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OCCUPATIONAL SAFETY AND HEALTH
Instructions for labor protection when pickling metals
Occupational Safety and Health / Standard instructions for labor protection Safe Operation 1. General safety requirements 1.1. On the basis of this instruction, labor protection instructions are developed for workers employed in the processes of applying metal coatings during pickling of metals (hereinafter referred to as workers engaged in pickling of metals). 1.2. Workers aged at least 18 years old who have mastered safe methods and techniques for performing work, methods and techniques for the correct handling of mechanisms, devices, tools, as well as with loads, are allowed to perform metal etching. 1.3. To work on hoisting machines controlled from the floor, to hang the load on the hook of such machines, workers are allowed at least 18 years old, trained in a special program, certified by the examination committee of the organization and having a certificate for the right to use hoisting machines and hooking loads. 1.4. When performing work, it is necessary to comply with the accepted technology. It is not allowed to use methods leading to violation of labor safety requirements. 1.5. In case of any questions related to its safe performance in the process of work, you must contact your immediate or higher manager. 1.6. Employees engaged in pickling metals are required to comply with the internal labor regulations of the organization. 1.7. When pickling metals, the worker may be exposed to dangerous and harmful production factors:
Therefore, failure to follow this instruction may result in poisoning, chemical burns, or electric shock to workers. 1.8. Workers engaged in pickling metals must be provided with personal protective equipment. 1.9. The room in which metal pickling is carried out must be isolated from other production areas and equipped with a supply and exhaust ventilation system with air purification. Supply and exhaust shop and exhaust ventilation from workplaces in the form of side suction should be checked daily and maintained in good condition. 1.10. Analysis of the state of the air environment in the production room should be carried out in accordance with the schedule approved by the employer. 1.11. Pickling baths should be installed so that the upper sides are 1 m from the floor, and workers do not have to bend over the baths when loading and unloading parts. 1.12. Hanging devices (traverses, baskets and others) must be durable and comfortable, made of a material resistant to acids and alkalis. 1.13. Baths for etching must be equipped with side suction. Local exhaust ventilation in baths operating at elevated temperatures should be switched on from the beginning of bath heating, and switched off after complete cooling. 1.14. Baths containing substances of hazard classes 1,2 and XNUMX, as well as solutions accompanied by the formation of fog with a high concentration of acid and alkali vapors, must be equipped with lids and filling devices. 1.15. Baths with solutions heated to high temperatures, with harmful emissions, as well as with long-term operations of the technological process, in addition to side suctions, must have lids that are closed during operation. 1.16. The internal surfaces of baths for aggressive substances, as well as pipelines to them, should be made of corrosion-resistant materials or coated with them. 1.17. Aluminum pickling baths must be equipped with lids, the opening and closing of which must be mechanized. 1.18. In the chemical processing of magnesium and its alloys, it is necessary to strictly comply with fire safety requirements. It is not allowed to get concentrated nitric acid on products made of magnesium and its alloys. To prevent ignition of products made of magnesium alloys, it is necessary that the concentration of nitric acid in the pickling bath be no more than 30 g/l. 1.19. When pickling magnesium and titanium alloys, the use of technological equipment (suspension brackets, grids, etc.) made of steel is not allowed. Steel hangers must be insulated with polymeric materials. 1.20. It is not allowed to store acids and alkalis in the room where magnesium and titanium products are processed. 1.21. Ventilation from fume cupboards or etching baths for copper and its alloys should be capable of removing nitrogen oxides and other harmful emissions. The use of heated pickling solutions is not allowed. 1.22. When pickling titanium and its alloys:
Etching in a caustic melt with oxidizing agents at temperatures above 470°C is not allowed due to the possibility of ignition of titanium in the melt, explosion and splashing of an alkaline solution, especially when processing thin sheets. Contact of titanium and its alloys with fuming nitric acid is not allowed. When titanium ignites in an alkali melt, it is necessary to immediately turn off the bath and unload the parts. 1.23. Devices installed near the baths must be protected from the ingress of electrolyte into them, the influence of magnetic fields, temperature, chemical effects of the environment and mechanical damage. 1.24. In the event of an accident, a metal pickling worker must stop work, notify their immediate or superior supervisor, and seek medical attention. 