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Instruction on labor protection for a smelter of non-ferrous metals and alloys

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General requirements for labor protection

1.1. The instructions apply to all departments of the enterprise.

1.2. The instruction was developed on the basis of DNAOP 0.00-8.03-93 "Procedure for the development and approval by the owner of labor protection regulations in force at the enterprise", DNAOP 0.00-4.15-98 "Regulations on the development of labor protection instructions", DNAOP 0.00-4.12-99 " Standard provision on training on labor protection issues.

1.3. According to this instruction, the melter of non-ferrous metals and alloys (hereinafter referred to as the melter) is instructed before starting work (initial briefing), and then every 3 months (repeated briefing).

The results of the briefing are recorded in the "Journal of registration of briefings on labor protection issues". After passing the briefing, the log must contain the signatures of the instructor and the smelter.

1.4. The owner must insure the glazier against accidents and occupational diseases.

In case of damage to the health of the smelter through the fault of the owner, he (the smelter) has the right to compensation for the harm caused to him.

1.5. For non-compliance with this instruction, the melter bears disciplinary, material, administrative and criminal liability.

1.6. Individuals at least 18 years of age who have undergone a medical examination and have no medical contraindications, have undergone special training in smelting production and have the appropriate qualifications, introductory labor safety briefing, workplace briefing and fire safety briefing are allowed to work independently as a smelter.

1.7. The melter must:

1.7.1. Comply with internal labor regulations.

1.7.2. Do not allow unauthorized persons to enter the workplace.

1.7.3. Don't clutter up your workspace.

1.7.4. Perform only the work that is entrusted to him by the head and in which he is instructed.

1.7.5. Remember personal responsibility for the implementation of the rules for the protection of work and responsibility for workmates.

1.7.6. Know how to provide first aid to victims of accidents.

1.7.7. Be familiar with the use of primary fire extinguishing equipment.

1.7.8. Do not follow instructions that are contrary to the rules of labor protection.

1.7.9. Do not turn on or stop (except in emergency cases) machines, mechanisms and installations on which he is not entrusted with work.

1.8. The main harmful and dangerous production factors that affect the smelter:

1.8.1. Electric shock.

1.8.2. Increased temperature of the working area.

1.8.3. Overvoltage of the visual analyzer.

1.8.4. The action of molten metal vapors.

1.8.5. Thermal burns.

1.8.6. Increased temperature of equipment and tools.

1.8.7. Increased gas contamination of the working area.

1.9. The melter is provided with overalls, safety shoes and personal protective equipment: a cloth suit or a cotton suit with fire-resistant impregnation, boots, canvas mittens, a felt hat, goggles.

1.10. Melting sections should be provided with general exchange supply and exhaust ventilation and protection from intense thermal radiation.

1.11. When working on furnaces with gas heating, the melter must have a certificate for the right to work with gas.

2. Safety requirements before starting work

2.1. Put on overalls, safety shoes and personal protective equipment.

2.2. Get an assignment from the work manager.

2.3. Prepare the workplace, remove unnecessary items from the floor. Cover wet areas with dry sand.

2.4. Check the serviceability of the tool - crowbars, scrapers, spoons, glasses for taking metal samples, etc.

2.5. Inspect and make sure that the crucibles and devices for their transfer, as well as lifting devices for lifting crucibles from the hearth, are in good condition.

Crucibles must not have cracks, scratches, shells or other damage.

2.6. Inspect serviced ovens:

2.6.1. Make sure that the walls, hearths of furnaces are in good condition.

2.6.2. For moving hearth furnaces, check the operation of the tilting mechanism and the serviceability of its guard.

2.6.3. Check the operation of lifting and loading mechanisms.

2.7. Inspect and make sure (before firing up the furnace) that the lining, nozzles, air ducts, valves, as well as all devices and tools necessary for operation, are in good condition.

2.8. On furnaces that are heated with oil:

2.8.1. Check for oil leakage through leaky pipelines and shut-off valves (valves, gate valves).

2.8.2. Remove oil spills from the furnace and around the furnace.

2.8.3. Check the stove and chimneys by opening the dampers.

2.8.4. Before starting the injectors, check the fuel oil level in the service tanks.

2.9. On stoves that are heated by gas:

2.9.1. Make sure there are no gas leaks.

2.9.2. Check if all shut-off valves are closed.

2.9.3. Fire up the gas stove with the door open.

2.9.4. Ignite the burner with a torch on a long rod, standing away from the stove.

2.10. In electric furnaces, inspect the spirals, electrical wiring, starting devices and grounding of the metal body of the furnace, if they fail, call the electrician on duty.

