Tap Metal Quality Inspection

• Document No. 111

• Tapfloor Quality Overinspection

• Client / Site

• Conducted on

  Date

• Prepared by

First tap on shift

• Capture time preparation started.

  Date

• Was OSMH on time for casting bay preparation?

  3 taps

  2 taps

  1 tap

  Prepared with fresh material

• Is skimmer sand available?

  Yes

  No

• Who built the skimmer?

• Did the tap floor co-ordinator observe and inspect the moisture content of casting bay material?

  Yes

  No

• What material was used to build the skimmer?

  Select Red Sand White sand RRP fine slag RRP & White sand mix RRP & Red sand mix White & Red sand mix RRP & White & Red mix

  • Red Sand
  • White sand
  • RRP fine slag
  • RRP & White sand mix
  • RRP & Red sand mix
  • White & Red sand mix
  • RRP & White & Red mix

• Is the casting bay prepared with 200mm overflows?

  Yes

  No

• What material was used to prepare the casting bay?

  Select Red Sand White sand RRP fine slag RRP & White sand mix RRP & Red sand mix White & Red sand mix RRP & White & Red mix

  • Red Sand
  • White sand
  • RRP fine slag
  • RRP & White sand mix
  • RRP & Red sand mix
  • White & Red sand mix
  • RRP & White & Red mix

• How many times have we tapped into this casting bay material?

  3 taps

  2 taps

  1 tap

  Prepared with fresh material

• Capture time taphole opened.

  Date

• Capture the accumulated MW input.

• Which material tapped first?

  Slag

  Metal

• What was the condition of the tap?

  Contaminated

  Clean

• Is the metal clean - Yes<br>Contaminated we need slag pickers to clean - No

  Yes

  No

• List any abnormal tapping conditions.

  Select Problems with spout Shortlaunder issues Skimmer block failure Skimmer froze Skimmer plate fell Metal went to slagbay Slag went to casting bay Skimmer boiling Casting bay boiling Raw mix tapping Slag cold and thick Metal cold and slow flow Metal under carbon None

  • Problems with spout
  • Shortlaunder issues
  • Skimmer block failure
  • Skimmer froze
  • Skimmer plate fell
  • Metal went to slagbay
  • Slag went to casting bay
  • Skimmer boiling
  • Casting bay boiling
  • Raw mix tapping
  • Slag cold and thick
  • Metal cold and slow flow
  • Metal under carbon
  • None

• How many ingots was tapped?

• Capture time ingots are removed from casting bay.

  Date

• Is the tap number identification board available, visible and updated in the lay down area?

  Yes

  No

• Was the ingots placed correctly in line in a single row?

  Yes

  No

• Capture time slag pickers started cleaning the ingots.

  Date

• Is the tap analysis available?

  Yes

  No

• Capture the tap Si analysis.

  Select 0.5 - 1.0 % 1.0 - 1.5 % 1.5 - 2.0 % 2.0 - 2.5 % 2.5 - 3.0 % 3.5 - 4.0 % 4.5 - 5.0 % 5.0 - 6.5 %

  • 0.5 - 1.0 %
  • 1.0 - 1.5 %
  • 1.5 - 2.0 %
  • 2.0 - 2.5 %
  • 2.5 - 3.0 %
  • 3.5 - 4.0 %
  • 4.5 - 5.0 %
  • 5.0 - 6.5 %

• Capture slag liquidus temperature.

• Capture metal liquidus

• Capture Tap Sulphur analysis.

  Select 0.1 - 0.2 % 0.2 - 0.3 % 0.3 - 0.4 % 0.4 - 0.45 % 0.45 - 0.50 % 0.5 + %

  • 0.1 - 0.2 %
  • 0.2 - 0.3 %
  • 0.3 - 0.4 %
  • 0.4 - 0.45 %
  • 0.45 - 0.50 %
  • 0.5 + %

• Was the metal inspected and approved by Services supervisor?

  Yes

  No

• Capture a photo of the ingot row showing quality and identification board.

  Media

• Capture name of who approved the metal to be loaded.

• Capture time ingots are removed from lay down area.

  Date

• Is the weighbridge operator informed of the tap number and Si analysis of the metal to be weighed?

