ACCURATE STEEL FORGINGS INDIA LTD
Contingency Plan – Gas Carburizing
Furnace (GCF)
1. Purpose
To define a contingency plan for addressing unplanned events, malfunctions, or
emergencies in the operation of a Gas Carburizing Furnace to minimize safety risks,
production downtime, and product quality issues.
2. Scope
This contingency plan applies to all operations involving the Gas Carburizing Furnace,
including heating, carburizing, soaking, and quenching processes at [Company/Plant Name].
3. Contingency Scenarios & Response
3.1 Power Failure
Immediate Action:
- Automatically trigger gas purge with inert gas (e.g., nitrogen) to prevent explosion.
- Engage Uninterruptible Power Supply (UPS) for SCADA and instrumentation.
- Manually shut off fuel supply if automatic valve fails.
Post-Event:
- Verify atmosphere, reheat or scrap load based on process status.
- Document event and restart cycle only with Metallurgist approval.
3.2 Gas Leak (Endo/Enriched Gases)
Immediate Action:
- Activate gas leak alarm and evacuation protocol.
- Shut off gas supply via ESD (Emergency Shut Down) system.
- Ventilate area using exhaust systems.
Post-Event:
- Conduct leak test and safety clearance before restart.
- Notify safety officer and document incident.
Document No.: EMG-PLAN-04 Revision No.: 00& Date: 01.12.2024
Prepared by: Ramkumar.S Approved by: Manikandan
ACCURATE STEEL FORGINGS INDIA LTD
3.3 Overheating / PID Malfunction
Immediate Action:
- Over-temperature trip relay shuts furnace down.
- Notify maintenance and metallurgy team immediately.
Post-Event:
- Inspect thermocouples, controllers, and safety interlocks.
- Validate furnace calibration before use.
3.4 Carbon Potential Out of Range
Immediate Action:
- Pause cycle and alert Metallurgist.
- Correct carbon potential using SCADA/human-machine interface.
Post-Event:
- Test hardness and microstructure of affected batch.
- Reprocess or scrap as per quality disposition.
3.5 Quench System Failure
Immediate Action:
- Hold load inside furnace if quench readiness not confirmed.
- Engage backup quench pump if available.
- If oil overheats, engage fire suppression and isolation systems.
Post-Event:
- Inspect oil level, contamination, and pump health.
- Metallurgist to evaluate part impact and document.
3.6 SCADA or Control System Failure
Immediate Action:
- Safely abort cycle and maintain atmosphere if possible.
- Log all manual readings (temp, carbon %).
Post-Event:
- IT/Instrumentation to restore system.
- Validate furnace condition before cycle resumption.
Document No.: EMG-PLAN-04 Revision No.: 00& Date: 01.12.2024
Prepared by: Ramkumar.S Approved by: Manikandan
ACCURATE STEEL FORGINGS INDIA LTD
3.7 Fire or Explosion
Immediate Action:
- Sound fire alarm, evacuate area immediately.
- Use CO₂/dry powder extinguishers if safe to do so.
- Shut off gas, power supply, and engage suppression systems.
Post-Event:
- Incident investigation and safety inspection.
- Restart only after management and safety clearance.
4. Emergency Contacts
Department Contact Person Phone
Safety Officer Balaji 9840890373
Maintenance Head Srinivasan 9840847848
Metallurgy Dept. Head Ramkumar 8148886069
Plant Manager John Peter 9840818086
5. Training & Awareness
- All furnace operators, quality, and maintenance staff to be trained on this plan quarterly.
- Mock drills for fire and gas leak scenarios conducted bi-annually.
- Training records maintained by HR/Safety department.
6. Review and Updates
This contingency plan shall be reviewed annually or after any major incident. All revisions
must be documented and approved.
7. Revision History
Revision Date Description Approved By
01 [Date] Initial Release [Approver Name]
Document No.: EMG-PLAN-04 Revision No.: 00& Date: 01.12.2024
Prepared by: Ramkumar.S Approved by: Manikandan
