Metal-Refining Furnace Operator and Tender

Other Titles

Automatic Furnace Operator, Central Melt Specialist, Control Room Operator, Electric Melt Operator, Furnace Operator, Melt Room Operator, Melter, Vacuum Melter

Operate or tend furnaces, such as gas, oil, coal, electric-arc or electric induction, open-hearth, or oxygen furnaces, to melt and refine metal before casting or to produce specified types of steel. Metal-Refining Furnace Operators and Tenders melt or refine metal by using metal-refining furnaces. Their job is to operate such furnaces which include oxygen furnaces as well as open-hearth furnaces. In this function, they carefully weigh and determine the amount of materials to be charged into a furnace. They then operate the furnace and check metal samples on regular intervals to make sure that the metal is heated to the required temperature. A part of their job is to drain the molten metal from the furnace and transfer it to another container. They also regulate the amount of air, fuel or electric current being supplied to a furnace.

Regulate supplies of fuel and air, or control flow of electric current and water coolant to heat furnaces and adjust temperatures.

Draw smelted metal samples from furnaces or kettles for analysis, and calculate types and amounts of materials needed to ensure that materials meet specifications.

Weigh materials to be charged into furnaces, using scales.

Record production data, and maintain production logs.

Observe air and temperature gauges or metal color and fluidity, and turn fuel valves or adjust controls to maintain required temperatures.

Operate controls to move or discharge metal workpieces from furnaces.

Inspect furnaces and equipment to locate defects and wear.

Drain, transfer, or remove molten metal from furnaces, and place it into molds, using hoists, pumps, or ladles.

Kindle fires, and shovel fuel and other materials into furnaces or onto conveyors by hand, with hoists, or by directing crane operators.

Prepare material to load into furnaces, including cleaning, crushing, or applying chemicals, by using crushing machines, shovels, rakes, or sprayers.

Remove impurities from the surface of molten metal, using strainers.

Observe operations inside furnaces, using television screens, to ensure that problems do not occur.

Sprinkle chemicals over molten metal to bring impurities to the surface.

Direct work crews in the cleaning and repair of furnace walls and flooring.

Scrape accumulations of metal oxides from floors, molds, and crucibles, and sift and store them for reclamation.

Operation Monitoring→ Watching gauges, dials, or other indicators to make sure a machine is working properly.

Operation and Control→ Controlling operations of equipment or systems.

Monitoring→ Monitoring/Assessing performance of yourself, other individuals, or organizations to make improvements or take corrective action.

Active Listening→ Giving full attention to what other people are saying, taking time to understand the points being made, asking questions as appropriate, and not interrupting at inappropriate times.

Complex Problem Solving→ Identifying complex problems and reviewing related information to develop and evaluate options and implement solutions.

Critical Thinking→ Using logic and reasoning to identify the strengths and weaknesses of alternative solutions, conclusions or approaches to problems.

Quality Control Analysis→ Conducting tests and inspections of products, services, or processes to evaluate quality or performance.

Reading Comprehension→ Understanding written sentences and paragraphs in work related documents.

Speaking→ Talking to others to convey information effectively.

Monitor Processes, Materials, or Surroundings→ Monitoring and reviewing information from materials, events, or the environment, to detect or assess problems.

Handling and Moving Objects→ Using hands and arms in handling, installing, positioning, and moving materials, and manipulating things.

Getting Information→ Observing, receiving, and otherwise obtaining information from all relevant sources.

Identifying Objects, Actions, and Events→ Identifying information by categorizing, estimating, recognizing differences or similarities, and detecting changes in circumstances or events.

Inspecting Equipment, Structures, or Material→ Inspecting equipment, structures, or materials to identify the cause of errors or other problems or defects.

Performing General Physical Activities→ Performing physical activities that require considerable use of your arms and legs and moving your whole body, such as climbing, lifting, balancing, walking, stooping, and handling of materials.

