Installation Division. “We needed to arrive at Tonkawa ready to work as soon as possible and deliver quickly and thoroughly so they could get back to the business of melting and producing castings, and minimize their risk of closing.” Several years after Tonkawa’s
melt deck was originally installed, an elevation change was required to accommodate the use of a larger capacity ladle under the spout of the furnaces. Rather than rais- ing the entire melt deck, only the area supporting the furnaces was elevated. As a result, the power sup- ply and workstation were two steps down from the furnaces, creating a number of inconveniences and chal- lenges that impacted overall work flow in the melt area. Additionally, the proximity of the power supply to the furnaces not only contributed to the limited workspace, but also increased the odds of the power sup- ply facing damage. Te damage to the melt deck
required it to be reconstructed. It was determined to be the ideal opportunity
“We would not have the opportunity to see what the future holds for Tonkawa if it weren’t for all the kind-hearted people who
cared about what happened to us.” —Sandy Salisbury Linton
to raise the entire deck to the same elevation and arrange the power sup- ply, workstation and furnaces onto one level. Te furnace installation company provided the layout concepts, and with the aid of Rajesh Krishnamurthy, applications engineer, Oklahoma State Univ., Tonkawa used the concepts to generate blueprints for the new deck construction. Te results yielded a modernized melt system with an even elevation, strategically placed power supply, enhanced worker safety and increased operator productivity. “Eliminating the steps and relocat- ing the power supply farther from the furnaces was a significant improve- ment to our melt deck,” Tonkawa Co-Owner Jim Salisbury said.
Within four days of insurance
company approval, all damaged equipment had been removed and shipped for repair. The insurance company required an autopsy on the damaged furnace before any repair work could begin. The forensic analysis was hosted by EMSCO in Anniston, Ala., in the presence of insurance company personnel, as well as an assembly of industry representatives from the companies who had received notices of potential subrogation from the insurance company. Tonkawa’s furnace was com-
pletely disassembled while the insurance company’s forensic inspector directed, photographed,
Tonkawa Foundry’s newly redesigned and reconstructed melt deck brings the furnaces, power supply and work station on the same level. August 2015 MODERN CASTING | 27
Image courtesy of Tonkawa Foundry
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