Instructions for labor protection during gas-thermal and electric-arc coating

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Instructions for labor protection during gas-thermal and electric-arc coating

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General requirements for labor protection

1.1. To perform work on applying coatings by gas-thermal and electric arc methods (hereinafter referred to as spraying), men are allowed at least 18 years old who have passed a medical examination, appropriate training and instruction, testing knowledge of labor protection requirements and having practical skills in equipment maintenance.

1.2. The admission to the work of a metallizer is issued by order of the organization after an introductory briefing and the issuance of a certificate of knowledge testing on labor protection.

1.3. Repeated briefing and testing of knowledge on labor protection and industrial sanitation should be carried out at least once a quarter with a mark in a special journal and a personal card of the metallizer.

At least once a year, knowledge is tested by a specially created commission chaired by an employee appointed by the employer. The results of testing the knowledge of metallizers must be documented in a protocol, the number of which is affixed to the certificate and approved by the seal of the organization.

1.4. Employees should undergo periodic medical examinations in the prescribed manner.

1.5. The employee is obliged to comply with the work and rest regime established in the organization.

1.6. In the process of spraying, the worker may be exposed to the following hazardous and harmful production factors:

increased dust content and gas contamination of the working area;
high frequency noise;
increased level of ultrasound;
increased brightness of light;
increased surface temperature of the product and equipment;
neuropsychic overload.

1.7. When preparing the surface of the base metal before spraying, the following safety measures must be taken:

mechanization and automation of the process;
sealing processes that are a source of harmful and dangerous production factors;
the use of ventilation and local suction;
use of blocking systems;
the use of screens, casings and other fences;
providing acoustic protection;
use of dust collection systems.

1.8. In shot-blasting chambers, blocking of starting devices with loading ones must be ensured.

1.9. The use of dry quartz sand for cleaning parts is not allowed.

1.10. When cleaning the surface of the base metal for spraying, it is necessary to ensure the tightness of the chambers and their remote control.

1.11. The start of cleaning chambers (drums) should be blocked with the start of ventilation.

1.12. Compressed air must be passed through an oil-moisture separator before entering the cleaning chambers.

1.13. Operations for filling and cleaning powders into the hoppers of spraying installations should be carried out using local suction or in special chambers and cabins equipped with exhaust ventilation.

1.14. When carrying out manual spraying processes, portable local suctions should be used to ensure that the concentration of harmful substances in the air is not higher than the permissible ones.

1.15. When applying coatings by the thermal method, the following requirements must be observed:

injection in the gas channels of the spray burner must be at least 0,012 MPa;
all components and parts associated with the communication of combustible gases must be sealed;
when powered from the mains, in places where oxygen and combustible gases are consumed, gas dismantling posts equipped with gates should be installed to prevent the spread of a reverse blow into the gas pipelines;
when powered from single cylinders, a safety device should be installed between the cylinder reducers and the metallizer.

1.16. The design of the burner for gas-thermal coating when igniting a combustible mixture must ensure ignition without backfire.

1.17. When applying coatings by the electric arc method, the following requirements must be met:

the open-circuit voltage of the DC power source in the manual process should not exceed 80 V, in the automatic or mechanized process - 90 V;
spray heads of electric arc devices must ensure stable burning of the electric arc;
the electric metallizer must be equipped with a device to protect workers from the action of an electric arc;
the section of the current-carrying wires to the electric metallizer must ensure long-term operation without heating above 50 ° C;
fastening of sleeves to the air pipeline and the fitting of the apparatus must be reliable and exclude the possibility of failure.

1.18. Manual application of coatings should be carried out in soundproof booths or in special areas, using soundproof casings.

1.19. The presence of outsiders in the area of cleaning and coating equipment during its operation or adjustment is not allowed, which must be ensured by the presence of safety signs made in accordance with GOST 12.4.026.

1.20. When performing spraying work, metallizers must be provided with personal protective equipment (PPE).

1.21. Protective equipment issued on an individual basis during work must be at the workplace of the metallizer.

1.22. When carrying out work on coating, the affecting noise should not exceed the values established by GOST 12.2.003. If the maximum permissible noise levels are exceeded, workers must use anti-noise headphones.

1.23. When carrying out coating work in closed vessels, as well as when spraying materials that emit toxic fumes and dust (lead, zinc, tin, copper, cadmium), it is necessary to use helmet masks with forced air supply for breathing.

1.24. To protect the eyes from flames and particles of molten metal, the operator must use safety goggles ZP with light filters.

1.25. Overalls should be comfortable and not hamper the movements of the metallizer, protect him from sparks and splashes of molten metal, industrial pollution.

1.26. All overalls of metallizers must be washed periodically.

1.27. Metal workers must be provided with gloves to protect their hands.

1.28. It is forbidden to use overalls and gloves made of synthetic materials.

1.29. The metallizer, in addition to these instructions, must know:

emergency response plan at your workplace;
instruction manual for the metallizer;
fire safety instructions at your workplace;
rules for the use of PPE;
rules for providing first aid in case of accidents;
personal hygiene rules.

