CH PRP

DOC No.
: ISO/QPO/BF (O)-15/03
BHILAI STEEL PLANT PAGE No. : Page 1 of 15
BHILAI – 490001 DATE OF ISSUE: 23.07.07
___________________________________________________________________________________
WORK INSTRUCTIONS
ON
CAST HOUSE PREPARATION

AND
OPENING / CLOSING OF TAPPING

REVISION RECORDS
REVISION REVISED BRIEF

PREPARED CHECKED CONTROLLING APPROVED
NO/ PAGE DESCRIPTION
BY BY AUTHORITY BY
DATE NO OF REVISION
Sd\-
Sd\- B SATYANA- Sd\- Sd\-
--
00 ORIGINAL MP SINGH -RAYANA SB SINGH SB SINGH
12.09.97 DOCUMENT Sr. Mgr. (O) AGM (O) GM (I) GM (I)
Sd\- Sd\-
Sd\- Sd\-
01 D GUPTA BK PRASAD
11 Article S AHMED S AHMED
14.06.02 AGM (O) DGM (O)
7.9.4 HOD (BF) HOD (BF)
BF BF
Sd/- Sd/- Sd/- Sd/-
02 04 Article RR NAGRE PK DWIVEDI RAVI KUMAR RAVI KUMAR
05.02.07 6.4 AGM (O) DGM (O) HOD (BF) HOD (BF)
03 04 Article TD GUPTA PK DWIVEDI P GAUTAM P GAUTAM

23.07.07 6.2 Sr.Mgr (O) DGM (O) HOD (BF) HOD (BF)
REVISIONS ARE NOT PERMITTED WITHOUT THE PRIOR APPROVAL OF THE

CONTROLLING AUTHORITY
DOC No. : ISO/QPO/BF (O)-15/03
___________________________________________________________________________________
DISTRIBUTION OF CONTROLLED COPIES

_________________________________________________________________________________
COPY NO DISTRIBUTION LOCATION REMARKS

_________________________________________________________________________________
1 MANAGEMENT REP. OFFICE OF THE M R FOR RECORD
2 HEAD OF DEPTT OFFICE OF THE HOD FOR CONTROL

BLAST FURNACE BLAST FURNACE AND RECORD
3 I/C FURNACES OFFICE OF THE FOR CONTROL

I/C FURNACES
4 SHIFT MGR PRODUCTION CONTROL FOR CONTROL

BLAST FURNACE BLAST FURNACE
5 MASTER HEARTHMAN FFCR FOR

BF 1 BF 1 IMPLEMENTATION






1.0 INTRODUCTION

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Cast house is an area constructed around the Blast Furnaces at
Tap Hole level, in order to facilitate the tapping of hot metal
and slag from the furnaces through runners.
The runners consist the following parts.
1) Main runner
2) Syphon hole & pit
3) Metal runner
4) Rocking runner
5) Slag runner
6) Perival runner
7) Spouts
Apart from the above runners the cast houses have the following
critical acquirements.
1 Mudgun
2 Drill Machine
3 Cast House crane
4 Telpher crane
5 Pusher car
6 Rocking runner
Cast house can be defined as a network of runners originating

from tap hole and acquirements in order to carry out cast house
preparation and periodical tapping of hot metal & slag.
2.0 SCOPE
This work instruction shall cover the preparation of cast house

for tapping and opening / closing of tapping.
3.0 REFERENCE
1 SOP on tapping of furnace

DOC NO. ISO/QPP/BF (O)-05/**
4.0 DEFINITIONS/ABBREVIATIONS
BF - Blast Furnace TH - Tap Hole

IC - Intermediate cooler CH - Cast House
HM - Hot Metal MC - Main cooler
5.0 RESPONSIBILITY
Master hearth-man (Shift) of the concerned furnace under guidance

and control of Furnace shift in-charge shall be responsible for
implementing this works instruction.
6.0 PROCEDURE

___________________________________________________________________________________
6.1 IMPORTANT SAFETY POINTS
1 All runners must be dry to avoid blasting.

