onthe col is caused by current owing through
A This requires that tbe continually cooled, not only o in-
crease its electrical efficiency but to prevent it from meting,
‘Typically, the cooling system is buit into the cl tse which
5 made of hollow copper tubing in which the cooling water
flows. The water picks up the heat caused by the current as
vwellas heat conducted from the metal through the refractory
and cartes ito heat exchange or removal.
Man electrical or mechanical fare damages the pump that
circulates the water, a dangerous heat buildup could lead
to coll insulation damage, col arcing, steam buildup and
water leaks. These could then lead to a major explosion that
could occur within minutes. Therefore, induction furnaces
must havea backup cooling system, such asa battery-powe
ered or engine-powered water pump or a city water con-
‘nection that can be engaged if normal pump operation fal
Cooling Water
Thickwalled Copper Tubing
Induction furnaces must have a water cooling system bull
into the cil eh. The water picks up the heat caused by the
current as well s heat conducted from the metal through
the refractory and cares i toa heat exchanger for removal
Induction Hating & Melting Saety Fundamentals Guide
In erain low power channel meting applications and induc-
tively heated susceptor heating or melting application, iis
Possible to cool the inductor col with a forced air lw. The
same considerations apply to such a cooing system, and an
emergency cooling system must be installed to back up the
primary system in case of fare
Modern induction systems aretypicaly equipped with closed
water cooling systems. Toaly closed systems offer the best
protection against low water flow caused by scaling or the
accumulation of contaminants inthe water passages. Open
water systems, however, were common in systems bulk be
fore 1960.
For safe operation, open water systems require frequent
‘leaning, treatment and maintenance as specified in their op-
erating manual. Without careful maintenance, an accumula-
tion of mineral, dt, scale and other contaminants wil block
the cooling water passages, causing components within the
power supply andor furnace to overheat
In the power supply, this overeating could cause the de-
composition of insulating materials and produce flammable
hydrogen, methane and propane gases. Tis could produce
an explosion resulting in injury or death.
Im the furnace, los or restricted flow of cooing water
could lead to overheating the copper cl resulting in fare
of the tubing. This could produce water leaks leading to a
vater/molten metal explosion causing injury or death
Because water or ar cooing is crucial o tr safe operation of
induction furnaces and power supplies, no induction system
should be operated without functioning water temperature
and flow interlocks. These interlocks must nat be bypassed,
de
Any event trat interferes with normal furnace cooling
an quickly lead to col damage and may lad to a cat
stophic explosion hat can cause injury or death
EX
‘Never clean out water Ines wit compressed ai while
power is on. The ar wil dspace the cooing water and
{the system wil overheat rapidly, and may result ia cat-
astropic explosion that can cause injury or death
Induction Heating & Meting Safety Fundamentals Guide
When material charged into the top portion of the furnace
isnotin contact withthe molten metal inte bottom of he fur
‘nace, the condition known as “bridging” exist. When bridg-
ing occurs, unmelted charge material is no longer serving
to moderate the temperature of the bath during the meting
cycle, Also, the air gap between the molten metal and the
bridge act as an insulator. The molten metalin he bottom of
ofurnce, under theimpactofmelting power, wll superheat,
This superheatin in an induction fumace wll occu very rap»
di and wl soon raise the temperature ofthe bath above the
‘maximum temperature rating of the refractory. Also, exces-
‘ve string in the botom ofthe furnace, due to the small
‘metal mass and high power density, wil combine with the
high metal temperatures to cause rapid lining erasion or pos-
sibly complete retractor are,
Without immediate attention ta “bridging” condition, a run
out or explosion wil acer. Ihe run-out s through the bot-
tom ofthe furnace it can cause a fre under the fumace and
inthe pit are with loss of hydraulics and water cooling.
I the molten metal mets through the furnace col and water
Gomes in contact with the molten meta, the water nstata-
‘neously tums into steam with an expansion rat of 1600101
I the water gets under the molten metal, this instantaneous
expansion will produce an explosion which could cause
Injury or death and extensive damage to equipment
Be sure to keep the furnace pit area clean and dry because it
is designed to hold molten metal in case of an emergency
Do not alow water or hydraul fad
à pas o accumulate in he pi.
EZ
His important that care be taken when charging th fu-
‘nace so that charge continues to feed into the molten
pool propery. thangs up due to interlocking or brdg-
ing, Superheating below can erode the refractory caus
ng molten metal to penetat to he col. This results in
loss ofthe melt and loss ofthe Ining, and represents a
very dangerous condition, Should he molten metal burn
through the col the water in te cil can cause an explo-
sion, which coud cause serious or possibly fatal injuries,
Bridging can occur in any induction furnace and all fumace
‘operators must be trained tobe able to recognize bridging
and its dangers. AI operators must be trained how to solve
abridging problem.
Bridging may reveal ise with one of several waning signs.
‘The clearest warning sign that bridging has occurred is that
the meti taking longer than expected, Rather than increase
‘the power, the operator must such off power and evacuate
al personnel from the area immediately. Under no circum-
‘stances should the operator increase power.
If ferous metal is being meted, the chemical reaction which
it ereates on contact wit the furnace Ining wil, under su
Derheated conditions, produce carbon monoxide, This gas
may reveal sl! as Small blue lames on or in the bridge.
‘The appearance o these flames indicates the bridge may be
pressurized, and it must not be breached. In the case of a
nonferrous charge, as production wil also occur, but there
are no flames or other visible indications.
Bridging can be minimized by using proper charge material and by
‘making sure the different sizes of charge material are added comet.
Wa bridge occurs, power must be tuned off immediatly. Al person-
el must be evacuated from the furnace area until enough time has.
lapsed o allow the molten metal to soli
Bridging occurs when a “cap” forms over the top of the fumace
allowing à buildup of superheated gases in the void below. If à
bridge develops, power must be tumed of immediately
The void separating molten metal trom the bridge of sold charge
material acts as an insulator
The molten metal will superheat and the temperature wil se rapid
When material charged into the top portion of the furnace
isnotin contact withthe molten metal inte bottom of he fur
‘nace, the condition known as “bridging” exist. When bridg-
ing occurs, unmelted charge material is no longer serving
to moderate the temperature of the bath during the meting
cycle, Also, the air gap between the molten metal and the
bridge act as an insulator. The molten metalin he bottom of
ofurnce, under theimpactofmelting power, wll superheat,
This superheatin in an induction fumace wll occu very rap»
di and wl soon raise the temperature ofthe bath above the
‘maximum temperature rating of the refractory. Also, exces-
‘ve string in the botom ofthe furnace, due to the small
‘metal mass and high power density, wil combine with the
high metal temperatures to cause rapid lining erasion or pos-
sibly complete retractor are,
Without immediate attention ta “bridging” condition, a run
out or explosion wil acer. Ihe run-out s through the bot-
tom ofthe furnace it can cause a fre under the fumace and
inthe pit are with loss of hydraulics and water cooling.
I the molten metal mets through the furnace col and water
Gomes in contact with the molten meta, the water nstata-
‘neously tums into steam with an expansion rat of 1600101
I the water gets under the molten metal, this instantaneous
expansion will produce an explosion which could cause
Injury or death and extensive damage to equipment
Be sure to keep the furnace pit area clean and dry because it
is designed to hold molten metal in case of an emergency
Do not alow water or hydraul fad
à pas o accumulate in he pi.
EZ
His important that care be taken when charging th fu-
‘nace so that charge continues to feed into the molten
pool propery. thangs up due to interlocking or brdg-
ing, Superheating below can erode the refractory caus
ng molten metal to penetat to he col. This results in
loss ofthe melt and loss ofthe Ining, and represents a
very dangerous condition, Should he molten metal burn
through the col the water in te cil can cause an explo-
sion, which coud cause serious or possibly fatal injuries,
Bridging can occur in any induction furnace and all fumace
‘operators must be trained tobe able to recognize bridging
and its dangers. AI operators must be trained how to solve
abridging problem.
Bridging may reveal ise with one of several waning signs.
‘The clearest warning sign that bridging has occurred is that
the meti taking longer than expected, Rather than increase
‘the power, the operator must such off power and evacuate
al personnel from the area immediately. Under no circum-
‘stances should the operator increase power.
If ferous metal is being meted, the chemical reaction which
it ereates on contact wit the furnace Ining wil, under su
Derheated conditions, produce carbon monoxide, This gas
may reveal sl! as Small blue lames on or in the bridge.
‘The appearance o these flames indicates the bridge may be
pressurized, and it must not be breached. In the case of a
nonferrous charge, as production wil also occur, but there
are no flames or other visible indications.
Bridging can be minimized by using proper charge material and by
‘making sure the different sizes of charge material are added comet.
Wa bridge occurs, power must be tuned off immediatly. Al person-
el must be evacuated from the furnace area until enough time has.
lapsed o allow the molten metal to soli
Bridging occurs when a “cap” forms over the top of the fumace
allowing à buildup of superheated gases in the void below. If à
bridge develops, power must be tumed of immediately
The void separating molten metal trom the bridge of sold charge
material acts as an insulator
The molten metal will superheat and the temperature wil se rapid
Induction Hating & Melting Saety Fundamentals Guide
Spill Pits May Keep You from Being Knee-Deep in Molten Metal
WARNING
Metal poured into a pit or runout area where excess
‘moisture, standing water, ols or other luis ae present
can cause an explosion, which could cause serious or
possibly fatal injures.
Induction meting furnaces must only be operated with ad
‘equate, careful maintained and dry spl pits. These ps,
often called run-out pits, are located under and in front of
Induction furnaces. They serve to contain any molten metal
spilled as aresult of accident run-out or dumping of te fur
‘nace in an emergency.
Without adequate pis, fre-lowing spied molten metal
would low across the floor, endangering workers, damaging
equipment and structures and could also produce devastat
ing fires and explosions. To accomplish the job or which
they are intended, sil pits need to meet the folowing stan
dards:
Adequate capaciy- There must bea pit foreach fumace large
enough to hold 150% of its furnaces capacity. This size a
‘ows room in he pit forthe almost inevitable accumulation
of metal spiled during routine pouring.
Proper construction Spi pts must be designed and bul by
‘qualified professional who are experienced in melt shop de-
sign and knowiedgeable about your instalation. Pits must be
constructed of concrete and ned with febrick. The aeaim-
‘mediately under the furnace must be sloped to carry spied
‘metal aay from the furnace and ino a deeper holding pi.
‘The area direct infront ofthe fumace must be covered with
steel grating
Invertadstel drums set o their ul depts in met shop sand
in he bottom of the pt aid in containment and ater removal
of spiled metal. Wit these drums, the molten metal fos
across the sand, melts through the bottoms ofthe inverted
drums and fils them. These can later be removed.
In channel or creess induction fumaces used forthe mel
and holding of ie, Gavalume®, Galfan® and other similar
alloys used forthe coating of steal ti, where the furnaces
are usually installed in a vault with the top of the furnace
Aush with the floor level, the vault self becomes the spill
pit and the same considerations for metal containment and
personnel safety must be given Additionally, these vault fll,
under OSHA's definition of a “confined space”, re. 29 CFR
© 2006 Inductotherm Corp.
1910.146(b). Access to these spaces and other confined ar-
‘eas may alo require permis under 29 CFR 1910.146().
‘Absolutely doy Sil pis must be kept completely dy at all
times. This requires careful vigilance since these pi are low.
points and can catch water from leak, cleaning operations
or ground seepage. Wet pits are bombs waiting to explode!
{On dry spl pts can safely contain a run-out or emergency
‘furnace dumping. Furnaces must not be operated if tei spill
pits are wet!
Water diversion system À water diversion system, bu into
your pit during construction or added later, may aidinkeeping
your pi dy. With his system, an aluminum channel or gutter
is placed at the top ofthe spl pit directly beneath the slope
running underneath the furnace. Tis channel collects any
‘water or iquid running down te slope befor it falls into the
pitand diverts the water away from the pt to a drain or sump.
‘Attentive mantenance- As with any key safety system, spill
pits must be checked daily. They must be kept clear of debris
and flammable materials. P covers must be kept clear of
sla and other blocking materials that woul interfere with
‘the passage of molten metal, Metal from any minor spills
must be regula removed from the spl pts o ensure that
adequate capacity is maintained.
H you know your spill pits propery sized, ey and clear of
debrs, you can operate your furnace withthe confidence of
‘knowing that if an emergency occurs, you can dump any.
‘molten meta rom the furnace into the spl pit
Aluminum Water
Diversion Gutter
Furnace Mounted
Above Spillvay
Containers
Set in Sand to
Capture Spilled Some
Metal pi
Under Furnace
sloped Lower Pit
With Water Runott
Pipe to Remove
Water Accumulation
Spill Pits May Keep You from Being Knee-Deep in Molten Metal
WARNING
Metal poured into a pit or runout area where excess
‘moisture, standing water, ols or other luis ae present
can cause an explosion, which could cause serious or
possibly fatal injures.
Induction meting furnaces must only be operated with ad
‘equate, careful maintained and dry spl pits. These ps,
often called run-out pits, are located under and in front of
Induction furnaces. They serve to contain any molten metal
spilled as aresult of accident run-out or dumping of te fur
‘nace in an emergency.
Without adequate pis, fre-lowing spied molten metal
would low across the floor, endangering workers, damaging
equipment and structures and could also produce devastat
ing fires and explosions. To accomplish the job or which
they are intended, sil pits need to meet the folowing stan
dards:
Adequate capaciy- There must bea pit foreach fumace large
enough to hold 150% of its furnaces capacity. This size a
‘ows room in he pit forthe almost inevitable accumulation
of metal spiled during routine pouring.
Proper construction Spi pts must be designed and bul by
‘qualified professional who are experienced in melt shop de-
sign and knowiedgeable about your instalation. Pits must be
constructed of concrete and ned with febrick. The aeaim-
‘mediately under the furnace must be sloped to carry spied
‘metal aay from the furnace and ino a deeper holding pi.
‘The area direct infront ofthe fumace must be covered with
steel grating
Invertadstel drums set o their ul depts in met shop sand
in he bottom of the pt aid in containment and ater removal
of spiled metal. Wit these drums, the molten metal fos
across the sand, melts through the bottoms ofthe inverted
drums and fils them. These can later be removed.
In channel or creess induction fumaces used forthe mel
and holding of ie, Gavalume®, Galfan® and other similar
alloys used forthe coating of steal ti, where the furnaces
are usually installed in a vault with the top of the furnace
Aush with the floor level, the vault self becomes the spill
pit and the same considerations for metal containment and
personnel safety must be given Additionally, these vault fll,
under OSHA's definition of a “confined space”, re. 29 CFR
© 2006 Inductotherm Corp.
1910.146(b). Access to these spaces and other confined ar-
‘eas may alo require permis under 29 CFR 1910.146().
‘Absolutely doy Sil pis must be kept completely dy at all
times. This requires careful vigilance since these pi are low.
points and can catch water from leak, cleaning operations
or ground seepage. Wet pits are bombs waiting to explode!
{On dry spl pts can safely contain a run-out or emergency
‘furnace dumping. Furnaces must not be operated if tei spill
pits are wet!
Water diversion system À water diversion system, bu into
your pit during construction or added later, may aidinkeeping
your pi dy. With his system, an aluminum channel or gutter
is placed at the top ofthe spl pit directly beneath the slope
running underneath the furnace. Tis channel collects any
‘water or iquid running down te slope befor it falls into the
pitand diverts the water away from the pt to a drain or sump.
‘Attentive mantenance- As with any key safety system, spill
pits must be checked daily. They must be kept clear of debris
and flammable materials. P covers must be kept clear of
sla and other blocking materials that woul interfere with
‘the passage of molten metal, Metal from any minor spills
must be regula removed from the spl pts o ensure that
adequate capacity is maintained.
H you know your spill pits propery sized, ey and clear of
debrs, you can operate your furnace withthe confidence of
‘knowing that if an emergency occurs, you can dump any.
‘molten meta rom the furnace into the spl pit
Aluminum Water
Diversion Gutter
Furnace Mounted
Above Spillvay
Containers
Set in Sand to
Capture Spilled Some
Metal pi
Under Furnace
sloped Lower Pit
With Water Runott
Pipe to Remove
Water Accumulation
Induction Heating & Meting Safety Fundamentals Guide
A
The ground detector isa primary safety device. Never
operate th unit with a faulty ground detection system.
Many factors (ining condition, et) influence the opera
tion and speed of operation ofthe ek detector. I leak
is suspected at anytime, cease operation and empty the
fumace
Top Cap
Non-Conductve Crucible
Wire Cage Ground
Leak Probe
Col
Retractor
‘The ground and leak detec-
tor system for use with most
coreless. induction furnaces
and power supply uns is cru-
Gil to safe meting and holding
operations. The system, which
includes both a ground detec-
tor module associated with the
power supply and a ground
leak probe, located inthe fur
nace (except in removable ru
ble furnaces), is designed to
provide important. protection
against electrical shock and
warning of metabto-col penetration, a highly dangerous
condition that could lead toa furnace eruption or explosion.
Fins of molten metal can
penetrate wom or dam-
aged refractory and come
Into contact with he coi
Key to this protection in furnaces with rammed Inings or
conductive crucibies isthe ground leak probe in the bottom
ofthe furnace. This probe is composed of aneleciricl ground
connected to several wires extending through the refractory
and in contac with the molten bath or conductive crucible
Wire to Ground:
‘This system serves to electrically ground the moten bath
In some small furnaces with nonconductve, nonremovable
Grucbls, whee the bath cannot be practical grounded, the
ground leak probe takes the form o a wire cage located be
‘ween the crucible and col This wire cage serves o ground
‘the bath metal penetrates through the crucible.
