STANDARD OPERATING PROCEDURE AND SAFETY
GUIDE FOR FURNACES
(Located in Rm. C-23 Head Hall)
Prepared
June 16, 2010
Table of Contents
1. Scope ........................................................................................................................................4
1.1 Objective ............................................................................................................................4
1.2 Regulations ........................................................................................................................4
2.Apparatus Overview and objective ...........................................................................................4
2.1 Apparatus overview ...........................................................................................................4
3. Hazards and control evaluation ..............................................................................................11
3.1 Possible fire event ............................................................................................................11
3.2 Ventilation........................................................................................................................12
3.3 Kinetic, thermal & accoustic............................................................................................12
3.4 Electrical ..........................................................................................................................12
3.5 General, physical & equipment concerns ........................................................................13
3.6 Access ..............................................................................................................................13
3.7 Training ............................................................................................................................14
3.8 Personal protective equipment .........................................................................................15
4. Operation................................................................................................................................16
4.1 Qualified personnel ..........................................................................................................16
4.2 Experiment preparation ....................................................................................................16
4.3 Lab instructions ................................................................................................................16
4.4 Operating procedure.........................................................................................................22
5. Inspections .............................................................................................................................25
5.1 Operational & Periodic inspections .................................................................................25
6. Typical test .............................................................................................................................26
Appendix A: Type 47900 & 48000 furnaces operation manual ................................................27
Appendix B: Experiment field notes sheet ................................................................................28
ii
C-23, Head Hall floor plan
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1. Scope
1.1 Objective
This standard operating procedure is intended to provide operating
instructions and safety information for the Department of Mechanical
Engineering’s Furnace apparatus located in C-23, Head Hall. This document
is intended as a guideline and supplement to proper training that must be
provided by qualified personnel before the apparatus is operated. The aim of
this document is to ensure that safe work practices have been developed for
the furnace experimental work. This SOP is primarily concerned with the
apparatus operating procedure, the hazards involved with the apparatus use
and safety precautions that must be taken to avoid injuries.
1.2 Regulations
This document has been developed in accordance with the Environmental
Health and Safety Office of the University of New Brunswick.
2. Apparatus Overview and Objective:
2.1 Apparatus overview
There are four different models of furnaces installed in C-23 Room. The
model name and number are given as follows:
Model name
a.
b.
c.
d.
Model number
Single set point models with OTP
8 Segment programmable models with OTP
PYRADIA
PYRADIA
F47915
F48025-80
100 SI
50 SI
a)
Single set point models with Over Temperature Protection
(F47915):
There are three F47915 furnaces installed in C-23 room. The F47915
furnace is general purpose laboratory and heat treating furnace. It consists of
a vented heating chamber. The vent on the top of furnace allows any fumes
or gases produced in the heating chamber to escape. The heating chamber is
heated by open coil electric resistance elements and is insulated with
ceramic fiber insulation. The insulation prevents the outer surface of
furnace from reaching extreme temperatures.
4
The F47915 furnace has a temperature controller. The temperature
controller is located under the heating chamber of furnace.
Figure 1: Furnace F47915
The F47915 furnace has a safety switch on the door for operator safety. The
safety switch shuts off the power to the furnace heating elements whenever
the furnace door is opened. Please refer to Appendix “A” to see the general
specifications of furnace type F47915.
5
Figure 2: Furnace F47915 electric resistance elements and ceramic
fiber insulation
The furnace temperature digital display displays the acquired temperature of
furnace once setpoint is set by the user.
b)
8 Segment programmable models with OTP (F48025-80):
There are three, 8 segment programmable models. They consist of a
microprocessor-based three mode PID (Proportional, Integral, Derivative),
programmable temperature controller with temperature overload protection
and appropriate output switching devices to control the furnace. The
Temperature digital display displays heating chamber (upper display) and
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set point (lower display) temperatures. The programmable controller can be
used as a single set point controller or as a programmable controller. The 8
segment digital model enables eight segments of programming.
