Furnace Operator

JOB DESCRIPTION

Furnace Operator

Melting Foundry Industry Ductile Iron Pipe Manufacturing Reports to Induction Furnace Engineer Melting Supervisor Shift Rotational as required

To operate monitor and maintain the Induction Furnace system used for melting scrap and pig iron for ductile iron pipe production ensuring safe efficient and continuous furnace operation with strict process control

• Furnace Operation Operate medium frequency induction furnaces as per melting schedule Able to handle multi task more then one function Also Training employees to perform different job functions Responsible for all activities of melting section Responsible for proper quantity of alloy addition to the furnace Charge scrap pig iron ferro alloys and additives as per charge mix instructions Monitor melt temperature chemical composition superheat power consumption and melting time Assist in tapping molten metal into ladles safely and efficiently Ensure proper slag removal and maintain slag condition Record all melting parameters in SCADA
• Training employees to perform different job functions
• Responsible for all activities of melting section
• Responsible for proper quantity of alloy addition to the furnace Charge scrap pig iron ferro alloys and additives as per charge mix instructions
• Monitor melt temperature chemical composition superheat power consumption and melting time
• Assist in tapping molten metal into ladles safely and efficiently
• Ensure proper slag removal and maintain slag condition
• Record all melting parameters in SCADA

• Perform routine inspection of furnace coils lining cooling system and power supply units
• Check water-cooling systems pumps and flow meters for proper operation
• Report any abnormal noise vibration overheating or leakage to maintenance engineers
• Assist during coil replacement lining installation and refractory checks
• Clean furnace pit platform and work area regularly

• Follow all safety procedures related to molten metal handling and furnace operation
• Use PPE face shield aluminized jackets gloves heat-resistant boots etc
• Ensure proper grounding and interlock functioning before furnace start
• Adhere to ISO 5S and plant safety standards

• Monitor chemical composition and adjust alloys during melting
• Maintain target carbon silicon magnesium for DI and temperature as instructed
• Coordinate with the metallurgy quality department for sample analysis
• Ensure molten metal quality is suitable for centrifugal casting and finishing operations

• Maintain furnace daily operation logs temperature power input materials downtime
• Report furnace downtime failures and production delays
• Document refractory life coil performance and melting efficiency

• Knowledge of induction furnace operation medium high-frequency
• Understanding of melting practice for ductile iron
• Ability to read process parameters and interpret melt chemistry
• Basic electrical mechanical troubleshooting skills
• Familiar with hydraulics cooling systems and PLC basics optional
• Strong safety awareness and teamwork

• Experience ITI in Foundry Metallurgy Mechanical Electrical or relevant trade 5 10 years experience in induction furnace operations preferably in ductile iron steel foundry
• Experience with 10 20 ton furnaces is an added advantage

• Ability to work in high-temperature environments Comfortable with heavy PPE Ability to work in rotating shifts

• Foundry melting shop with high heat dust and noise levels Coordination with casting metallurgy and maintenance teams