In certain applications such as zinc, Gahalume®, Galtan®,
using induction meting and holding coreles furnaces where
‘oxides build up more readily onthe refractory floor ofthe
furnace, grounding ofthe metal bath is accomplished either
‘through he grounded conductive jacket ofthe thermocouple
measuring the molten metal bath temperature or by using
separately grounded probe. Removing or changing the
configuration ofthis protection by, for example using eec-
cal non-conductive thermocouple protective sheaths or
compromising he grounding ofthe thermocouple ar probes
assembly, wi result ina deterioration of the ground and leak
detection system. Tis may esul in injury or death
Top and
Bottom Coil
Cooling Sections
Boom of Manon Metal Bath
or Conductive Crucible.
Probes Must
be in Contact
with Charge
or Crucible
Bottom of
Furnace Shel
Wire o Ground]
A
The ground detector isa primary safety device. Never
operate th unit with a faulty ground detection system.
Many factors (ining condition, et) influence the opera
tion and speed of operation ofthe ek detector. I leak
is suspected at anytime, cease operation and empty the
fumace
Top Cap
Non-Conductve Crucible
Wire Cage Ground
Leak Probe
Col
Retractor
‘The ground and leak detec-
tor system for use with most
coreless. induction furnaces
and power supply uns is cru-
Gil to safe meting and holding
operations. The system, which
includes both a ground detec-
tor module associated with the
power supply and a ground
leak probe, located inthe fur
nace (except in removable ru
ble furnaces), is designed to
provide important. protection
against electrical shock and
warning of metabto-col penetration, a highly dangerous
condition that could lead toa furnace eruption or explosion.
Fins of molten metal can
penetrate wom or dam-
aged refractory and come
Into contact with he coi
Key to this protection in furnaces with rammed Inings or
conductive crucibies isthe ground leak probe in the bottom
ofthe furnace. This probe is composed of aneleciricl ground
connected to several wires extending through the refractory
and in contac with the molten bath or conductive crucible
Wire to Ground:
‘This system serves to electrically ground the moten bath
In some small furnaces with nonconductve, nonremovable
Grucbls, whee the bath cannot be practical grounded, the
ground leak probe takes the form o a wire cage located be
‘ween the crucible and col This wire cage serves o ground
‘the bath metal penetrates through the crucible.
In certain applications such as zinc, Gahalume®, Galtan®,
using induction meting and holding coreles furnaces where
‘oxides build up more readily onthe refractory floor ofthe
furnace, grounding ofthe metal bath is accomplished either
‘through he grounded conductive jacket ofthe thermocouple
measuring the molten metal bath temperature or by using
separately grounded probe. Removing or changing the
configuration ofthis protection by, for example using eec-
cal non-conductive thermocouple protective sheaths or
compromising he grounding ofthe thermocouple ar probes
assembly, wi result ina deterioration of the ground and leak
detection system. Tis may esul in injury or death
Top and
Bottom Coil
Cooling Sections
Boom of Manon Metal Bath
or Conductive Crucible.
Probes Must
be in Contact
with Charge
or Crucible
Bottom of
Furnace Shel
Wire o Ground]
AI of these probe configurations are designed to provide
Shock protection to met deck workers by helping to ensure
hat theres no voltage potemtal in the malen bath. 1 molten
‘metal were to touch the col, the ground leak probe would
conduct eurent from the coi to ground. This would be de
tected by the ground detector module and the power would
be shutoff to stop any coil arcing, This also would prevent
high voltage from being cared by the molten metal o fur
race charge.
‘Such high voltage could cause serious or even fatal electrical
Shock tothe operator it he/she were to come into conductive
contact with the bath,
(Col cooing sections in the top and bottom of a steel
shell fumace serve to maintain uniform refractory tem
peratures throughout the furnace to maximize lining ie. In
Inductotherm steel sel fumaces, these cating sections are
electrical isolated from the active col, principally to insulate
the active col rom ground leakage atthe top and bottom
ofthe furnace. Ia fin of metal eaches the cooling col, the
‘metal simply freeze,
‘The ground and leak detector can sense metal penetration to
the cooling sections while maintaining AC isolation ofthese
cooling sections from the achve col. This improved arrange
ments accomplished by incorporating a simple device in
all new steel shell furnaces to put low-level DC voltage on
the top and bottom cooing cols With this voltage, a metal
fin touching a cooling section wil tip the ground and leak
detector, turning off the power tothe furnace and alerting
the operator tothe problem. And since the voltage on the
Goaling col i lov, the faut wl generate only extremely low
Induction Hating & Melting Saety Fundamentals Guide
current, up to 150 millamperes. Unike systems which di
reclly connect ther cooling col sections to the active col
o provide ground fault detector protection, this lo current
poses no risk to the ol. avoids the danger of à large fault
Diowing a hole in the tubing used for cooling col
Your coreless furnace (exce! removable crucible and some
special vacuum furnaces) must not be operated without a
‘unetioning ground detector and ground leak probe.
As a normal safety precaution, power to the furnace must
always be tumed off during stagging, sampling and tempera-
ture measuring,
‘The ground leak probe works in conjunction with the ground
detector module mounted inside or external to the power
supply. The electrica circuito inthe ground detector module
Continvally monitors the electrical integrity ofthe systems.
This module turns off power to the furnace if any improper
‘rounds detected in he power supply, bus or induction col
‘This is crucial to furnace safety
It the fumace refractory tning or crucible cracks or other
ie fails and a portion of he metal bath touches the ner.
ized furnace ol, the col could arc and rupture. This could
alow wate o get into the bath, causing metal eruption or
explosion. Both parts of the system, the ground leak probe
and the ground detector, must function properly for safe
meting operations.
‘A handheld ground leak probe test device veis the integ-
fy of the furnace's ground probe system. Note the use of
Personal Protective Equipment (PPE)
Shock protection to met deck workers by helping to ensure
hat theres no voltage potemtal in the malen bath. 1 molten
‘metal were to touch the col, the ground leak probe would
conduct eurent from the coi to ground. This would be de
tected by the ground detector module and the power would
be shutoff to stop any coil arcing, This also would prevent
high voltage from being cared by the molten metal o fur
race charge.
‘Such high voltage could cause serious or even fatal electrical
Shock tothe operator it he/she were to come into conductive
contact with the bath,
(Col cooing sections in the top and bottom of a steel
shell fumace serve to maintain uniform refractory tem
peratures throughout the furnace to maximize lining ie. In
Inductotherm steel sel fumaces, these cating sections are
electrical isolated from the active col, principally to insulate
the active col rom ground leakage atthe top and bottom
ofthe furnace. Ia fin of metal eaches the cooling col, the
‘metal simply freeze,
‘The ground and leak detector can sense metal penetration to
the cooling sections while maintaining AC isolation ofthese
cooling sections from the achve col. This improved arrange
ments accomplished by incorporating a simple device in
all new steel shell furnaces to put low-level DC voltage on
the top and bottom cooing cols With this voltage, a metal
fin touching a cooling section wil tip the ground and leak
detector, turning off the power tothe furnace and alerting
the operator tothe problem. And since the voltage on the
Goaling col i lov, the faut wl generate only extremely low
Induction Hating & Melting Saety Fundamentals Guide
current, up to 150 millamperes. Unike systems which di
reclly connect ther cooling col sections to the active col
o provide ground fault detector protection, this lo current
poses no risk to the ol. avoids the danger of à large fault
Diowing a hole in the tubing used for cooling col
Your coreless furnace (exce! removable crucible and some
special vacuum furnaces) must not be operated without a
‘unetioning ground detector and ground leak probe.
As a normal safety precaution, power to the furnace must
always be tumed off during stagging, sampling and tempera-
ture measuring,
‘The ground leak probe works in conjunction with the ground
detector module mounted inside or external to the power
supply. The electrica circuito inthe ground detector module
Continvally monitors the electrical integrity ofthe systems.
This module turns off power to the furnace if any improper
‘rounds detected in he power supply, bus or induction col
‘This is crucial to furnace safety
It the fumace refractory tning or crucible cracks or other
ie fails and a portion of he metal bath touches the ner.
ized furnace ol, the col could arc and rupture. This could
alow wate o get into the bath, causing metal eruption or
explosion. Both parts of the system, the ground leak probe
and the ground detector, must function properly for safe
meting operations.
‘A handheld ground leak probe test device veis the integ-
fy of the furnace's ground probe system. Note the use of
Personal Protective Equipment (PPE)
Induction Heating & Meting Safety Fundamentals Guide
“Tokeep the ground leak probes working propery ina rammed
lining fumace care must b taken when nstalin the lining
to ensure tha the ground leak probe wires come into contact
‘wth the ning form, Also, when patching a furnace ining it
is essential thatthe ground leak probe wires remain exposed,
permiting contact with the fumace charge. Ifthe wires are
100 short, extra lengths of 304 stainless steel wire must be
‘welded to the existing wires to extend the wires into the
charge material or into contact with a conductive crucible.
Its important to check your forace's ground leak probes
daly, especialy in rammed ining furnaces and furnaces with
conducive crucibles. The probes can be covered during im-
proper furnace rlning: can bum off; can be isolate by slag,
or otherwise be prevented from providing a solid electrical
ground. his check can be done wi Inductotherm's ground
leak probe testing device, an easy-to-use, handheld ool for
verfin your fumace' ground connection. I can be used
‘wth any sytem equipped with ground leak probes
tea
In case of a ground fui trip, the melt deck around the
fumace must be cleared ofall personne immediately
This i o reduce the risk of jury to personnel should
there be an eruption of molten meta.
It after a reasonable period of ime there ae no indica
tions ofan imminent eruption, such a rumbing sounds,
vibrations, etc, only quali maintenance personnel
‘may then cautiously proceed to troubleshoot the cause
ofthe ground fault trip, Furnace capacity must be taken
int consideration when determining ati a reasonable
periodo! time, in doubt, keep all personnel safely away
from the furnace until the metal charge has soii
A
Testing the integrity ofthe probes requires the foundry
worker to take measurements usinga special instrument
In rammed ing furnaces and furnaces wth conductive
crucibles, the frequent checking of probe wires is espe-
cially erica
Located atthe bottom ofthe furnace, they can be eas
iy buried during reining, covered with la, burt of or
otherwise damaged.
Failreto ensure thatthe ground leak probe res are pro-
viding a solid ground wil result in the loss of protection for
the operator and furnace provided by the ground and leak
detection system.
Your meting system's ground detector circuit must also be
checked dall In atypical system, tis is done by pushing
the test button on the detector, which briefly simulates an
actual ground faut.
Because of the crucial safety functions ground and leak
detection systems have in coreless induction melting and
holding furnaces, your turnace must not be operated without
a fully-unctonal ground and leak detection system.
An independent molten metal leak detector can be used in
‘certain applications to detect the presence of molten meta
close othe coll. The system includes a series of mesh panels
that are placed on the coll grout covering the inner diam
er (1.0) ofthe furnace coll A similar method is also used
to extend the molten metal leak detection to include the
bottom of the furnace nthe event that molten metal reaches
the panel an alarm wil sound, An independent molten met-
al leak detection system isnot a substitute forthe ground
and leak detection system
ES
In compliance with NEC 2002 requirements (6655), all
‘power supplies shipped after January 1, 2002, wil in-
corporate ground leak detector (GLO) uns that wll ot
be equipped with probe disconnect buttons inthe GLO
circuit Furnace earth leak detector probes wil be hard
red tothe furnace ground cosest to the probes. Its
the user’ responsibility toensure that thefurnace ground
is securely Bonded to the approved system ground and
‘the metal bath is grounded through the furnace ground
probes at al times.
Under no circumstances should a furnace be operated
withthe furnace ground probes disconnected from the
furnace ground,
Do not operate the equipment if the metal charge ormol-
ten bath inthe fumace isnot grounded through ground
probe wires, Falure to ensure that ground probe wires
are in contact with the charge or molten bath coud ead
o high voltage onthe bath during operation, This could
cause serious injury or death from electrical Shock or
‘maiten metal eruption.
“Tokeep the ground leak probes working propery ina rammed
lining fumace care must b taken when nstalin the lining
to ensure tha the ground leak probe wires come into contact
‘wth the ning form, Also, when patching a furnace ining it
is essential thatthe ground leak probe wires remain exposed,
permiting contact with the fumace charge. Ifthe wires are
100 short, extra lengths of 304 stainless steel wire must be
‘welded to the existing wires to extend the wires into the
charge material or into contact with a conductive crucible.
Its important to check your forace's ground leak probes
daly, especialy in rammed ining furnaces and furnaces with
conducive crucibles. The probes can be covered during im-
proper furnace rlning: can bum off; can be isolate by slag,
or otherwise be prevented from providing a solid electrical
ground. his check can be done wi Inductotherm's ground
leak probe testing device, an easy-to-use, handheld ool for
verfin your fumace' ground connection. I can be used
‘wth any sytem equipped with ground leak probes
tea
In case of a ground fui trip, the melt deck around the
fumace must be cleared ofall personne immediately
This i o reduce the risk of jury to personnel should
there be an eruption of molten meta.
It after a reasonable period of ime there ae no indica
tions ofan imminent eruption, such a rumbing sounds,
vibrations, etc, only quali maintenance personnel
‘may then cautiously proceed to troubleshoot the cause
ofthe ground fault trip, Furnace capacity must be taken
int consideration when determining ati a reasonable
periodo! time, in doubt, keep all personnel safely away
from the furnace until the metal charge has soii
A
Testing the integrity ofthe probes requires the foundry
worker to take measurements usinga special instrument
In rammed ing furnaces and furnaces wth conductive
crucibles, the frequent checking of probe wires is espe-
cially erica
Located atthe bottom ofthe furnace, they can be eas
iy buried during reining, covered with la, burt of or
otherwise damaged.
Failreto ensure thatthe ground leak probe res are pro-
viding a solid ground wil result in the loss of protection for
the operator and furnace provided by the ground and leak
detection system.
Your meting system's ground detector circuit must also be
checked dall In atypical system, tis is done by pushing
the test button on the detector, which briefly simulates an
actual ground faut.
Because of the crucial safety functions ground and leak
detection systems have in coreless induction melting and
holding furnaces, your turnace must not be operated without
a fully-unctonal ground and leak detection system.
An independent molten metal leak detector can be used in
‘certain applications to detect the presence of molten meta
close othe coll. The system includes a series of mesh panels
that are placed on the coll grout covering the inner diam
er (1.0) ofthe furnace coll A similar method is also used
to extend the molten metal leak detection to include the
bottom of the furnace nthe event that molten metal reaches
the panel an alarm wil sound, An independent molten met-
al leak detection system isnot a substitute forthe ground
and leak detection system
ES
In compliance with NEC 2002 requirements (6655), all
‘power supplies shipped after January 1, 2002, wil in-
corporate ground leak detector (GLO) uns that wll ot
be equipped with probe disconnect buttons inthe GLO
circuit Furnace earth leak detector probes wil be hard
red tothe furnace ground cosest to the probes. Its
the user’ responsibility toensure that thefurnace ground
is securely Bonded to the approved system ground and
‘the metal bath is grounded through the furnace ground
probes at al times.
Under no circumstances should a furnace be operated
withthe furnace ground probes disconnected from the
furnace ground,
Do not operate the equipment if the metal charge ormol-
ten bath inthe fumace isnot grounded through ground
probe wires, Falure to ensure that ground probe wires
are in contact with the charge or molten bath coud ead
o high voltage onthe bath during operation, This could
cause serious injury or death from electrical Shock or
‘maiten metal eruption.
Le
Molten metal splash area, Wear Personal Protective
Equipment (PPE),
==
Esplosions in a furnace containing molten metal may
result in serious fies, damage to property andor ser
Ous injury or death to personnel. Explosions have been
‘caused by wet scrap uid trapped in closed or partially
closed containers, ice accumulations in scrap charged
into the furnace and even by supposedly defused shell
cases which actually have lv primer.
Use extreme care o ensure thatthe material charged is
safe and will not explode
‘Al material charged into the furnace must be completely
‘ry. Bundled or bled scrap and soft rink cans should
be dried thoroughly to eliminate rapped moisture before
adding tothe met
‘Tho use of drying and preheating systems and remote charg-
ing systems can significant reduce accidents related to
furnace charging operations. However, it does not eliminate
‘the need for Personal Protective Equipment (PPE.
Many serious melt shop accidents occur during furnace
charging when mel shop workers come in close proxim=
ity to the molten bath, Splashes caused by dropping large
pieces of scrap and waterímolten metal explosions caused
by wot or damp scrap can be reduced through the use of dry
ing and preheating systems and remotely-contoled charg=
ing systems.
These systems, however, cannot remove trapped liquids,
such as oll in cans. Such materials must be shredded and
died before they are used
Drying & preheating systems pass scrap through an ol oF
gas fueled flame tunel, eating the srapand minimizing the
‘moisture that could cause a water/moltn metal explosion,
‘These systems also burn off ol, producing a cleaner charge
and reducing the energy required in the furnace to melt the
scrap. Sorap dryers must be used with any heel meting
Induction Heating & Meting Safety Fundamentals Guide
EX
Be sure no one is on or near the furnaces or charging
equipment wien hey are operating. The If tit, indexing
and swing movements could injure bystanders.
furnace and
sorapisitro-
duced into a
pool of mol
ten metal.