Communicating with Supervisors, Peers, or Subordinates→ Providing information to supervisors, co-workers, and subordinates by telephone, in written form, e-mail, or in person.

Making Decisions and Solving Problems→ Analyzing information and evaluating results to choose the best solution and solve problems.

Controlling Machines and Processes→ Using either control mechanisms or direct physical activity to operate machines or processes (not including computers or vehicles.

Estimating the Quantifiable Characteristics of Products, Events, or Information→ Estimating sizes, distances, and quantities; or determining time, costs, resources, or materials needed to perform a work activity.

Judging the Qualities of Things, Services, or People→ Assessing the value, importance, or quality of things or people.

Documenting/Recording Information→ Entering, transcribing, recording, storing, or maintaining information in written or electronic/magnetic form.

Evaluating Information to Determine Compliance with Standards→ Using relevant information and individual judgment to determine whether events or processes comply with laws, regulations, or standards.

Organizing, Planning, and Prioritizing Work→ Developing specific goals and plans to prioritize, organize, and accomplish your work.

Coordinating the Work and Activities of Others→ Getting members of a group to work together to accomplish tasks.

Operating Vehicles, Mechanized Devices, or Equipment→ Running, maneuvering, navigating, or driving vehicles or mechanized equipment, such as forklifts, passenger vehicles, aircraft, or water craft.

Updating and Using Relevant Knowledge→ Keeping up-to-date technically and applying new knowledge to your job.

Repairing and Maintaining Mechanical Equipment→ Servicing, repairing, adjusting, and testing machines, devices, moving parts, and equipment that operate primarily on the basis of mechanical (not electronic principles.

Training and Teaching Others→ Identifying the educational needs of others, developing formal educational or training programs or classes, and teaching or instructing others.

Establishing and Maintaining Interpersonal Relationships→ Developing constructive and cooperative working relationships with others, and maintaining them over time.

Guiding, Directing, and Motivating Subordinates→ Providing guidance and direction to subordinates, including setting performance standards and monitoring performance.

Processing Information→ Compiling, coding, categorizing, calculating, tabulating, auditing, or verifying information or data.

Analyzing Data or Information→ Identifying the underlying principles, reasons, or facts of information by breaking down information or data into separate parts.

Coaching and Developing Others→ Identifying the developmental needs of others and coaching, mentoring, or otherwise helping others to improve their knowledge or skills.

Adjust equipment controls to regulate gas flow.

Adjust equipment controls to regulate coolant flow.

Adjust flow of electricity to tools or production equipment.

Calculate specific material, equipment, or labor requirements for production.

Collect samples of materials or products for testing.

Measure ingredients or substances to be used in production processes.

Clean materials to prepare them for production.

Record operational or production data.

Adjust temperature controls of ovens or other heating equipment.

Monitor instruments to ensure proper production conditions.

Operate cranes, hoists, or other moving or lifting equipment.

Inspect production equipment.

Skim impurities from molten metal.

Place materials into molds.

Ignite fuel to activate heating equipment.

Load materials into production equipment.

Signal others to coordinate work activities.

Watch operating equipment to detect malfunctions.

Direct operational or production activities.

Clean production equipment.

Control Precision→ The ability to quickly and repeatedly adjust the controls of a machine or a vehicle to exact positions.

Manual Dexterity→ The ability to quickly move your hand, your hand together with your arm, or your two hands to grasp, manipulate, or assemble objects.

Near Vision→ The ability to see details at close range (within a few feet of the observer).

Problem Sensitivity→ The ability to tell when something is wrong or is likely to go wrong. It does not involve solving the problem, only recognizing there is a problem.

Arm-Hand Steadiness→ The ability to keep your hand and arm steady while moving your arm or while holding your arm and hand in one position.

Reaction Time→ The ability to quickly respond (with the hand, finger, or foot) to a signal (sound, light, picture) when it appears.

Selective Attention→ The ability to concentrate on a task over a period of time without being distracted.