2 All hearth men attending tapping must be fully dressed with
safety appliances to save them from injury.
3 No water logging in and around tracks where ladles are
placed to avoid blasting.
4 Only dry metallic objects are to be inserted in HM pool.
5 Ladle should be filled 200-300 mm below top level.
6.2 SAFETY APPLIANCES
1 Safety shoes
2 Safety helmet
3 Woollen Patti
4 Anklet
5 Flame retardent suit / Canvas coat 03
6 Gloves
7 Face shield / goggles
8 Nose pads
9 Ear plugs
6.3 WORKING PROCEDURE
ACTIVITY KEY POINTS
6.4 CAST HOUSE MAKING

a)In single taphole furnaces (1-3) main runner,syphon and metal runner
is made during monthly schd.shut down by dry ramming mass & periwall
has to be opened after every tapping. On requirement & visual
inspection runner to be repair to achieve through put life of runner
& existing practice is to be used for preparation of cast house as
maintained.
b)In twin taphole fces (4-7) main runner up to R/R to be made by

castable runner mass. After achieving desired through put life,
periwall is to be opened for making of trough. However intermediate
opening of periwall is to be done for inspection and repair of the
trough or in case of shifting of tap hole for prolonged time.
For making of branch runner, R/R and slag runner existing practice
to be adopted.
6.4.1
ACTIVITY KEY POINTS
Taphole making
1 Visually observe the tap hole condition.
2 If tap hole is deep by around 4-5" with

respect to the plane of TH arch. (Furnace

___________________________________________________________________________________
shift incharge shall take decision for making
in consultation with the Sr. Head Keeper)
3 Arrange frame mass (TH gola)
4 Cool tap hole and then break it and its

surrounding mass by chisel rod uniformly.
5 Fix TH gola around the broken tap hole in

limited number and ram it with tap hole
rammer.
6 Continue the process of. gola fixing and

ramming till the tap hole comes to the level
of TH area.
IMPORTANT - TH gola should be properly

rammed so that TH becomes compact and strong.
7 Bring the mudgun to tapping closing

position and take the impression of the
mudgun nozzle on the rammed mass slowly.
8 Again ram the surrounding area and take

final impression.
9 Cover the area around arch by thin layer

of water bonded clay and cut the TH upto the
old clay.
10 Fire the TH with coke oven gas for 1-1/2

hrs with oxygen.
11 The tap hole is ready for tapping.
NOTE 1 : Where hydraulic drilling machine has

been provided, check the centering by fixing
a drill rod. It should co-incide with the
dug up hole, otherwise get necessary
adjustment.
NOTE 2 : Mud gun centering shall be checked

after breaking the TH.
IMPORTANT : After the TH is broken the

Furnace shift incharge will observe the
condition of arch bricks, any major gas
leakages etc. and will log it in log book.
He must inform the concerned Furnace I/C /
Shift Manager before fixing clay, if there is
any abnormality.

___________________________________________________________________________________
6.4.2
ACTIVITY KEY POINTS
Main runner making
1 Main runner is divided into three parts

to facilitate easy and quick making.
1. 1st Half
2. 2nd Half
3. Syphon and pit
2 The Fce shift incharge takes decision of

making the runner by seeing the metal pool
(depth of jam) and side erosion of runners.
3 Demand and arrange special runner mass.
4 The hearthmen under guidance of Sr. Head

Keeper will do the making. Decant the slag
and put bari in metal pool. Pour water
immediately to get the bari welded with the
metal jam.
5 Clean the muck of the runner, expose the

jam, pull the bari with the help of CH crane
to take out the jam.
6 If the rod comes out without jam due to

ineffective cooling or some other problem,
make groove by oxygen lancing. Fasten the CH
crane hook and pull out the jam.
7 Clean the loose held material and muck.
8 Add special runner mass and spread

uniformly to have slope gradient.
9 Ram adequately by hand rammer or

electric vibro rammer.
10 Dry the required portion with CO gas for

1 hr. to 1 1/2 hrs. depending upon depth of
powder added.
11 Runner is ready for tapping
6.4.3
ACTIVITY KEY POINTS
Syphon hole making

___________________________________________________________________________________
1 Arrange water bonded clay
2 If syphon hole gets eroded slag starts
going towards metal side.
3 Scrub of the old & burnt clay from the

skimmer plate and clean it.
4 Place the format below the skimmer plate.
5 Start adding clay around the mould/format

and skimmer plate.
6 Compact the clay by ramming after adding

dry sand.
7 Remove the format and ram further around

the hole.
8 Start drying by coke oven gas immediately

otherwise clay will fall down. Dry for an
hour.
9 The syphon hole is ready for tapping.