Charging systems include belt and vibratory conveyors,
charge buckets and chutes. They signiicanty enhance safety
by permitting furnaces to be charged remotely, keeping the
‘melt shop worker ata distance or behind protective bari,
Care should be taken so thatthe charge continues to feed
into the moten poo! propery. it hangs up due to intertock-
ing or bridging, superheating below can erode te eractory,
causing molten meal to penetrate o the coll. This results
in loss of te ining and represents a very dangerous con-
tion. Should the molten metal burn through the col, the
water in the call can cause an explosion, causing possibly
fatal injures.
Al charging systems Invohe moving equipment that can
‘cause injury or death This equipment may include charge
cars tat pivot and/or travel across the melt deck, magnets
and charge buck
ets carried by
overhead cranes
and operating belt
conveyors. You
must be alert to
the path moving
equipment follows
and tay outofthat
path during opera»
tion. Being struck
by moving ear
injury or death
Molten metal splash area, Wear Personal Protective
Equipment (PPE),
==
Esplosions in a furnace containing molten metal may
result in serious fies, damage to property andor ser
Ous injury or death to personnel. Explosions have been
‘caused by wet scrap uid trapped in closed or partially
closed containers, ice accumulations in scrap charged
into the furnace and even by supposedly defused shell
cases which actually have lv primer.
Use extreme care o ensure thatthe material charged is
safe and will not explode
‘Al material charged into the furnace must be completely
‘ry. Bundled or bled scrap and soft rink cans should
be dried thoroughly to eliminate rapped moisture before
adding tothe met
‘Tho use of drying and preheating systems and remote charg-
ing systems can significant reduce accidents related to
furnace charging operations. However, it does not eliminate
‘the need for Personal Protective Equipment (PPE.
Many serious melt shop accidents occur during furnace
charging when mel shop workers come in close proxim=
ity to the molten bath, Splashes caused by dropping large
pieces of scrap and waterímolten metal explosions caused
by wot or damp scrap can be reduced through the use of dry
ing and preheating systems and remotely-contoled charg=
ing systems.
These systems, however, cannot remove trapped liquids,
such as oll in cans. Such materials must be shredded and
died before they are used
Drying & preheating systems pass scrap through an ol oF
gas fueled flame tunel, eating the srapand minimizing the
‘moisture that could cause a water/moltn metal explosion,
‘These systems also burn off ol, producing a cleaner charge
and reducing the energy required in the furnace to melt the
scrap. Sorap dryers must be used with any heel meting
Induction Heating & Meting Safety Fundamentals Guide
EX
Be sure no one is on or near the furnaces or charging
equipment wien hey are operating. The If tit, indexing
and swing movements could injure bystanders.
furnace and
sorapisitro-
duced into a
pool of mol
ten metal.
Charging systems include belt and vibratory conveyors,
charge buckets and chutes. They signiicanty enhance safety
by permitting furnaces to be charged remotely, keeping the
‘melt shop worker ata distance or behind protective bari,
Care should be taken so thatthe charge continues to feed
into the moten poo! propery. it hangs up due to intertock-
ing or bridging, superheating below can erode te eractory,
causing molten meal to penetrate o the coll. This results
in loss of te ining and represents a very dangerous con-
tion. Should the molten metal burn through the col, the
water in the call can cause an explosion, causing possibly
fatal injures.
Al charging systems Invohe moving equipment that can
‘cause injury or death This equipment may include charge
cars tat pivot and/or travel across the melt deck, magnets
and charge buck
ets carried by
overhead cranes
and operating belt
conveyors. You
must be alert to
the path moving
equipment follows
and tay outofthat
path during opera»
tion. Being struck
by moving ear
injury or death
Induction Heating & Meting Safty Fundamentals Guide
EN
Whenever you are working on a furnace ora dose cap-
ture hood when itis In he Lid position, suppor i in
that position with a stuctural brace which is strong
enough to keep it rom dropping if hydraulic pressure is
lost A furnace ora close capture hood which suddenly
and unexpectedly swings down from atited position wll,
cause injury or death
ER
Do not stand or place any part f your body under the
charge bucket wi ts suspended by he iting al,
A
‘Always watch for moving equipment. Be sure no one
is on or near the fumaces or charging equipment when
they are operating. The it, it, ndexing and swing move
ments could injure bystanders.
Charging platform
shown in extended
positon on a zinc
cathode channel
meting furnace
In melt shops, as
in many manutac-
turing. operations,
moving equipment
poses a trapping
hazard to the un-
wary. "Trapping" is
the term forthe sit-
vation where part
or all ofa worker's
body becomes
caught between
‘maving equipment
and another ob
ject or structure
Induction heating ofa bie,
Trapping aso includes stations where a worker's limbs or
clothing get caught in or on moving equipment
Trapping can result in injury or death, The loss of amb
or limbs is a common injury in trapping accidents. Tap
ping hazards on the melt deck may include moving charge
buckels carried by overhead cranes, traversing or pivoting
charge conveyors, belt conveyors, moving ladles and iting
furnaces.
‘Additional trapping hazard exist in induction heating and
meling shops; eg, inductively heated bars, tubes, ral,
looms, bilets, sabs, etc, use high power electrical sup
plies and powerful mechanical devices, suchas power driven
roll tables, pushers, pinch rolls, eto, to heat up the parts
and keep them in motion through the induction system. Un-
der no circumstances should personnel atempt to interfere
with such devices in operation. Only qualified and trained
personnel under tit lockouttagout procedures ae allowed
to carry outwork on these systems. Under no circumstances
can any ofthe interlocks, guards and other safety devices
provided on the equipment be bypassed or defeated in any
way to operate the system,
(Other trapping hazards exist in manufacturing environments
where induction furnaces ae used to melt and hold meta
These include Its, indexing bogies, ar knives, movable
launders and others. As with any piece of equipment, al
personnel associated wit his equipment must be trained to
understand its functions and no guar, intrick or any other
device provided forthe sate operation ofthe system may be
defeated, bypassed or removed o operat it. Access fo these
systems must always be restricted to authorized personnel
only
Induction furnaces tt forward to pour and then return to the
‘upright postion for charging and meting. While in motion,
EN
Whenever you are working on a furnace ora dose cap-
ture hood when itis In he Lid position, suppor i in
that position with a stuctural brace which is strong
enough to keep it rom dropping if hydraulic pressure is
lost A furnace ora close capture hood which suddenly
and unexpectedly swings down from atited position wll,
cause injury or death
ER
Do not stand or place any part f your body under the
charge bucket wi ts suspended by he iting al,
A
‘Always watch for moving equipment. Be sure no one
is on or near the fumaces or charging equipment when
they are operating. The it, it, ndexing and swing move
ments could injure bystanders.
Charging platform
shown in extended
positon on a zinc
cathode channel
meting furnace
In melt shops, as
in many manutac-
turing. operations,
moving equipment
poses a trapping
hazard to the un-
wary. "Trapping" is
the term forthe sit-
vation where part
or all ofa worker's
body becomes
caught between
‘maving equipment
and another ob
ject or structure
Induction heating ofa bie,
Trapping aso includes stations where a worker's limbs or
clothing get caught in or on moving equipment
Trapping can result in injury or death, The loss of amb
or limbs is a common injury in trapping accidents. Tap
ping hazards on the melt deck may include moving charge
buckels carried by overhead cranes, traversing or pivoting
charge conveyors, belt conveyors, moving ladles and iting
furnaces.
‘Additional trapping hazard exist in induction heating and
meling shops; eg, inductively heated bars, tubes, ral,
looms, bilets, sabs, etc, use high power electrical sup
plies and powerful mechanical devices, suchas power driven
roll tables, pushers, pinch rolls, eto, to heat up the parts
and keep them in motion through the induction system. Un-
der no circumstances should personnel atempt to interfere
with such devices in operation. Only qualified and trained
personnel under tit lockouttagout procedures ae allowed
to carry outwork on these systems. Under no circumstances
can any ofthe interlocks, guards and other safety devices
provided on the equipment be bypassed or defeated in any
way to operate the system,
(Other trapping hazards exist in manufacturing environments
where induction furnaces ae used to melt and hold meta
These include Its, indexing bogies, ar knives, movable
launders and others. As with any piece of equipment, al
personnel associated wit his equipment must be trained to
understand its functions and no guar, intrick or any other
device provided forthe sate operation ofthe system may be
defeated, bypassed or removed o operat it. Access fo these
systems must always be restricted to authorized personnel
only
Induction furnaces tt forward to pour and then return to the
‘upright postion for charging and meting. While in motion,
they can pose special hazards for melt shop workers. One
preventable accident occurs ia melt shop workers foot be-
comes trapped between a descending furnace back platform
and the working deck.
A mel shop worker must know the path a furnace or other
piece of mobile equipment wil travel when iis et into mo-
tion and remain behind designated safety barers until the
machine completes is duty cycle and retums 1 its normal
testing poston.
Trapping aso is à hazard during maintenance operations,
en workers must be within a piece of equpment’s mo-
tion path, That's why Special steps must be taken to disable
the equipment electrically (lock out power) and secure it me-
chanically before maintenance work begins. In a melt shop,
this is particulary true of fumaces.
If work ls to be performed on atte furnace, the furnace
‘must be secured nthe it postion witha mechanical sup
port Reliance on hydralics alone could lead tothe fumace
Induction Heating & Melting Saety Fundamentals Guide
{rapping without warning, causing injury or death to anyone
trapped undemeat
Charge conveyors and buckets can traverse across the melt
deck and index forward tothe furnaces, Workers must be
alert and remain clear o ll moving equipment
‘Bopies on rails are used to index a channel pot coating fur
‘ace 0 an from its operating positon
Maintaining Your Refractory Lining
Proper and welhmaintained refractory linings are impor
tant forthe safe operation of al metal melting furnaces. In
induction furnaces, they are absolutly erica. The physics
Of electrical induction demand that the reractory lining be-
‘ween the induction cos and the bath be as thin as possible.
At the same time it must be thick enough to fully protect
the coils and prevent metal run-out in the face of attacks
by molten metal, chemical agents and mechanical shocks.
Assuring that the furnace ning remains within manufacturer
specified limits requires careful treatment of the ning during
all furnace operations as well as comprehensive inspection
and monitoring procedure.
Moten ei an ——— BE
Hard Sintered Refractory
co |]
Powdery etactoy Ine Layer |
Farc Shel ame
—
rout = ZU
=
© 2006 Inductotherm Corp.
Without question, metal runout ranks among the most
severe accidents that can occur during meting and hold
ing operations. Run-outs occur when molten metal breaks
‘through the furnace ining. I cooling, electrical, hydraulic or
control Ines become damaged, there isan imminent danger
‘of fire or waterímolen metal explosion.
‘The integrity ofthe furnace nin can be compromised by:
+ Installation ofthe wrong refractory material for a particular
application
+ Inadequate or improper instalation of refractory material
+ Inadequate or improper sintering of refractory material
+ Inadequate or improper preheating of a used ning from cold
+ Failure to montorrecord normal ining wear and allowing
the ining to become too thin
+ Falret property maintain the furnace
The sudden or cumulative effects of physical shocks or me
chanical stress
«The sudden or cumulative eters of excessive temperatures
‘or improper thermal eyeling of ating
+ Excessive slag or dross buildup
preventable accident occurs ia melt shop workers foot be-
comes trapped between a descending furnace back platform
and the working deck.
A mel shop worker must know the path a furnace or other
piece of mobile equipment wil travel when iis et into mo-
tion and remain behind designated safety barers until the
machine completes is duty cycle and retums 1 its normal
testing poston.
Trapping aso is à hazard during maintenance operations,
en workers must be within a piece of equpment’s mo-
tion path, That's why Special steps must be taken to disable
the equipment electrically (lock out power) and secure it me-
chanically before maintenance work begins. In a melt shop,
this is particulary true of fumaces.
If work ls to be performed on atte furnace, the furnace
‘must be secured nthe it postion witha mechanical sup
port Reliance on hydralics alone could lead tothe fumace
Induction Heating & Melting Saety Fundamentals Guide
{rapping without warning, causing injury or death to anyone
trapped undemeat
Charge conveyors and buckets can traverse across the melt
deck and index forward tothe furnaces, Workers must be
alert and remain clear o ll moving equipment
‘Bopies on rails are used to index a channel pot coating fur
‘ace 0 an from its operating positon
Maintaining Your Refractory Lining
Proper and welhmaintained refractory linings are impor
tant forthe safe operation of al metal melting furnaces. In
induction furnaces, they are absolutly erica. The physics
Of electrical induction demand that the reractory lining be-
‘ween the induction cos and the bath be as thin as possible.
At the same time it must be thick enough to fully protect
the coils and prevent metal run-out in the face of attacks
by molten metal, chemical agents and mechanical shocks.
Assuring that the furnace ning remains within manufacturer
specified limits requires careful treatment of the ning during
all furnace operations as well as comprehensive inspection
and monitoring procedure.
Moten ei an ——— BE
Hard Sintered Refractory
co |]
Powdery etactoy Ine Layer |
Farc Shel ame
—
rout = ZU
=
© 2006 Inductotherm Corp.
Without question, metal runout ranks among the most
severe accidents that can occur during meting and hold
ing operations. Run-outs occur when molten metal breaks
‘through the furnace ining. I cooling, electrical, hydraulic or
control Ines become damaged, there isan imminent danger
‘of fire or waterímolen metal explosion.
‘The integrity ofthe furnace nin can be compromised by:
+ Installation ofthe wrong refractory material for a particular
application
+ Inadequate or improper instalation of refractory material
+ Inadequate or improper sintering of refractory material
+ Inadequate or improper preheating of a used ning from cold
+ Failure to montorrecord normal ining wear and allowing
the ining to become too thin
+ Falret property maintain the furnace
The sudden or cumulative effects of physical shocks or me
chanical stress
«The sudden or cumulative eters of excessive temperatures
‘or improper thermal eyeling of ating
+ Excessive slag or dross buildup
Induction Heating & Meling Safety Fundamentals Guide
‘Any ofthese situations can lead to a metal run-out from an
Induction furnace. Therefore, careful attention to a fumace'
lining is absolutely ritial to sate meting and holding.
Choosing the Right Refractory
Refractory materia consist of several chemical compounds,
‘The bulk of any lining material consists of a class of com
pounds called oxides. Refractor linings used in induction
fumaces are commonly made of alumina, silica, magnesia,
(or zirconia plus smaller amounts of binding materials
(Choosing the right refractory material for your specific melt-
ing or holding application is crucial. You must take ino ac
count the specific metal you will be melting, the tempera-
{ures you wil be reaching, the length of your met, how long
you wil be holding metal in the furnace, how much inductive
tiring vil ake place, what addtives or alloying agents you
willbe using and your furnace relining practices.
‘The best way to select the ight refractory is through close
consultation with your refractory vendor. They wll have the
‘mast current information on the specifications and peror
‘mance characteristics of tational and new refractory ma-
terial. Your refactory vendor should be your source fr in-
structions and taining forthe instalation and sintering of the
chosen refractory material
Proper Installation ofa Furnace Lining
Proper instalation is as important to the safe operation
ofthe furnaces as the selection of the right material for
your application. Ifthe refractory material is inadequately
Compacted during instalation, voids or aras of low density
may create weak spots easly attacked by the molten met
al. Ifthe crucible created with a form that ls improperly
centered, or one that has been somehow distorted dur
ing storage or shipment, ning thickness wil be uneven
As ars lle lining may fall before the end ofits expected
service ite
It is especialy cfitca that the reracory manufacturers
procedures for drying and sintering be followed and never
hurried. I sufficient time is nat allowed forthe retrctory
materials to bond, te ining will be more prone to attack by
Wear ai fier masks when mixing dry powders. Inhala-
tion without protection may cause severe nation of the
respiratory system, leading to silicosis or cancer. Please
‘afer tothe manufacturer warning,
molten metal and sag. Te sintering schedule must nat be
interrupted for any reason once it as begun
In some cases, sintering o te ining in both coreless and
channel fumace applications is parlaly done using gas
boners, is vitally important thatthe refractory manufatur-
rs recommendations wih respect to bumer sie, numbers,
controls, monitoring equipment, and heat-up schedules be
strictly adhered to. Additionally, tis highly recommended
that trained supervisory personnel be availabe throughout
the heat-up schedule to monitor ts progress.
It is mandatory that you follow the refractory manufac-
{ure’s instructions for installation, curing, day-to-day
‘maintenance and start-up procedure of the iia ine
ng as it is important that the refractory temperature be
propery controled during the process.
Coreless fumaces sometime use preformed crucibles for
nonferrous meting in place of rammed linings. One advan-
tage of crucibles is that they can be manufactured with a
protective glaze. In addition to minimizing oxidation of the
refractory materia, the glaze can sealover any small cracks
that develop during routine melt shop operation.
The protective effect of he glaze lasts only so long as the
coating remains undamaged. Should it become chipped or
‘othenuise compromised during instalation or subsequent
‘operations, a small rack wil rather than “set-eal,” begin
to spread. Metal run-out may occur
Automated Sintering Control Systems
‘Computerized control of meting operations represents the
most technologically advanced form of automation
Failure to ensure that ground probe wie are in contact
with thelinin form, crucible or metal could resultin high
voltage on the molten bath during operation. This could
cause serious injury or death from electric shock.
FN
Maintaining the integrity ofthe furnace lining is the key
to preventing a run-out
© 2006 Inductotherm Corp.
