Master Caster Furnace Operator LPCS 035

Mission:

To efficiently and safely operate the Master Caster and Air Master Melt Furnaces to consistently produce alloys to meet PCC's metallurgical specifications. To produce vacuum ingots and castings.

Principal Accountabilities:

• Preparation
  
  

Objective: To check equipment, and assure accurate proportions of each element in alloys produced in compliance with all Process Control Procedures.

Essential Job Functions:

• Checks vacuum level, power supplies, liners and other furnace systems.
• Prepares metal materials for air master melt and master caster process to meet element proportions per metallurgist schedule.
• Builds Master Heat recipes using an alloy blending system.
• Weighs materials to be melted (Revert and Virgin).
• Uses and updates Electronic Heat Log and Furnace Clocks.
• Loads and Fires Shells in Burnouts in accordance with Requirements (monitors all shell temps throughout cycle).
• Prepare all Charges and Recharges for furnace loading (includes welding of hooks for overhead lifting).
  
  

Marginal Job Function:

• Notifies appropriate personnel of low raw materials levels as needed.
• Orders Raw materials (Revert, Alloy and Elements) as needed for production.
• Melting
  
  

Objective: to operate both the Master Caster and Air Master Melt furnaces in order to complete melting and pouring of ingots and castings.

Essential Job Functions:

• Maintains and monitors vacuum levels throughout melts according to PCC specifications.
• Charges furnace by adding virgin or revert materials as required.
• Takes sample of molten metal for lab analysis; makes calculations and adjusts the composition when out of ranges (Use an Alloy Blending System).
• Approves start of pouring process when heat composition meets specifications.
• Enter Pour Programs for each Workorder to be poured on Master Heat.
• Operates the Master Caster furnace to pour alloy ingots and large vacuum castings; operates hydraulic systems, doors, cranes and hoists.
• Assembles air casting bottom pour ladles and trigger mechanisms.
• Operates Air Master Melt furnace to pour alloy ingots and large castings; operate hydraulic systems, large overhead cranes and bottom pour ladles.
• Slag,DeOx, and prepares air master Melt heats in a variety of alloys for pouring into ingots and castings.
• Pours test bar material to the casting specifications for each heat.
• Rebuilds Master Caster bottom pour ladle systems. This includes Backpacks, Stopper Rods, Nozzles, and Hosts.
• Weighs, marks, and documents all heats correctly throughout the master melt process.
• Maintenance
  
  

Objective: to maintain air master melt and master caster power supply and furnace systems.

Essential Job Functions:

• Maintains and monitors condition of melting coils, furnace linings, pouring ladles and equipment.
• Cleans furnace of soot deposits.
• Rebuilds vacuum ladles and backpack actuators.
• Leak checks and repairs minor or major vacuum leaks.
• Changes oil in diffusion and other pumps.
• Troubleshoots mechanical and electrical failures on furnace systems.
• Rebuilds Burnout Furnaces as needed.
• Works with maintenance to perform preventative maintenance and repair the furnaces as needed.
• Completes accurate logs, production reports and records.
• Provides work direction, training, and working supervision as assigned.
• Meets all production and quality standards.
• Safety
  
  

Objective: to take responsibility for and demonstrate safe work practices.

NOTE: for job positions that require respiratory protection (more than a filtering face piece – dust mask):

In compliance with the Oregon Occupational Safety and Health Division Personal Protective Equipment standard for Respiratory Protection, OAR 437, Div. 2/I 1910.134 and Oregon Health Division Rules for the Control of Radiation, OAR 333. Div. 120 (333-120-300 through 330), certain tasks within this job position require/may require the use of a NIOSH-approved respirator. An individual will not be assigned to these tasks if the person is not able to work under these conditions. Respirator selection will be based on the work performed, exposure information, duration of use and any other relevant factors. If a tight-fitting respirator is required, facial hair, temple pieces on glasses or other items that interferes with the face-to-face piece seal of the respirator are not permitted.

Essential Job Functions:

• Adheres to plant and department safety rules.
• Safely operates all equipment and tools.
• Identifies and reports safety problems.
  
  

Other (marginal) Accountabilities

• Performs other tasks as directed.
  
  

Essential Equipment, Vehicles, Tools And/Or Machinery Used:

• Air Master Melt Furnace
• Master Caster Furnace
• Burnout furnaces (for Air Casting and Vacuum Casting)
• Pneumatic tools (e.g. air hammers, air chisels)
• forklift
• hoists
• overhead crane
• special lifting devices
• hydraulic presses
• electric rammer
• basic hand tools (e.g. wrenches, screwdrivers, prybars, etc.)
• torches (gas, air arc, arc welding)
• electric grinder
• linear actuators
• drill press
• CB radios
  
  

TRAINING

• Training is provided on the job.
• PCC's Forklift Driving Safety Certification Training must be completed.
  
  

Qualifications

• Basic knowledge of vacuum and air master melt operations and vacuum furnace operations as demonstrated by the competent performance of all Assistant Master Melt Vacuum Furnace Operator duties
  
  

OR

any equivalent combination of experience and training.

• Ability to read, interpret, and follow specifications on Technique Cards, Process Control Procedures and Standard Operating Procedures.
• Ability to perform basic mathematical calculations (addition, subtraction, multiplication, division) and calculate percentages.
• Ability to work independently and as a team member, with limited supervision.
• Ability to provide work direction and coordinate the work of others.
• Ability to communicate effectively, both verbally and in writing.
• Physical ability to perform essential job functions.
• Ability to use computer human interfaces to enter master melt and casting data and build heat requirements.