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