The F48025-80 furnace has a temperature controller. The temperature
controller is located under the heating chamber of furnace. The furnace also
has a door safety switch for operator safety. The door safety switch removes
the power to the furnace heating elements whenever the furnace door is
opened for operator’s safety.
Figure 3: Furnace F48025-80
The furnace temperature digital display displays both the set and acquired
temperatures of the furnace.
7
Figure 4: Furnace F48025-80 electric resistance elements and
ceramic fiber insulation
Please refer to Appendix “A” to see the general specifications of furnace
type F48025-80.
c)
PYRADIA 100 SI:
This furnace has a Temperature digital display which displays the
acquired temperature, once the desired temperature is set. The main console
of the furnace consists of operating controllers along with the temperature
digital display. The heating chamber is heated by open coil electric
resistance elements and is insulated with ceramic fiber insulation. The
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insulation prevents the outer surface of furnace from overheating for safety
of the operator. This furnace also has a door lock for the operator’s safety.
Figure 5: PYRADIA 100 SI furnace
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Figure 6: PYRADIA 100 SI furnace heating coils and ceramic
fiber insulation
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d)
PYRADIA 50 SI:
This model of PYRADIA furnace has the same controller as 100 SI only
smaller in size and heating capabilities.
Figure 7: PYRADIA 50 SI furnace
3. Hazards and Controls Evaluation:3.1 Possible fire event
The furnaces are associated with very high temperatures.
To prevent a fire, it is recommended that the furnace should not be operated
for more than three hours if it is operating in the temperature range of
1093°C to 1200°C. It is however acceptable to operate it for more than 3
hours if the furnace is operating at a temperature below 1093°C. This is true
only for F47915 and F48025-80 furnace models. The PYRADIA model
100SI and 50SI should not be operated continuously for more than 3 hours at
elevated temperature (1100°C) as well.
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Be certain that there is no combustible material near the furnace while it is
in operation. In the event of fire, evacuate the room immediately. Pull the
nearest fire alarm (see C-23 floor plan). Should you return to attempt to
extinguish the fire, do not do so alone. Make only one attempt at
extinguishing and if unsuccessful leave the facility immediately. If
successful stay at the scene and have someone alert the Security and Traffic
department (ph. # 4830) and the Environmental Health and Safety office.
(ph. # 5075). Please refer to C-23, Head hall floor plan to see the locations
of fire extinguisher, fire alarm pull station and first aid kit.
3.2 Ventilation
With exception of the fume hoods, there are no room exhaust fans in lab C23. The room is centrally ventilated. When the furnaces are in operation, the
doors of room C-23 are kept opened to introduce fresh air into the room and
exhaust the hot air from the room. If the furnace contents produce smoke,
give off gas, or produce odors of any kind then the furnace should be placed
in an operating fume hood with the fume hood door fully closed.
3.3 Kinetic, Thermal and Acoustic
The furnaces are not associated with kinetic and acoustic hazards.
The furnaces are associated with very high temperatures and pose a serious
thermal threat if they are not handled carefully by the operator. Wear all the
recommended safety equipment while using the furnace. It is essential to use
forceps or tongs when inserting or removing the furnace specimen. A face
shield must be worn while the furnace door is open to protect your face from
harmful heat radiation. Use large forceps or tongs with a large furnace, like
the PYRADIA 100 SI.
3.4 Electrical
There is no electrical hazard associated with the furnace if furnace is
handled carefully and instructions are followed. In an emergency, you
should shutdown the furnace power switch and unplug the AC power cable
from electrical outlet.
Models F47915 and F48025-80 are well designed with safety in mind. Both
have a safety switch on the furnace door which cuts power to the heating
elements when opened.
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The PYRADIA models 100SI and 50SI are not designed with a door safety
switch, so do not touch the heating elements of these furnaces by hand or
with any metal object while they are energized.
Always unplug the PYRADIA model 100SI furnace after shutting it off. The
furnaces should be checked regularly for bare or cut electrical wires each
time prior to operating them.