‘Any ofthese situations can lead to a metal run-out from an
Induction furnace. Therefore, careful attention to a fumace'
lining is absolutely ritial to sate meting and holding.
Choosing the Right Refractory
Refractory materia consist of several chemical compounds,
‘The bulk of any lining material consists of a class of com
pounds called oxides. Refractor linings used in induction
fumaces are commonly made of alumina, silica, magnesia,
(or zirconia plus smaller amounts of binding materials
(Choosing the right refractory material for your specific melt-
ing or holding application is crucial. You must take ino ac
count the specific metal you will be melting, the tempera-
{ures you wil be reaching, the length of your met, how long
you wil be holding metal in the furnace, how much inductive
tiring vil ake place, what addtives or alloying agents you
willbe using and your furnace relining practices.
‘The best way to select the ight refractory is through close
consultation with your refractory vendor. They wll have the
‘mast current information on the specifications and peror
‘mance characteristics of tational and new refractory ma-
terial. Your refactory vendor should be your source fr in-
structions and taining forthe instalation and sintering of the
chosen refractory material
Proper Installation ofa Furnace Lining
Proper instalation is as important to the safe operation
ofthe furnaces as the selection of the right material for
your application. Ifthe refractory material is inadequately
Compacted during instalation, voids or aras of low density
may create weak spots easly attacked by the molten met
al. Ifthe crucible created with a form that ls improperly
centered, or one that has been somehow distorted dur
ing storage or shipment, ning thickness wil be uneven
As ars lle lining may fall before the end ofits expected
service ite
It is especialy cfitca that the reracory manufacturers
procedures for drying and sintering be followed and never
hurried. I sufficient time is nat allowed forthe retrctory
materials to bond, te ining will be more prone to attack by
Wear ai fier masks when mixing dry powders. Inhala-
tion without protection may cause severe nation of the
respiratory system, leading to silicosis or cancer. Please
‘afer tothe manufacturer warning,
molten metal and sag. Te sintering schedule must nat be
interrupted for any reason once it as begun
In some cases, sintering o te ining in both coreless and
channel fumace applications is parlaly done using gas
boners, is vitally important thatthe refractory manufatur-
rs recommendations wih respect to bumer sie, numbers,
controls, monitoring equipment, and heat-up schedules be
strictly adhered to. Additionally, tis highly recommended
that trained supervisory personnel be availabe throughout
the heat-up schedule to monitor ts progress.
It is mandatory that you follow the refractory manufac-
{ure’s instructions for installation, curing, day-to-day
‘maintenance and start-up procedure of the iia ine
ng as it is important that the refractory temperature be
propery controled during the process.
Coreless fumaces sometime use preformed crucibles for
nonferrous meting in place of rammed linings. One advan-
tage of crucibles is that they can be manufactured with a
protective glaze. In addition to minimizing oxidation of the
refractory materia, the glaze can sealover any small cracks
that develop during routine melt shop operation.
The protective effect of he glaze lasts only so long as the
coating remains undamaged. Should it become chipped or
‘othenuise compromised during instalation or subsequent
‘operations, a small rack wil rather than “set-eal,” begin
to spread. Metal run-out may occur
Automated Sintering Control Systems
‘Computerized control of meting operations represents the
most technologically advanced form of automation
Failure to ensure that ground probe wie are in contact
with thelinin form, crucible or metal could resultin high
voltage on the molten bath during operation. This could
cause serious injury or death from electric shock.
FN
Maintaining the integrity ofthe furnace lining is the key
to preventing a run-out
© 2006 Inductotherm Corp.
‘The most advanced melt shop meting automation systems
provide fully programmable control of sintering, the ability
to schedule and contro furnace col-start procedures and
Computerized control of the meting process. With furnace
‘thermocouple feedback, computerized control of sintering
an be more accurate and reliable than manual control
Automated control systems are designed to assist a fly-
trained and experienced operator in running the furnace and
power supply. They are not a substitute forthe direct, caretul
and continuous attention that an operator must give o the
fumace and power supply whenever they are operating,
Monitoring Normal Lining Wear
Induction furnace refractor ning and crucibles are subject
o normal wear as a result ofthe seraping action of metal on
the furnace walls, Ths i largely due tothe inductive string
action causedby theinduction urnace's electromagnetic field
In theory. refractory wear shouldbe uniform; in practice this
never occurs. The mos intense wear occurs:
‘At the slagmetal interface
+ Where sidewalls jin the floor
+ On less dense areas caused by poor lining instalation
The emptied furnace must be visually inspected. Special
attention must be paid to high-wear areas described above
Observations must be accurately logged.
‘Although useful, visual inspections are not always possible
"Nor can visual inspection alone reveal al potential wear prob-
lems, Some rtial wear areas, such asthe inductor molten
‘meta loop of a channel furnace or pressure pour, remain
covered with molten metal between rlrings. The presence
of a low density refractory area can likewise escape notice
during visual inspections. These limitations make lning- wear
monitoring programs essential.
Directly measuring the interior diameter of the furnace pro
vides exellent information about the condition of the lining
A base-ine plot must be made after each reining. Subse-
‘quent measurements will show a precise rat of ning wear
or sla buldup. Determining the at at which the refractory
material erodes wil make possible to schedule relining be-
fore the refralory material becomes dangerously worn
Calipers are insuficint for is purpose and must not be
used. Measurements must only be made using an accuatey-
positioned center post equipped wit a radial measuring arm
‘Some warning signs of ning wear are
«Ina fixed frequency power supply, an increase inthe num
Induction Hating & Melting Saety Fundamentals Guide
ber of capacitors needed tobe switched into the circuit to
maintain unity power factor
«Ina variable frequency power supply. runing at frequency.
limit could be an indication of ning wear
Useful though they may be, changes i electrical characteris-
ties must never be used as a substitute fr physical measure
ment and observation ofthe lining tel,
A state-of-the-art automatic ting wear detection system
‘which graphically displays the ning condition (e, Saveway
‘or equivalent) can be used.
‘Two commercial available instruments can be used to pro-
vide localized temperature readings. À magnetic contact ter.
‘mometer attached tothe steel shell of à channel furace wil
indicate lining wear by revealing the position of a hot spot.
Infrared thermometers make it possible to remotely measure
temperature by ooking ata furnace through the eyepiece of
device resembling a hand-held video camera.
Regardless ofthe instrument used to monitor lining wear, it
is essential to develop and adhere toa standard procedure.
‘Consult your relractory vendor or information and training
for how to monitor the condition of your ining,
‘Accurate data recording and plotting wi help t assure max
imum furnace utilization between clnings, while minimizing
‘the risk of using a furnace witha dangerously thin ining,
Physical Shock & Mechanical Stress
‘The sudden or cumulative efect of physical shocks and me
chanical stress can lead to a fallure of relractory material
Most refractory materials end o bereativl rite and very
‘weak in tension. Bulky charge materials must always be low
ere ino the furnace. It must be “dump charge,” be sure
‘there is adequate material beneath the charge to cushion its
impact. The charge must also be property centered to avoid
damaging contact withthe sidewal
Mechanical stress caused bythe different thermal expansion
rates of he charge and refractory material can be avoided
by assuring metal does not become jammed within the
furnace. Except when itis done for safely reasons, dealing
‘witha bridge for example, the melt must never be alowed to
sol in the furnace, Inthe event o a prolonged failure, a
loss of coolant event, or oer prolonged furnace shutdown,
the furnace must be emptied.
Excossve Temperatures & Thermal Shock
Refractory manufacturer ake furnace temperature extremes
into account in formulating their products. For this reason it
is important that refractory material e used only in applica-
provide fully programmable control of sintering, the ability
to schedule and contro furnace col-start procedures and
Computerized control of the meting process. With furnace
‘thermocouple feedback, computerized control of sintering
an be more accurate and reliable than manual control
Automated control systems are designed to assist a fly-
trained and experienced operator in running the furnace and
power supply. They are not a substitute forthe direct, caretul
and continuous attention that an operator must give o the
fumace and power supply whenever they are operating,
Monitoring Normal Lining Wear
Induction furnace refractor ning and crucibles are subject
o normal wear as a result ofthe seraping action of metal on
the furnace walls, Ths i largely due tothe inductive string
action causedby theinduction urnace's electromagnetic field
In theory. refractory wear shouldbe uniform; in practice this
never occurs. The mos intense wear occurs:
‘At the slagmetal interface
+ Where sidewalls jin the floor
+ On less dense areas caused by poor lining instalation
The emptied furnace must be visually inspected. Special
attention must be paid to high-wear areas described above
Observations must be accurately logged.
‘Although useful, visual inspections are not always possible
"Nor can visual inspection alone reveal al potential wear prob-
lems, Some rtial wear areas, such asthe inductor molten
‘meta loop of a channel furnace or pressure pour, remain
covered with molten metal between rlrings. The presence
of a low density refractory area can likewise escape notice
during visual inspections. These limitations make lning- wear
monitoring programs essential.
Directly measuring the interior diameter of the furnace pro
vides exellent information about the condition of the lining
A base-ine plot must be made after each reining. Subse-
‘quent measurements will show a precise rat of ning wear
or sla buldup. Determining the at at which the refractory
material erodes wil make possible to schedule relining be-
fore the refralory material becomes dangerously worn
Calipers are insuficint for is purpose and must not be
used. Measurements must only be made using an accuatey-
positioned center post equipped wit a radial measuring arm
‘Some warning signs of ning wear are
«Ina fixed frequency power supply, an increase inthe num
Induction Hating & Melting Saety Fundamentals Guide
ber of capacitors needed tobe switched into the circuit to
maintain unity power factor
«Ina variable frequency power supply. runing at frequency.
limit could be an indication of ning wear
Useful though they may be, changes i electrical characteris-
ties must never be used as a substitute fr physical measure
ment and observation ofthe lining tel,
A state-of-the-art automatic ting wear detection system
‘which graphically displays the ning condition (e, Saveway
‘or equivalent) can be used.
‘Two commercial available instruments can be used to pro-
vide localized temperature readings. À magnetic contact ter.
‘mometer attached tothe steel shell of à channel furace wil
indicate lining wear by revealing the position of a hot spot.
Infrared thermometers make it possible to remotely measure
temperature by ooking ata furnace through the eyepiece of
device resembling a hand-held video camera.
Regardless ofthe instrument used to monitor lining wear, it
is essential to develop and adhere toa standard procedure.
‘Consult your relractory vendor or information and training
for how to monitor the condition of your ining,
‘Accurate data recording and plotting wi help t assure max
imum furnace utilization between clnings, while minimizing
‘the risk of using a furnace witha dangerously thin ining,
Physical Shock & Mechanical Stress
‘The sudden or cumulative efect of physical shocks and me
chanical stress can lead to a fallure of relractory material
Most refractory materials end o bereativl rite and very
‘weak in tension. Bulky charge materials must always be low
ere ino the furnace. It must be “dump charge,” be sure
‘there is adequate material beneath the charge to cushion its
impact. The charge must also be property centered to avoid
damaging contact withthe sidewal
Mechanical stress caused bythe different thermal expansion
rates of he charge and refractory material can be avoided
by assuring metal does not become jammed within the
furnace. Except when itis done for safely reasons, dealing
‘witha bridge for example, the melt must never be alowed to
sol in the furnace, Inthe event o a prolonged failure, a
loss of coolant event, or oer prolonged furnace shutdown,
the furnace must be emptied.
Excossve Temperatures & Thermal Shock
Refractory manufacturer ake furnace temperature extremes
into account in formulating their products. For this reason it
is important that refractory material e used only in applica-
Induction Heat
& Mating Satty Fundamentals Guide
tions that match a products specified temperature rang-
fs. Should actual fumace conditions heat or cool the
‘ining beyond its specified range, the resulting thermal shock
can damage the integrity ofthe lining. Cracking and spaling
can be early warning signs of thermal shock and a potently
serious metal run-out,
‘Thermal shock can also be caused by excessive heating
or improper cooling. The best way to avoid overheating Is
10 monitor the bath and take a temperature reading when
the charge lqueis.Excassive overheating of the bath must
be avoided. Careful monitoring is essential, Temperatures
exceeding the refacton’ rating can soften ts surface and
cause rapid erosion, leading to catastrophic failure, The
high heating rates of medium frequency coreess furnaces
enable them to quickly overheat, Channeltype holding
fumaces have low heating rates and thickenings in the
upper case. However, temperature control is also necessary
because the inductor linings tend tobe thinner. nal types
of induction furnaces, kowatt-hour counters, timing devices
and computerized control systems can help prevent acciden-
tal overheating
When working with a cold holding furnace, be sure itis
properly preheated to the reractoy manufacturer's spec
fications before filing it with molten metal. In the case of
‘mating cold charge material, slowing the rte of the inital
‘heat-up unt the ing is completely expanded wil minimize
the risk of thermal shock toa cod furnace. Te gradual eat
ing ofthe charge allows cracks inthe refractory to seal over
before molten metal can penetrate. When cooling a furnace
following a met campaign, follow the refractory manufactur
ers recommendations.
A mel shop worker lagsafumace equipped with a back
‘lagging mechanism designed o faciale slag removal.
‘Thermal damage tothe refractory can also result from over
filing a coreess furnace. If the level of molten meta inthe
furnace is higher than the top cooling turn on the col, the
refractory material in the top of the furnace is not being
cooled and is exposed to thermal stresses that could lead
to its failure. Ovrfing may also cause metal penetration
between the working refractory lining andthe top cap rfrac-
tory material. Either situation may lead to metal ur-out and
possibly a watermoten metal explosion, Serius injury or
‘death coud result
Slag or dross is an unavoidable by-product of melting metal
Sag forms wen rust, dit and sand from the charge and
refractory material erode from the furnace lining rise tothe
top of the bath, Dross is created when oxides form during
the meting of nonferrous metals such as aluminum, zinc,
Galvalume, et. Chemical reactions between the slag or dross
and te ning increase the rat a which te ni erodes.
AA highly abrasive materia, lg or dross wl erode refractory
material near the top ofthe molten meal. ti not uncommon
{or this part ofthe furnace to be patched between scheduled
relnings. In extreme circumstances, this erosion may expose
the induction col, creating the risk ofa water/molten metal
explosion. Careful monitoring ofthe refractory thickness is
necessary so it can be patched or replaced before the coli
ate exposed,
The manual process
‘of removing slg rom
ver large fumaces Is
atime consumingand
labor intensive opera-
tion. I also exposes
furnace operators to
high levels of rad
ant heat and physical
‘exertion Where over
head clearances per-
mit, ag removal can
be accomplished us-
ing a clamshell type
lag scoop operated
from an overhead or
jib crane.
Clamshel type slag
S200p in ne closet
noving sag.
& Mating Satty Fundamentals Guide
tions that match a products specified temperature rang-
fs. Should actual fumace conditions heat or cool the
‘ining beyond its specified range, the resulting thermal shock
can damage the integrity ofthe lining. Cracking and spaling
can be early warning signs of thermal shock and a potently
serious metal run-out,
‘Thermal shock can also be caused by excessive heating
or improper cooling. The best way to avoid overheating Is
10 monitor the bath and take a temperature reading when
the charge lqueis.Excassive overheating of the bath must
be avoided. Careful monitoring is essential, Temperatures
exceeding the refacton’ rating can soften ts surface and
cause rapid erosion, leading to catastrophic failure, The
high heating rates of medium frequency coreess furnaces
enable them to quickly overheat, Channeltype holding
fumaces have low heating rates and thickenings in the
upper case. However, temperature control is also necessary
because the inductor linings tend tobe thinner. nal types
of induction furnaces, kowatt-hour counters, timing devices
and computerized control systems can help prevent acciden-
tal overheating
When working with a cold holding furnace, be sure itis
properly preheated to the reractoy manufacturer's spec
fications before filing it with molten metal. In the case of
‘mating cold charge material, slowing the rte of the inital
‘heat-up unt the ing is completely expanded wil minimize
the risk of thermal shock toa cod furnace. Te gradual eat
ing ofthe charge allows cracks inthe refractory to seal over
before molten metal can penetrate. When cooling a furnace
following a met campaign, follow the refractory manufactur
ers recommendations.
A mel shop worker lagsafumace equipped with a back
‘lagging mechanism designed o faciale slag removal.
‘Thermal damage tothe refractory can also result from over
filing a coreess furnace. If the level of molten meta inthe
furnace is higher than the top cooling turn on the col, the
refractory material in the top of the furnace is not being
cooled and is exposed to thermal stresses that could lead
to its failure. Ovrfing may also cause metal penetration
between the working refractory lining andthe top cap rfrac-
tory material. Either situation may lead to metal ur-out and
possibly a watermoten metal explosion, Serius injury or
‘death coud result
Slag or dross is an unavoidable by-product of melting metal
Sag forms wen rust, dit and sand from the charge and
refractory material erode from the furnace lining rise tothe
top of the bath, Dross is created when oxides form during
the meting of nonferrous metals such as aluminum, zinc,
Galvalume, et. Chemical reactions between the slag or dross
and te ning increase the rat a which te ni erodes.
AA highly abrasive materia, lg or dross wl erode refractory
material near the top ofthe molten meal. ti not uncommon
{or this part ofthe furnace to be patched between scheduled
relnings. In extreme circumstances, this erosion may expose
the induction col, creating the risk ofa water/molten metal
explosion. Careful monitoring ofthe refractory thickness is
necessary so it can be patched or replaced before the coli
ate exposed,
The manual process
‘of removing slg rom
ver large fumaces Is
atime consumingand
labor intensive opera-
tion. I also exposes
furnace operators to
high levels of rad
ant heat and physical
‘exertion Where over
head clearances per-
mit, ag removal can
be accomplished us-
ing a clamshell type
lag scoop operated
from an overhead or
jib crane.