Information Ordering→ The ability to arrange things or actions in a certain order or pattern according to a specific rule or set of rules (e.g. , patterns of numbers, letters, words, pictures, mathematical operations).

Multilimb Coordination→ The ability to coordinate two or more limbs (for example, two arms, two legs, or one leg and one arm) while sitting, standing, or lying down. It does not involve performing the activities while the whole body is in motion.

Deductive Reasoning→ The ability to apply general rules to specific problems to produce answers that make sense.

Depth Perception→ The ability to judge which of several objects is closer or farther away from you, or to judge the distance between you and an object.

Extent Flexibility→ The ability to bend, stretch, twist, or reach with your body, arms, and/or legs.

Hearing Sensitivity→ The ability to detect or tell the differences between sounds that vary in pitch and loudness.

Perceptual Speed→ The ability to quickly and accurately compare similarities and differences among sets of letters, numbers, objects, pictures, or patterns. The things to be compared may be presented at the same time or one after the other. This ability also includes comparing a presented object with a remembered object.

Rate Control→ The ability to time your movements or the movement of a piece of equipment in anticipation of changes in the speed and/or direction of a moving object or scene.

Static Strength→ The ability to exert maximum muscle force to lift, push, pull, or carry objects.

Auditory Attention→ The ability to focus on a single source of sound in the presence of other distracting sounds.

Finger Dexterity→ The ability to make precisely coordinated movements of the fingers of one or both hands to grasp, manipulate, or assemble very small objects.

Flexibility of Closure→ The ability to identify or detect a known pattern (a figure, object, word, or sound) that is hidden in other distracting material.

Glare Sensitivity→ The ability to see objects in the presence of glare or bright lighting.

Inductive Reasoning→ The ability to combine pieces of information to form general rules or conclusions (includes finding a relationship among seemingly unrelated events).

Oral Expression→ The ability to communicate information and ideas in speaking so others will understand.

Response Orientation→ The ability to choose quickly between two or more movements in response to two or more different signals (lights, sounds, pictures).It includes the speed with which the correct response is started with the hand, foot, or other body part.

Trunk Strength→ The ability to use your abdominal and lower back muscles to support part of the body repeatedly or continuously over time without 'giving out' or fatiguing.

Visual Color Discrimination→ The ability to match or detect differences between colors, including shades of color and brightness.

Production and Processing→ Knowledge of raw materials, production processes, quality control, costs, and other techniques for maximizing the effective manufacture and distribution of goods.

Mechanical→ Knowledge of machines and tools, including their designs, uses, repair, and maintenance.

Public Safety and Security→ Knowledge of relevant equipment, policies, procedures, and strategies to promote effective local or national security operations for the protection of people, data, property, and institutions.

Administration and Management→ Knowledge of business and management principles involved in strategic planning, resource allocation, human resources modeling, leadership technique, production methods, and coordination of people and resources.

Education and Training→ Knowledge of principles and methods for curriculum and training design, teaching and instruction for individuals and groups, and the measurement of training effects.

Database user interface and query software -- Process safety management software

Industrial control software -- Process control software

Inventory management software -- Production tracking system software

Office suite software -- e.g., Corel WordPerfect Office; Microsoft Office; Google Workspace; Apache OpenOffice.org

Spreadsheet software -- e.g., Corel Quattro Pro; Microsoft Excel; Google Sheets

Ammeters→ Digital ammeters

Belt conveyors→ Conveyor belt systems; Pivoting conveyors

Blow torch→ Oxygen lances

Closed circuit television CCTV system→ Closed circuit television monitors

Control unit→ Control computers

Core drying ovens→ Drying systems

Ear plugs→ Hearing protection plugs

Electric furnace→ Electric arc furnaces

Electrical or power regulators→ Rheostats

Evaporative coolers→ Evaporative cooling systems

Flowmeters→ Fluid flow meters

Forklifts→ Wheeled forklifts

Foundry ladles→ Foundry casting ladles; Foundry transfer ladles; Foundry treatment ladles

