Occupational safety instructions for the kiln operator on the maintenance of tunnel kilns powered by natural gas

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Occupational safety instructions for the kiln operator on the maintenance of tunnel kilns powered by natural gas

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General provisions

1.1. This instruction contains requirements for ensuring the safe operation of tunnel furnaces operating on natural gas.

1.2. Persons at least 18 years of age who have undergone special training, a medical examination, and have a certificate with a photo for the right to service stoves operating on gaseous fuel are allowed to service furnaces.

1.3. Personnel re-inspection is carried out at least once every 12 months.

1.4. When entering duty, personnel are required to familiarize themselves with the entries in the log, check the serviceability of the equipment and all stoves, gas equipment installed in the workshop, and the serviceability of lighting and telephones.

Acceptance and handover of duty must be documented by the shift supervisor with an entry in the shift log indicating the results of checking the furnaces and related equipment (pressure gauges, safety valves, feeding devices, equipment automation equipment).

1.5. It is not allowed to accept and hand over the shift during the liquidation of the accident.

1.6. Unauthorized persons access to the workshop is allowed by the head of the enterprise.

1.7. The workshop premises, furnaces and all equipment, passages must be kept in good condition and proper cleanliness.

1.8. Exit doors should open easily to the outside.

1.9. The burner's responsibilities include:

conducting the process of firing bricks with natural gas, monitoring and regulating the operation of burners, checking gas and air pressure;
monitoring the fuel combustion process and compliance with temperature conditions;
observance of the established mode of pushing the trolleys into the furnace;
keeping a log of the operation of furnaces and recording instrumentation readings.

1.10. The roaster is responsible for the safe operation of tunnel kilns. Operation must be carried out in accordance with the "Safety Rules in the Gas Industry".

2. Safety requirements before starting work

2.1. Accept a shift from the previous burner with a signature indicating acceptance of the shift in the logbook.

2.2. Check the serviceability of the furnace and flue ducts of furnaces, shut-off and control devices;

serviceability of instrumentation, fittings, feeding devices, fans;
serviceability of equipment for burning gas fuel;
absence of plugs on the gas pipeline, feed materials, purge lines.

2.3. Check on the pressure gauge that the pressure of the gas and air in front of the burners is consistent with the fan running.

2.4. In the event of a malfunction of the safety automation, stop work and report to the shift foreman. Resuming work if the safety automatic system malfunctions is possible only with the written permission of the shift foreman, which must indicate safety measures.

2.5. If the gas equipment was turned off during the period of major repairs of the furnaces, putting them back into operation is permitted only with the written permission of the person responsible for the safe operation of the gas equipment of the workshop.

2.6. Make sure that the gas pressure in the GRU corresponds to the working pressure

3. Furnace emergency shutdowns

3.1. The automatic safety system does not work (there is no voltage on the panel, the magnetic heads do not work, the SPD does not work, the control light on the panel does not light up.

3.2. When the fan and smoke exhauster stop.

3.3. With a decrease in vacuum less than 0,5 mm of water column.

3.4. With decreasing and increasing gas pressure.

3.5. When the power supply is interrupted.

3.6. In the event of a fire that threatens the operating personnel and the furnace.

3.7. When slipping and tearing off the burner flame

3.8. When a gas pipeline breaks inside the workshop.

3.9. Sudden interruption of gas supply.

3.10. In the event of an emergency stop of the furnace, you must:

stop the supply of gas, air, open the valve of the purge plug;
in the event of a fire, personnel must call the fire brigade and take all measures to extinguish it, while continuing to monitor the boilers.

4. Safety requirements at the end of work

4.1. Tidy up the workplace

4.2. Hand over the shift to the shift manager, recording in the log all comments on the operation of the gas equipment, and sign in the log about the handover of the shift.

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