TOP-FTEMP

Trinity Operating Procedures - TOPs

TOP-FTEMP: Monitoring and Control of Forging Temperature

Rev: 12/06/2017

Scope: This procedure covers the monitoring and control of furnace and billet temperatures. It does not cover manually-controlled preheat furnaces which operate well below hot forging temperatures.

Procedure:

STEP WHO WHEN INFO TO USE WHAT TO DO

1 All production workers Constantly Personal observation Watch color and behavior of steel to be sure not overheated (not white, no sparks or bubbling in still air); if there is any reason to suspect that the induction heaters' pyrometers are not operating properly, immediately report to Forging Production Supervisor or Production Leadman; If need to make adjustments on furnace temp controls, report to Forging Production Supervisor or Production Leadman; IF OVERHEAT, STOP PRODUCTION AND REPORT IMMEDIATELY TO FORGING PRODUCTION SUPERVISOR OR PRODUCTION LEADMAN TO INITIATE STEP 7.

2 Forging Engineer Whenever changes are needed to Material Reference List Customer Purchase Order; raw material supplier; Material Reference List Review and evaluate the change requested, make sure to have evidence to support the change. Update Trinity Forge Material Reference List. Notify QA Assistant supplying forging temperature, temperature tolerance, and emissivity.

3 QA Assistant When receive notice of changes to Material Reference List Forging temperature, temperature tolerance, and emissivity of new grade specified by Forging Engineer Make changes to Material Reference List as required.

*For steps 4 and 5, it is mandatory that anyone using a pyrometer must sign it out and back in on the Sign Out Sheet for Pyrometers in the QC Supervisor's office

4 QC Specialist or QC Inspector As new jobs are started (or early each shift for continuing jobs) Own readings; Material Reference List; Traveler (if includes forging temperature) With the emissivity set per Forging Material Reference List (if not noted the setting should be 0.85) use hand-held pyrometer* to measure temperature of forging billet between furnace and hammer; record reading per TOP-PROQC; if reading outside of forging temperature guidelines (or Traveler), report immediately to Forging Production Supervisor (if not available, to Production Leadman , QC Supervisor or QA Manager).

5 Maintenance Man Once a day and as requested by Forging Production Supervisor or Production Leadman Own readings For each hammer in operation: make sure reject gates are mechanically functional; use hand-held optical pyrometer* with the emissivity per Material Reference List (if not noted the setting should be 0.85) to check the consistency of gas furnace hearth temperatures (at least 3 spots across hearth, all within 75° F of each other) and to check the accuracy of induction heater pyrometers (readings within 50°F of the hand-held pyrometer); record results on Furnace Temperature Log; if results fall outside these ranges, report immediately per TOP-BRKDN ; and to Forging Production Supervisor , QC Supervisor, and/or QA Manager; if have any reason to suspect the possibility of overheating, report immediately to Production Supervisor , QC Supervisor, and/or QA Manager. If adjustments need to be made to furnace temp controls, make adjustments and lock (possibly locked with passwords); forward Furnace Temperature Log to Maintenance Supervisor.

6 Maintenance Supervisor Each production day Furnace Temperature Log Review day's Furnace Temperature Log; if Furnace Temperature Log is not turned in, instruct Maintenance Man to proceed immediately per step 5 of this TOP and consider invoking TOP-ENFRC.

7 Forging Production Supervisor or Production Leadman Randomly, or as requested
Personal observation; any observations or data from above steps; Material Reference List Review any measurements presented; visually check color and behavior of steel (not white, no sparks or bubbling in still air); Make sure pyrometer is properly aimed at the billet; report any malfunctioning induction heater pyrometers per TOP-BRKDN; and to QC Supervisor or QA Manager; if need to make adjustment on furnace temp controls, report to Maintenance Supervisor; If quality forgings cannot be produced at recommended maximum forging temperature production call VP-Manufacturing or QC Supervisor, and a representative from the engineering department to determine the next step; compare furnace pyrometer reading with the QC hand-held pyrometer; proper settings on the hand-held pyrometer are verified (measuring distance & emissivity); IF OVERHEAT, STOP PRODUCTION, NOTIFY QC SUPERVISOR, SEPARATE OUT ANY FORGINGS WHICH MAY HAVE BEEN OVERHEATED, IDENTIFY THOSE WHICH ARE KNOWN OVERHEATS.

8 QA Manager If possible overheats reported Discussions; personal investigation Determine scope of problem and scrap all questionable parts if cost of testing not justified; if justified, have samples heat treated if required by Traveler, then send samples out for destructive testing to determine if internal damage (excessive grain growth or grain boundary precipitates) may have occurred; if so, scrap all questionable parts and submit findings as a Corrective Action Report (see TOP-CARRR); if testing results okay, return parts to normal process and notify Materials Manager with approval to use elevated temperatures on future orders.

