Contact with Molten Material
Coming into contact with molten metal.
Cooling Element Monitoring
Have I completed a Furnace Inspection that includes looking for water leaks, shankers, dark spots and missing bricks?
Have I checked for adequate water flow and temperature at the tundish?
Do I know and understand the steps to take when a low flow or temperature warning is noted?
Have I performed your daily faceplate inspections to verify they are free from visible damage?
Engineered Molten Metal Conveyance Systems
Have I inspected the fixed transport systems (launders, bowls, tundish, tapholes, etc.) to ensure they are in good condition and maintained as required?
Fire Suppression Systems (Molten Metal Hauler)
Does the Molten Metal hauler I am using have a fire suppression system installed?
Does the discharge/charge indicator on the Fire Suppression System show that it is ready for use?
Are the safety pins installed on all actuators?
Does the fire suppression system have a tag to show it is routinely tested and has the test been completed within one year of a service check?
Is the discharge line (tank and fittings) connected and in good condition?
Are the caps fitted to the nozzles?
Are the nozzles free of blockage? Note: It is not necessary to check every nozzle is free from blockage. A sample of nozzles is fine.
Are the nozzles pointed in the proper direction (towards the potential fire source)?
Furnace and Tap Hole Integrity
Are emergency tap hole plugs and supplies available and in good condition?
Do I monitor tapholes and launders 100% of the time when tapholes are running?
Did I complete your pre-op inspections as required?
Is adequate freeboard maintained in the bowls below tap holes? (i.e. Do I stop tap before freeboard is gone?)
Do you I straight into the tap hole and not off to the side, top or bottom?
Do I minimize oxygen lance pressure to avoid damaging the insert and faceplate?
Did I inspect and test the oxygen lance couplers and hoses before use, and are they in good condition?
Are areas below furnaces and tap holes free of accumulated water?
Are warning lights/signs/barricades in place for your tapping operations?
Are spill detection and containment systems maintained and operating as designed?
Are time, wear, tonnage or condition-based refractory repair schedules being met and do inspections indicate that they are effective?
Is the tapping machine properly aligned to allow for burning to the center of the tap hole?
Are tap hole replacement procedures for cool down times and notification requirements described and followed?
Did I inspect lance pipe prior to use to ensure it is free of blockage and fit for use
Hot Metal PPE
Am I wearing Hot Metal PPE as required for the task being performed?
Have I inspected my Hot Metal PPE prior to use?
Is my Hot Metal PPE in good condition and free from any modification?
Am I wearing the Hot Metal PPE correctly?
Pot Level Control
Am I visually checking the pot level during the fill?
Is the slag pot level control system functioning correctly? Note: Check that the level indicator corresponds to visual pot inspection.
Is there a minimum of 18 inches pot freeboard being met?
Is the foaming slag indicator light and alarm functional? Note: This is to ensure the pot fill rate meets the standard fill cycle.
Process Controls
Am I taking samples according to the schedule?
Am I sending the samples to the lab in a timely manner?
Am I taking temperatures according to the SOP requirements (as a minimum)?
Am I taking furnace levels according to the SOP requirements (as a minimum)?
Are charge materials controlled to protect against explosive bath conditions?
Are furnace process controls maintaining stable furnace conditions?
Access Control
Are controls (signs, gates, radio systems, etc.) for restricting access of people and vehicles to the Kress haul road in place and in working order?
Have crossing gates been provided at vehicle crossing locations of the Kress haul road, and are they closed during molten metal hauling operation?
Are physical controls i.e. barriers and signage in place to prevent unauthorized access?
Are furnace area entry protocols in place and enforced for non-area personnel entry?
Slag Chemistry Management
Are slag temperatures within upper and lower limits?
Do observed slag conditions indicate furnace process stability?
Are pot cooling systems operating as designed?
Are pot cooling cycle times within described parameters?
Integrity of Cooling System Components
Have I inspected vessels for hot spots?
Have I inspected the steam lines to ensure that no water can come into contact with molten material?
Have I confirmed that we are not currently using the auxiliary boiler?
Have I confirmed that the system has been purged to prevent water from entering the vessel?