  Yes

  No

• To which bunker allocation was metal assigned to?

  4 Max

  5 Max

  6 Max

Second tap on shift

• Capture time preparation started.

  Date

• Was OSMH on time for casting bay preparation?

  Yes

  No

• Is skimmer sand available?

  Yes

  No

• Who built the skimmer?

• Did the tap floor co-ordinator observe and inspect the moisture content of casting bay material?

  Yes

  No

• What material was used to build the skimmer?

  Select Red Sand White sand RRP fine slag RRP & White sand mix RRP & Red sand mix White & Red sand mix RRP & White & Red mix

  • Red Sand
  • White sand
  • RRP fine slag
  • RRP & White sand mix
  • RRP & Red sand mix
  • White & Red sand mix
  • RRP & White & Red mix

• Is the casting bay prepared with 200mm overflows?

  Yes

  No

• What material was used to prepare the casting bay?

  Select Red Sand White sand RRP fine slag RRP & White sand mix RRP & Red sand mix White & Red sand mix RRP & White & Red mix

  • Red Sand
  • White sand
  • RRP fine slag
  • RRP & White sand mix
  • RRP & Red sand mix
  • White & Red sand mix
  • RRP & White & Red mix

• How many times have we tapped into this casting bay material?

  3 taps

  2 taps

  1 tap

  Prepared with fresh material

• Capture time taphole opened.

  Date

• Capture the accumulated MW input.

• Which material tapped first?

  Slag

  Metal

• What was the condition of the tap?

  Contaminated

  Clean

• Is the metal clean - Yes<br>Contaminated we need slag pickers to clean - No

  Yes

  No

• List any abnormal tapping conditions.

  Select Problems with spout Shortlaunder issues Skimmer block failure Skimmer froze Skimmer plate fell Metal went to slagbay Slag went to casting bay Skimmer boiling Casting bay boiling Raw mix tapping Slag cold and thick Metal cold and slow flow Metal under carbon None

  • Problems with spout
  • Shortlaunder issues
  • Skimmer block failure
  • Skimmer froze
  • Skimmer plate fell
  • Metal went to slagbay
  • Slag went to casting bay
  • Skimmer boiling
  • Casting bay boiling
  • Raw mix tapping
  • Slag cold and thick
  • Metal cold and slow flow
  • Metal under carbon
  • None

• How many ingots was tapped?

• Capture time ingots are removed from casting bay.

  Date

• Is the tap number identification board available, visible and updated in the lay down area?

  Yes

  No

• Was the ingots placed correctly in line in a single row?

  Yes

  No

• Capture time slag pickers started cleaning the ingots.

  Date

• Is the tap analysis available?

  Yes

  No

• Capture the tap Si analysis.

  Select 0.5 - 1.0 % 1.0 - 1.5 % 1.5 - 2.0 % 2.0 - 2.5 % 2.5 - 3.0 % 3.5 - 4.0 % 4.5 - 5.0 % 5.0 - 6.5 %

  • 0.5 - 1.0 %
  • 1.0 - 1.5 %
  • 1.5 - 2.0 %
  • 2.0 - 2.5 %
  • 2.5 - 3.0 %
  • 3.5 - 4.0 %
  • 4.5 - 5.0 %
  • 5.0 - 6.5 %

• Capture slag liquidus temperature.

• Capture metal liquidus

• Capture Tap Sulphur analysis.

  Select 0.1 - 0.2 % 0.2 - 0.3 % 0.3 - 0.4 % 0.4 - 0.45 % 0.45 - 0.50 % 0.5 + %

  • 0.1 - 0.2 %
  • 0.2 - 0.3 %
  • 0.3 - 0.4 %
  • 0.4 - 0.45 %
  • 0.45 - 0.50 %
  • 0.5 + %

• Was the metal inspected and approved by Services supervisor?

  Yes

  No

• Capture a photo of the ingot row showing quality and identification board.

  Media

• Capture name of who approved the metal to be loaded.

• Capture time ingots are removed from lay down area.

  Date

• Is the weighbridge operator informed of the tap number and Si analysis of the metal to be weighed?