Clamshel type slag
S200p in ne closet
noving sag.
Induction Hating & Melting Saety Fundamentals Guide
Inductive Stirring
Ina coreles or channel induction furnace, the meal charge
‘material is meted or heated by current generated by anelec-
tromagnetic fiel. When the metal becomes molten, this
field also cause the bath to move in a “igure eight” pattern
as illustrated in the drawing shown. This is called inductive
sting It also serves the important purpose of mixing the
‘meta, producing a more homogeneous aly.
The amountofstiringis determined bythe sizeof the urnac,
the power put into the metal, the frequency ofthe electromag
netic field and the type and amount of metal in the furnace
Inductive Sting circulates high-temperature metal away
{rom the furnace walls, preventing overheating of he rerac-
tory tning of the fu
nace to gradual wear
vay through the action
‘ofthe moving metal on
the furnace wal.
This gradual wear rer
quires that furnaces
be relined periodically.
It is vital that Inings
be replaced promptly
when they wear down
to thelr minimum thickness to prevent aur.
Melt Automation Technology Helps The Operator To
Prevent Accidental Superheating & Lining Damage
‘Modernindvction meting systemsareoften high poweredand
‘melthecharge very api. Th has spurred the development
of computerized mating systems designed to provide the ur-
‘nace operator with the ability to precisely contro the meting
process and reduce the isk of accldentalsuperheating. Some
ofthese systems operate on special computers, some are PC
based and some are built into the melting equipment si.
Induction meting operations lend themselves to computer-
‘aed contol. À ypial sytem takes the weight ofthe furnace
charge either from load calls or as entered ty the operator,
the desired pouring temperature; and then calculates the ilo
watt hours needed to complete the mel. then tums ofthe
System or drops to holding power when Ih melts compete.
‘Thermocouple ratings can be transmitted tothe computer
to further enhance accuracy.
This precise meting contro optimizes power usage by mini-
mizing temperature overshoot, saves time by reducing re
quent temperature checks and enhances safety by reducing
the chance of accidental superheatng of the bath which can
cause excessive erosion, Ining alure and the possibiity of
a fumace explosion.
Automated control systems are designed to assist a fully-
trained and experienced operator in running the furnace and
power supply. They are nota substitute fr the direct, careful
and continuous attention that an operator must give tothe
furnace and power supply whenever they ae operating
‘Screen rom Metminder® 200 met control computer.
Inductive Stirring
Ina coreles or channel induction furnace, the meal charge
‘material is meted or heated by current generated by anelec-
tromagnetic fiel. When the metal becomes molten, this
field also cause the bath to move in a “igure eight” pattern
as illustrated in the drawing shown. This is called inductive
sting It also serves the important purpose of mixing the
‘meta, producing a more homogeneous aly.
The amountofstiringis determined bythe sizeof the urnac,
the power put into the metal, the frequency ofthe electromag
netic field and the type and amount of metal in the furnace
Inductive Sting circulates high-temperature metal away
{rom the furnace walls, preventing overheating of he rerac-
tory tning of the fu
nace to gradual wear
vay through the action
‘ofthe moving metal on
the furnace wal.
This gradual wear rer
quires that furnaces
be relined periodically.
It is vital that Inings
be replaced promptly
when they wear down
to thelr minimum thickness to prevent aur.
Melt Automation Technology Helps The Operator To
Prevent Accidental Superheating & Lining Damage
‘Modernindvction meting systemsareoften high poweredand
‘melthecharge very api. Th has spurred the development
of computerized mating systems designed to provide the ur-
‘nace operator with the ability to precisely contro the meting
process and reduce the isk of accldentalsuperheating. Some
ofthese systems operate on special computers, some are PC
based and some are built into the melting equipment si.
Induction meting operations lend themselves to computer-
‘aed contol. À ypial sytem takes the weight ofthe furnace
charge either from load calls or as entered ty the operator,
the desired pouring temperature; and then calculates the ilo
watt hours needed to complete the mel. then tums ofthe
System or drops to holding power when Ih melts compete.
‘Thermocouple ratings can be transmitted tothe computer
to further enhance accuracy.
This precise meting contro optimizes power usage by mini-
mizing temperature overshoot, saves time by reducing re
quent temperature checks and enhances safety by reducing
the chance of accidental superheatng of the bath which can
cause excessive erosion, Ining alure and the possibiity of
a fumace explosion.
Automated control systems are designed to assist a fully-
trained and experienced operator in running the furnace and
power supply. They are nota substitute fr the direct, careful
and continuous attention that an operator must give tothe
furnace and power supply whenever they ae operating
‘Screen rom Metminder® 200 met control computer.
Induction Heating & Meting Safety Fundamentals Guide
Electrical Monitoring of Lining Wear
A limited amount of information about the condon of the
refraciry material can be ascertained from changes in the
fumace's electrical characteristics. An important limitation of
these measurements is that they reveal average condtons.
Electrical measurement wil nt isolate a localized problem
Such asa gouge ora voi beneath the lining surface.
One situation in which electrical measurements are very
‘sell is in estimating wear in the induction loop of chan
nel furnaces. Molten metal is always present inthe furnace,
‘making visual inspections between shut-downs impossible.
Lning wear causes changes in furnace voltage, current and
‘ower readings. rom hese values itis possible to calculate
resistance, reactance and the power factor ofthe channel
Loop. Comparing one or more of these characteristics with
values from previous measurements indicates erosion (or
‘build up) ofthe refractory in he inductor loop. Always main
tai a start-up log and regular meter readings,
This technique provides absolutely no information about
the condition of the ring inthe main bath. The main bath
or upper case retractory can be subject to chemical attack
al the sag line. The slag line canbe at any level in the fur-
nace depending on how itis operated. The lining must be
checked visually and also the outside shel temperature must
be checked. the refractory lining is thin, his wil show as a
hot spot on the shell. Once detected, the furnace ining must
be careuly inspected. I the lining is severely eroded, the
fumace must be removed from service immediately. Normal
shel temperatures may be as high as 500* the shel tem
perature Is above 500°F or I localized hotspots are more
‘han 100% above adjacent ares, the ing must be careful
Inspected to determine why.
Similar electrical measurements can be made of coreless
fumace linings but, as noted, these measurements reveal
average conditions. They vill not disclose à localized
problem so total relance on tis is not practica. Coeless
furnaces are emptied with sufficient frequency to permit
visual inspection and physical measurements, which are
always more accurate
Inappications using corelssfumaces for holding metal con-
tinuously with infrequent opportunites fr emptying the fur-
nace itis prudent to schedule partial emptying ofthe coreless
fumace to inspect the exposed lining walls. Th fumace is
emptied down to approximately 14 to 12 ol ts capaci.
(Gas burners are used to maintain temperature inthe furnace
as metal is emptied, to maintain the exposed refractory walls
at or near operating temperature. Ths is done to minimize
thermal stress on the exposed refractory material. Visual in-
specton wil reveal erosion or build-up of oxides onthe In-
ing wall Buld-ups reduce the efficiency ofthe furnace and
should be scraped using appropriate mechanical scrapers
Erosion as lo be evaluated by tained and experienced
petsonneltoes-
tablish. whether
the refractory
material should
be replaced
This computer
contro! system
Gacultes coin
ductance to check average Ining wear in a coreless furnace
wee eee
Induction Electrical System Safety
‘When melt shops relied on fuel-fred furnaces, the electr
cal hazards in foundries were similar to those in any other
industry. Electrical motors, lit-ruck battey chargers,
heaters, lights and office equipment operated at standard
vollages. The switches, connectors and circuit interupters
encountered at work were simply larger versions of those
found at home,
Like all industrial workers, met shop workers realized the
need to rat electricity as a force tobe respected. But their
years of experience in living with electrical devices taught
them electrical hazards could be easly avoided.
The introduction of induction furnaces made it neces-
sary for workers to work in close proximity to high vol
Electrical Monitoring of Lining Wear
A limited amount of information about the condon of the
refraciry material can be ascertained from changes in the
fumace's electrical characteristics. An important limitation of
these measurements is that they reveal average condtons.
Electrical measurement wil nt isolate a localized problem
Such asa gouge ora voi beneath the lining surface.
One situation in which electrical measurements are very
‘sell is in estimating wear in the induction loop of chan
nel furnaces. Molten metal is always present inthe furnace,
‘making visual inspections between shut-downs impossible.
Lning wear causes changes in furnace voltage, current and
‘ower readings. rom hese values itis possible to calculate
resistance, reactance and the power factor ofthe channel
Loop. Comparing one or more of these characteristics with
values from previous measurements indicates erosion (or
‘build up) ofthe refractory in he inductor loop. Always main
tai a start-up log and regular meter readings,
This technique provides absolutely no information about
the condition of the ring inthe main bath. The main bath
or upper case retractory can be subject to chemical attack
al the sag line. The slag line canbe at any level in the fur-
nace depending on how itis operated. The lining must be
checked visually and also the outside shel temperature must
be checked. the refractory lining is thin, his wil show as a
hot spot on the shell. Once detected, the furnace ining must
be careuly inspected. I the lining is severely eroded, the
fumace must be removed from service immediately. Normal
shel temperatures may be as high as 500* the shel tem
perature Is above 500°F or I localized hotspots are more
‘han 100% above adjacent ares, the ing must be careful
Inspected to determine why.
Similar electrical measurements can be made of coreless
fumace linings but, as noted, these measurements reveal
average conditions. They vill not disclose à localized
problem so total relance on tis is not practica. Coeless
furnaces are emptied with sufficient frequency to permit
visual inspection and physical measurements, which are
always more accurate
Inappications using corelssfumaces for holding metal con-
tinuously with infrequent opportunites fr emptying the fur-
nace itis prudent to schedule partial emptying ofthe coreless
fumace to inspect the exposed lining walls. Th fumace is
emptied down to approximately 14 to 12 ol ts capaci.
(Gas burners are used to maintain temperature inthe furnace
as metal is emptied, to maintain the exposed refractory walls
at or near operating temperature. Ths is done to minimize
thermal stress on the exposed refractory material. Visual in-
specton wil reveal erosion or build-up of oxides onthe In-
ing wall Buld-ups reduce the efficiency ofthe furnace and
should be scraped using appropriate mechanical scrapers
Erosion as lo be evaluated by tained and experienced
petsonneltoes-
tablish. whether
the refractory
material should
be replaced
This computer
contro! system
Gacultes coin
ductance to check average Ining wear in a coreless furnace
wee eee
Induction Electrical System Safety
‘When melt shops relied on fuel-fred furnaces, the electr
cal hazards in foundries were similar to those in any other
industry. Electrical motors, lit-ruck battey chargers,
heaters, lights and office equipment operated at standard
vollages. The switches, connectors and circuit interupters
encountered at work were simply larger versions of those
found at home,
Like all industrial workers, met shop workers realized the
need to rat electricity as a force tobe respected. But their
years of experience in living with electrical devices taught
them electrical hazards could be easly avoided.
The introduction of induction furnaces made it neces-
sary for workers to work in close proximity to high vol
age power supplies and open air-cooled bus bars, appara
{us commonly associated with dangerous power company
substations. They also had to lear that a certain amount of
sparking andarcing between the metal pieces ina cod charge
is normal in an induction meting furnace and not necessarily
2 sign of an imminent catastrophe
Wile induction systems present more exposed conductive
surfaces than othe industrial equipment, they are designed
witha variety of safety systems to deal with these hazards.
For example, current handling bus bars and components are
surrounded by enclosure. Safety interlocks tur off power
power supply access panels or doors ae opened while the
‘unit is runing. They are aso designed to prevent accidental
starting if acess panel or doors are open.
High-current bus
bar is encased in
clear plastic to
prevent accidental
contac.
This power cabinet
door latching bar
provides both a
to door dan electrical ineock.
It your power unit does not have safety locks and interlocks
On ll doors and access panels, it shouldbe modified to ado
these devices. Your equipment manufacturer shoud be able
to assist you in adding these important safety devices Cab
net door oc are the most important bare o unauthorized
access tothe dangerous electrical elements inside the power
Cabinets. These doors must be kept locked a al times
Safety Recommendations or Supervisors & Managers
Supervisors need o be especialy avare of electrical safety
Increased use of induction fumace technology has made it
necessary fora growing number of maintenance and repair
‘workers lo come nto lose proximity to high current con-
ductors.
Many maintenance technicians, particulary those who work
vith low-voltage devices, such as control systems, do not
fully appreciate the risk posed by the high levels of voltage
and current used in induction meting tis imperative these
Individual be impressed wih the fact tat shortcuts, such as
‘overriding safety interlocks during troubleshooting, are ab-
solely unacceptable when working with even the smallest
induction fumaces and power supplies.
© 2006 Inductotherm Corp.
Induction Heating & Meting Safety Fundamentals Guide
FA
The following procedures can help minimize te risk of
electrical accidents while servicing induction furnace
coils, power supplies and conductors:
+ Post warning notices forall systems operating at high
vallages as required by OSHA and local codes.
+ Allow only fuly- qualified and tained personnel to per-
form the maintenance or repair
‘Disconnect and lockout the power supply during main-
tenance
“Forbid entry into any enclosures until the main circuit
interrupter is locked in the OFF position and breaker
poles ae confirmed tobe open
‘= Wait 5 minutes after opening a breaker before opening
cabinet dors. This allows capacitor time to discharge
Test all bus bar for residual voltage before touching
“1 the power supply energizes more than one furnac
leads tothe furnace undergoing maintenance or repair
must be disconnected from both ends ofthe coil andthe
furnace induction ol grounded
A
The following are basic rues for electrical safety on the
mel deck
+ Only trained induction system operator ae to be per-
mitted to run induction meting equipment. trained op
erator must be fully Knowledgeable about the system's
controls, alarms and limits, diagnostic functions. and
safety features, and must be fully versed in he rules and
procedures related 1 the system's operation
+ Induction melting equipment must not be run if any
sal systems ae inoperable or bypassed
+ Unless a system operator is also trained electrical
Service technician, he must never open the power supply
Cabinet doors or gain access to any secure high voltage
+ Power tothe furnace must be tuned off whenever any
process involving contact withthe metal bath i taking
Place, such as taking samples, checking metal tempera-
ture or stagging. This isto prevent electrocution it safety
systems should fail and the bat is in conductive contact
with the induction call
Keep cabinet doors locked at
{us commonly associated with dangerous power company
substations. They also had to lear that a certain amount of
sparking andarcing between the metal pieces ina cod charge
is normal in an induction meting furnace and not necessarily
2 sign of an imminent catastrophe
Wile induction systems present more exposed conductive
surfaces than othe industrial equipment, they are designed
witha variety of safety systems to deal with these hazards.
For example, current handling bus bars and components are
surrounded by enclosure. Safety interlocks tur off power
power supply access panels or doors ae opened while the
‘unit is runing. They are aso designed to prevent accidental
starting if acess panel or doors are open.
High-current bus
bar is encased in
clear plastic to
prevent accidental
contac.
This power cabinet
door latching bar
provides both a
to door dan electrical ineock.
It your power unit does not have safety locks and interlocks
On ll doors and access panels, it shouldbe modified to ado
these devices. Your equipment manufacturer shoud be able
to assist you in adding these important safety devices Cab
net door oc are the most important bare o unauthorized
access tothe dangerous electrical elements inside the power
Cabinets. These doors must be kept locked a al times
Safety Recommendations or Supervisors & Managers
Supervisors need o be especialy avare of electrical safety
Increased use of induction fumace technology has made it
necessary fora growing number of maintenance and repair
‘workers lo come nto lose proximity to high current con-
ductors.
Many maintenance technicians, particulary those who work
vith low-voltage devices, such as control systems, do not
fully appreciate the risk posed by the high levels of voltage
and current used in induction meting tis imperative these
Individual be impressed wih the fact tat shortcuts, such as
‘overriding safety interlocks during troubleshooting, are ab-
solely unacceptable when working with even the smallest
induction fumaces and power supplies.
© 2006 Inductotherm Corp.
Induction Heating & Meting Safety Fundamentals Guide
FA
The following procedures can help minimize te risk of
electrical accidents while servicing induction furnace
coils, power supplies and conductors:
+ Post warning notices forall systems operating at high
vallages as required by OSHA and local codes.
+ Allow only fuly- qualified and tained personnel to per-
form the maintenance or repair
‘Disconnect and lockout the power supply during main-
tenance
“Forbid entry into any enclosures until the main circuit
interrupter is locked in the OFF position and breaker
poles ae confirmed tobe open
‘= Wait 5 minutes after opening a breaker before opening
cabinet dors. This allows capacitor time to discharge
Test all bus bar for residual voltage before touching
“1 the power supply energizes more than one furnac
leads tothe furnace undergoing maintenance or repair
must be disconnected from both ends ofthe coil andthe
furnace induction ol grounded
A
The following are basic rues for electrical safety on the
mel deck
+ Only trained induction system operator ae to be per-
mitted to run induction meting equipment. trained op
erator must be fully Knowledgeable about the system's
controls, alarms and limits, diagnostic functions. and
safety features, and must be fully versed in he rules and
procedures related 1 the system's operation
+ Induction melting equipment must not be run if any
sal systems ae inoperable or bypassed
+ Unless a system operator is also trained electrical
Service technician, he must never open the power supply
Cabinet doors or gain access to any secure high voltage
+ Power tothe furnace must be tuned off whenever any
process involving contact withthe metal bath i taking
Place, such as taking samples, checking metal tempera-
ture or stagging. This isto prevent electrocution it safety
systems should fail and the bat is in conductive contact
with the induction call
Keep cabinet doors locked at
Induction Heating & Meling Safty Fundamentals Guide
Only ful-traned personnel are to have access to high-risk
areas, À safety lockout system is another effective measure
to prevent electrical shock.
