Occupational safety instruction for roller kiln calciner

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OCCUPATIONAL SAFETY AND HEALTH
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Occupational safety instructions for a roller kiln calciner. Full document

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General safety requirements

1.1. To service a roller kiln for firing tiles powered by natural gas, persons are allowed at least 18 years of age who have passed a medical examination, trained in the "Safety Rules in the Gas Industry" in the scope of work performed, who have a certificate for admission to servicing gas-consuming units, who have been instructed at the worker place and internship during the first 10 work shifts under the supervision of an experienced worker.

1.2. The calciner must know the device, the scheme of gas supply to furnaces, automatic safety and regulation, first aid measures for suffocation by natural gas and poisoning by its combustion products, the rules for storing and using personal protective equipment.

1.3. The burner must be familiar with and comply with all requirements of this manual.

1.4. For violation of the requirements of the instructions, the perpetrators are liable in the prescribed manner in accordance with applicable law.

2. Safety requirements before starting work

2.1. Before starting work, put on the required overalls, check the condition of personal protective equipment, and make sure that there is no smell of gas in the workshop.

2.2. Verify:

entries in the watch log and gas equipment operation log;
illumination, uncluttered workplace, the presence of fences and visible grounding of service equipment;
serviceability of gas burners, shut-off equipment, instrumentation, safety and regulation automation;
the presence of gas pressure in the supply gas pipeline - 0,70 kgf / cm2, in the bypass after the gas control unit 150-75 mm Hg. Art., secondary air pressure in the common manifold after the fan 100-200 mm of water. Art. and on burners - 60-70 mm of water. Art.;
the presence of a sufficient amount of suitable products or semi-finished products;
efficiency of supply and exhaust ventilation.

2.3. Report all detected malfunctions to the master and proceed to work on his order after troubleshooting.

2.4. If malfunctions are detected that can lead to an accident, immediately turn off the furnace in accordance with the sequence specified in the section of this manual "Safety requirements in emergency situations".

3. Ignition of the roller kiln for firing tiles

Ignition of the roller kiln for firing tiles R-1.

3.1. The ignition of the roller kiln is carried out by order of the head of production.

3.2. Before ignition, notify the instrumentation and A fitter and an electrician.

3.3. Ignition is carried out in the following sequence:

turn on the exhaust fan, wait for the light on the main electrical panel to light up, adjust the vacuum, ventilate the working space of the furnace for 20 minutes;
check the condition of the shut-off valves (all gate valves, valves, taps must be closed, with the exception of taps for purge candles);
open valve No. 7 DN 50 at the gas consumption metering unit;
open the DN 50 valve in front of the gas control unit, make sure that there is a gas pressure in front of the GRU of 0,70 kgf / cm2;
turn on the solenoid valve in front of the gas control unit and put the hammer-type safety shut-off valve into operation;
blow the supply gas pipeline d 76 through the valve of the purge plug DN 25 for 10-15 seconds;
open the valves DN 25 on the control units of the collectors and blow the collectors one by one through the purge candles at their ends for 10-15 seconds. every;
determine the end of the purge by analyzing the soap emulsion, if the gas in the bucket of soap emulsion burns evenly without pops, you can start to ignite the burners. Determine the quality of the gas with a portable gas analyzer.

Ignition of the roller kiln for firing tiles R-2.

turn on the air supply fan to the burners, wait for the light on the main electronic control panel to light up and adjust the air pressure in the general corrector after the fan 150-200 mm w.c. Art. and on burners using valves 20-25 mm w.c. Art.;
turn on the accelerated cooling fan, wait for the light on the main electronic control panel to light up;
close the valves DN 50 on the bypass line, open the manual valves before and after the pressure regulator and adjust the outlet gas pressure to 200 mm w.c. using the screw. Art.;
open the gas supply valve to the burner and, using the valve on the manifold control unit, adjust the gas pressure to 20-25 mm of water. Art.;
press the ignition button of the corresponding burner on the electronic control panel of the collector; in this case, a voltage of 220 V is applied to the spare candle, a spark discharge occurs and at the same time the gas supply electrovalve to the burner opens;
after making sure that the burner torch is burning steadily (through the peephole), proceed to the ignition of the next burner;
if the burner does not ignite, turn off the gas supply valve to the burner and eliminate the cause, re-ignite after the malfunction has been eliminated.

3.4. During and after the ignition of the burners, constantly monitor the outlet pressure from the regulator and maintain it at 75 mm of water. Art.

3.5. Upon completion, make appropriate entries in the watch log and the gas equipment operation log.

4. Safety requirements during work

4.1. Do not leave a working furnace unattended for a period of temporary absence (lunch, shift change, etc.), it is allowed to replace the calciner.

4.2. Follow the indications of instrumentation and safety automation.

4.3. Monitor the operation of the burners visually through the eyes and inspection hatches in tinted glasses.

4.4. With an increase in burner performance, it is necessary to increase the gas supply to 40 mm of water. Art., then air pressure up to 70 mm of water. Art.

4.5. Control over the parameters of gas and air pressure is carried out using a portable Y-shaped pressure gauge by connecting a rubber hose to the fittings on the corresponding gas and air supply paths.

5. Switching off the kiln

5.1. Turning off the kiln, turning off is done by shutting off the gas supply valve and the air supply valve, followed by turning off the ignition button on the electronic control panel of the collector.

5.2. With a complete shutdown of the kiln, it is necessary:

turn off all the burners one by one in the sequence described in paragraph 5.1.;
close the valves DN 25 on the collector control unit;
close the manual valves before and after the pressure regulator and the valves DN 50;
open the cocks of the blowing plugs at the ends of the collectors and the cock of the safety plug DN 25 on the control unit;
close the inlet valve Du 50 No. 7 at the gas consumption metering unit;
blow gas pipelines with compressed air for 5 minutes;
install a plug DN 50 after the valve No. 7 (for a long time, more than 8 hours);
turn off the fans;
make appropriate entries in the logbook for the operation of gas equipment.

6. Safety requirements in emergency situations

6.1. Emergency shutdown of the firing line for gas is carried out in the following cases:

during a power outage;
when the gas pressure drops;
with increasing gas pressure;
when the exhaust fan (smoke exhauster) is turned off;
when the air supply fan to the burners is turned off;
when the fast cooling fan is turned off;
in case of fire, natural disaster and other situations when it is required to immediately turn off the gas to the line.

6.2. In the event of an emergency stop:

check the closing of the membrane solenoid valve on the gas control unit (it should work with the simultaneous activation of an acoustic signal);
close valve No. 7 DN 50 at the gas consumption metering unit;
open the cocks of the purge candles at the ends of the manifolds and the cock of the safety candle on the bypass line of the gas control unit;
inform the foreman or shift supervisor;
make notes about the causes of the emergency, stop in the logbook and the logbook for the operation of gas equipment.

7. Safety requirements at the end of work

7.1. Upon completion of work, clean the workplace, make appropriate entries in the logs, report the detected and corrected problems to the shifter or foreman.

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