3.5 General, physical and equipment concerns
The operator shall not wear open toed shoes while operating the furnace as
the heat treated specimen could fall on the operator’s foot, resulting in a
serious burn.
The heat treated specimens should be placed on specimen holders, which
are good insulators. Do not place the heat treated specimen on any table or
bench of Laboratory until it achieves a room temperature.
Figure 8: Heat treated specimen holder
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3.6 Access
All personal in the C-23 laboratory should be preauthorized by the faculty in
charge or under the supervision of authorized personal (lab technician or
teacher assistant). No person other than the faculty in charge or specifically
authorized personal are permitted to make alterations to, or run experiments
with the furnaces.
3.7 Training
All individuals using the furnace shall be required to receive training in the
proper operation and maintenance of the furnace and its controls. Training
will include such topics as the complete operation and controls of the
furnace. Training programs shall be administered by qualified personnel at
UNB.
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3.8 Personal Protective Equipment
Following personal protective equipments are mandatory while doing the
experiment:
• Safety gloves
• Face shield
• Forceps (small and large)
Figure 9: Personal protective equipment
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4. Operation
4.1 Qualified Personal
These notes in the operation section will provide a guideline to the
individual that has been trained by a qualified personal to operate the
furnaces of all models. Only after the individual has been trained and feels
confident with the furnace startup, operation and shutdown procedures
should he attempt to operate the furnace using these notes. Do not proceed if
you are not properly trained or are unsure in any manner of the safety
operation and safety concerns.
4.2 Experiment preparation
Following steps should be carried out to prepare for the experiment:•
Ensure that the system’s physical integrity is not compromised (cut or
bare furnace power cable, furnace surface cracks etc.)
•
Ensure that there is no combustible material present near the
furnace before powering it
•
Wear all the safety equipments and ensure that the specimen holders
for holding the heat treated specimens are in place before starting the
furnace
4.3 Lab Instructions
4.3.1 Instructor Responsibilities
The SOP of furnaces should be read and understood. This document
provides all the necessary information regarding the furnaces startup
procedure, operation, hazards involved & safety precautions to be taken
while using furnaces of all models. The lab instructor shall remain in the
room while the experiment is in progress. After the full students group has
assembled and before any explanation has begun the instructor should relay
all safety precautions and hazards as outlined in section 3. Inform them that
they must contact the instructor should any problems or concerns arise
during the experiment. Make the group aware of the fire extinguisher
locations, fire alarm pull stations and exits. Any student from the group
missing his any personal protective equipment should not be allowed by the
instructor to enter the laboratory C-23 and proceed with the experiment.
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4.3.2 Data Locations and Functions of buttons and indicators
The data display locations and functions of buttons and indicators of all the
four models of furnaces are discussed as follows:
a)
F47915 Furnaces Single set point models with (OTP):
Please refer to figure 10 to see the description of displays and buttons of this
model of furnace:
•
OP1 (Output 1) - Illuminates on the Digital display when the furnace
is switched ON (furnace functions normally and displays set or
acquired temperature when OP1 is illuminating)
•
OP2 (Output 2) - Illuminates on the Digital display below OP1
indicating warning - When the temperature is set a certain percentage
less than the furnace acquired temperature then OP2 illuminates
indicating warning to the operator
•
PAGE button - Page button allows the user to select new list of
parameters
•
SCROLL button - Scroll button allows user to select a parameter
within a list of parameters
•
DOWN button - Pressing DOWN button decreases the temperature
value and releasing DOWN button sets the desired (set point)
temperature value
•
UP button - Pressing UP button increases the temperature value and
releasing UP button sets the desired (set point) temperature value
Please refer to Appendix “A” to see the details and description of controller
parameters, alarms, tuning and single ramp and dwell program of Single set
point models (F47915) with over temperature protection (OTP).