  Yes

  No

• To which bunker allocation was metal assigned to?

  4 Max

  5 Max

  6 Max

Third tap on shift

• Capture time preparation started.

  Date

• Was OSMH on time for casting bay preparation?

  Yes

  No

• Is skimmer sand available?

  Yes

  No

• Who built the skimmer?

• Did the tap floor co-ordinator observe and inspect the moisture content of casting bay material?

  Yes

  No

• What material was used to build the skimmer?

  Select Red Sand White sand RRP fine slag RRP & White sand mix RRP & Red sand mix White & Red sand mix RRP & White & Red mix

  • Red Sand
  • White sand
  • RRP fine slag
  • RRP & White sand mix
  • RRP & Red sand mix
  • White & Red sand mix
  • RRP & White & Red mix

• Is the casting bay prepared with 200mm overflows?

  Yes

  No

• What material was used to prepare the casting bay?

  Select Red Sand White sand RRP fine slag RRP & White sand mix RRP & Red sand mix White & Red sand mix RRP & White & Red mix

  • Red Sand
  • White sand
  • RRP fine slag
  • RRP & White sand mix
  • RRP & Red sand mix
  • White & Red sand mix
  • RRP & White & Red mix

• How many times have we tapped into this casting bay material?

  3 taps

  2 taps

  1 tap

  Prepared with fresh material

• Capture time taphole opened.

  Date

• Capture the accumulated MW input.

• Which material tapped first?

  Slag

  Metal

• What was the condition of the tap?

  Contaminated

  Clean

• Is the metal clean - Yes<br>Contaminated we need slag pickers to clean - No

  Yes

  No

• List any abnormal tapping conditions.

  Select Problems with spout Shortlaunder issues Skimmer block failure Skimmer froze Skimmer plate fell Metal went to slagbay Slag went to casting bay Skimmer boiling Casting bay boiling Raw mix tapping Slag cold and thick Metal cold and slow flow Metal under carbon None

  • Problems with spout
  • Shortlaunder issues
  • Skimmer block failure
  • Skimmer froze
  • Skimmer plate fell
  • Metal went to slagbay
  • Slag went to casting bay
  • Skimmer boiling
  • Casting bay boiling
  • Raw mix tapping
  • Slag cold and thick
  • Metal cold and slow flow
  • Metal under carbon
  • None

• How many ingots was tapped?

• Capture time ingots are removed from casting bay.

  Date

• Is the tap number identification board available, visible and updated in the lay down area?

  Yes

  No

• Was the ingots placed correctly in line in a single row?

  Yes

  No

• Capture time slag pickers started cleaning the ingots.

  Date

• Is the tap analysis available?

  Yes

  No

• Capture the tap Si analysis.

  Select 0.5 - 1.0 % 1.0 - 1.5 % 1.5 - 2.0 % 2.0 - 2.5 % 2.5 - 3.0 % 3.5 - 4.0 % 4.5 - 5.0 % 5.0 - 6.5 %

  • 0.5 - 1.0 %
  • 1.0 - 1.5 %
  • 1.5 - 2.0 %
  • 2.0 - 2.5 %
  • 2.5 - 3.0 %
  • 3.5 - 4.0 %
  • 4.5 - 5.0 %
  • 5.0 - 6.5 %

• Capture slag liquidus temperature.

• Capture metal liquidus

• Capture Tap Sulphur analysis.

  Select 0.1 - 0.2 % 0.2 - 0.3 % 0.3 - 0.4 % 0.4 - 0.45 % 0.45 - 0.50 % 0.5 + %

  • 0.1 - 0.2 %
  • 0.2 - 0.3 %
  • 0.3 - 0.4 %
  • 0.4 - 0.45 %
  • 0.45 - 0.50 %
  • 0.5 + %

• Was the metal inspected and approved by Services supervisor?

  Yes

  No

• Capture a photo of the ingot row showing quality and identification board.

  Media

• Capture name of who approved the metal to be loaded.

• Capture time ingots are removed from lay down area.

  Date

• Is the weighbridge operator informed of the tap number and Si analysis of the metal to be weighed?

  Yes

  No

• To which bunker allocation was metal assigned to?

