WORK INSTRUCTION- Steel

Melting Shop Division

Godawari Power and Ispat Ltd.

Doc. No.: WI-SMS-Production01

Revision No: 00
Effective Date: 03-11-14

TITLE: SOP for Operation

Objective: To standardize the melting process
Roles and Responsibilities (Scope 1):
Responsi

Shift Incharge/ Dy. Manager (Process)

ble
Account

Manager (Process)

able
Consulte

AGM / DGM - Production

d
Informed

AGM / DGM - Production

Location: Furnace Area

Pre-requisites: 1. Furnace daily checks are carried out for safety
2. Availability of required raw material
Safety :

1. Ensure usage of required PPEs

Fresh Checks
Furnace new lining
Procedure:
1) Furnace condition to be checked by the melter and first hand

before

starting the furnace .Visual inspection is done to check following.

There should not be any cut in the furnace.
Check for the formation of furnace ring.
Check the Life of furnace from the log sheet
Check for any erosion by putting standard rod in the furnace and measuring
the depth.
Check frequency on the furnace panel.
Approved By:

Issued By:

G S Bansal Sr VP

G S Bansal Sr VP

WORK INSTRUCTION- Steel

Melting Shop Division

Godawari Power and Ispat Ltd.

Doc. No.: WI-SMS-Production01

Revision No: 00
Effective Date: 03-11-14

TITLE: SOP for Operation

2) After this melter calls the crane operator through signals which
are as following.
1 time blowing horn electrical b/d
2 times blowing horn mechanic b/d
3 times blowing horn crane operator call - charge mix
6 times blowing horn slide gate ladle
7 times blowing horn transfer ladle
Crane operator then adds scrap and PI as per the daily plan of charge mix
(Refer Charge mix report Production report).
Melter conveys the number of magnet of scrap and PI to be added through non
verbal communication.
3) Switch on the furnace & increase the power pot slowly upto
full power load as following :
4) As per capacity FC 1 to 5 2750 KW, FC 6 4500 KW, FC 7 & 8
5000 KW & FC 9 & 10 5500 KW.
5) Meanwhile crane operator keeps accumulating DRI near
furnace.
5) When liquid pool developed then put sponge Iron + pellet
which is kept near furnace in furnace with the help of EOT crane.
6) Furnace helper then slowly starts material pocking & after
some time slag removal process is started.
7) When molten level in furnace reaches the level (estimation
of melter) of molten metal then helper extracts sample through rod and same
is send to quality lab wherein test is done as per Quality checklist .This
checklist is then given back to helper who gives to shift in charge.
8) After receiving the lab report shift in charge instructs melter to initiate
action based on carbon level.
Approved By:

Issued By:

G S Bansal Sr VP

G S Bansal Sr VP

WORK INSTRUCTION- Steel

Melting Shop Division

Doc. No.: WI-SMS-Production01

Revision No: 00
Effective Date: 03-11-14

Godawari Power and Ispat Ltd.

TITLE: SOP for Operation

If carbon is out of specification.(refer quality checklist) Low carbon sponge
iron to be used or mil scale is added
Met coke is added in case carbon is low.
9) Melter keeps on adding DRI till furnace is half filled.
Helper takes another sample and send it to Lab for carbon testing ( as per
check list).
10) After receiving the lab report shift in charge instructs melter take action as
per step 8.
11) Melter keeps adding DRI to increase the level of metal. Helpers repeatedly
removes slag.
In this way the melter fillup the furnace up to level of molten metal & then
again take one sample & send to the lab to check the % of carbon ( as per
check list).
12) After receiving the lab report shift in charge instructs melter to initiate
action based on carbon level.
If carbon is out of specification.(refer quality checklist) Low carbon sponge
iron to be used or water is sprinkled on sponge or mil scale is added ?
Met coke is added in case carbon is low.
13) After that De-slagging is done continuously with the help of spoon by
bariman.
14) After that % of carbon will be set by the
melter as per product which is wire Rod or TMT.
15) Melter then instructs to the first hand to increase the liquid metal level
according to the furnace capacity by adding DRI
16) After that cleaning the slag 80% rest slag reduced with the help of met
coke & pig iron.10 kg/Ton Pig iron is added and 0.5 Kg per Ton of met coke.

Approved By:

Issued By:

G S Bansal Sr VP

G S Bansal Sr VP

WORK INSTRUCTION- Steel

Melting Shop Division

Godawari Power and Ispat Ltd.

Doc. No.: WI-SMS-Production01

Revision No: 00
Effective Date: 03-11-14

TITLE: SOP for Operation

18) Temperature is then measure using temp tips. If temperature is less than
1630 degree celsius continue heating.
Once temperature reaches 1630 addition of the Ferro aluminum & SiMn is done
(how much to add SiMn)
Requirement of SiMn as per chart
0-3mm

17.50 kg/MT

Si 13% , Mn
52%

3-12 mm
Lumps

min

15.50 kg/MT

value)
Si 13%,Mn-

13.0 kg/MT

55%
Si
-14.5%+/0.5%,Mn 60%
+/- 1%

After addition of SiMn and Ferro Aluminium mixing of liquid metal is done with
the help of bari
19 ) Final temperature is taken and in case temperature is in the range of 1680
- 1700 shift In charge calls ladle for tapping.
20) Shift in charge, SI instruct melter to pour the liquid metal

into ladle,

During tapping teamerman will provide the purging of nitrogen. 3 minutes

purging at pressure of 1.5kg/cm2
21) After complete tapping first hand take final temperature in the ladle.
If temperature is in the range of 1650-1660 degree C, ladle is sent to CCM for
casting. Then take one lollypop sample & send to the lab for testing.
23) Finally ladle send to the CCM for casting.
24) Melter updates the data in the production sheet along with remark in case
deviation is there against the plan.

Furnace side
Approved By:

Issued By:

G S Bansal Sr VP

G S Bansal Sr VP

WORK INSTRUCTION- Steel

Melting Shop Division

Godawari Power and Ispat Ltd.

Doc. No.: WI-SMS-Production01

Revision No: 00
Effective Date: 03-11-14

TITLE: SOP for Operation

STD Fce Temp

1670-1700C

Pitside Temp (TFR Ladle)

1620-1630C

Pitside Temp (Slidgate Ladle)

1650-1660C

Approved By:

Issued By:

G S Bansal Sr VP

G S Bansal Sr VP