1.30. Personnel must be able to provide first aid in case of poisoning, burns of the skin and mucous membranes, electric shock.

When carrying out coating work in a specially designated place, there should be first aid equipment: sterile dressing material, hemostatic tourniquet, adhesive plaster, bandages, iodine tincture, ammonia, washing syringe, burn ointment.

1.31. Employees are responsible for violation of the requirements of this instruction in accordance with applicable law.

2. Labor protection requirements before starting work

2.1. Inspect, tidy up and put on overalls and safety shoes.

2.2. Check the serviceability and completeness of the PPE.

2.3. Inspect the workplace, remove from it everything that may interfere with work, clear the aisles and do not clutter them up.

2.4. Prepare a soapy solution to check the tightness of the equipment connections.

2.5. Check the availability of equipment for spraying (metallizers), sleeves, power supplies.

2.6. Check the serviceability of hoses, tools, fixtures, pressure gauges, gearboxes, the presence of suction in the equipment.

2.7. Check the tightness of all detachable and solder joints.

2.8. Remove oil and moisture from the air or gas transported by the sprayed material.

2.9. Check ventilation operation.

2.10. Check if the lighting is working.

2.11. Inspect primary fire extinguishing equipment and make sure they are in good working order.

3. Labor protection requirements during work

3.1. Spraying work should be carried out only in overalls and with the use of PPE.

3.2. Before connecting the regulator to the cylinder valve, check:

the presence of seals or other marks (paint) on the safety valve, indicating that the factory or after repair adjustment is not violated;
serviceability of the pressure gauge and the period of its verification;
the state of the thread of the fittings;
the presence of a gasket in the valve;
the presence of filters in the inlet fittings.

3.3. The fastening of the sleeves on the connecting nipples of the metallizers must be reliable; for this, special clamps must be used.

3.4. For gas metallizers:

carry out a preliminary adjustment of the powder or wire feed speed;
light a standby gas flame, and then select a predetermined powder or wire feed rate;
carry out spraying, evenly moving the metallizer; the distance of the spray nozzle from the base metal surface should be 150 - 180 mm.

3.5. For electrometallizers:

open the air cock;
lay the wire on the coil so that it unwinds during operation; the wire must be clean, smooth, without oxides and films;
charge the device with a wire;
with the power off, adjust and adjust the spray head;
turn on the wire feed: the end of the wire should be in the center of the air nozzle at a distance of 2 - 3 cm from the outer end of the nozzle;
to carry out spraying: for optimal results, work with the maximum compressed air pressure (0,5 - 0,6 MPa).

3.6. When applying coatings, heating of the metallized surface above 70°C should be avoided.

3.7. It is forbidden to use metallizers for thermal spraying when:

injections in gas channels less than 0,12 MPa;
violation of the tightness of components and parts of the metallizer;
with uncleaned from oil and moisture air or other gas transporting the spray material.

3.8. It is forbidden to use an electric arc metallizer:

without a protective screen on the air cap;
with a faulty device;
without PPE.

3.9. It is forbidden to adjust and adjust the spray head of the electric arc apparatus under voltage.

3.10. It is forbidden to repair metallizers and other equipment at the workplace.

4. Labor protection requirements in emergency situations

4.1. In the event of dangerous situations that can lead to accidents or accidents, the metalworker is obliged to report the emergency to the head of the workshop or labor protection engineer.

4.2. If flashback occurs, immediately close the gas metallizer valves and cool the spray head.

4.3. If an internal or external source of heating (ignition) appears, which can lead to an explosion of cylinders, it is necessary to immediately evacuate the cylinders. If it is impossible to remove them from the danger zone, it is necessary to cool the cylinders with water until they are completely cool.

4.4. In the event of a fire, you must:

stop working;
turn off the equipment in use;
call the fire brigade, inform the work manager and start extinguishing the fire with the available means.

4.5. In case of an accident, the victim or eyewitness is obliged to notify the head of the shop (shift) or foreman, who must organize the provision of first aid to the victim.

4.6. In case of injury, immediately stop work, notify the supervisor and seek medical attention.

5. Labor protection requirements at the end of work

5.1. After stopping the operation of the gas metallizer, it is necessary:

close the valves of all cylinders;
release gases from all communications;
release the pressure springs of the gearboxes;
detach the sleeves;
clean the metallizer from accumulated dust and wipe thoroughly;
blow out the metallizer with compressed air.

5.2. After stopping the operation of the electrometallizer, it is necessary:

turn off the wire feed;
turn off the current;
close the air cock;
clean the metallizer from accumulated dust and wipe thoroughly;
blow compressed air through the drive and pressure rollers of the wire feed mechanism;
after 30 hours from the start of work, change the lubricant in the gearbox.

5.3. Remove and put in order overalls, PPE.

5.4. Wash face and hands with warm water and soap, take a shower.

5.5. Turn off the lights.

5.6. Report to the foreman about the completion of work and leave your workplace only with the permission of the foreman.

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