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    SOP For CCM Operation

    Uploaded by

    Murali Krishnan Nair
    1) The document provides standard operating procedures for continuous casting machine (CCM) operations at Godawari Power and Ispat Ltd. 2) It details safety requirements and checks that must be performed before each cast, including ensuring adequate supplies of materials, gases, and equipment. 3) Step-by-step instructions are provided for processes during casting like temperature checks, slag removal, and cutting of billets. Mould tube replacement procedures are also outlined.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd

    SOP For CCM Operation

    Uploaded by

    Murali Krishnan Nair
    3K views3 pages
    1) The document provides standard operating procedures for continuous casting machine (CCM) operations at Godawari Power and Ispat Ltd. 2) It details safety requirements and checks that must be performed before each cast, including ensuring adequate supplies of materials, gases, and equipment. 3) Step-by-step instructions are provided for processes during casting like temperature checks, slag removal, and cutting of billets. Mould tube replacement procedures are also outlined.

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    Ccm

    Original Title

    SOP for CCM Operation

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    1) The document provides standard operating procedures for continuous casting machine (CCM) operations at Godawari Power and Ispat Ltd. 2) It details safety requirements and checks that must be performed before each cast, including ensuring adequate supplies of materials, gases, and equipment. 3) Step-by-step instructions are provided for processes during casting like temperature checks, slag removal, and cutting of billets. Mould tube replacement procedures are also outlined.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
    3K views3 pages

    SOP For CCM Operation

    Uploaded by

    Murali Krishnan Nair
    1) The document provides standard operating procedures for continuous casting machine (CCM) operations at Godawari Power and Ispat Ltd. 2) It details safety requirements and checks that must be performed before each cast, including ensuring adequate supplies of materials, gases, and equipment. 3) Step-by-step instructions are provided for processes during casting like temperature checks, slag removal, and cutting of billets. Mould tube replacement procedures are also outlined.

    Copyright:

    © All Rights Reserved
    Download as DOCX, PDF, TXT or read online from Scribd
    Download as docx, pdf, or txt
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    At a glance
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    The key takeaways from the document are the standard operating procedures (SOP) for CCM (Continuous Casting Machine) operation at a steel plant. It details the roles and responsibilities, prerequisites, safety requirements, checks to be carried out before casting, and steps during the casting process.

    The safety requirements mentioned are: only trained personnel should carry out checks, use of necessary personal protective equipment, and use of standard tools.

    The checks to be carried out before casting include checking for oxygen cylinders, LPG cylinders, cutting torch, oxygen regulator, availability of cone plugs, oil, casting powder, slag bari, chillers, ferro silicon, and argon cylinders.

    WORK INSTRUCTION- Steel

    Melting Shop Division

    Doc. No.: SMS CCM - 00


    Revision No: 00
    Effective Date: 10-11-14

    Godawari Power and Ispat Ltd.

    TITLE: SOP for CCM operation

    Objective: To standardize CCM operation


    Roles and Responsibilities :
    Responsi
    ble
    Account
    able
    Consulte
    d
    Informed

    Mould Operator/Shift Incharge


    Manager
    AGM/DGM
    GM

    Location:
    Pre-requisites:
    Safety Requirements: 1. only trained person must carry out checks.
    2. Usage of necessary PPEs.
    3. Usage of standard tools
    Checks to be carried out before casting
    1. Check for the presence of oxygen cylinders. One trolley containing 50 numbers of
    cylinder must be present at CCM area. Pressure of cylinder should be 120kg/cm2. Spare
    trolleys two numbers must be present at the site .In case same is not there, report it to
    oxygen department for the replacement of trolleys.
    2. Check for the presence of LPG cylinder .Five numbers of cylinder must be present.
    3. Check for the presence of cutting torch. Operator will light and check whether torch is
    operational or not.
    4. Check for the working of oxygen regulator .Pressure of same should be 2.5-3 kg/cm2.
    5. Shift in charge /engineer of CCM will check availability of CI cone plug 30 X 60 .Minimum
    10 numbers of CI cone must be present.
    6. Check for the availability of copper cone plug, 2-4 numbers must be at site.
    7. Check for the availability of rapeseed oil in the tank.200 litrs of oil must be present.
    Standard rod to be kept for measuring level.
    8. Check for the availability of casting powder - 10 bags must be present at site.
    9. Check for the availability of slag bari of 8 mm.
    10.Check for the availability of chillers - 5 kgs minimum must be present at site.
    Approved By:
    G S Bansal Sr VP

    Issued By:
    G S Bansal Sr VP

    WORK INSTRUCTION- Steel


    Melting Shop Division

    Godawari Power and Ispat Ltd.

