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Safety Operating Procedures for Medium-Frequency Induction Furnaces
Aug 24,2020
Next, let’s take a closer look at the specific operational procedures we should follow for the safe operation of medium-frequency induction furnaces.
1. Before starting the furnace, carefully check that the electrical equipment, water cooling system, induction coil copper tubing, and other components are in good condition; otherwise, do not start the furnace.
2. If the furnace lining erosion exceeds the specified limit, it should be repaired promptly. Melting operations are strictly prohibited in crucibles with excessively deep erosion.
3. The energization and furnace startup must be supervised by a dedicated person. After energization, it is strictly forbidden to touch the inductor or cables. The operator on duty must not leave their post without authorization and should pay close attention to the external conditions of both the inductor and the crucible.
4. When loading materials, check carefully to ensure that no flammable, explosive, or other hazardous substances are mixed into the charge. If any such substances are found, remove them immediately. Never add cold or wet materials directly into the molten steel. Once the melt has filled up to the upper level, absolutely avoid adding large chunks of material to prevent crust formation.
5. During furnace repair and crucible ramming, it is strictly forbidden to mix iron filings with iron oxide. The crucible must be rammed tightly and densely.
6. The pouring area and the pit in front of the furnace shall be free of obstructions and standing water to prevent molten steel from splashing onto the ground and causing an explosion.
7. Molten steel must not be overfilled. When pouring from a ladle held by hand, two workers should coordinate closely and walk steadily, avoiding sudden starts or stops. After pouring, any leftover steel must be poured into the designated location; dumping it randomly is strictly prohibited.
8. The medium-frequency generator room must be kept clean. Flammable, explosive materials and other debris are strictly prohibited from being brought into the room, and smoking is forbidden inside.
How can a medium-frequency furnace be operated safely, and what are the operational procedures?
1. Purpose: This procedure is intended to guide operators in the correct operation and use of the equipment.
2. Scope of Application: This procedure is intended to guide the operation and safe handling of the 135 kW medium-frequency furnace.
3. Management Content
Operation procedure:
Medium-frequency furnace Pre-boot check:
1. Before starting the mid-frequency furnace, the automatic feeding and adjustment operator must strictly ensure that the production line’s automatic power control system is sensitive and reliable, and that all equipment is operating normally.
2. Before starting the adjustment work, you must first open the water separator to drain any accumulated water remaining in the air lines.
3. Before starting up the adjustment machine, it is essential to check whether the pneumatic control system is sensitive and reliable, including both the manual control mechanism and the motorized control mechanism. Inspection method: Press the manual button and activate the motorized impact plate separately; the system should be able to flexibly control the clamping device in response to these actions.
(1) Medium-frequency furnace operation section:
1. Connect the cooling water, check that all outlet pipes are unobstructed, and ensure the water pressure gauge reads > 0.8 kg/cm².
2. Close the wall-mounted iron-cased switch, then close the “main power switch.” The AC voltmeter shows a reading, and the incoming-line indicator light illuminates, indicating that all three phases of the power supply are energized.
3. Press the “Control Circuit On” button, and the yellow indicator light labeled “Control Circuit On” will illuminate. The two lighting lamps on the control box will also light up, and at the same time, the rectifier trigger ammeter, the 15V AC-DC voltage regulator, and the 24V power amplifier power supply meter will all display readings.
4. Set the “Check—Work” switch on the control box to the “Work” position.
5. Press the “Main Circuit Close” button, and the yellow indicator light for the main circuit will illuminate.
6. Turn the potentiometer on the right front door counterclockwise to the O position (it’s best to do this during adjustment), then press the “Inverter Start” button. At this point, the DC voltage should read approximately 100 volts (if there is no voltage, the start-up will fail). After about 2 to 3 seconds, you’ll hear the medium-frequency furnace emit a sound, and the yellow indicator light for inverter operation will illuminate.
7. Under conditions where the impedance frequency is appropriately matched, you can adjust the potentiometer on the right door clockwise to increase the rectified voltage, thereby raising the DC current and also increasing both the intermediate-frequency furnace voltage and power. At this point, you should ensure that: Ua = (1.2–1.4) Ud.
8. When the temperature has reached the appropriate level, you can reduce the power and then press the “Inverter Stop” button.
9. If no further heating is required, first disconnect the main circuit, then disconnect the control circuit, and finally switch off the main power switch.
10. After a power outage, do not immediately shut off the cooling water. You must continue to run the water for at least another 15 minutes before stopping it.
11. Pay attention to the water on the ground—make sure no iron filings fall into the cable trenches to prevent short circuits. Also, regularly (once a month) check the cable trenches for standing water or debris.
12. If the furnace chamber is cracked, immediately shut down the machine and replace the furnace tube. Otherwise, it could pose a serious threat to personal safety. When replacing the furnace tube, take care to avoid damaging the induction coil, and allow it to dry thoroughly. Only use it after confirming that its insulation resistance meets the required standards.
13. If the equipment suddenly malfunctions during operation, it should be immediately shut down for repair. Before restarting after troubleshooting, the furnace must be empty of material (i.e., started under no-load conditions) to ensure successful startup; it cannot be started with a load.
(2) Safety Operating Procedures for Medium-Frequency Furnaces:
1. Before starting, first check the cooling water, lubrication, and grounding conditions. Only after confirming that they are normal can you start the machine.
2. The cooling water pressure must not fall below the specified value. Water supply can be stopped only 15 minutes after the machine has been shut down.
3. Do not start the machine continuously when it is hot, and do not operate it under overload conditions.
4. In the event of a water outage or abnormal conditions such as overheating of the billet, the machine should be stopped immediately.
5. During operation, the current and voltage must be matched according to specifications, and the operator must not leave the machine unattended.
6. Each shift must inspect the furnace chamber; if any abnormalities are detected, the machine should be stopped immediately. Each shift must also check the cable trenches for standing water or debris and address any issues promptly.
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Kangda Electric Furnace specializes in the manufacture of the following equipment: KGCL series medium-frequency power supplies, KGPS series medium-frequency power supplies, GTR series medium-frequency induction heating furnaces...
Contact Information
Address: Yuhe Industrial Park, Weicheng District, Weifang City, Shandong Province
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