6.4.4
ACTIVITY KEY POINTS
Syphon pit making
1 If there is a metal pool in the pit it is

to be made.
2 Insert bari after decanting slag and cool

it with water.
3 Take out the jam as in 9.1.2.
4 Clean and add special RMP.
5 Ram it properly and maintain slope for full

drainage.
6 Dry it with coke oven gas for about 1 hour.
7 Pit is ready for tapping.
IMPORTANT Furnace shift incharge shall check

the runner after cleaning, for any damage of
side wall / bottom bricks dislodged during
jam removal. He shall inform shift manager
/furnace incharge for necessary action and
log in the furnace log book for future
reference.

___________________________________________________________________________________
6.4.5
ACTIVITY KEY POINTS
Metal runner making

1 Cool the runner by water spraying water.
2 Remove solidified metal jams manually or

with the help of CH crane.
NOTE 3: Bari can be inserted if metal pool is

more.
3 Clean the runner and add ordinary or

special runner mass.
4 Spread it properly for maintaining slope

and ram it.
5 Dry it properly.
6 Runner is ready for tapping.
6.4.6
ACTIVITY KEY POINTS
Rocking runner
1 Insert rod after decanting slag if any.
Cool it properly by adding water.
2 Remove the jam with the help of telpher

crane and clean properly.
3 Make the spouts with sic water bond clay.
4 Add special RMP, level and raw it properly

to give the correct shape.
5 Dry with coke oven gas for 1 1/2 hrs.to 2

hrs. depending upon the depth of jam.
NOTE 4: In any above runners if the metal

pool is high and lot of water has been added.
Dry the naked runner first before adding
special RMP to avoid boiling.
IMPORTANT While making rocking runner

special care shall be taken to keep
sufficient clearance between rocking runner
side and metal spout.
6.4.7

___________________________________________________________________________________
ACTIVITY KEY POINTS
Slag runner making

1 Clean the runner after removing slag jams
and metal jams if any.
2 Add ordinary runner mass. Level it to give

a slope.
3 Ram it properly. No need of heating.
6.4.8
ACTIVITY KEY POINTS
Making of spouts 1. Check the spouts after each cast and, if

1. Metal spout needed, repair/make it.
2. RR spout
3. Slag spout 2. Clean and make with SiC hydrous clay.
4. Periwal runner
spout 3. Above this add spl./ordinary RMP.
4. Dry metal spout before tapping to avoid

boiling.
IMPORTANT SAFETY FACTOR: While inserting

bari for taking out metallic jam in any
runner, ensure that the bari/rod is dry and
warm to avoid explosion and accident.
6.5
ACTIVITY KEY POINTS
Cast house preparation

(Without making)
1. Check the TH condition. TH ring should

be clear and distinct.
2. Remove the jam in & around TH and main

runner.
3. Dress the runner with sand.
4. Remove jam of slag head, perival exit and

perival runner.

___________________________________________________________________________________
5. Close the perival by runner sand.
6. Check the height of metal & slag head.

Keep slag head 100-150mm above metal head.
7. Clean the slag runner and close cutters if

provided. Make a sand dam in slag head.
8. Remove the jam of metal runner and close

cutters if provided.
9. Fill the mudgun and check that adequate

clay is coming out of nozzle. See there is
no leakage from nose reducer interface or
reducer-barrel interface. Cover the reducer
hinge with M/G clay to avoid jamming.
10. Check all the movements of M/G, Drill

machine, rocking runners & pusher cars, check
all coupling bolts. In case of any problem
inform concerned maintenance shift I/C and
shift manager.
11. Keep nose sleeve and asbestos rope for

emergency purposes.
12. The cast house is ready for tapping.
NOTE 5 : Drilling machine shall be checked

just after closing TH.
6.6
ACTIVITY KEY POINTS
Checking of
hydraulic drilling
machine & mud gun
1. Check that required air pressure for

drill operation is there.
2. Check that air is coming through the drill

rod and drill machine is working normally in
both rotation and percussion mode.
3. Check that air compressor is working.
4. Check that hydraulic pressure is perfect

and pumps are working normally.

