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Labor safety instructions for the operator of an oxidation plant for processing tar into bitumen. Full document

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General provisions

1.1. Persons who have reached the age of 18, have a certificate for the right to work on reactors and have passed a medical examination are allowed to work at compressor and non-compressor installations for the oxidation of tar.

1.2. A machinist servicing an oxidation plant for processing tar into bitumen who is hired must undergo introductory training in labor protection, industrial sanitation, fire safety, techniques and methods of providing first-aid to victims; must be familiarized, against signature, with the working conditions, rules and benefits for working in harmful and dangerous working conditions, and the rules of behavior in the event of accidents.

1.3. Before starting work directly at the workplace, the driver must undergo initial training on safe methods of performing work.

On the conduct of introductory briefing and briefing at the workplace, appropriate entries are made in the Logbook for the registration of introductory briefings on labor protection issues and the Logbook for the registration of briefings on labor protection issues. At the same time, the signatures of both the one who was instructed and the one who instructed are required.

1.4. A driver servicing an oxidation plant for processing tar into bitumen who is hired, after initial instruction at the workplace, must undergo an internship for 2-15 shifts (depending on length of service, experience and the nature of the work) under the supervision of an experienced qualified operator in servicing the oxidation plant. installation, which is assigned by order (instruction) for the enterprise.

1.5. A driver servicing an oxidation plant for processing tar into bitumen must undergo repeated training on the rules and techniques of safe work and labor protection:

• periodically, at least once a quarter;
• with unsatisfactory knowledge of labor protection no later than a month;
• in connection with an admitted case of injury or violation of labor protection requirements that did not lead to injury.

1.6. The operator who services compressor and non-compressor units must periodically undergo a medical examination (at least once a year).

1.7. The machinist who works with black viscous materials is provided with special food - milk or equivalent food products, carbonated salt water.

1.8. Persons not involved in tar processing are prohibited from staying in the reactor area.

1.9. When performing work on servicing an oxidation plant for processing tar into bitumen, the oxidation plant operator must work in overalls, special footwear and personal protective equipment provided for by the Standard Industry Standards: a cotton suit for protection against bitumen with linings made of film materials; combined mittens.

If necessary, the driver must use: universal filtering respirator RU-60G; industrial filter gas mask GP-5 or sealed goggles with a rubber half mask - PO-3.

When in contact with hot and cold black viscous materials, to protect hands from contamination, the oxidation unit operator must work in rubber gloves and use KHIOT-6 paste.

Workwear, safety shoes and personal protective equipment received by workers must be in good working order and appropriate for their height and size.

1.10. It is prohibited to take special clothing, safety footwear and personal protective equipment outside the enterprise.

1.11. At oxidation plants, it is prohibited to use fire, to be at work places without special clothing, to pollute the area with petroleum products, to block passages, driveways and work areas, to use fire equipment for other purposes, to work with faulty tools, and to smoke in an undesignated place.

1.12. There must be signs on the installation territory ("Traffic prohibited", "No unauthorized entry").

1.13. Hot surfaces of equipment and pipelines with fittings located outdoors, in places where a driver may accidentally touch them, must have thermal insulation. At the same time, the use of slag wool, asphalt crumbs and other fibrous materials that can spontaneously ignite when tar gets into them is not allowed.

The temperature on the insulation surface should not exceed 45°C. If it is impossible to provide thermal insulation, the hot surface must be fenced off.

1.14. It is prohibited to hang clothes to dry or place any materials on hot surfaces of pipelines and apparatus. Clothes should be dried in specially designated areas.

1.15. The operator must know that the electrical equipment of the reactor, boilers and storage facilities must be made explosion-proof in accordance with the requirements of the Rules for the Technical Operation of Consumer Electrical Installations and the Rules for the Safe Operation of Consumer Electrical Installations.

1.16. When visibility is less than 100 m (snowfall, fog, night time, etc.), artificial lighting should be used. Lamps must be explosion-proof with guide reflectors. For portable lamps, a voltage of no more than 42 V should be used in the protective fittings.

