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Accident Prevention Manual For Business & Industry:: Engineering & Technology 13th Edition
Accident Prevention Manual For Business & Industry:: Engineering & Technology 13th Edition
Compiled by
Dr. S.D. Allen Iske, Associate Professor
University of Central Missouri
CHAPTER 25
HOT WORKING OF METALS
Hazardous Materials
• Dusts, solvents, and other materials present a health
hazard in foundries.
• Dust is generated in many foundry processes and
presents a twofold problem:
1) Cleaning to remove deposits
2) Control at the point of origin to prevent further dispersion and
accumulation
• Vacuum cleaning is the best way to remove dust in foundries.
• Once dust has been removed, prevent further accumulation by using
local exhaust systems (LEV) that remove it at the point of origin.
Hazardous Materials (Cont.)
• Solvents: evaluate each solvent on the basis of its
chemical ingredients
• Proper labeling, substituting less hazardous for more hazardous
chemicals, limiting the quantities in use, and using other methods
of control can help minimize the toxic and flammable hazards
involved in using solvents.
• Other materials: many metal resins, and other substances
present safety and health hazards
Hazardous Materials (Cont.)
• Other hazardous materials that are found in various
stages and locations of hot metal operations include:
• acrolein
• beryllium
• carbon as sea coal
• carbon monoxide (CO)
• chromium
• fluorides
• lead
• magnesium dust or chips
• manganese
• phosphorus
• resins and resin dusts
• silica
• sulfur dioxide
Hazardous Materials (Cont.)
• Iron-oxide: fumes and dusts
are created during melting,
burning, pouring, grinding,
welding, and machining of
ferrous castings
• Use LEV to vent these fumes.
Medical Program
• Baseline physical examinations, including chest x-rays,
audiometric tests, and pulmonary function tests
• Periodic physical examinations to detect incipient disease
and to help reclassify workers as needed
• Adequate first aid facilities and employee training in first
aid
• Observe regulatory requirements if respirators must be
worn
• Industrial hygiene monitoring where needed
Medical Program (Cont.)
• Charging
• Dangers are principally confined to handling material.
• Never unevenly load or overload barrows or buggies.
• Break open scrap cylinders, tanks, and drums before charging to
prevent an explosion.
• Install railings or other safeguards underneath the elevators,
machines, hoists, and cranes.
Cupolas (Cont.)
• Charging floor
• Use bolted, heavy steal plates.
• Install brick flooring near the furnace to avoid extremely hot steel
flooring.
• Observe good housekeeping.
• Construct railings from angle iron at 42 in. high, and 4-in. toeboards
around all floor openings.
• Place guardrails across the charging opening.
Cupolas (Cont.)
• Carbon monoxide (CO)
• Is generated during some cycles in the operation.
• CO is an explosion hazard if it gets into the wind boxes and blast
pipes.
• Supply adequate ventilation in the back of the cupola, and open two or
more tuyeres after the blowers are shut down.
• Locate CO indicators around the cupola that light and give a loud
sound.
• If CO concentration is continually above 200 ppm, an engineering
assessment should be considered.
• OSHA 8-hour TWA is 35 ppm and the ceiling limit is 200ppm.
Cupolas (Cont.)
• Blast gates
• Blast Gates and explosion doors are successfully used to prevent
damage from gas explosions.
• Often placed in front of tuyeres so fresh air can enter when the
blowers are down.
• Never close them until the blast has entered the wind box and
driven out all gas.
• Equip positive-pressure blowers with safety valves.
• Every cupola should have at least one safety tuyere, with a small
channel.
Cupolas (Cont.)
• Tapping out
• Operators should not thrust the bott directly into the stream of
metal.
• Dropping the cupolas bottom doors
• Place temporary supports under the bottom doors.
• One of the best methods for doing this is to use a block and tackle
with a wire rope and chain leader attached to the props that support
the doors.
• Carefully inspect beneath the cupola for water.
• Have one worker check the danger zone and warn nearby
employees with a horn or other signal.
Cupola (Cont.)
• Suggested method of raising the bottom doors of the
cupola by mechanical means.
• Pre-setup activities
• Clean around the hammer.
• Do not perform maintenance work on the equipment when setting
up a die.
• Ensure good lighting and flooring.
Setup and Removal of Dies (Cont.)
Setup
1. Prop the ram securely and shut off and lockout the power.
2. Drive die dowels into the dowel holes in the die shank.
3. After the bottom die of a steam hammer has been set in place,
drive the bottom key to help line up the die and partially tighten it.
4. Invert the top die and set it in position so the dies are face to face
with the match lines aligned. (Reverse this procedure for a
gravity-drop hammer: set and key the top die first.)
5. Remove the safety prop between the ram and sow block.
6. Let the ram descend slowly until it engages the die.
Setup and Removal of Dies (Cont.)
• Removing dies
• Clear the area around the hammer.
• Shutoff and lock out the hammer’s energy sources.
• Use a special type of adjustable knockout that is held in position
mechanically rather than manually.
• After die keys have been driven out, raise the ram and prop it at
once.
• After removing the dies from the hammer, extract the dowels.
• Load the removed dies onto low, steel pallets and take them from
the area as soon as possible.
Setup and Removal of Dies (Cont.)
• Adjustable knockout key
Forging Upsetters
• This is a horizontal machine that forges hot bar stock,
usually round, into many forms via squeezing action.
• Enclose the machine as much as possible, except for the
feed area.
• For safe operating conditions, keep the area around the
machine clean and clear of obstructions and litter.
• Use lockout procedures before attempting to make any
changes to dies, heading tools, stock gauges, or
backstops.
Nondestructive Testing
• Visual observation cannot locate all small, below-the-
surface defects in casts and forged metals without
damaging the parts being tested.
• Proper nondestructive testing reveals defects inherent in
metals and other solid materials or those that result from
processing or in-service use.
Nondestructive Testing (Cont.)
• The types of testing most commonly used for forged and
cast metals are the following:
1. magnetic particle inspection
2. penetrant inspection
3. ultrasonic methods
4. triboelectric method
5. electromagnetic tests
6. radiography