SAFETY GUIDELINES FOR IRON & STEEL SECTOR

MINISTRY OF STEEL, STEEL MAKING- Doc. No: SG/33

GOVT. OF INDIA Route–INDUCTION Rev no. : 00
FURNACE (IF) Effective Date: --

1. OBJECTIVE:
The main function of IF Steel Making is to convert Solid Metallics like Steel
Scrap, Sponge Iron, etc. into Liquid Steel by Induction heating. This gets
further processed into Billets, Blooms and Ingots, and by various solidifying
processes like Ingot casting or Continuous casting.

Entire process of IF steel making, is associated with various safety hazards.

Most safety hazards in IF arise from the high temperature of liquid steel.
These hazards are enumerated in this guideline.

2. SCOPE:
This guideline of safety is applicable to all Electric Induction Furnace (IF) of
standalone units or a Mini Steel Plant having induction furnaces.

3. PROCESS :

I. Process of IF Steel Making area includes the following areas

a) Scrap Yard: The scrap is kept in the scrap yard generally under a shed.
The scrap is prepared as per the requirements of steel grade with different
quantities of scrap, sponge iron, other additives etc.

b) IF unit: This is the melting unit consisting of refractory lined crucible, water
cooled panels (WCP),water cooled power cables, hydraulic tilting
mechanism, Capacitor bank, etc. All Metallic charge and flux is charged
into the Furnace either manually or from the Scrap/DRI lifted with an EOT
crane. Power is put on through the power cables to induction coil which
starts melting the charge. The Metallic charge melts to form liquid steel. As
soon as the Liquid bath achieves a Temperature of around 1650°C, it is
tapped into Steel ladle for further processing. Normally a spare crucible is
kept for alternate use. The crucible is selected with the help of a
changeover system.

c) Water cooling system: The induction furnace coil, panel and power
cables are water cooled. An effective cooling water system is provided with
suitable water pumps, cooling towers and heat exchanger having backup
system for emergencies or break downs.

d) Transformer: The main energy on which an IF operates is an electrical

energy. It is considered to be a very high energy intensive process. In
these days, the induction furnaces are generally designed for running at

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medium frequency. The transformer is one of the major equipment which is

selected based on the requirement of melt rate and rating of induction coil.
This transformer steps down voltage from HV (e.g33kV) to LV (e.g 850 V).
Power is controlled through a variable power pot available on the furnace
platform. A capacitor bank is also provided for compensation to take care
of power factor.

e) Material feeding System: Depending upon the size of operation, the

material is fed into the furnace manually or through EOT Cranes having
magnets.

f) Pit side: The molten metal is poured in to the Bottom Pouring set through
teeming ladle for casting in ingot moulds. The ingots are taken out
manually from the moulds. In case of continuous casting the molten metal
is transferred in a teeming ladle for carrying out continuous casting after
loading on the ladle turret/ladle stand/ladle transfer car as per the shop
facility with the help of EOT Crane.
g) Fume Extraction System: A movable elbow collects the fumes from the
top of the crucible and transfer it to the dust collector/ baghouse through
ducts. The solid dust is collected in the hoppers and the fumes/air is
released through chimney.

II. The EIF comprises of the following major operations/critical

equipments:-

S.No. Operation Equipments

1 Scrap processing Shearing machines,

2 Electrical distributionTransformer, Cables, Capacitors,

Motors,
3 Melting system Panel, Changeover, choke, DM water
plant, Hydraulic power pack
4 Crucibles and lining Coil/Crucibles, Vibrators
arrangements
5 Pump house Water pumps, cooling tower, heat
exchanger
6 Material Handling EOT Cranes, Transfer trolley
system
7 Fume extraction Hood, Ducts, ID Fan, Bag house
system
8 Dispatch yard

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4.0 PROCESS HAZARD ANALYSIS & NECESSARY RISK CONTROL

MEASURES:

Sl. no . Area/Section Hazards Risk Control Measures

A) ELECTRIC INDUCTION FURNACE
1) IF proper Water Leakage from  Stop operation.
coil, Water Cooled  Stop tilting or stop
panel or power any Furnace
cables. movement
 Identify the leakage
point
 Develop and Follow
SOP

Metal splash or  Stop operation.

explosion due to  Ensure use of PPEs
water coming into  Proper protection
contact with molten system like Ground
metal. (Water may Leak Detector (GLD)
be present in scrap etc. in place
material or from  Ensure No
leaks in the furnace unauthorized person
cooling systems) on furnace platform
 Ensure no wet scrap
and leakage of water

Metal splash or  Stop operation

explosion due to  Proper Segregation
improper scrap of scrap
charging/wet  Inspection of scrap
scrap/chemicals in and approval process
scrap for worthiness
 Safe scrap charging
through
cranes/vibrators
charging trolley
 Use of Hydraulic
pusher for melting
(Refer SG-23 : Safety
Guidelines for Safe
handling of Liquid Metal)
Material Handling  Regular Maintenance
System of EOT cranes in
respect of wire ropes,
brakes, lifting hook,
rails/wheels,

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electrical
system/motors etc.
 Provision of proper
limit switches
 Emergency main
switch of cranes to be
provided near
platform or at an
easily accessible
place.
 Bell/Siren is to be
provided in the cabin
for crane operator
 Annual inspection of
Cranes/Lifting tackles
by competent person
every year as per
factory act
 Display of safe
working load on each
crane
 Proper Guarding of
all stairs and crane’s
CT Trolley
(Refer SG-14 : Safety
Guidelines for work on
Electric Overhead
Travelling (EOT) Crane)

Melting system  Water Temperature &

protection flow sensors
 Ground leak detector
 Circuit breakers and
tripping mechanism
 Frequency monitoring
 Lining conditions of
crucibles & ladle etc.

Bridging in IF :  Develop and follow

Leading to SOP
superheating of
furnace bottom and
erosion of ramming
mass and rupture of
cooling water tubes.
2) IF turnaround Burn Injury due to  Proper PPE and

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activity splashing slag visor. ( Refer SG-18 :

Personal Protective
Equipment (PPE)
Management )
 Covering of all
exposed area with
cloth

 Air compressors/
pressure vessels
should be checked
regularly for proper
working of Pressure
switches, safety
valves and Pressure
gauges.
 Auto drain valve is to
be provided on each
Pressure Vessels pressure vessel
 Six monthly testing of
PV Thickness and
hydraulic testing
every four years by
competent person as
per the factory act.
(Refer SG-01 : Safety
Guidelines on storage,
handling & use of gas
cylinders)
Person hit by  Siren, gong bell
moving machines during movement
machines.
 Auto announcement
during any operation.
 Permit to work prior
to undertaking any
maintenance job.
( Refer SG-09 : Safety
Guidelines in Equipment
& machine Guarding)
3) Electrical Electrical failures  Proper Earthing pits
system and shock  Earthing of all
electrical
motors/gadgets
 Work permit system
 Transformer testing

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(dielectric strength
and dehydration of
Transformer oil)

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