1.17. The driver must:

• know the technology of neutralizing oxidation gases from the reactor in the afterburning furnace;
• be able to use emergency power supply to prevent the flame from jumping from the afterburner into the reactor during a power outage.

1.18. To work safely in oxidation plants, the operator must know:

• the oxidation of tar to bitumen takes place in the temperature range of 180-240°C;
• Tar and bitumen at a flash point (200°C) are flammable and flammable substances;
• vapors from tar and bitumen are toxic and have a harmful effect on the central nervous system, respiratory organs and eyes;
• hot tar and bitumen that come into contact with human skin stick and cause severe burns;
• corrosion products in the form of sulphide (pyrophoric) iron self-explode in air, so it is prohibited to open unprepared equipment for inspection and repair;
• Acute poisoning occurs as a result of toxic substances entering the body in unacceptable concentrations. These include carbon monoxide and hydrogen sulfide - oxidation by-products.

1.19. The installation must be equipped with telephone and alarm systems.

1.20. Bitumen melting boilers of an oxidizing plant must be equipped with a circulation system that reduces violent foaming of viscous substances.

1.21. The compressor unit operator must know: the technological diagram, operating procedures, the location of communications and pipeline switching, and the storage locations of protective devices.

2. Safety requirements before starting work

2.1. Before starting work, the driver must put on overalls and accept the oxidation unit. Check the machinery, electric motor, steam line valves, sampling valves, cooling water supply line, instrumentation and alarms.

Check the presence and condition of fire extinguishing means and the steam extinguishing line in the reactor.

Check the presence of raw materials in the reactor using a level gauge, a control valve.

Measure the temperature in the reactor, make sure there is no water in the reactor.

Check the absence of unauthorized persons on the territory of the oxidizing plant.

All malfunctions in the installation and deviations in the technological process should be recorded in the journal and reported to the foreman.

2.2. Before starting up the installation, it is necessary to run-in (test) pumps, compressors and other equipment available at the installation.

2.3. All devices and individual components of the installation that have undergone repairs must be subjected to a leak test before starting up.

2.4. The working areas of the installation, passages, shoots, levers, and valves must be clean and dry.

Places contaminated with bitumen should be regularly cleaned and sanded.

2.5. To protect hands from tar or bitumen, the oxidation plant operator must lubricate them for 5-10 minutes. before starting work, apply a thin layer of KHIOT-6 paste or Selissky ointment, Shapiro anti-burn paste (pastes and ointment are easily washed off with water).

3. Safety requirements during work

3.1. When servicing pumps for pumping black viscous materials, the following rules must be observed:

• It is allowed to turn on the pump only after heating all the necessary pipelines;
• the pressure of viscous materials in the pipeline should not exceed permissible;
• If extraneous noise is detected in the pump, it is necessary to stop operation and eliminate the malfunction.

To heat the pipelines, steam or induction electric heating should be used. Do not use open flames.

3.2. The connection of the steam hoses must be reliable; each hose at the point of connection to the underwater line must have a shut-off valve.

Before disconnecting the hose, the steam supply must be stopped.

3.3. The necks of bitumen melting boilers must be closed with a grate with a mesh size of 150x150 mm, as well as metal lids that close tightly.

3.4. Filling boilers with viscous materials is allowed no more than 3/4 of the capacity, but not higher than the design level.

3.5. When preparing raw materials in boilers, it must be taken into account that the presence of water in the raw materials will cause foaming and emission, which can lead to fire and burns.

To avoid rapid foaming of viscous materials, bitumen melting boilers are equipped with a circulation system, which eliminates the possibility of the formation of stagnant zones and equalizes the temperature of the tar throughout the volume. The temperature difference in the lower and upper layers of tar should not exceed 15-20°C.