Satety Lockous are Key Systems
‘The safest way to prevent power being tumed on accidenaly
while equipment is being serviced is with a safety lockout”
{agout system. This is required by OSHA standard 29 CFR
1910.147
With this system,
the individual per.
forming the ser
vice work uses a
lock to secure the
circuit interrupter
in the off postion.
He or she keeps
the ont key until
the service work
is complete and the
equipment is ready
to be restored to operation At that time, the same individual
ho put on the lock, removes I, allowing the breaker to be
closed and power o be tuned on.
A one
Do not perform any maintenance on he system withthe
power on. Turn cabinet switch o circuit interruptr oft
Padlock or secure the input power disconnecting device
(circuit interrupter switch inthe “OFF” (open) position
to prevent accidental ve power on te system.
À wanna
The lockouttagout procedure must be followed before
entering any remote and/or main contol cabinet or
{enclosure or working on any equipment or system which
has exposed or enclosed electrical motors or any eect
cally controlled solenoid,
Induction Power Units Include
Some or All of These Safety Systems
Safety Interlocks
Safety Inerlocks are designed to turn off power automat
cally when power cabinet service access doors are opened
Equipment must nt be operated unless all interlocks are in
proper working order.
System Sef Diagnostics
System Sel Diagnostics in many advanced induction power
systems prevent the unit from operating when a faults de
{ected and identity the locaton of he faul
Ground and Leak Detection Systems
These systems are cuca. Thy tum off power if metal in
the furnace comes close Lo or touches the induction col rit
Inverter outputs otherwise grounded
Capacitor Pressure Switches
‘These help prevent pressure buldup inside the capacitor case
by shutting down the power supply if pressure builds up due
10 capacitor malfunctions. I this pressure buildup is unde-
tected and power remains on, the capacitor wil explode.
Battery-Operated DC Pump
A battery-operated DC pump provides emergency cooling
‘water to your furnace if normal power i interrupted.
Uttra-Fast Acting AC interrupter Module
This serves as a soldstte circuit interrupter and expedites
the system's response to emergency conditions.
Current Limiting Reactors and Quick-Acting Circuit Interupter
These provide protection against component failure and
major line disturbances on smaller systems.
À van
‘The AClisnot a disconnet. Aways ensure hate circuit
interrupter is off and locked ouf ha control voltage is
locked "ff," and natal capacitor are discharged before
performing maintenance onthe furnace or power supo.
© 2006 Inductotherm Corp.
Only ful-traned personnel are to have access to high-risk
areas, À safety lockout system is another effective measure
to prevent electrical shock.
Satety Lockous are Key Systems
‘The safest way to prevent power being tumed on accidenaly
while equipment is being serviced is with a safety lockout”
{agout system. This is required by OSHA standard 29 CFR
1910.147
With this system,
the individual per.
forming the ser
vice work uses a
lock to secure the
circuit interrupter
in the off postion.
He or she keeps
the ont key until
the service work
is complete and the
equipment is ready
to be restored to operation At that time, the same individual
ho put on the lock, removes I, allowing the breaker to be
closed and power o be tuned on.
A one
Do not perform any maintenance on he system withthe
power on. Turn cabinet switch o circuit interruptr oft
Padlock or secure the input power disconnecting device
(circuit interrupter switch inthe “OFF” (open) position
to prevent accidental ve power on te system.
À wanna
The lockouttagout procedure must be followed before
entering any remote and/or main contol cabinet or
{enclosure or working on any equipment or system which
has exposed or enclosed electrical motors or any eect
cally controlled solenoid,
Induction Power Units Include
Some or All of These Safety Systems
Safety Interlocks
Safety Inerlocks are designed to turn off power automat
cally when power cabinet service access doors are opened
Equipment must nt be operated unless all interlocks are in
proper working order.
System Sef Diagnostics
System Sel Diagnostics in many advanced induction power
systems prevent the unit from operating when a faults de
{ected and identity the locaton of he faul
Ground and Leak Detection Systems
These systems are cuca. Thy tum off power if metal in
the furnace comes close Lo or touches the induction col rit
Inverter outputs otherwise grounded
Capacitor Pressure Switches
‘These help prevent pressure buldup inside the capacitor case
by shutting down the power supply if pressure builds up due
10 capacitor malfunctions. I this pressure buildup is unde-
tected and power remains on, the capacitor wil explode.
Battery-Operated DC Pump
A battery-operated DC pump provides emergency cooling
‘water to your furnace if normal power i interrupted.
Uttra-Fast Acting AC interrupter Module
This serves as a soldstte circuit interrupter and expedites
the system's response to emergency conditions.
Current Limiting Reactors and Quick-Acting Circuit Interupter
These provide protection against component failure and
major line disturbances on smaller systems.
À van
‘The AClisnot a disconnet. Aways ensure hate circuit
interrupter is off and locked ouf ha control voltage is
locked "ff," and natal capacitor are discharged before
performing maintenance onthe furnace or power supo.
© 2006 Inductotherm Corp.
Line Isolation
Al induction furnaces need to be designed so thatthe cur-
‘ent flow from the output ie or from output components
externa othe converting device to ground under operating
and ground fault conditions shall be limited o a value that
does not cause 50 volts or more to ground to appear on any
accessible pat or the heating equipment and it load
This protection may be provided through an isolation trans-
former located either between the inverter and the furnace
(secondary isolation) or between the incoming power line
and the inverter (primary isolation),
Induction Heating & Meting Safety Fundamentals Guide
Thee
=> ale = Al
El
For Trained Electrical Technicians Only
Evang
Disconnect all electrical power (circuit interupter and
control power) ad follow proper lckoutagout proce
dures before working on the equipment, Unless speci
cally cale fr, do not troubleshoot the equipment with
elecrcal power applied. Proper Personal Protective
Equipment (PP) is required fr lve electrical testing,
Avani
AA capacitors store hazardous electrical energy. Check
all capacitors fr residual charge before doing any work
Inside cabinet.
Obviously there wil be times when electrical measurements
need to be taken from energized circuits. This work must
only be done by qualified electricians. Any manufacturers
‘manuals, ic diagrams or drawings that are sed 1 guide
the work must be double-check tobe sure they are com-
plete and upto dat.
Before performing a test on an energized circuit, the techn-
an must very that he has Selected the appropriate measur
ng instruments rated for proper voltage and curren nd fully
‘understands he manufacture’ directions. Power cords and
test leads must be inspected and, i necessary, replaced with
part recommended by the instrument super, The rating of
‘the measuring instruments must be higher than te electrical
parameters ofthe electrical equipment. Power supply set-
tings must never be set o exceed the capacity ofthe instru»
‘ments or the test leads. Test instruments must be properly
fused and grounded,
Before the technician enters the energized areas, power
Sources and current paths shouldbe clearly identified, The
cuit must be turned off and locked out until test instru-
ments are properly set and leads connected, Technicians
must never touch leads, instruments, or stings while the
Circuit is energized. Power must be tured off and capac:
tors fly discharged before changing instrument settings or
dsconnecting leads from the system. I resistance measure-
ments are part ofthe test program, power must be discon-
nected and all capacitors fully discharged before they are
performed
Technicians conducting tests near energized circuits must
be dressed in appropriate Personal Protective Equipment
(PPE), including dry, insulated gloves as required by gov-
fering codes (ie. NFPA 70E). They must stand on a dry,
insulated surface capable of witistanding the voltages that
may be encountered. The floor beneath the insulated surface
must be dry, as must the technicians’ hands and shoes,
supervisor must not allow technicians performing test to
ok alone he/she cannot be personaly present during the
test he alerts nearby personnel to the nature ofthe work take
ing pace and instructs them how to react in an emergency.
Alter the jobs complete, temporary grounds and bypass con-
nectionsare removed and covers, guard and fuses replace,
Supervisors must vey that al safety devices and interlocks
are fully operational. If modifications have been made to the
Al induction furnaces need to be designed so thatthe cur-
‘ent flow from the output ie or from output components
externa othe converting device to ground under operating
and ground fault conditions shall be limited o a value that
does not cause 50 volts or more to ground to appear on any
accessible pat or the heating equipment and it load
This protection may be provided through an isolation trans-
former located either between the inverter and the furnace
(secondary isolation) or between the incoming power line
and the inverter (primary isolation),
Induction Heating & Meting Safety Fundamentals Guide
Thee
=> ale = Al
El
For Trained Electrical Technicians Only
Evang
Disconnect all electrical power (circuit interupter and
control power) ad follow proper lckoutagout proce
dures before working on the equipment, Unless speci
cally cale fr, do not troubleshoot the equipment with
elecrcal power applied. Proper Personal Protective
Equipment (PP) is required fr lve electrical testing,
Avani
AA capacitors store hazardous electrical energy. Check
all capacitors fr residual charge before doing any work
Inside cabinet.
Obviously there wil be times when electrical measurements
need to be taken from energized circuits. This work must
only be done by qualified electricians. Any manufacturers
‘manuals, ic diagrams or drawings that are sed 1 guide
the work must be double-check tobe sure they are com-
plete and upto dat.
Before performing a test on an energized circuit, the techn-
an must very that he has Selected the appropriate measur
ng instruments rated for proper voltage and curren nd fully
‘understands he manufacture’ directions. Power cords and
test leads must be inspected and, i necessary, replaced with
part recommended by the instrument super, The rating of
‘the measuring instruments must be higher than te electrical
parameters ofthe electrical equipment. Power supply set-
tings must never be set o exceed the capacity ofthe instru»
‘ments or the test leads. Test instruments must be properly
fused and grounded,
Before the technician enters the energized areas, power
Sources and current paths shouldbe clearly identified, The
cuit must be turned off and locked out until test instru-
ments are properly set and leads connected, Technicians
must never touch leads, instruments, or stings while the
Circuit is energized. Power must be tured off and capac:
tors fly discharged before changing instrument settings or
dsconnecting leads from the system. I resistance measure-
ments are part ofthe test program, power must be discon-
nected and all capacitors fully discharged before they are
performed
Technicians conducting tests near energized circuits must
be dressed in appropriate Personal Protective Equipment
(PPE), including dry, insulated gloves as required by gov-
fering codes (ie. NFPA 70E). They must stand on a dry,
insulated surface capable of witistanding the voltages that
may be encountered. The floor beneath the insulated surface
must be dry, as must the technicians’ hands and shoes,
supervisor must not allow technicians performing test to
ok alone he/she cannot be personaly present during the
test he alerts nearby personnel to the nature ofthe work take
ing pace and instructs them how to react in an emergency.
Alter the jobs complete, temporary grounds and bypass con-
nectionsare removed and covers, guard and fuses replace,
Supervisors must vey that al safety devices and interlocks
are fully operational. If modifications have been made to the
Induction Heating & Meling Safety Fundamentals Guide
equipment, the appropriate changes must be made imme:
diately to equipment manuals, diagrams and drawings, The
reason for the alteration, person making the changes and the
person under whose authority they were acting should be
‘ated; along withthe time and date the modifications were
completed. Everyone, including subcontractors and other
fit personne, having copes ofthe original equipment
‘manuals or drawings must be promptly provided with copies
othe updated documentation,
Common Regulatory Electrical Notices & Requirements
NFPA 70E- 1103
“The safety related work practices shal be implemented by
employees. The employer shall provide safety related work
practices and shal train the employee who shal then imple
ment the training”
(OSHA 1910.03 (0) (2) /NEC 11027 (A)
“Live parts of electric equipment operating at 50 vols or
mare shall be guarded against acidental contact by ap-
proved cabinets or other forms of approved enclosures, or
by any ofthe folowing means:
(OSHA 1910383 (a) (1)
“Live part to which an employee may be exposed shall be
e-energized before the employee works on or near them,
‘unless the employer can demonstrate that de-enerizng in
troduces addtional or increased hazards or is infeasible due
to equipment design or operational imitations. Live paris
‘that operate ales than $0 volts to ground need not be de-
energized if thee will be no increased exposure to electrical
‘burs or to explosion due to electric ars.”
OSHA 1910233 (6) 2) (1) ©
“Store electric energy which might endanger personnel
shall be released. Capacitors shall be discharged and high
capacitance elements shall be short-circuited and grounded,
Ifthe stored electric energy might endanger personnel.”
OSHA 1910338 (2) (1V (8)
"A qual person shallus test equipment to est th circuit
elements and electrical ars of equipment to which employ
ns willbe exposed and shal verity that he icul elements
and equipment prt are d-energized. The test sal aso de
termine if any energized condition exists as a result of inad-
‘erent induced voltage or unrelated voltage back fee even
though specific parts ofthe circuit have been de-enerpzed
and presumed to be safe the circuit to be tested is over 600
volts, nominal, the test equipment shal be checked for proper
operation immediately before and immediately afte this test.”
OSHA 1910338 (6) 2) (i) ©
Stored electric energy which might endanger personnel
hal be released. Capacitors shall be discharged and high
capacitance elements shall be short-circuited and grounded,
if the stored electric energy might endanger personne
OSHA 1910334 © (3)
“Test instruments and equipment and her accessories shall
be rated for the circuits and equipment to which they wil
be connected and shall be designed fr the environment in
ich they wil be used.”
SHA 1910306 (g) (2) (1)
“Where doors are used for access to voltages from 500 10
1000 volts AG or DC, ether door locks or interocks shall be
provided. Where doors are used for access to voltages ol
over 1000 vols AC or DC, ether mechanical ockouts with
disconnecting means to prevent access until voltage is re-
moved from the cubicle, or both door interlocking and me-
chanical door locks, Shall be provided.”
SHA 1910.308 (9) (2) iv
Danger labels shal be attached on the equipment and shall
be plainly visible even when doors are open or panels are re
moved from compartments containing voltages of over 250
volts AC oF DC.
Hydraulic System Safety
‘The fumace hydraulic system provides motive power to per-
form a number of functions including openingcosing the
fumace cover, Ling the furnace and pushing ou the lining
General cleanliness atthe ydraule connections is critical
There I a hazard wherever heat, molen metal or flame is
near hydraulic equipment
Ha line or fting ruptures, it can send a combustible spray
‘of ol into the heat source causing injury or death. Therefor,
the hydraulic system must be inspected daly and any leaking
‘components repaired or replaced. Also, resistant fluids
must be used with induction fumace tydraulc systems to
minimize the danger offre,
equipment, the appropriate changes must be made imme:
diately to equipment manuals, diagrams and drawings, The
reason for the alteration, person making the changes and the
person under whose authority they were acting should be
‘ated; along withthe time and date the modifications were
completed. Everyone, including subcontractors and other
fit personne, having copes ofthe original equipment
‘manuals or drawings must be promptly provided with copies
othe updated documentation,
Common Regulatory Electrical Notices & Requirements
NFPA 70E- 1103
“The safety related work practices shal be implemented by
employees. The employer shall provide safety related work
practices and shal train the employee who shal then imple
ment the training”
(OSHA 1910.03 (0) (2) /NEC 11027 (A)
“Live parts of electric equipment operating at 50 vols or
mare shall be guarded against acidental contact by ap-
proved cabinets or other forms of approved enclosures, or
by any ofthe folowing means:
(OSHA 1910383 (a) (1)
“Live part to which an employee may be exposed shall be
e-energized before the employee works on or near them,
‘unless the employer can demonstrate that de-enerizng in
troduces addtional or increased hazards or is infeasible due
to equipment design or operational imitations. Live paris
‘that operate ales than $0 volts to ground need not be de-
energized if thee will be no increased exposure to electrical
‘burs or to explosion due to electric ars.”
OSHA 1910233 (6) 2) (1) ©
“Store electric energy which might endanger personnel
shall be released. Capacitors shall be discharged and high
capacitance elements shall be short-circuited and grounded,
Ifthe stored electric energy might endanger personnel.”
OSHA 1910338 (2) (1V (8)
"A qual person shallus test equipment to est th circuit
elements and electrical ars of equipment to which employ
ns willbe exposed and shal verity that he icul elements
and equipment prt are d-energized. The test sal aso de
termine if any energized condition exists as a result of inad-
‘erent induced voltage or unrelated voltage back fee even
though specific parts ofthe circuit have been de-enerpzed
and presumed to be safe the circuit to be tested is over 600
volts, nominal, the test equipment shal be checked for proper
operation immediately before and immediately afte this test.”
OSHA 1910338 (6) 2) (i) ©
Stored electric energy which might endanger personnel
hal be released. Capacitors shall be discharged and high
capacitance elements shall be short-circuited and grounded,
if the stored electric energy might endanger personne
OSHA 1910334 © (3)
“Test instruments and equipment and her accessories shall
be rated for the circuits and equipment to which they wil
be connected and shall be designed fr the environment in
ich they wil be used.”
SHA 1910306 (g) (2) (1)
“Where doors are used for access to voltages from 500 10
1000 volts AG or DC, ether door locks or interocks shall be
provided. Where doors are used for access to voltages ol
over 1000 vols AC or DC, ether mechanical ockouts with
disconnecting means to prevent access until voltage is re-
moved from the cubicle, or both door interlocking and me-
chanical door locks, Shall be provided.”