___________________________________________________________________________________
5. Check the centering of drill machine.
6. The furnace shift incharge shall check/get

checked the equipments.
6.7
ACTIVITY KEY POINTS
Opening of
tapping
1. Ensure that the CH is ready
2. Check that metal ladles and slag ladles

are properly placed below spouts, where
pusher cars are provided. Ladles must be
coupled properly.
3. If slag is taken in SGP, check runner &

spout and inform SGP personnel.
4. Ask electrician to attend tapping. The

furnace shift incharge will check the
schedule and if it is due will ask his Sr.
Head Keeper and crew to open tapping.
5. Turn the drill machine to drilling

position.
6. The Sr. Head Keeper will position the

drill at the centre of TH with the help of
hearthmen and drill the TH to the maximum
possible extent without damaging the drill
machine. Remove the drill machine.
7. If tapping does not open, connect 1/4"
lancing pipe with oxygen hose and start

lancing till it softens or opens.
NOTE 6 : Lancing should be straight to the

drilled TH and also in drilling direction.
8. Poke the TH manually with poking rod or

percussion rod (for hydraulic drill machine)
to normalise the flow.
9. Switch on "TAPPING" signal.
6.8
ACTIVITY KEY POINTS

___________________________________________________________________________________
Sampling
1. Take sample of metal and slag with the
help of dry & heated sample spoon and mould.
Take sample after 20-30 minutes of slag
flowing.
2. Send to sample to R&C Laboratory for

analysis.
NOTE 7 : The Sr. Head Keeper and his crew

will remain alert during tapping to face any
eventuality.
6.9
ACTIVITY KEY POINTS
Closing of
tapping
1 Once the furnace is dry close tapping.
2 Check the TH ring, it should be intact.
3 Check that adequate clay is coming out of

mudgun nozzle by pushing out some clay.
4 Turn the mudgun to the taphole in closing

position, holding the nozzle over the
taphole. Push adequate clay to get the
required TH length (Fce 1 - 3 = 2.0 m and 4 -
7 = 2.2 m)
5 Check the ladle in perival spout position

and open perival. Poke it to drain fully.
6 Switch off the tapping signal and inform

production control. Log the same in FFCR log
book.
IMPORTANT
1 If the TH ring is not proper and damaged,

M/G will not sit properly reduce blast and
close tapping. In case of non-closure, take
the M/G in parking position, reduce blast.
Wrap the nose with asbestos rope and put
hydrous clay. Close the tapping.
2 If nose has burnt due to any reason push

clay first, insert the nose sleeve and close

___________________________________________________________________________________
tapping.
3 Inform shift manager and arrange for

sufficient number of metal /slag ladles to
avoid falling of metal / slag on the track.
6.10
ACTIVITY KEY POINTS
Perival
holding
1 In BF 4, 5, 6 & 7 perival shall not be
opened after each cast in castable runners.
In such case perival shall be hold.
2 After closing of tapping put paddy husk in

main runner and syphon pit to keep the slag &
metal liquid at top surface.
3 Clean the TH area properly. Before opening

the cast check that the upper layer of metal
& slag is liquid and there is proper
connection when tapping is opened.
4 Keep one metal ladle empty below the

perival spout which will take care of
accidental self opening of perival.
6.11
ACTIVITY KEY POINTS
Tap hole
changing
Where two tapholes are provided change tap
hole for the following reasons.
1 Break down of any equipment viz M/G, drill

machine or SGP in some cases.
2 Cast house preparation is in progress in one

tap hole.
3 Scheduled opening.
The furnace shift incharge shall take

decision in consultation with the Shift
Manager/Furnace Incharge.

___________________________________________________________________________________
6.12
ACTIVITY KEY POINTS
Flushing of top
slag through monkey
Flushing of top slag shall be done as per
requirement of furnace operation in single
tap hole furnaces and in emergency in other
furnaces.
1 Remove the stopper and clean the monkey

hole.
2 Check the stopper alignment ( it should

freely go into monkey and sit in the centre
of monkey).
3 Make the hole with hydrous clay and patch

clay around IC and MC to protect these from
damage.
4 Check the runner slag is cleaned and ladle

is in position.
5 Open the monkey by poking or lancing as per

requirement.
6 When monkey starts blowing or the ladles

are filled, close the monkey by lowering
stopper into monkey.
NOTE 8 : If monkey burns during flushing,

close monkey at the earliest.
NOTE 9 : If monkey does not close
1 if monkey is not burnt, clean the monkey

hole area so that stopper goes freely into
monkey, reduce blast pressure and close
monkey.
2 if monkey is burnt, reduce water so that

foaming of slag is reduced, clean the monkey
hole area, close monkey and increase monkey
water.
NOTE 10 : If monkey stopper is burnt, close

monkey with hand stopper after reducing blast
pressure.