Revision history:

Release Date	Description of Change	Owner	Approver
12/06/2017	Updated to comply with revised Quality Manual and new TOPs format.	Tim Ellis	Todd Sheppard

Documents are controlled only when viewed on-line at trinityforge.com in the original English -- printed copies or translations are not controlled documents.
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STEP	WHO	WHEN	INFO TO USE	WHAT TO DO
1	All production workers	Constantly	Personal observation	Watch color and behavior of steel to be sure not overheated (not white, no sparks or bubbling in still air); if there is any reason to suspect that the induction heaters' pyrometers are not operating properly, immediately report to Forging Production Supervisor or Production Leadman; If need to make adjustments on furnace temp controls, report to Forging Production Supervisor or Production Leadman; IF OVERHEAT, STOP PRODUCTION AND REPORT IMMEDIATELY TO FORGING PRODUCTION SUPERVISOR OR PRODUCTION LEADMAN TO INITIATE STEP 7.
2	Forging Engineer	Whenever changes are needed to Material Reference List	Customer Purchase Order; raw material supplier; Material Reference List	Review and evaluate the change requested, make sure to have evidence to support the change. Update Trinity Forge Material Reference List. Notify QA Assistant supplying forging temperature, temperature tolerance, and emissivity.
3	QA Assistant	When receive notice of changes to Material Reference List	Forging temperature, temperature tolerance, and emissivity of new grade specified by Forging Engineer	Make changes to Material Reference List as required.
*For steps 4 and 5, it is mandatory that anyone using a pyrometer must sign it out and back in on the Sign Out Sheet for Pyrometers in the QC Supervisor's office
4	QC Specialist or QC Inspector	As new jobs are started (or early each shift for continuing jobs)	Own readings; Material Reference List; Traveler (if includes forging temperature)	With the emissivity set per Forging Material Reference List (if not noted the setting should be 0.85) use hand-held pyrometer* to measure temperature of forging billet between furnace and hammer; record reading per TOP-PROQC; if reading outside of forging temperature guidelines (or Traveler), report immediately to Forging Production Supervisor (if not available, to Production Leadman , QC Supervisor or QA Manager).
5	Maintenance Man	Once a day and as requested by Forging Production Supervisor or Production Leadman	Own readings	For each hammer in operation: make sure reject gates are mechanically functional; use hand-held optical pyrometer* with the emissivity per Material Reference List (if not noted the setting should be 0.85) to check the consistency of gas furnace hearth temperatures (at least 3 spots across hearth, all within 75° F of each other) and to check the accuracy of induction heater pyrometers (readings within 50°F of the hand-held pyrometer); record results on Furnace Temperature Log; if results fall outside these ranges, report immediately per TOP-BRKDN ; and to Forging Production Supervisor , QC Supervisor, and/or QA Manager; if have any reason to suspect the possibility of overheating, report immediately to Production Supervisor , QC Supervisor, and/or QA Manager. If adjustments need to be made to furnace temp controls, make adjustments and lock (possibly locked with passwords); forward Furnace Temperature Log to Maintenance Supervisor.
6	Maintenance Supervisor	Each production day	Furnace Temperature Log	Review day's Furnace Temperature Log; if Furnace Temperature Log is not turned in, instruct Maintenance Man to proceed immediately per step 5 of this TOP and consider invoking TOP-ENFRC.
7	Forging Production Supervisor or Production Leadman	Randomly, or as requested	Personal observation; any observations or data from above steps; Material Reference List	Review any measurements presented; visually check color and behavior of steel (not white, no sparks or bubbling in still air); Make sure pyrometer is properly aimed at the billet; report any malfunctioning induction heater pyrometers per TOP-BRKDN; and to QC Supervisor or QA Manager; if need to make adjustment on furnace temp controls, report to Maintenance Supervisor; If quality forgings cannot be produced at recommended maximum forging temperature production call VP-Manufacturing or QC Supervisor, and a representative from the engineering department to determine the next step; compare furnace pyrometer reading with the QC hand-held pyrometer; proper settings on the hand-held pyrometer are verified (measuring distance & emissivity); IF OVERHEAT, STOP PRODUCTION, NOTIFY QC SUPERVISOR, SEPARATE OUT ANY FORGINGS WHICH MAY HAVE BEEN OVERHEATED, IDENTIFY THOSE WHICH ARE KNOWN OVERHEATS.
8	QA Manager	If possible overheats reported	Discussions; personal investigation	Determine scope of problem and scrap all questionable parts if cost of testing not justified; if justified, have samples heat treated if required by Traveler, then send samples out for destructive testing to determine if internal damage (excessive grain growth or grain boundary precipitates) may have occurred; if so, scrap all questionable parts and submit findings as a Corrective Action Report (see TOP-CARRR); if testing results okay, return parts to normal process and notify Materials Manager with approval to use elevated temperatures on future orders.