Foundry molds

Foundry shovels

Furnaces→ Anneal furnaces; Argon purging systems; Basic oxygen furnaces; Blast furnaces; Channel induction furnaces; Coal furnaces; Coreless induction furnaces; Electric induction furnaces; Gas furnaces; Ladle refining furnaces; Oil furnaces; Open-hearth furnaces; Removable crucible furnaces; Vacuum furnaces

Goggles→ Chemical protection goggles

Hoists→ Power hoists

Loading equipment→ Scrap charging buckets

Overhead crane→ Foundry overhead cranes

Pressure indicators→ Air gauges; Pressure gauges

Protective gloves→ Heat reflective gloves

Pulverizing machinery→ Slag crushing machines

Pyrometers

Respirators→ Protective respirators

Roller conveyors→ Holding conveyors

Safety glasses→ Industrial safety glasses

Scissor lift or lift table→ Scissor lifts

Single gas monitors→ Helium leak detectors

Spray gun→ Sprayers

Surface thermometers→ Digital thermometers

Vacuum pumps→ Industrial vacuum pumps

Vibrating conveyors→ Vibratory conveyors

Voltage or current meters→ Digital voltmeters

Wattmeters→ Digital wattmeters

Weigh belt feeder→ Feed scales

Realistic→ Realistic occupations frequently involve work activities that include practical, hands-on problems and solutions. They often deal with plants, animals, and real-world materials like wood, tools, and machinery. Many of the occupations require working outside, and do not involve a lot of paperwork or working closely with others.

Investigative→ Investigative occupations frequently involve working with ideas, and require an extensive amount of thinking. These occupations can involve searching for facts and figuring out problems mentally.

Conventional→ Conventional occupations frequently involve following set procedures and routines. These occupations can include working with data and details more than with ideas. Usually there is a clear line of authority to follow.

Dependability→ Job requires being reliable, responsible, and dependable, and fulfilling obligations.

Attention to Detail→ Job requires being careful about detail and thorough in completing work tasks.

Self Control→ Job requires maintaining composure, keeping emotions in check, controlling anger, and avoiding aggressive behavior, even in very difficult situations.

Independence→ Job requires developing one's own ways of doing things, guiding oneself with little or no supervision, and depending on oneself to get things done.

Cooperation→ Job requires being pleasant with others on the job and displaying a good-natured, cooperative attitude.

Analytical Thinking→ Job requires analyzing information and using logic to address work-related issues and problems.

Integrity→ Job requires being honest and ethical.

Adaptability/Flexibility→ Job requires being open to change (positive or negative) and to considerable variety in the workplace.

Concern for Others→ Job requires being sensitive to others' needs and feelings and being understanding and helpful on the job.

Initiative→ Job requires a willingness to take on responsibilities and challenges.

Achievement/Effort→ Job requires establishing and maintaining personally challenging achievement goals and exerting effort toward mastering tasks.

Stress Tolerance→ Job requires accepting criticism and dealing calmly and effectively with high stress situations.

Leadership→ Job requires a willingness to lead, take charge, and offer opinions and direction.

Persistence→ Job requires persistence in the face of obstacles.

Innovation→ Job requires creativity and alternative thinking to develop new ideas for and answers to work-related problems.

Social Orientation→ Job requires preferring to work with others rather than alone, and being personally connected with others on the job.

Support→ Occupations that satisfy this work value offer supportive management that stands behind employees. Corresponding needs are Company Policies, Supervision: Human Relations and Supervision: Technical.

Independence→ Occupations that satisfy this work value allow employees to work on their own and make decisions. Corresponding needs are Creativity, Responsibility and Autonomy.

Working Conditions→ Occupations that satisfy this work value offer job security and good working conditions. Corresponding needs are Activity, Compensation, Independence, Security, Variety and Working Conditions.