Occupational safety instructions for the asphalt concrete plant nozzle operator

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OCCUPATIONAL SAFETY AND HEALTH
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Occupational safety instructions for an asphalt concrete plant injector. Full document

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

General labor protection requirements

1. Persons who have reached 18 years of age, are recognized as fit for this work by a medical commission, have been trained in safe methods and techniques of work, and have a qualification certificate are allowed to work as an asphalt concrete plant injector.

2. An injector operator entering work must undergo introductory training on labor safety, environmental requirements and initial training at the workplace, about which entries must be made in the appropriate logs with the obligatory signature of the person being instructed and the person instructing.

3. Initial instruction at the workplace is carried out with each injector individually with a practical demonstration of safe techniques and work methods.

4. All injectors, after initial instruction at the workplace and testing of knowledge, for 2 to 5 shifts (depending on length of service, experience and nature of the work) perform work under the supervision of a foreman or foreman, after which they are issued permission to work independently. Admission to independent work is recorded by the date and signature of the instructor in the instruction registration log.

5. Repeated instruction of the injector is carried out at least once every 3 months.

6. When changing the technological process, replacing or upgrading equipment, devices, tools, if the injector violates safety requirements that can lead or have led to injury, accident, explosion or fire, as well as when there are breaks in work for more than 30 calendar days, an unscheduled briefing

7. About the repeated and unscheduled briefing, a corresponding entry is made in the briefing registration log at the workplace with the obligatory signature of the instructed and instructing.

8. When registering an unscheduled briefing, the reason that led to its holding is indicated.

9. The knowledge gained during the briefing is checked by the employee who conducted the briefing.

10. An injector operator who has received instructions and has demonstrated unsatisfactory knowledge is not allowed to work. He must undergo training again.

11. Every year, injectors must undergo testing of knowledge of safe methods and techniques of work, about which a corresponding note is made on the certificate. The results of testing knowledge of safety requirements are documented in the minutes of the commission meeting.

12. The injector must know:

manufacturer's instructions for the installation of nozzles and communications;
principles of operation of nozzles, methods of their regulation, removal, cleaning and installation;
instructions for labor protection;
internal regulations and requirements for compliance with work and rest schedules;
installed sound and light alarms.

13. At the workplace of the injector must be:

necessary locksmith tools and inventory;
fire fighting equipment;
personal protective equipment and first aid;
drinking boiled water.

14. The injector must work in special clothing, safety shoes and other personal protective equipment established by regulations and provided for by the collective agreement.

15. The nozzle operator must keep his workplace clean and tidy. There should be no foreign objects in the workplace.

16. The presence of unauthorized persons in the working area of the injector is prohibited.

17. Admission of an injector while intoxicated to the workplace is prohibited. An injector who finds himself drunk while on duty is immediately removed from work and held strictly accountable in accordance with current legislation.

18. The injector must comply with occupational safety requirements. In case of violations, he is obliged to take possible measures to prevent and eliminate the danger and report this to the foreman or foreman.

19. The workplace of the injector must have sufficient lighting (50 lux).

20. Each injector must have a valve on the side to regulate the fuel supply.

21. The distance from the main fuel lines to the injectors must be at least 2 meters.

22. For failure to comply with the requirements of the labor protection instructions developed on the basis of this Standard Instruction, the injector is liable in accordance with the internal labor regulations and current legislation.

Safety requirements before starting work

23. Before starting work, the nozzle operator must:

put on overalls and safety shoes, prepare personal protective equipment;
read the logbook with records of the operation of nozzles and communications in the previous shift;
receive from the foreman or foreman precise and specific instructions on how to complete the task, safe techniques and work methods;
check the serviceability of communication and signaling equipment;
check the availability and completeness of the necessary tools and devices;
check the availability of fire extinguishing equipment and first aid.

24. Before igniting a nozzle operating on liquid fuel (fuel oil), it is necessary:

check the presence and serviceability of flame shields;
to avoid an explosion, make sure there is no fuel in the firebox and, if there is any, remove it by wiping the inside of the firebox with a rag;
check the pressure of liquid fuel (fuel oil) in the fuel line;
ventilate the furnace for 10 - 15 minutes;
if there is a fan for air supply, ventilate the firebox with the fan turned on;
Check for air vacuum in the firebox (up to the damper), and adjust the draft if necessary.

25. Before lighting a gas burner:

open the valve valve on the purge candle;
check gas pressure and vacuum in the furnace;
ventilate the furnace for 10 - 15 minutes;
check the presence of traction in front of the gate;
purge the gas line through the purge plug for 2 minutes.

26. Gas pipelines must have a hermetically sealed connection that prevents gas leakage.

27. The nozzle operator must report the results of checking the nozzle (gas burner) and communications to the foreman or foreman. Take appropriate measures if necessary.

28. It is prohibited to ignite a faulty nozzle (burner). After eliminating the malfunction, ignition should only be performed with the permission of the foreman or foreman.

29. The nozzle operator must ignite the nozzle (burner) only with the permission of the foreman (foreman) 2 - 3 minutes after receiving the general signal to start work.

30. When igniting and adjusting the nozzle, the nozzle operator must be on the side of the firebox. Do not stand in front of the nozzle.

31. In the absence of automatic ignition, the injector must be ignited with a torch made of oil (fuel oil) rags or rags soaked in oil, wound on a piece of thick wire (rod) at least 1,5 m long.