SHA 1910.308 (9) (2) iv
Danger labels shal be attached on the equipment and shall
be plainly visible even when doors are open or panels are re
moved from compartments containing voltages of over 250
volts AC oF DC.
Hydraulic System Safety
‘The fumace hydraulic system provides motive power to per-
form a number of functions including openingcosing the
fumace cover, Ling the furnace and pushing ou the lining
General cleanliness atthe ydraule connections is critical
There I a hazard wherever heat, molen metal or flame is
near hydraulic equipment
Ha line or fting ruptures, it can send a combustible spray
‘of ol into the heat source causing injury or death. Therefor,
the hydraulic system must be inspected daly and any leaking
‘components repaired or replaced. Also, resistant fluids
must be used with induction fumace tydraulc systems to
minimize the danger offre,
Induction Heating & Melting Saety Fundamentals Guide
Do Not Use “Substitute/Unauthorized” Parts
À warn
Do not use “substiute/unauthorized” parts in your
melting system,
Maintain your melting system's high level of quality, reli
ably, safety and performance by using only recommended
and authorized OEM replacement pars. Failure to comply wil
void equipment warranty, can cause equipment mafunction,
resuling in equipment andor property damage including i
{uty risk to personne
VITON Seal Safety Advisory
Aa warning
Hydrolluorc acid is extremely corrosive and almost im-
possible to remove, particularly from human issue.
(Operators and maintenance staf working with Inductotherm
equipment must take careful note ofan urgent safety hazard
associated with ol seals and “O” rings made ofa substance
called VITON. VITON seas are used in Inductotherm equip-
ment and we want you to be aware of a potential problem
hich has been brought to our attention
il safe under designed operating conditions, VITON has
been found to decompose into dangerous hydrofluoric acid
if exposed to high temperatures. When inspecting equipment
‘which has been exposed to a high temperature, check if any
‘gaskets, seals or “0” rings have suffered from decomposi-
tion, These will appear asa charred or black sticky mess
You must not, under any circumstances, touch ether the seal
‘or the equipment until a substantial cooling period has been
allowed and he equipment has been decontaminated
Disposable, heavy-duty plastic gloves approved to withtand
contact with hydrofluoric acid, safety glasses and a face
shield must be wom and the affected area must be cleaned
using wire woo! and a detergent solution. The loves must be
safely discarded after use.
Furnace Arcing
À WARM
Furnace inspection covers must never be removed and
loft ff he furnace while the furnace is operating, Fallre
to reinstall can result in electrical shock andor arcing
due to metalic charge materials coming in contact with
the col.
The sparking and arcing ofthe charge materials in the fur
ace are characteristic of induction meting and not patcu-
larly hazardous. Induction furnaces met metal by creating
2 flow of heatgenerating electric current within the charge
materials.
© 2006 Inductotherm Corp.
Although rare, a fault may
develop between the coll and
the furnace structure, gener-
aly resulting in coll damage
and power failure. ts typi
cally caused by loose metal
lc chips hat work her way
between the coil and furnace
structure, underscoring the
importance of good mel
‘hop housekeeping practices,
Furnace controls aso ca fai
‘due to poor foundry housekeeping practices.
Do Not Use “Substitute/Unauthorized” Parts
À warn
Do not use “substiute/unauthorized” parts in your
melting system,
Maintain your melting system's high level of quality, reli
ably, safety and performance by using only recommended
and authorized OEM replacement pars. Failure to comply wil
void equipment warranty, can cause equipment mafunction,
resuling in equipment andor property damage including i
{uty risk to personne
VITON Seal Safety Advisory
Aa warning
Hydrolluorc acid is extremely corrosive and almost im-
possible to remove, particularly from human issue.
(Operators and maintenance staf working with Inductotherm
equipment must take careful note ofan urgent safety hazard
associated with ol seals and “O” rings made ofa substance
called VITON. VITON seas are used in Inductotherm equip-
ment and we want you to be aware of a potential problem
hich has been brought to our attention
il safe under designed operating conditions, VITON has
been found to decompose into dangerous hydrofluoric acid
if exposed to high temperatures. When inspecting equipment
‘which has been exposed to a high temperature, check if any
‘gaskets, seals or “0” rings have suffered from decomposi-
tion, These will appear asa charred or black sticky mess
You must not, under any circumstances, touch ether the seal
‘or the equipment until a substantial cooling period has been
allowed and he equipment has been decontaminated
Disposable, heavy-duty plastic gloves approved to withtand
contact with hydrofluoric acid, safety glasses and a face
shield must be wom and the affected area must be cleaned
using wire woo! and a detergent solution. The loves must be
safely discarded after use.
Furnace Arcing
À WARM
Furnace inspection covers must never be removed and
loft ff he furnace while the furnace is operating, Fallre
to reinstall can result in electrical shock andor arcing
due to metalic charge materials coming in contact with
the col.
The sparking and arcing ofthe charge materials in the fur
ace are characteristic of induction meting and not patcu-
larly hazardous. Induction furnaces met metal by creating
2 flow of heatgenerating electric current within the charge
materials.
© 2006 Inductotherm Corp.
Although rare, a fault may
develop between the coll and
the furnace structure, gener-
aly resulting in coll damage
and power failure. ts typi
cally caused by loose metal
lc chips hat work her way
between the coil and furnace
structure, underscoring the
importance of good mel
‘hop housekeeping practices,
Furnace controls aso ca fai
‘due to poor foundry housekeeping practices.
Induction Heating & Meling Safety Fundamentals Guide
Melt Shop “Confined Spaces”
Furnace Spl Pts
These ft OSHA's definition ofa “confined space" under 29
(GFR 1910.146(0). They also may be “permi required con
fined spaces” under 29 GFR 1910.148().
Furnaces
The internal working volume of a furnace large enough fora
person to work inside fits OSHAS definition of a “confined
space.” When alnig is being removed or installed in such
a fumace, “permit required confined space” procedures are
required,
Vacuum Chambers
Vacuum chambers clearly
ate “confined spaces” under
OSHA's regulations, They
may also be considered
“permit required confined
spaces.” When insulating
{he col terminations or pass thrus Inside the chamber, the
‘materials used (resins and hardeners) release fumes which
are considered to be hazardous.
Furnace Lids
Under no circumstances must these covers or lids
be used as wakways across the top of the furnace.
Severe burn injuries, including death, wil result should
personnel fal on or through such covers.
In some applications using channel or coreless furnaces for
‘meting and holding meta, such as coting and pre-mel pots
used in galvanizing, galvalume,galvannealing coating instal-
lation, temporary lids als known as covers ar provided to
cover the large exposed surfaces ofthe molten metal inorder
to reduce radiant losses,
These are usually light steel fabrications lined with a ther:
‘mall insulating materia, which are manual placed over the
top ofthe furace plat.
Launders
Launders canbe ied, movable, electric resistance oras.
fired. They are almost always retractor ined. Launders
‘may appear innocuously benign to some, but because
‘hey convey molten metal, they present the same risks
of severe injuries, including death, as those outlined in
this safety guide
Launders ae often used to dispense molten metal from one
source, usually the primary meting furnace to another, eher
a secondary holding furnace or cating system o some type.
Launders must be moisture tee, retractries need o be in
stalled and curedisintred in accordance with manufacturers
recommendations, covers if provided must be securely
instale, all electrical or gas train controls, safety devices,
intrlcks, guards, et, must be operational
Operating personnel must be trained in the operation of
the manufacturer's equipment and must know what to ex-
ect and what procedures to adopt In case of emergencies.
AI codes and regulations governing this equipment must
be strictly adhered to prior to
operating. Proper Personal
Protective Equipment (PPE)
must be worn during opera-
tion, and access tothe aun-
der areas must be restricted
to authorized personnel ony.
© 2006 Inductotherm Corp.
to authorized personnel only.
Melt Shop “Confined Spaces”
Furnace Spl Pts
These ft OSHA's definition ofa “confined space" under 29
(GFR 1910.146(0). They also may be “permi required con
fined spaces” under 29 GFR 1910.148().
Furnaces
The internal working volume of a furnace large enough fora
person to work inside fits OSHAS definition of a “confined
space.” When alnig is being removed or installed in such
a fumace, “permit required confined space” procedures are
required,
Vacuum Chambers
Vacuum chambers clearly
ate “confined spaces” under
OSHA's regulations, They
may also be considered
“permit required confined
spaces.” When insulating
{he col terminations or pass thrus Inside the chamber, the
‘materials used (resins and hardeners) release fumes which
are considered to be hazardous.
Furnace Lids
Under no circumstances must these covers or lids
be used as wakways across the top of the furnace.
Severe burn injuries, including death, wil result should
personnel fal on or through such covers.
In some applications using channel or coreless furnaces for
‘meting and holding meta, such as coting and pre-mel pots
used in galvanizing, galvalume,galvannealing coating instal-
lation, temporary lids als known as covers ar provided to
cover the large exposed surfaces ofthe molten metal inorder
to reduce radiant losses,
These are usually light steel fabrications lined with a ther:
‘mall insulating materia, which are manual placed over the
top ofthe furace plat.
Launders
Launders canbe ied, movable, electric resistance oras.
fired. They are almost always retractor ined. Launders
‘may appear innocuously benign to some, but because
‘hey convey molten metal, they present the same risks
of severe injuries, including death, as those outlined in
this safety guide
Launders ae often used to dispense molten metal from one
source, usually the primary meting furnace to another, eher
a secondary holding furnace or cating system o some type.
Launders must be moisture tee, retractries need o be in
stalled and curedisintred in accordance with manufacturers
recommendations, covers if provided must be securely
instale, all electrical or gas train controls, safety devices,
intrlcks, guards, et, must be operational
Operating personnel must be trained in the operation of
the manufacturer's equipment and must know what to ex-
ect and what procedures to adopt In case of emergencies.
AI codes and regulations governing this equipment must
be strictly adhered to prior to
operating. Proper Personal
Protective Equipment (PPE)
must be worn during opera-
tion, and access tothe aun-
der areas must be restricted
to authorized personnel ony.
© 2006 Inductotherm Corp.
to authorized personnel only.
Induction Heating & Melting Saety Fundamentals Guide
Mechanical Component Inspection
4
‘Ay WARNING
Lock out source of hydraulic or pneumatic pressure and
bleed of pressure before servicing equipment.
À wane
Disconnect all electrical power (circuit interupter
and control power) and follow OSHA 1910.147 lockout)
tagout procedures before working on the equipment.
‘According to OSHA 1910333, do not troubleshoot
the equipment vith electrical power applied. Personal
Protective Equipment (PPE) i required for Iv electrical,
testing.
The following components must be inspected during each
furnace reine or every two years, whichever comes fist.
Some components may require more frequent inspections
and these items are addressed in the specific equipment
‘manuals. Under no circumstances should th following in-
spections be performed it the equipment contains molten
metal
Structure & Welds
“The structure ofthe furnace, and ancillary equipment such as
conveyors, charge buckets, ining pushout mechanisms, te.
must be inspected for any signs of damage. This includes de-
formations, cracking excessive corrosion, and damage from
excessive heating. A welds must be visually inspected for
signs of failure. The equipment must not be used if any ofthe
structural components or welds are damage,
Hardware
All fasteners must be checked for tightness according to
torque spectications outined in the equipment manuals,
“The fasteners must also be inspected for any signs of fi
ur, including excessive corrosion. Replace al fasteners and
‘washers showing any signs of flue, including excessive
corrosion, before restating the equipment. Fasteners must
‘only be replaced with fasteners of an equivalent grade and
material
Hydraulics & Pneumatics
The hydraulic and pneumatic components, including inter-
(connecting piping, must be inspected for damage and leaks.
Repair al leaks before restarting te equipment. The au
lic and pneumatic hoses must be checked fr wear, cracking,
and damage. Replace all worn, cracked or damaged hoses
before restarting the equipment. Leaking hydraulic uid can
create boa fre and slip hazard.
Water Hoses
Water hoses must be checked for wear, cracking, and dam
age. Replace all wor, cracked or damaged hoses and clamps
before restarting the equipment
Bearings
Bearings and pivot joints must be inspected for excessive
‘wear. Worn bearings can result in misalignment of mating
structures, resulting in binding and structural loads in excess
‘of what the equipment was designed for. Failure to replace
‘worn bearings in a timely fashion may resul in unsafe opera-
tion and much costier repairs due to wearing ofthe bearing
bores.
Water Cooled Power Cables
Water cooled power cables must be inspected for damage
and leaks. The hose must be inspected for cracking due
10 age and heat related deterioration Replace al damaged
or leaking water cooled power cables before restating the
equipment. The guard or insulation used to protect person
na from the exposed lead ends must be in place and in good
condition,
Protective Barriers
AA protective barriers such as melt operator heat shields
bus bar covers, hydraulic cylinder splash shields, et. must
be inspected on a regular basis to make sue that they have
not been damaged or her function compromised in any way
‘through use. Repair or replace as necessary.
Mechanical Component Inspection
4
‘Ay WARNING
Lock out source of hydraulic or pneumatic pressure and
bleed of pressure before servicing equipment.
À wane
Disconnect all electrical power (circuit interupter
and control power) and follow OSHA 1910.147 lockout)
tagout procedures before working on the equipment.
‘According to OSHA 1910333, do not troubleshoot
the equipment vith electrical power applied. Personal
Protective Equipment (PPE) i required for Iv electrical,
testing.
The following components must be inspected during each
furnace reine or every two years, whichever comes fist.
Some components may require more frequent inspections
and these items are addressed in the specific equipment
‘manuals. Under no circumstances should th following in-
spections be performed it the equipment contains molten
metal
Structure & Welds
“The structure ofthe furnace, and ancillary equipment such as
conveyors, charge buckets, ining pushout mechanisms, te.
must be inspected for any signs of damage. This includes de-
formations, cracking excessive corrosion, and damage from
excessive heating. A welds must be visually inspected for
signs of failure. The equipment must not be used if any ofthe
structural components or welds are damage,
Hardware
All fasteners must be checked for tightness according to
torque spectications outined in the equipment manuals,
“The fasteners must also be inspected for any signs of fi
ur, including excessive corrosion. Replace al fasteners and
‘washers showing any signs of flue, including excessive
corrosion, before restating the equipment. Fasteners must
‘only be replaced with fasteners of an equivalent grade and
material
Hydraulics & Pneumatics
The hydraulic and pneumatic components, including inter-
(connecting piping, must be inspected for damage and leaks.
Repair al leaks before restarting te equipment. The au
lic and pneumatic hoses must be checked fr wear, cracking,
and damage. Replace all worn, cracked or damaged hoses
before restarting the equipment. Leaking hydraulic uid can
create boa fre and slip hazard.
Water Hoses
Water hoses must be checked for wear, cracking, and dam
age. Replace all wor, cracked or damaged hoses and clamps
before restarting the equipment
Bearings
Bearings and pivot joints must be inspected for excessive
‘wear. Worn bearings can result in misalignment of mating
structures, resulting in binding and structural loads in excess
‘of what the equipment was designed for. Failure to replace
‘worn bearings in a timely fashion may resul in unsafe opera-
tion and much costier repairs due to wearing ofthe bearing
bores.
Water Cooled Power Cables
Water cooled power cables must be inspected for damage
and leaks. The hose must be inspected for cracking due
10 age and heat related deterioration Replace al damaged
or leaking water cooled power cables before restating the
equipment. The guard or insulation used to protect person
na from the exposed lead ends must be in place and in good
condition,
Protective Barriers
AA protective barriers such as melt operator heat shields
bus bar covers, hydraulic cylinder splash shields, et. must
be inspected on a regular basis to make sue that they have
not been damaged or her function compromised in any way
‘through use. Repair or replace as necessary.
Induction Heating & Meling Safety Fundamentals Guide
Working with molten metal always has, and always wil
be, dangerous occupation, Responsible melt shop workers
acknowledge the risks and the possibilty of serious ac»
dents. Responsible managers can minimize te risks by
instiling among melt shop workers the importance of ac-
cident prevention.
‘While itis impossible to remove te risk rom meting metal,
itis possible to make the mel shop an accidentes work.
place. To accomplish this goal requires a true partnership
between melt shop managers, the suppliers who equip
the met shop, and the melt shop workers who operate their
equipment,
It requires management to make safety a key corporate val
ue, then to communicate that to the melt shop workers both
by electing the safest available equipment and by expending
every possible effort o assure that workers ar instructed in
its proper use,
Safety training needs to extend beyond melt shop workers,
Maintenance crews, laborers, crane and lick operators
and outside contractors whose work oceasionaly takes them
into the met shop all need to understand basic melt shop
safety measures. Obviously, the amount of met shop safe-
ty training required by any one individual depends on how
Closely he or she works with meting, holding and pouring
equipment
Training for office workers and vistors must include mak-
ing them aware ofthe importance of remaining behind “do
not enter areas and wearing appropriate Personal Protective
Equipment (PPE,
Meting system operators must know how to safely operate
their equipment and must aso know he warning signs of a
potential dangerous situation and how to react to prevent
‘or control uncommon problems such a bridging or run-out
situations.