    Doc. No.: SMS CCM - 00


    Revision No: 00
    Effective Date: 10-11-14

    TITLE: SOP for CCM operation

    11.Check for the availability of slag bari


    12.Check for the availability of Ferro silicon 10 kgs minimum must be present at site.
    13.Prepare launder and mould jacket safety cover
    14.
    Check for the availability of argon cylinder minimum 2 numbers of cylinder on each
    caster pressure 7kg/cm2.
    Dummy bar is put in mould tube by Skid bank operator (SBO) and then packing is done
    using asbestos sheet .Caster In- charge informs mould operator that dummy bar is
    inserted in mould and mould operator can prepare machine .Mould operator does sealing
    by application of tundish board and put in mould tube and then chiller is put.
    Shift in charge does the centering of tundish trolley though motor. For this he puts rod in
    the tundish nozzle and ensure that center of tundish and mould is matched.
    After this Nozzle filling compound is put and mould tube sealing is done through chiller.
    Shift in charge checks primary cooling water pressure inlet and outlet as per following
    details:
    Inlet Pressure - 4kg/cm2.
    Outlet pressure - 2 kg/cm2.
    Emergency valve must be in open condition and water pressure must be 2.5 kg/cm2.
    When Slide gate ladle reaches the CCM platform, purging is done using argon.
    Temperature is taken of metal in slide gate ladle and same should be 1615- 1625 degree
    C for CCM2 and 1610-1615 degree C for CCM 1.If temperature is higher than continue
    purging and if lower the return the ladle to the furnace.
    Ladle is opened and when tundish level is th, then tundish nozzle is opened
    .Continuous slag removal is done by the mould operator.
    Transfer ladle arrives
    Level of slide gate ladle is checked by using lancing pipe. Marking on lance pipe to be
    checked for estimation of metal volume in the slide gate. If molten metal is less than 3T
    then transfer is done. If volume in slide gate is more then transfer ladle is kept on hold.
    When metal is transferred completely into slide gate ladle. Temperature of slide gate is
    taken .Temperature must be 1580-90 degree.
    1) If more then
    a) Purging required
    b) Addition of chiller
    c) Add some pcs of jam
    2) If less then
    a) Ladle return to furnace
    During casting
    Approved By:
    G S Bansal Sr VP

    Issued By:
    G S Bansal Sr VP

    WORK INSTRUCTION- Steel


    Melting Shop Division

    Godawari Power and Ispat Ltd.

    Doc. No.: SMS CCM - 00


    Revision No: 00
    Effective Date: 10-11-14

    TITLE: SOP for CCM operation

    When level is more than half teamer man tells shift in charge to open tundish nozzle. SIC
    tells mould operator to open tundish nozzle. Mould operator opens all nozzle sequentially.
    Fitter notices speed meter of casting in case it shows some reading he starts secondary
    cooling water.
    Mould operator then control casting speed using knob.
    Mould operator maintains distance of 150 mm of liquid metal from the top and
    accordingly he maintains speed.
    Once dummy bar is cut mould operator maintains the speed and removes slag by using
    slag bari.
    Then gas cutter will cut head of billet to make it free from dummy bar. When billet
    reaches 4 meter or 6 meter gas cutter cuts the piece and then SBO pushed same to
    cooling bed from where billet is lifted using crane.
    Mould Tube replacement after Campaign
    CCM 01 Mould tube to be replaced after 450 heats.
    CCM 02 Mould tube to be replaced after 600 heats.
    Replaced mould shall be checked against standard parameter. In case it is
    within permissible limits it will be reused else it will be discarded

    Approved By:
    G S Bansal Sr VP

    Issued By:
    G S Bansal Sr VP

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