  4 Max

  5 Max

  6 Max

Fourth tap on shift

• Capture time preparation started.

  Date

• Was OSMH on time for casting bay preparation?

  Yes

  No

• Is skimmer sand available?

  Yes

  No

• Who built the skimmer?

• Did the tap floor co-ordinator observe and inspect the moisture content of casting bay material?

  Yes

  No

• What material was used to build the skimmer?

  Select Red Sand White sand RRP fine slag RRP & White sand mix RRP & Red sand mix White & Red sand mix RRP & White & Red mix

  • Red Sand
  • White sand
  • RRP fine slag
  • RRP & White sand mix
  • RRP & Red sand mix
  • White & Red sand mix
  • RRP & White & Red mix

• Is the casting bay prepared with 200mm overflows?

  Yes

  No

• What material was used to prepare the casting bay?

  Select Red Sand White sand RRP fine slag RRP & White sand mix RRP & Red sand mix White & Red sand mix RRP & White & Red mix

  • Red Sand
  • White sand
  • RRP fine slag
  • RRP & White sand mix
  • RRP & Red sand mix
  • White & Red sand mix
  • RRP & White & Red mix

• How many times have we tapped into this casting bay material?

  3 taps

  2 taps

  1 tap

  Prepared with fresh material

• Capture time taphole opened.

  Date

• Capture the accumulated MW input.

• Which material tapped first?

  Slag

  Metal

• What was the condition of the tap?

  Contaminated

  Clean

• Is the metal clean - Yes<br>Contaminated we need slag pickers to clean - No

  Yes

  No

• List any abnormal tapping conditions.

  Select Problems with spout Shortlaunder issues Skimmer block failure Skimmer froze Skimmer plate fell Metal went to slagbay Slag went to casting bay Skimmer boiling Casting bay boiling Raw mix tapping Slag cold and thick Metal cold and slow flow Metal under carbon None

  • Problems with spout
  • Shortlaunder issues
  • Skimmer block failure
  • Skimmer froze
  • Skimmer plate fell
  • Metal went to slagbay
  • Slag went to casting bay
  • Skimmer boiling
  • Casting bay boiling
  • Raw mix tapping
  • Slag cold and thick
  • Metal cold and slow flow
  • Metal under carbon
  • None

• How many ingots was tapped?

• Capture time ingots are removed from casting bay.

  Date

• Is the tap number identification board available, visible and updated in the lay down area?

  Yes

  No

• Was the ingots placed correctly in line in a single row?

  Yes

  No

• Capture time slag pickers started cleaning the ingots.

  Date

• Is the tap analysis available?

  Yes

  No

• Capture the tap Si analysis.

  Select 0.5 - 1.0 % 1.0 - 1.5 % 1.5 - 2.0 % 2.0 - 2.5 % 2.5 - 3.0 % 3.5 - 4.0 % 4.5 - 5.0 % 5.0 - 6.5 %

  • 0.5 - 1.0 %
  • 1.0 - 1.5 %
  • 1.5 - 2.0 %
  • 2.0 - 2.5 %
  • 2.5 - 3.0 %
  • 3.5 - 4.0 %
  • 4.5 - 5.0 %
  • 5.0 - 6.5 %

• Capture slag liquidus temperature.

• Capture metal liquidus

• Capture Tap Sulphur analysis.

  Select 0.1 - 0.2 % 0.2 - 0.3 % 0.3 - 0.4 % 0.4 - 0.45 % 0.45 - 0.50 % 0.5 + %

  • 0.1 - 0.2 %
  • 0.2 - 0.3 %
  • 0.3 - 0.4 %
  • 0.4 - 0.45 %
  • 0.45 - 0.50 %
  • 0.5 + %

• Was the metal inspected and approved by Services supervisor?

  Yes

  No

• Capture a photo of the ingot row showing quality and identification board.

  Media

• Capture name of who approved the metal to be loaded.

• Capture time ingots are removed from lay down area.

  Date

• Is the weighbridge operator informed of the tap number and Si analysis of the metal to be weighed?

  Yes

  No

• To which bunker allocation was metal assigned to?

  4 Max

  5 Max

  6 Max