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Figure 10: Single set point with OTP (F47915) Model buttons and
displays
b)
F48025-80 Furnaces 8 Segment programmable models with
(OTP):
Please refer to figure 11 to see the description of displays and buttons:
•
OP1 (Output 1) - Illuminates on the Digital display when the furnace
is switched ON (furnace functions normally and displays setpoint
value in the lower display and acquired temperature value in the
upper display when OP1 is illuminating)
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•
AUTO/MANUAL Mode - In AUTO mode, the furnace automatically
adjusts to keep the furnace temperature value at the setpoint. Manual
mode is disabled in this furnace
•
RUN/HOLD Button - Run/Hold button starts the program once
pressed - RUN light illuminates. Pressing button then holds the
program, HOLD light will illuminate. Pressing button again
cancels HOLD and switches to RUN mode illuminating RUN light.
Pressing and holding button down for 2 seconds exits the program,
and turns off both RUN and HOLD lights. At the end of program
RUN light flashes.
•
PAGE button - Page button allows the user to select new list of
parameters
•
SCROLL button - Scroll button allows the user to select a parameter
within a list of parameters
•
DOWN button - Pressing DOWN button decreases the temperature
value in lower display and releasing DOWN button sets the desired
temperature value (setpoint) in lower display
•
UP button - Pressing UP button increases the temperature value in
lower display and releasing UP button sets the desired temperature
value (setpoint) in lower display
Please refer to Appendix “A” to see the details and description of
controller parameters, alarms and programming the controller of 8
Segment programmable models (F48025-80) with over temperature
protection (OTP).
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Figure 11: F48025-80 Furnaces 8 Segment programmable
models with (OTP)
c)
PYRADIA 100 SI & PYRADIA 50 SI:
Please refer to figure 12 to see the description of displays and buttons:
•
START - When pressed once starts the cycle set by the operator,
Temp/Off light will light up indicating furnace heating chamber
temperature. Pressing it again, holds the program, Pressing it once
more ends the program
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•
SELECT - Allows user to set and select different parameters. When
pressed once the TEMP/OFF light blinks demanding the user to set
the setpoint temperature using UP and DOWN buttons and once set
then press and hold ENTER button until the displayed temperature
blinks to select the setpoint temperature. Pressing SELECT button
again causes the DELAY TIME light to blink, enter the delay time in
Hours: Minutes using UP and DOWN keys. Press and hold ENTER
button until the displayed value blinks to select the delay time. Repeat
the same procedure for selecting RATE/HR and HOLD TIME.
•
DOWN button - Pressing DOWN button decreases the value on
display
•
UP button - Pressing UP button increases the value on display
•
ENTER button - Pressing and holding ENTER button for 2 seconds
sets the value
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Figure 12: PYRADIA 100SI and 50SI buttons and display
4.4 Operating Procedure
4.4.1 Operation of Furnaces
All the models of furnaces operate in a quite similar way but with a few
differences. The operation of all the models of furnace is discussed below as
follows:
a)
F47915 Furnaces Single set point models with (OTP):
After preparing for the experiment as mentioned in section 4.2, follow these
steps to operate this furnace model:
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• Turn on the controller by pressing the Power ON/OFF switch (see
figure 10). When the controller is turned ON, it will perform a short
self test and then display the measured (acquired) value on the
Temperature digital display as well as the orange CYCLE light will
turn ON
• Select an OTP value 20° above the working temperature value for
your safety. The operator should set a “Deviation High” alarm value.
To set this value press the SCROLL button until “Idhi” appears on the
display. Press the UP or DOWN buttons to select the OTP value you
desire
• Press and release the UP or DOWN buttons to view the setpoint. Keep
pressing the button in order to change the value and release it when
the desired setpoint value is displayed on the Temperature digital
display. A few seconds after the button is released, the controller will
accept the new set value and revert to the HOME DISPLAY
displaying the acquired temperature value.