32. It is prohibited to use flammable liquids (gasoline, kerosene, etc.) for ignition, or to ignite when cleaning the mixer tray or a faulty firebox.

33. When igniting a liquid fuel injector, you must:

light a kindling torch;
insert a burning pilot torch into the firebox and at the same time open the nozzle spray valve;
gradually open the valve installed on the oil line;
by changing the supply of fuel, steam or air, adjust combustion;
When the combustion becomes stable, remove the pilot torch from the firebox and extinguish it in a metal box with water.

34. When igniting a gas burner, you must:

light a kindling torch and, inserting it into the furnace, light the burner;
after heating the ceramic nozzle, turn on the air blast completely;
bring the burner to operating mode, adding gas first, and then air;
when the combustion decreases, first reduce the air supply, and then the gas.

35. If, when igniting, adjusting or during operation of the nozzle (burner), the flame comes off, flashes or fades, it is necessary to turn off the burner and eliminate the malfunction.

Safety requirements during work

36. During work, the nozzle operator must:

regulate the supply of fuel and air required for combustion in the stove or firebox through the nozzles;
comply with the specified technological mode of production;
monitor the readings of instrumentation;
monitor the condition of the injectors and related communications.

37. When operating burners using gaseous fuel, it is necessary to monitor the gas pressure using a pressure gauge, which must be within the limits specified in the burner passport (0,35 - 0,4 kgf/sq. cm, 0,035 - 0,04 MPa).

38. When operating the injector on liquid fuel (fuel oil), it is necessary to monitor the pressure using a pressure gauge installed in the fuel line. It is necessary to maintain the pressure within 1,5 - 2 kgf/sq.m. cm.

39. To ensure complete combustion of fuel with maximum heat transfer, it is necessary to ensure the correct supply of air and fuel to the firebox.

Normal injector combustion is characterized by a bright, dazzling flame and the absence of smoke and soot in the exhaust gases.

40. When an insufficient amount of fuel is supplied to the firebox, a “lean mixture” is obtained, which is characterized by inconsistent intermittent combustion and the absence of a dazzling flame. In this case, it is necessary to open the fuel supply valve at the same opening of the air throttle, achieving normal combustion.

41. When an excess amount of fuel is supplied to the firebox, a “rich mixture” is obtained, in which all the fuel does not have time to burn and exits along with the flue gases, forming black smoke. In this case, it is necessary to reduce the fuel supply by closing the fuel system valve, achieving normal combustion.

42. Lean and rich mixtures reduce the temperature of the injector flame due to chemical incomplete combustion, which leads to excessive fuel consumption.

43. With a smoky flame, increase the air supply to the burner. To reduce the intensity of combustion, you must first reduce the air supply and then the gas supply.

44. It is prohibited to re-ignite the nozzle without first ventilating the firebox and drying drum.

45. The nozzle operator of an asphalt concrete plant is prohibited from:

supply a large amount of fuel when igniting the nozzle, since if there is insufficient steam or air pressure, incomplete combustion of the fuel may occur and its accumulation in the mixer drum will cause an explosion;
operation of drying drums in case of malfunction of furnaces, gas burners or nozzles operating on liquid fuel;
operation of drying drums if there is an emission of burner flames into the atmosphere through pilot holes, cracks in the frontal part of the furnace and labyrinth seals;
supply fuel to the injector when the flame goes out.

Safety requirements in emergency situations

46. In the event of a fire, explosion, or interruption in the supply of electricity, air, or fuel, an emergency stop of work is carried out; in this case, it is necessary to turn off the fuel supply motor, extinguish the firebox, inform the foreman or responsible worker about the incident and begin to eliminate the emergency situation.

47. If clothes catch fire, it is necessary to throw a tarpaulin, padded jacket or coat over the victim, extinguish the fire, immediately remove burnt clothing and begin providing first aid to the victim in accordance with "Instructions for providing first aid in case of accidents".

Safety requirements at the end of work

48. After receiving a general signal about the end of work:

the supply of mineral material to the dryer is stopped;
The injector reduces the amount of fuel and air supplied to the injector.

49. Upon completion of drying of the mineral material located in the drying drum, the injector turns off the electric motor for supplying fuel to the injector. To ensure uniform cooling of the drying drum and the dust removal unit, to avoid deformation of individual parts and to ventilate the drum from explosive gases accumulated in it, the fan continues to supply air to the rotating drying drum for 5 - 12 minutes.

50. After the drying drum, oven, firebox, nozzle and other communications have completely cooled, the nozzle operator must:

ventilate the firebox, oven for 10 - 15 minutes;
turn off the electric motor driving the fan of the dust cleaning unit and the air supply fans to the nozzle;
clean nozzles, taps, fuel and air lines, fuel supply pumps, fans, communications and other equipment of the technological cycle;
to make, if necessary, a change of nozzles;
put tools and equipment in the designated place.

51. During shift work, the nozzle operator must transfer the shift to the shift worker, inform him about the operation of the nozzle and communications, entries in the work log, possible cases of emergency, violations of labor safety and measures taken.

52. Delivery and acceptance of shifts to be carried out in the presence of a foreman or foreman.

53. Put workwear, safety shoes and other personal protective equipment in order and put them in the designated place.

54. At the end of the shift, you should clean your hands from fuel oil using soap-lanolin paste, wash your face and hands with warm water and soap, or take a shower and change clothes.

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