2.11. Before turning on the electric furnace, check the reliability of the grounding of metal parts, the serviceability of the wires, make sure that there are no foreign objects.

2.12. Check ventilation and air curtain operation.

3. Safety requirements during work

3.1. When loading the furnace with a mixture, it is necessary to ensure that the wet mixture or mixture with ice or snow is thoroughly dried before loading and has the temperature of the smelting room.

3.2. In order to avoid splashing of metal, heavy pieces of charge (preheated) are loaded into the crucible (furnace) carefully.

3.3. The charge must not be allowed to hang on the walls of the furnace.

3.4. When opening the oven door, be careful not to burn yourself with hot gas.

3.5. When breaking additives and filler materials, beware of flying particles. This work should be done after making sure that no one is nearby.

3.6. When loading the furnace manually with batch pieces weighing more than 20 kg, mechanized loading devices should be used.

3.7. Wet and contaminated waste from cleaning the pits of casting machines should be stored separately and should be dried and cleaned of iron before loading into the furnace.

3.8. Wet waste must be loaded onto a dry oven floor under the supervision of a work manager.

3.9. It is forbidden to load waste contaminated with iron or its oxides (scale) into the furnace, because this can lead to an explosion.

3.10. The oven door must be closed while the oven is in operation. It can only be opened for loading, pouring metal and removing slag.

3.11. When loading melting furnaces and releasing metal, the gas supply should be turned off.

3.12. Moisture and rust must not be allowed to enter the molten metal.

3.13. To avoid splashing of metal, do not pour the sample into wet glasses. Knocking out the glass should be performed after the metal has completely hardened. Pliers for transferring a glass with a sample must have a serviceable notch on the cheeks.

3.14. When working with liquid metal, the eyes must be protected with goggles.

3.15. When using a metal tool (crowbar, scraper, spoon) that comes into contact with molten metal, canvas gloves should be worn.

3.16. If the working tool (shovels, sledgehammers, crowbars, etc.) overheats, it must be cooled in a barrel of clean water.

3.17. Tongs for pulling crucibles from furnaces should have reliable stops, and the cheeks of the pliers should tightly wrap around the crucible.

3.18. Do not place crucibles with molten metal on a wet floor, and crucibles must be stored in a dry place.

3.19. When releasing metal from the furnace, it is necessary:

3.19.1. Make sure there is no moisture in the chute and bucket.

3.19.2. Before installing the bucket for pouring, you must make sure that there is no moisture on the site.

3.20. When filling the ladle with metal, make sure that the ladle is installed along the axis of the chute, and the metal jet hits the center of the ladle.

3.21. Do not fill the bucket with metal to the top.

The metal level should not reach the sides: for manual buckets - by 40-50 mm, in those moved by lifting devices - by 100-150 mm (approximately 7/8 of its volume).

3.22. When refining an aluminum alloy with gaseous chlorine (from a cylinder), it is necessary:

3.22.1. Make sure that there is no leakage of chlorine from the cylinder and hose.

3.22.2. Lower the Karts tube along the center of the ladle (crucible) at a distance of at least 120-150 mm to the bottom.

3.22.3. Chlorine should be supplied only after the tube is in the desired position and with ventilation turned on, the tube should be removed only after the end of the chlorine supply.

3.22.4. If chlorine is exhausted into the room, you should immediately inform the manager about this, remove the workers nearby, put on a gas mask and take measures to degas.

3.23. When refining with zinc chloride, it should be stored in a hermetically sealed container. Before adding it must be dried and heated.

The additive is carried out by quickly lowering a special cone with zinc chloride to the bottom of the ladle (crucible).

3.24. Phosphorus addition should be carried out using special tongs. Phosphorus must first be dried. Store phosphorus in an airtight container.

3.25. When the supply of fuel oil or air to the oil furnace is stopped, immediately close the oil and then the air valves of the nozzle, and then close the main valves.

3.26. During operation, it is necessary to carefully adjust the nozzles, preventing incomplete combustion of fuel oil (black smoke).

3.27. It should be remembered that during the operation of the electric furnace, carbon electrodes and water-cooled electrode holders are energized. Work related to touching conductive parts should be performed only when the furnace is turned off, wearing rubber gloves.

3.28. At any position of the electrode relative to the furnace, flexible wires should not touch the metal structures of the furnace frame, fences, etc. Access to the wires is allowed only when the electric furnace is turned off.