‘A melt shop's personnel department and staff must play an
active role in supporting melt shop safety eforts.Person-
nel typically has the first contact with anew hired employ-
ee and they can ensue that new employees are given full
information on the safety procedures appropriate to ther jobs
and that they further understand that wearing appropriate
Personal Protective Equipment (PPE) onthe jobs a condition
‘ofemployment. Both of these requirements shouldbe clearly
‘sated inthe employe's job description or work rules,
Personnel managers aro also in a position to identity em
ployees who serve on local volunteer fie departments and
“emergency medial teams. I these individuals work ouside
production area, time spent familaiing them with Ihe melt
‘hop layout andthe nature of melt shop emergencies could
make a fe or death difference during an emergency Finally,
the personnel manager 5 often best able to coordinate the
‘scheduling of refresher and new equipment traning.
Melt shop supervisors play a key ole in assuring safe op-
eration of meting, holding and pouring equipment. In most
mel shops, they bear frontline responsiliy for implement-
ing and monitoring established safety procedures and new
‘worker raining, aswell as equipment inspection and maint
nance. In the event ofan emergency, workers often wil look
o the supervisor for instructions.
‘The only way to assure that no one is ever injured in the
met shop is to kee al personnel away from molten metal,
fürnaces and holding and pouring equipment. While his may
‘seem Ike a farfetched solution, leading furnace manufactur
ers have actually made considerable progress in designing
remote furnace charging, operating and pouring systems.
Until these tecnologies are in common use, there are sev-
‘eral stops melt stop supervisors can take o minimize worker
contact with high risk areas.
Workers shown here ARE NOT wearing proper clothing.
Al operating personnel & onlookers in proximity to molten
‘metal must wear Personal Protective Equipment (PPE)
Working with molten metal always has, and always wil
be, dangerous occupation, Responsible melt shop workers
acknowledge the risks and the possibilty of serious ac»
dents. Responsible managers can minimize te risks by
instiling among melt shop workers the importance of ac-
cident prevention.
‘While itis impossible to remove te risk rom meting metal,
itis possible to make the mel shop an accidentes work.
place. To accomplish this goal requires a true partnership
between melt shop managers, the suppliers who equip
the met shop, and the melt shop workers who operate their
equipment,
It requires management to make safety a key corporate val
ue, then to communicate that to the melt shop workers both
by electing the safest available equipment and by expending
every possible effort o assure that workers ar instructed in
its proper use,
Safety training needs to extend beyond melt shop workers,
Maintenance crews, laborers, crane and lick operators
and outside contractors whose work oceasionaly takes them
into the met shop all need to understand basic melt shop
safety measures. Obviously, the amount of met shop safe-
ty training required by any one individual depends on how
Closely he or she works with meting, holding and pouring
equipment
Training for office workers and vistors must include mak-
ing them aware ofthe importance of remaining behind “do
not enter areas and wearing appropriate Personal Protective
Equipment (PPE,
Meting system operators must know how to safely operate
their equipment and must aso know he warning signs of a
potential dangerous situation and how to react to prevent
‘or control uncommon problems such a bridging or run-out
situations.
‘A melt shop's personnel department and staff must play an
active role in supporting melt shop safety eforts.Person-
nel typically has the first contact with anew hired employ-
ee and they can ensue that new employees are given full
information on the safety procedures appropriate to ther jobs
and that they further understand that wearing appropriate
Personal Protective Equipment (PPE) onthe jobs a condition
‘ofemployment. Both of these requirements shouldbe clearly
‘sated inthe employe's job description or work rules,
Personnel managers aro also in a position to identity em
ployees who serve on local volunteer fie departments and
“emergency medial teams. I these individuals work ouside
production area, time spent familaiing them with Ihe melt
‘hop layout andthe nature of melt shop emergencies could
make a fe or death difference during an emergency Finally,
the personnel manager 5 often best able to coordinate the
‘scheduling of refresher and new equipment traning.
Melt shop supervisors play a key ole in assuring safe op-
eration of meting, holding and pouring equipment. In most
mel shops, they bear frontline responsiliy for implement-
ing and monitoring established safety procedures and new
‘worker raining, aswell as equipment inspection and maint
nance. In the event ofan emergency, workers often wil look
o the supervisor for instructions.
‘The only way to assure that no one is ever injured in the
met shop is to kee al personnel away from molten metal,
fürnaces and holding and pouring equipment. While his may
‘seem Ike a farfetched solution, leading furnace manufactur
ers have actually made considerable progress in designing
remote furnace charging, operating and pouring systems.
Until these tecnologies are in common use, there are sev-
‘eral stops melt stop supervisors can take o minimize worker
contact with high risk areas.
Workers shown here ARE NOT wearing proper clothing.
Al operating personnel & onlookers in proximity to molten
‘metal must wear Personal Protective Equipment (PPE)
Perhaps the single most effective step a melt shop super-
visor can take s o límit routine equipment maintenance
activities to periods when furnaces are not operating. Pro-
ducton downtime canbe predicted more accurately with the
help of deal recordkeeping. Although production super-
visors are usual responsibe for keping equipment operat
ng logs, itis the maintenance supervisor whois likely to be
‘mast knowiedgeable about the type of information that needs
to be entered, In met shops where melting operations carry
over from shit to shi, the use of forms and checklists will
aid in assuring uniform data collection.
Insisting the og book be neatly maintained not only makes.
data ready avalble, but also reinforces the importance of
good equipment monitoring practices. One of he shift su
penisor fist asks ofthe day must bea careful inspection
fog entries made during his absence
In smaller met shops, the production supervisor may also
have responsibitis for overseing maintenance work and
equipment troubleshooting. In these situation there is
sometimes the temptation to perform maintenance as rapid
as possible to quick brig the furnace back into production
Production supervisors who find themselves responsible for
equipment maintenance must continua remind themselves
that induction furnaces can be very unforgiving. Accidents
caused by improper or rushed maintenance may be serious
and sometimes catastrophic,
Production supervisors must never be pressured into bring
Inga furnace or other met shop equipment into production
ntl they are ensured tht its safe. They must also keep
equipment out of production when ring or other sched-
‘led maintenance works due
Preparing For Accidents
"No matter how carefully equipmentis manufactured, workers
raid or procedures followed, the possibly of an accident
Is always present wherever molten metal s present. For this
reason, melt shop supervisors must always be prepared to
eal with the unexpected
A carelul supervisor anticipates he types of emergencies
{at can aise a diferent stages inthe meting process. He
as, both in his mind and on paper, an action plan that gives
first priority to minimizing injury to his workers and assisting
those already injured
Ahoughal accident plans must address issues suchasevac
‘ating personnel, providing emergency staid treatment and
noting emergency squads and fie departments, each met
shop's plans must also be unique. The plan must fake into
© 2006 Inductotherm Corp.
Induction Heating & Melting Saety Fundamentals Guide
account not only the type and capac ofthe meting equip
ment, but also the experience level of equipment operators.
A neuyhired furnace operator cannot be expected to react
as confidently toa run-out accident as an experienced melt
shop hand.
The potential catastrophic nature of wate/molen metal ex
plosions makes i crucial that accident plans be written and
‘that they be understood by everyone in the mel shop and
adjacent plant areas. Local ire departments and emergency
medical squads must be included in planing efforts, ami
iarized with molten metal hazards, the mek shop layout, and
encouraged to participate in dll. Everyone who might be
expected to become involved in rescue or first aid activites
must knowhow to isolate furnace power supplies.
Written accident plans must clearly estab
+ Who will decide the extent of an emergency situation and
‘the criteria for making that decision
+ Who wil be in overall command
‘+ Each persons responsibilities during the emergency
Speciy Saler Equipment
Furnace manufacturers and other melt shop equipment sup-
pliers are continually attempting to make the mel shop the
safest possible work environment, That's why vital lin
‘duction meting systems today include safety features such
as ground leak detectors and backup cooing systems,
In the past, specitying new melt shop equipment typically
has been the responsiblity of senior level management. Pro-
duction and maintenance supervisors simply had to leam
o work with the equipment on the flor. But as companies.
around the world work to make ther operations more com-
petitive, they are increasingly turning to frontline supervisors
{or equipment recommendations,
Selecting the proper furnace, power supply or preheating
and charging system is, of course, a complex technical task.
Frontine supervisors who become involved in equipment se-
lection, however, re in a good postion to also evaluate a
system's safety features, safety certcations, overall quality
and operational efcences.
An induction furnace is a place where three ingredients that
are not otherwise brought together ~ water, molten metal
and electric current ~ are in close proximiy'to each other.
‘The quali of the components that make up an induction
furnace system andthe care that goes into its assembly and
maintenance are the melt shop worker’ fist ine of defense
against accidents.
visor can take s o límit routine equipment maintenance
activities to periods when furnaces are not operating. Pro-
ducton downtime canbe predicted more accurately with the
help of deal recordkeeping. Although production super-
visors are usual responsibe for keping equipment operat
ng logs, itis the maintenance supervisor whois likely to be
‘mast knowiedgeable about the type of information that needs
to be entered, In met shops where melting operations carry
over from shit to shi, the use of forms and checklists will
aid in assuring uniform data collection.
Insisting the og book be neatly maintained not only makes.
data ready avalble, but also reinforces the importance of
good equipment monitoring practices. One of he shift su
penisor fist asks ofthe day must bea careful inspection
fog entries made during his absence
In smaller met shops, the production supervisor may also
have responsibitis for overseing maintenance work and
equipment troubleshooting. In these situation there is
sometimes the temptation to perform maintenance as rapid
as possible to quick brig the furnace back into production
Production supervisors who find themselves responsible for
equipment maintenance must continua remind themselves
that induction furnaces can be very unforgiving. Accidents
caused by improper or rushed maintenance may be serious
and sometimes catastrophic,
Production supervisors must never be pressured into bring
Inga furnace or other met shop equipment into production
ntl they are ensured tht its safe. They must also keep
equipment out of production when ring or other sched-
‘led maintenance works due
Preparing For Accidents
"No matter how carefully equipmentis manufactured, workers
raid or procedures followed, the possibly of an accident
Is always present wherever molten metal s present. For this
reason, melt shop supervisors must always be prepared to
eal with the unexpected
A carelul supervisor anticipates he types of emergencies
{at can aise a diferent stages inthe meting process. He
as, both in his mind and on paper, an action plan that gives
first priority to minimizing injury to his workers and assisting
those already injured
Ahoughal accident plans must address issues suchasevac
‘ating personnel, providing emergency staid treatment and
noting emergency squads and fie departments, each met
shop's plans must also be unique. The plan must fake into
© 2006 Inductotherm Corp.
Induction Heating & Melting Saety Fundamentals Guide
account not only the type and capac ofthe meting equip
ment, but also the experience level of equipment operators.
A neuyhired furnace operator cannot be expected to react
as confidently toa run-out accident as an experienced melt
shop hand.
The potential catastrophic nature of wate/molen metal ex
plosions makes i crucial that accident plans be written and
‘that they be understood by everyone in the mel shop and
adjacent plant areas. Local ire departments and emergency
medical squads must be included in planing efforts, ami
iarized with molten metal hazards, the mek shop layout, and
encouraged to participate in dll. Everyone who might be
expected to become involved in rescue or first aid activites
must knowhow to isolate furnace power supplies.
Written accident plans must clearly estab
+ Who will decide the extent of an emergency situation and
‘the criteria for making that decision
+ Who wil be in overall command
‘+ Each persons responsibilities during the emergency
Speciy Saler Equipment
Furnace manufacturers and other melt shop equipment sup-
pliers are continually attempting to make the mel shop the
safest possible work environment, That's why vital lin
‘duction meting systems today include safety features such
as ground leak detectors and backup cooing systems,
In the past, specitying new melt shop equipment typically
has been the responsiblity of senior level management. Pro-
duction and maintenance supervisors simply had to leam
o work with the equipment on the flor. But as companies.
around the world work to make ther operations more com-
petitive, they are increasingly turning to frontline supervisors
{or equipment recommendations,
Selecting the proper furnace, power supply or preheating
and charging system is, of course, a complex technical task.
Frontine supervisors who become involved in equipment se-
lection, however, re in a good postion to also evaluate a
system's safety features, safety certcations, overall quality
and operational efcences.
An induction furnace is a place where three ingredients that
are not otherwise brought together ~ water, molten metal
and electric current ~ are in close proximiy'to each other.
‘The quali of the components that make up an induction
furnace system andthe care that goes into its assembly and
maintenance are the melt shop worker’ fist ine of defense
against accidents.
Induction Heating & Melting Safety Fundamentals
Equipment Manuals Must Be Your Primary Safety Source
This “Induction Heating & Melting Safety Fundamentals
Guide” provides safety information of a general nature and
IS not intended to be a substitute forthe more etai and
speci operational and safety information provided in In
ductotherm's equipment manuals. These equipment manu-
als must alvays be your primary source of information on
the proper and safe operation of Inductotherm equipment
Safety Must Bea Key Corporate Value
Please read this guide thoroughly and have al of the ap
propre personnel in your organization read and follow the
instructions carefully. tis our fm bai that management,
Oumers and supervisors play à key role in assuring safe op-
eration of melting, holding, pouring and heating equipment,
In most me shops, they bear frontine responsibilty for
implementing and monitoring established safety procedures
and new worker training, as well as equipment inspection
and maintenance,
ile itis impossible to remove the risk from meting meta,
itis possible to make the melt shop an accident-ree work
place. To accomplish tis goal requires a tre partnership
between melt shop managers, the supplers who equip the
‘melt shop and the malt shop workers who operate the
equipment.
lt requires management to make safety a key corporate value
and then to communicate that othe melt shop workers bath
by selecting the safest avalale equipment and by expending
‘every possible effort to assure that personnel are instructed
ints proper use,
Inductotherm Melt Shop Safety Training Program
Working wih molten metal always ha been a dangerous ob
Inthe past, the heat, noise and fumes produced by combus-
tion furnaces constantly reminded mel shop workers of melt
shop hazards. But while today’s high-efficiency induction
urnaces have improved working conditions by making melt
Shops cole, cleaner and generally ess hostile workplaces,
‘they cannot eliminate the dangers inherent in molten metal
“The goal ofthis guide andthe Inductotherm melt shop Safety
Training K is to make all melt shop workers aware ofthe
lWesaving precautions that must always be taken whenever
metals mate.
Induction furnaces make today’s met shops safer and more
product than at any time in history. Sadly, many of the
deaths and injuries that have occurred could have been pre
vented by observing common-sense safety precautions,
For this reason, Inductotherm has created the Inductotherm
Heatingand Meting Safety Program and has made itavalable
{or free to all melt shops, whether they have Inductotherm
‘equipment or nat.
‘We want every melt shop employee, owner and superior to
become knowledgeable about the safety hazards associated
‘wth melting metal. This melt shop safety taining rogram is
‘one way we ae working to achieve tis goa.
For more information, cal 1868 NDUCTO [188.469.8286] or vst www inductothem com
Leading apa e Mat
Son San o ea
important Personal Pra
suet FF) ms so
(©2006 Indem Corp. A gs Rese ae: 2575
Thermal Pro
Eis
Exypre in proxi
Equipment Manuals Must Be Your Primary Safety Source
This “Induction Heating & Melting Safety Fundamentals
Guide” provides safety information of a general nature and
IS not intended to be a substitute forthe more etai and
speci operational and safety information provided in In
ductotherm's equipment manuals. These equipment manu-
als must alvays be your primary source of information on
the proper and safe operation of Inductotherm equipment
Safety Must Bea Key Corporate Value
Please read this guide thoroughly and have al of the ap
propre personnel in your organization read and follow the
instructions carefully. tis our fm bai that management,
Oumers and supervisors play à key role in assuring safe op-
eration of melting, holding, pouring and heating equipment,
In most me shops, they bear frontine responsibilty for
implementing and monitoring established safety procedures
and new worker training, as well as equipment inspection
and maintenance,
ile itis impossible to remove the risk from meting meta,
itis possible to make the melt shop an accident-ree work
place. To accomplish tis goal requires a tre partnership
between melt shop managers, the supplers who equip the
‘melt shop and the malt shop workers who operate the
equipment.
lt requires management to make safety a key corporate value
and then to communicate that othe melt shop workers bath
by selecting the safest avalale equipment and by expending
‘every possible effort to assure that personnel are instructed
ints proper use,
Inductotherm Melt Shop Safety Training Program
Working wih molten metal always ha been a dangerous ob
Inthe past, the heat, noise and fumes produced by combus-
tion furnaces constantly reminded mel shop workers of melt
shop hazards. But while today’s high-efficiency induction
urnaces have improved working conditions by making melt
Shops cole, cleaner and generally ess hostile workplaces,
‘they cannot eliminate the dangers inherent in molten metal
“The goal ofthis guide andthe Inductotherm melt shop Safety
Training K is to make all melt shop workers aware ofthe
lWesaving precautions that must always be taken whenever
metals mate.
Induction furnaces make today’s met shops safer and more
product than at any time in history. Sadly, many of the
deaths and injuries that have occurred could have been pre
vented by observing common-sense safety precautions,
For this reason, Inductotherm has created the Inductotherm
Heatingand Meting Safety Program and has made itavalable
{or free to all melt shops, whether they have Inductotherm
‘equipment or nat.
‘We want every melt shop employee, owner and superior to
become knowledgeable about the safety hazards associated
‘wth melting metal. This melt shop safety taining rogram is
‘one way we ae working to achieve tis goa.
For more information, cal 1868 NDUCTO [188.469.8286] or vst www inductothem com
Leading apa e Mat
Son San o ea
important Personal Pra
suet FF) ms so
(©2006 Indem Corp. A gs Rese ae: 2575
Thermal Pro
Eis
Exypre in proxi
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