1.25. An employee engaged in pickling metals must observe the rules of personal hygiene: before eating and after finishing work, wash their hands with warm water and soap. Food must be taken in rooms specially equipped for this purpose. 1.26. Workers involved in pickling metals should be able to provide first aid to the victim. 1.27. Metal pickling workers who do not comply with the requirements of this instruction are held liable in accordance with applicable law. 2. Safety requirements before starting work 2.1. Inspect the workplace, put it in order, clear the aisles and do not clutter them up. 2.2. Inspect, tidy up and put on personal protective equipment. 2.3. When working at baths, lubricate the mucous membrane of the nose, hands, face with petroleum jelly or lanolin. 2.4. Do not work with electrolytes if the skin on the hands and face is damaged. 2.5. Make sure the floor is dry and the foot grate next to the tub is stable and in good working order. 2.6. Prepare the necessary tools and fixtures for work in accordance with the requirements of the technological documentation. 2.7. Parts degreased in trichlorethylene should be pre-washed in water before immersion in strong alkalis to avoid the formation of monochlorethylene (self-igniting substance). 2.8. Check availability and serviceability:
2.9. Place the parts in the bath in accordance with the requirements of the technological documentation. 2.10. Check the illumination of the workplace. The voltage of local lighting should not exceed 50 V. 2.11. When working with lifting mechanisms, it is necessary to check their serviceability and comply with the requirements of the relevant labor protection instructions. 3. Safety requirements during work 3.1. Keep the work area clean and free from clutter. 3.2. It is not allowed to check the fastening of parts on the hangers by shaking them over the bathtub. 3.3. Prepare pickling solutions strictly following the following sequence:
3.4. Solutions for etching carbon steels are prepared by pouring a thin stream of sulfuric or other acid into cold water, with thorough mixing. To reduce the release of hydrogen and harmful gases during etching of ferrous metal parts, cover the bath mirror with special additives. 3.5. Before pickling parts with thick scale, it is necessary to loosen the oxides in hot strong alkali. 3.6. With the electrolytic pickling method, it is not allowed to load, unload, shake parts, clean the rods and fix contacts while the bath is operating with the power turned on. 3.7. Set the pickling mode, especially the temperature of the solution and the duration of exposure of the parts in the pickling bath, in accordance with the requirements of the technological documentation. 3.8. It is not allowed to heat pickling solutions with sulfuric acid to a temperature above 80°C, and with hydrochloric acid - above 35°C. When pickling, an automatic temperature controller must be used. 3.9. When the ventilation is turned off, stop work. 3.10. Transport the cleaned parts using a lifting mechanism to a designated area for drying. 3.11. Manage the transport operation and stack the parts in such a way that they are in a stable position. 3.12. Check the serviceability of the system of interlocks, alarms, limit switches and devices for hanging parts and the reliability of their fastening. 3.13. Do not allow unauthorized persons who are not related to this work to pickle metals. 4. Safety requirements in emergency situations 4.1. When ventilation is turned off, work must be stopped. Workers must leave the premises immediately and tightly close doors leading to other premises. 4.2. When titanium ignites in the alkali melt, turn off the bath and unload the parts. Dry sand, dolomite dust, fire extinguishers charged with powder substances should be used to extinguish burning titanium. The use of water, carbon dioxide, nitrogen to extinguish titanium is not allowed. 4.3. If acid or alkali gets on an open part of the body, it is necessary to wash the affected areas with water, and then neutralize:
4.4. In case of poisoning with acid vapors, take the victim to fresh air and free from clothing that restricts breathing, call medical personnel with an oxygen bag. Artificial respiration in this case is contraindicated. 4.5. In case of injury, poisoning and sudden illness, the victim should be provided with first (pre-medical) aid and, if necessary, his delivery to a healthcare facility should be organized. 4.6. In case of electric shock, take measures to release the victim from the action of the current as soon as possible. 4.7. When rotating parts of machines, slings, cargo hooks and other equipment capture parts of the body or clothing, give a signal to stop work and, if possible, take measures to stop the machine (equipment). You should not try to free yourself from the grip if it is possible to attract others. 4.8. In the event of a fire:
5. Safety requirements at the end of work 5.1. Turn off the current on the bath. 5.2. Tidy up the workplace, put the tools and fixtures in the tool box. 5.3. Before handing over the shift, check the serviceability of the pickling bath:
Record the results of the check in the shift acceptance and delivery log, inform the foreman about malfunctions. 5.4. Remove overalls and other personal protective equipment and hang in a specially designed place. 5.5. Wash hands and face with warm soapy water, rinse mouth and shower.
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