Upcast operation specification and emergency meassures

1. The workers should be in position 10 minutes earlier and communicate with the workers in last shift about the production condition and machine status in last working shift.

2. The workers should wear working suit and working shoes,check whether the voltage and electric current of the melting and holding furnaces are normal,whether the water discharge of water jacket and coil is smooth,whether the copper liquid level is within the standard,whether liquid level scaleplate is flexible,whether the thicknesses of charcoal in melting and holding furnaces are within normal range.

3. Clean out the fine charcoal ash and add new charcoal in thickness:15-20CM.The consuming speed of charcoal in melting furnace is fast,so charcoal should be added in time.

4. During the production,workers should watch out continuously for the voltage and electric current of melting and holding furnaces and water discharge of water jacket and coil.If the water discharge flow be found smaller,the workers should unclog in time. Check the liquid level scaleplate every 3 hours to see whether it’s flexible.The workers in every working shift should examine under the furnace platform whether there is any water leak in the hose joint of water jacket and coil.If there is,workers should handle timely by consolidate them.

5. The highest level of copper liquid should be 3cm lower than protection jacket. The level should be checked every 4 hours.If less than 3cm,adjustment should be done timely.

6. When putting copper into the furnace,try not to let the copper liquid contact air.If liquid leaks,workers should cover with charcoal as soon as possible.

7. The temperature of holding furnace should be 1145℃-1155℃,the quantity of copper added every time should be within 100KG-150KG.Whether copper should be added depends on the temperature.Usually,when adding copper,the liquid level is low and temperature is high. If liquid level is high and temperature is also high,then the voltage of holding furnace should be lowered by one grade.If liquid level is low and temperature is also low.then workers should heighten the voltage of the holding furnace by one grade.

8. There must be 2 special workers on the furnace platform for 24 hours a day.(expect for dinner time and toilet time,1 worker is enough)

9. Every time before putting the crystallizer installed with protection jacket back to the copper liquid in the holding furnace,the circulating water valve of the crystallizer should be opened and make sure the crystallizer is discharging water in the backwater cabinet.

10. If sudden power failure happens,workers should open the tap water valve and close water pump valve,check the water discharging situation of the two water jackets and coil.If the water discharging flow is small,then the copper rods should be cut, and crystallizes should be raised.After the protection jacket get black,workers should close the valves of the circulating water of crystallizers.

11. The electrician and dynamo worker should be 24 -hour in working position.If sudden power failure happens,the dynamo should be started immediately.The electrician should connect power to the furnace timely.

12. After the power failure and power network is back, firstly start the water pump,then shut down the tap water valve,then power the holding and melting furnaces.If the outage time exceeds 15min,firstly power with 210V for 1 hour,then power with 250V for 2 hours,finally power 300V until the temperature get back to normal state.

13. If the water pump has no water supply,workers should turn on the tap water within 1 minute and then start the spare water pump.After make sure the spare pump can supply water ,then turn off the tap water valve.

14. When the furnace is in temperature preserving state,the voltage for melting and holding furnaces is 210V.The temperature of holding furnace should be kept in 1138℃-1140℃.

15. The principal of the factory should educate the workers that: observe the two water jackets and coils, and water discharge situation of crystallizers all the time. Make sure the workers familiar the emergency situatio