3.29. When turning the oven on and off, wear rubber gloves and stand on a dielectric mat.

3.30. If it is not possible to turn off the high-voltage circuit breaker, the electrician on duty must be called.

3.31. Loading the charge and replacing the electrodes in the electric furnace should be carried out only after the voltage has been removed.

3.32. Spilling of metal must be carried out with a special spoon on a handle with a length of at least 1 m. Before proceeding with pouring, it is necessary to dry and clean the molds into which the metal is poured.

4. Safety requirements after finishing work

4.1. Stop the stove by gradually reducing the fuel and air supply. Disconnect the electric oven from the mains.

4.2. Tidy up the workplace.

4.3. Clean tools and accessories and put them in the place provided for them.

4.4. Take off overalls, personal protective equipment, clean them and put them in the place provided for them.

4.5. Wash hands, face with soap. Take a shower if possible.

4.6. Report to the head of work on all the shortcomings that occurred during work.

5. Safety requirement in emergency situations

5.1. An emergency situation may arise in the event of: electric shock, explosion, release of harmful substances, gas outflow, oil spill, etc.

5.2. In the event of an emergency, it is necessary to stop the operation of the furnaces in the above way, protect the danger zone, prevent unauthorized persons from entering it, and report what happened to the work manager.

5.3. If there are casualties, provide them with first aid. If necessary, call an ambulance.

5.4. Providing first aid.

5.4.1. First aid for electric shock.

In case of electric shock, it is necessary to immediately release the victim from the action of electric current by disconnecting the electrical installation from the power source, and if it is impossible to disconnect it, pull it away from the conductive parts by clothing or using insulating material at hand.

If the victim has no breathing and pulse, it is necessary to give him artificial respiration and indirect (external) heart massage, paying attention to the pupils. Dilated pupils indicate a sharp deterioration in the blood circulation of the brain. In this state, the revival must begin immediately, and then call an "ambulance".

5.4.2. First aid for injury.

To provide first aid in case of injury, it is necessary to open an individual package, apply a sterile dressing material, which is placed in it, to the wound and tie it with a bandage.

If somehow the individual package was not found, then a clean handkerchief, a clean linen rag, etc. must be used for dressing. On a rag that is applied directly to the wound, it is advisable to drip a few drops of tincture of iodine to get a stain larger than the wound, and then apply the rag to the wound. It is especially important to apply the tincture of iodine in this way to contaminated wounds.

5.4.3. First aid for fractures, dislocations, shocks.

In case of fractures and dislocations of the limbs, it is necessary to strengthen the damaged limb with a splint, plywood plate, stick, cardboard or other similar object. The injured arm can also be hung with a bandage or handkerchief from the neck and bandaged to the torso.

In case of a skull fracture (unconsciousness after a blow to the head, bleeding from the ears or mouth), it is necessary to apply a cold object to the head (a heating pad with ice, snow or cold water) or make a cold lotion.

If a fracture of the spine is suspected, it is necessary to put the victim on the board, without lifting him, turn the victim on his stomach face down, while observing that the torso does not bend in order to avoid damage to the spinal cord.

In case of a fracture of the ribs, a sign of which is pain during breathing, coughing, sneezing, movements, it is necessary to tightly bandage the chest or pull it off with a towel during exhalation.

5.4.4. First aid for thermal burns.

In case of burns with fire, steam, hot objects, in no case should you open the formed blisters and bandage the burns with a bandage.

For first-degree burns (redness), the burned area is treated with cotton wool soaked in ethyl alcohol.

For second-degree burns (blisters), the burned area is treated with alcohol or a 3% manganese solution.

For third-degree burns (destruction of skin tissue), the wound is covered with a sterile dressing and a doctor is called.

5.4.5. First aid for bleeding.

In order to stop bleeding, you must:

• raise the injured limb up;
• close the bleeding wound with a dressing (from a bag) folded into a ball, press it from above, without touching the wound itself, hold for 4-5 minutes. If the bleeding stops without removing the applied material, put another pad from another bag or a piece of cotton on top of it and bandage the wounded area (with some pressure);
• in case of severe bleeding that cannot be stopped with a bandage, compression of the blood vessels that feed the wounded area is applied by bending the limb at the joints, as well as with fingers, a tourniquet or a clamp. In case of heavy bleeding, you should immediately call a doctor.

5.5. If a fire occurs, start extinguishing with the available fire extinguishing equipment. If necessary, call the fire department.

5.6. Follow the instructions of the head of work to eliminate the emergency.

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