3.6. To prevent foaming and the release of oil products, defoamers SKTN-1 (2-3 drops per 10 tons of bitumen) and MKT-1 (4-6 drops per 10 tons of bitumen or tar) should be used.

3.7. Before supplying air to the oxidation column from the compressor unit, the oxidation column, air collectors, and mother liquor must first be purged to completely remove moisture and oil.

3.8. The driver should not allow fluctuations in the air pressure supplied for oxidation to exceed 1,5-2,5 kg/cm2.

3.9. Air consumption for oxidation must be increased gradually. At first, no more than 80-120 nm3/h is supplied; as the tar oxidizes, the air supply increases to 250 nm3/h and then from 360 to 400 nm3/h.

3.10. It is prohibited to supply air into the column through the mother liquor while pumping the product out of it.

3.11. All gland and flange pump connections of pipelines and fittings must be sealed and not leak oil products.

3.12. To avoid bitumen emissions or equipment rupture, do not allow water to enter the reactor or other equipment that contains hot bitumen.

3.13. To extinguish viscous materials that have ignited, the reactor is equipped from the outside with a collector for supplying water vapor.

3.14. When operating installations for the production of bitumen, it is prohibited:

• load non-dehydrated tar into the reactor;
• overestimate the level of the product in the reactor above the design level in order to avoid a release;
• to increase the temperature of the oxidation process above 240°C;
• maintain the temperature difference between the vapor and liquid phases less than 15 °C;
• sharply increase air consumption (in compressor units);
• release bitumen into a cluttered container with a temperature above 170 ° C;
• increase the pressure in the reactor above 1 Pa /900 mm water column/ (for compressor units).

3.15. A non-compressor oxidation plant must have means of controlling temperature, level of oxidation product and air flow.

3.16. The compressor oxidation plant must be equipped with a set of instruments that provide measurement and recording:

• the level of the oxidizing product along the height of the column;
• free oxygen content in the vapor phase using a stationary gas analyzer;
• pressure and temperature in the column;
• temperature difference between the vapor and liquid phases.

3.17. For continuous oxidation, in addition to instruments for conducting the technological process, the oxidation plant must be equipped with a set of instruments that must provide:

• regulation of the oil product level in the column;
• maintaining a constant level of a given cost of raw materials;
• regulation of air consumption;
• air pressure regulation;
• monitoring the content of free oxygen in the gases that exit the column.

3.18. In order to prevent spontaneous combustion of the product in the reactor, after 150-200 hours of operation, it is necessary to clean the internal walls and gas outlet pipelines of the reactor, which form slags that contribute to spontaneous combustion, mechanically or by washing.

3.19. Any switching on pipelines with hot bitumen and tar, as well as opening of valves and valves of steam and air lines must be carried out carefully, by gradually turning the flywheel of the valves or valves.

In this case, gloves must be used.

3.20. When taking bitumen samples, you must stand on the windward side. Samples should be taken in a clean and dry metal container with a lid by slowly opening the tap. It is prohibited to take bitumen samples without gloves, appropriate protective clothing and safety glasses or a mask.

3.21. When operating an oxidation plant, it is necessary to carry out the following basic electrical safety measures:

• all conductive parts must be insulated or fenced, and fences and other metal non-conductive parts must be grounded;
• it is forbidden to leave the installation energized without supervision;
• Repairing electrical equipment is only permitted when the line is de-energized.

3.22. When using furnaces with flame tubes in oxidizing plants, the following safety measures must be taken:

• each furnace must be equipped with an effective fire extinguishing system, the condition of which should be checked at least once per shift;
• the stove should be ignited with a burner or torch on a metal rod at least 1,5 m long, soaked in fuel oil, while standing sideways to the firebox to avoid burns in case of flame emission;
• before ignition, it is necessary to check the condition of the nozzles and burners, make sure that all valves are closed and the combustion chamber is purged;
• to ignite the injectors, you must first open the valve on the steam or air supply line, and then bring the lit torch to the injector or turn on the electric igniter and supply liquid fuel;
• To ignite the gas burner, first bring in a lit torch (or turn on the electric igniter) and open the gas valve, and then supply air.

