TL;DR
Water entering a molten steel bath causes a violent steam explosion. If a panel leak is suspected, stop the heat immediately. Never continue melting with a confirmed water leak into the furnace.
What you might see
- steam visible from the furnace shell during melt
- cooling water return flow higher than supply
- violent boiling reaction in the molten bath
- furnace pressure fluctuations from steam generation
Likely causes
Water-cooled panel fatigue cracking from thermal cycling over service life
Panel weld failure from arc radiation and splash impingement
Cooling water pressure surge from an upstream valve opening too fast
Flow restriction in the panel causing local boiling and pressure spike that ruptures the panel
Required tools
- Individual panel flow indicators or meters
- Panel supply valve isolation capability
- LOTO kit for cooling water system
Safety first
- Water into molten steel is a steam explosion hazard. Evacuate the furnace bay immediately if a panel leak is confirmed.
- Extreme thermal radiation from the open EAF. Aluminized PPE is mandatory for all furnace floor personnel.
- Molten steel spatter from tilting the furnace. Keep clear of the tilt arc and tapping spout area.
Procedure
- 1
STOP the heat immediately if steam is visible inside the furnace or the cooling water return flow exceeds the supply flow.
Warning: Water entering molten steel causes a steam explosion. This is a life-safety emergency. Evacuate all non-essential personnel from the furnace bay immediately. - 2
Open the furnace roof and tilt the furnace to the slag-off position to drain the bath away from the suspected leaking panel.
Warning: Do not add any scrap or oxygen to the furnace until the leak is confirmed stopped. - 3
Isolate the cooling water supply to the suspected panel section by closing the panel supply valve.[1]
- 4
Identify which panel is leaking by checking the individual panel flow indicators. The leaking panel will show higher return flow or visible dripping.[1]
- 5
After the furnace is emptied and cooled, inspect the isolated panel for the leak location.
- 6
Replace the failed panel before returning the furnace to service.
- 7
Review the cooling water system for pressure surges or flow restrictions that may have caused the panel failure.
Sources
Danieli Danieli Q-One / Digimelter Electric Arc Furnace (EAF) general technical documentation, Danieli
General EAF water-cooled panel operation and safety procedures (general)
More guides for Danieli Danieli Q-One / Digimelter
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An electrode break stops melting on one phase. Stop the heat, raise the electrodes to the retracted position, and recover the broken stub from the scrap charge before jointing and continuing.
How to detect and manage furnace shell hot spots on a Danieli Q-One / Digimelter EAF
A hot spot on the EAF shell means the refractory lining is thin or damaged at that point. Stop the heat if the shell temperature approaches the critical limit and apply gunning refractory during the next planned stop.
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