Please refer to figure 10 to see the furnace buttons and displays and
also please refer to Appendix “A” to see the details of how to view %
output power and display Units, Alarms, Sensor break protection,
Tuning and Single Ramp and Dwell program
b)
F48025-80 Furnaces 8 Segment programmable models with
(OTP):
After preparing for the experiment as mentioned in section 4.2, follow
these steps to operate this furnace model:
• Turn on the controller by pressing the Power ON/OFF switch (see
figure 11). When the controller is turned ON, it will perform a short
self test and then display the measured (acquired) value in the upper
display and the desired (setpoint) value in the lower display as well as
the orange CYCLE light will turn ON
• Select an OTP value 20° above the working temperature value for
your safety. The operator should set a “Deviation High” alarm value.
To set this value press the SCROLL button until “Idhi” appears on the
display. Press the UP or DOWN buttons to set the OTP value you
desire
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• Press and Hold the UP or DOWN button in order to change the set
value and release it when the desired setpoint value is displayed in the
lower display
Please refer to figure 11 to see the furnace buttons and displays and
also please refer to Appendix “A” to see the details of how to view %
Output power and display Units, Alarms, Sensor break protection,
Tuning and running the program in 8 segment programmable models
c)
PYRADIA 100 SI & PYRADIA 50 SI:
After preparing for the experiment as mentioned in section 4.2, follow
these steps to operate this furnace model:
• Turn on the controller by pressing the Power ON/OFF switch (see
figure 12). Power indicator red light will illuminate indicating the
furnace is ON
• Then Press the SELECT button, Temp/Off light will start blinking
asking the user to set a temperature value. Use UP and DOWN
buttons to set a value of temperature and then press and hold ENTER
until the set value on digital display blinks
• Press the SELECT button again and delay time Light will start
blinking asking the user to set a Delay time value in Hours: Minutes.
Use UP and DOWN buttons to set a value and then press and hold
ENTER until the set value on digital display blinks
• Press the SELECT button again and Rate/hour Light will start
blinking asking the user to set a Rate/hour value in °F. Use UP and
DOWN buttons to set a value and then press and hold ENTER until
the set value on digital display blinks
• Press the SELECT button again and Hold Time Light will start
blinking asking the user to set a Hold time value in Hours: Minutes.
Use UP and DOWN buttons to set a value and then press and hold
ENTER until the set value on digital display blinks
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• After setting all the parameters, the Temp/Off light will become solid.
At this point if the START button is pressed the program will start
and the furnace will start heating indicated by the Red “Heating” light
indicator and the acquired temperature of furnace will be displayed
on the digital display
4.4.2 Shutdown
The shutdown procedure of all the furnace models is same except the
PYRADIA 100SI model requires some additional steps to shut it
down. Follow the following steps to shutdown the furnaces:
•
Turn OFF the furnace by turning the Power switch OFF (see figures
10, 11 and 12) to see the power switches of all the models of furnace.
This will shutdown the furnace
•
For the PYRADIA 100SI model, also remove the Power cable from
the electrical outlet before leaving the Lab
5.0 Inspection
Inspections at regular intervals will be performed on all the furnaces to
ensure that all the furnaces are kept in a safe and well maintained condition.
The inspection includes checking of any cracks in furnace and regular check
for bare & cut power cables of the furnace
5.1 Periodic & Operational Inspections
Visual inspections are the responsibility of the person who is conducting
experiments on a regular basis with the furnaces and should be carried out
everytime before operating the apparatus. A complete periodic inspection of
the apparatus shall be performed by the person who is conducting
experiments on a regular basis with this apparatus but will alert the faculty in
charge in case of any deficiencies in the apparatus. The deficiencies such as
those listed below shall be examined during both the periodic & operational
inspection and the faculty in charge will determine if the deficiencies will
affect the safe operation of the apparatus.
a. Functions, digital display and warning labels
b. Worn, cut or bare power cables
c. crack or corroded furnace surface
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d. Broken or displaced heating coils
e. Test the functionality of the Door safety switch
f. Pierced ceramic insulation
6.0 Typical Tests
The actual test procedure will be outlined in the lab script as issued by the
professor. A typical test includes heat treatment of different materials
specimens. A typical field notes sheet that can be used with furnace is in
Appendix ‘B’.
26
Appendix ‘A’
27
Appendix ‘B’
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