4. Safety requirements after finishing work

4.1. After finishing work, the operator of the oxidizing plant must:

• put in order the equipment and apparatus;
• clean, wipe, lubricate, conduct an external inspection, report any defects noticed to the technician;
• collect, clean and place tools and devices in the designated place;
• tidy up the workplace, passages and approaches to the equipment and communications of the installation from tar, bitumen, dirt, unnecessary items;
• check the correctness of the entries in the plant operation logs, make an entry in the logs about all shortcomings and labor safety violations identified during the work.

4.2. During continuous operation of the oxidation plant, the driver must:

• hand over the shift to the shift worker, informing him about the operation of the installation directly at the workplace, and also familiarize him with the entries in the log;
• report completion of work to the foreman, informing him about the operation of the installation equipment.

4.3. Take off your overalls and hang them in a specially designated place.

4.4. Wash face and hands with warm soapy water or shower and change.

5. Safety requirements in emergency situations

5.1. The installation must have an "Emergency Response Plan" which should be followed in appropriate cases.

5.2. The oxidation plant operator, regardless of the work performed, must be aware of emergency situations that may arise when heating tar and during its processing into bitumen.

5.3. Deviation from the normal operation of the oxidation plant, which is accompanied by a violation of the tightness of equipment and pipelines, large contamination of the area, the occurrence of a fire, interruption of the supply of electricity, water or steam to extinguish the fire, failure of one or more dispersants, breakdown of mechanisms or devices without which it is impossible to carry out and control of a given oxidation regime, necessarily require the declaration of an emergency.

5.4. If an emergency occurs, it is necessary to immediately disconnect the oxidation unit from the power supply, stop the air supply to the reactor and turn off the furnace.

5.5. If a small amount of tar or bitumen catches fire, the fire source must be extinguished with sand, special powders, a carbon dioxide fire extinguisher, water sprayed in thin streams, or steam.

5.6. Fires of these products that have spilled over a large area are extinguished with a full stream or strong jets of water.

If it is impossible to quickly extinguish the fire on your own, you should immediately call a special fire brigade and remove people from the danger zone.

5.7. If tar or bitumen in tanks ignites, steam must be supplied deep into them, knowingly draining the condensate from the steam line.

5.8. If coke waste ignites inside the upper bottom of the column in compressor units, it is necessary to:

• stop the oxidation of the tar in the column;
• stop the supply of tar to the column;
• stop heating the tar;
• stop air from entering the column;
• tap the upper bottom, as a result of which coke will be sprinkled.

If after the measures taken the combustion does not stop, the oil product must be pumped out of the column.

5.9. If fire occurs inside the column as a result of low tar level in the column or uneven heating, you should:

• stop heating the tar;
• close the air access to the column;
• after repayment, thoroughly mix the tar with air from the compressor.

5.10. In the case of tar foaming during oxidation and the release of petroleum products through the explosion valve and the exhaust pipe of the column as a result of intensive air supply for oxidation or water entering the air duct, it is necessary:

• stop the air supply to the column;
• remove people from the danger zone;
• remove spilled bitumen;
• troubleshoot.

5.11. In the event of a spill of tar or bitumen in the area due to a pipeline explosion, you should:

• disconnect the pipeline section and continue working. If it is not possible to disconnect a section of the pipeline, the installation must be stopped;
• remove people from the danger zone;
• take measures to reduce the oil spill, and then clean it up.

5.12. In the event of an explosion (activation of the warning valve) in the column during rolling and oxidation as a result of high temperature or the presence of an explosive concentration, you should:

• immediately stop the air supply for oxidation;
• stop the supply of tar to the column;
• in case of violation of the column, ensure the withdrawal of people from the danger zone;
• take measures to reduce the oil spill, and then clean it up;
• clean the top of the column and its insulation from oil products.

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