___________________________________________________________________________________
6.13 IMPORTANT
PROBLEMS USUALLY FACED DURING TAPPING
Short or Weak Taphole - If the taphole is short and flow of

metal & slag is very fast, reduce blast immediately taking care
of the furnace and seeing tuyere condition. Timely blast
reduction will help in avoiding coke rush also. If the taphole
is weak and tapping is continuing with splashes of metal and slag
which may create drainage problem, reduce blast in ratio of tap
hole length/flow of metal.
6.13.1 DOUBLE STREAM
If the during tapping metal & slag starts coming in two or more
stream, poke immediately to make single stream. If double stream
continues, tapping shall be closed at the earliest.
6.13.2 SPILLAGE OF METAL & SLAG AND COKE RUSH
If due to any reason there is spillage of metal and slag in the

CH or below the track which can create hindrance to further
tapping or can cause closing problem, reduce blast and close
tapping immediately even in not dry condition.
If there is a tendency of coke rush adjust blast regime and top

pressure to tackle it.
7.0 RECORDS
Parameters related to taphole condition, tapping details shall be

logged in furnace log book.


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DOC No.

CAST HOUSE PREPARATION

OPENING / CLOSING OF TAPPING

REVISION REVISED BRIEF

03 04 Article TD GUPTA PK DWIVEDI P GAUTAM P GAUTAM

REVISIONS ARE NOT PERMITTED WITHOUT THE PRIOR APPROVAL OF THE

DISTRIBUTION OF CONTROLLED COPIES

COPY NO DISTRIBUTION LOCATION REMARKS

1 MANAGEMENT REP. OFFICE OF THE M R FOR RECORD

2 HEAD OF DEPTT OFFICE OF THE HOD FOR CONTROL

3 I/C FURNACES OFFICE OF THE FOR CONTROL

4 SHIFT MGR PRODUCTION CONTROL FOR CONTROL

5 MASTER HEARTHMAN FFCR FOR

6 MASTER HEARTHMAN FFCR FOR

7 MASTER HEARTHMAN FFCR FOR

8 MASTER HEARTHMAN FFCR FOR

9 MASTER HEARTHMAN FFCR FOR

10 MASTER HEARTHMAN FFCR FOR

11 MASTER HEARTHMAN FFCR FOR

REVISIONS ARE NOT PERMITTED WITHOUT THE PRIOR APPROVAL OF THE

The runners consist the following parts.

Cast house can be defined as a network of runners originating

This work instruction shall cover the preparation of cast house

1 SOP on tapping of furnace

BF - Blast Furnace TH - Tap Hole

Master hearth-man (Shift) of the concerned furnace under guidance

REVISIONS ARE NOT PERMITTED WITHOUT THE PRIOR APPROVAL OF THE

1 All runners must be dry to avoid blasting.

6.2 SAFETY APPLIANCES

6.3 WORKING PROCEDURE

ACTIVITY KEY POINTS

6.4 CAST HOUSE MAKING

b)In twin taphole fces (4-7) main runner up to R/R to be made by

2 If tap hole is deep by around 4-5" with

REVISIONS ARE NOT PERMITTED WITHOUT THE PRIOR APPROVAL OF THE

3 Arrange frame mass (TH gola)

4 Cool tap hole and then break it and its

5 Fix TH gola around the broken tap hole in

6 Continue the process of. gola fixing and

IMPORTANT - TH gola should be properly

7 Bring the mudgun to tapping closing

8 Again ram the surrounding area and take

9 Cover the area around arch by thin layer

10 Fire the TH with coke oven gas for 1-1/2

11 The tap hole is ready for tapping.

NOTE 1 : Where hydraulic drilling machine has

NOTE 2 : Mud gun centering shall be checked

IMPORTANT : After the TH is broken the

REVISIONS ARE NOT PERMITTED WITHOUT THE PRIOR APPROVAL OF THE

ACTIVITY KEY POINTS

Main runner making

1 Main runner is divided into three parts

2 The Fce shift incharge takes decision of

3 Demand and arrange special runner mass.

4 The hearthmen under guidance of Sr. Head

5 Clean the muck of the runner, expose the

6 If the rod comes out without jam due to

7 Clean the loose held material and muck.

8 Add special runner mass and spread

9 Ram adequately by hand rammer or

10 Dry the required portion with CO gas for

11 Runner is ready for tapping

ACTIVITY KEY POINTS