Safety Technical Operating Procedures for Coal Powder Preparation

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Safety Technical Operating Procedures 1. Students working at this position must abide by these safety technical rules in addition to carefully following the safety operating procedures specific to that position. 2. Before starting work, one must wear the appropriate clothing as required; female staff must wear work hats, otherwise they are not allowed to carry out operations. 3. Before starting any equipment or tools, it is necessary to check and confirm that they are safe before using them. 4. It is strictly prohibited to leave one’s post or be absent from it during the furnace heating process. 5. After work, carry out proper handover procedures; if no handover is required, turn off the power supply, extinguish any flames, clean the work area, and only leave after ensuring it is safe. 6. The processed workpieces should be stacked neatly in designated areas, ensuring safety and unobstructed passages, with the work area kept clean. 7. The maximum operating temperature of the combustion chamber shall not exceed 900 ℃; anyone who violates this rule shall bear the resulting consequences (use in special cases requires approval from the supervising authority). 8. Operators must receive specialized training and work with a valid certificate after passing the assessment. 9. Strictly follow the operating procedures. One must achieve the “three understandings and three abilities” (understanding the fire hazards associated with one’s own position, knowing the measures to prevent fires, and understanding how to extinguish fires in their early stages) ； Know how to use fire extinguishing equipment, handle emergencies that arise, and call the police). 10. Formulate and implement various post responsibility systems and safety regulations. 11. Equipe or install smoke and dust prevention as well as spark extinguishing devices to prevent the spread of flying sparks. 12. In coal-fired furnaces, it is necessary to carefully inspect and remove items such as *pipes from the coal pile at the time of feeding coal. And submit it to the security department in a timely manner. 13. Coal powder handling workshops that use coal powder are explosive hazard areas, and their electrical equipment must meet fire and explosion prevention requirements ； During the preparation and transportation of pulverized coal, it is necessary to control the temperature of the coal powder, and steam or spray water fire extinguishing equipment should be installed in the workshop. 14. Before ignition, the coal dust in the combustion furnace should be removed, and it is necessary to check whether the explosion-proof door is functional ； After ignition, the coal powder amount, as well as the air volume and wind speed, need to be adjusted appropriately. 15. Conduct regular maintenance; the ash and dirt inside the combustion chamber should be removed promptly. Fire safety requirements for the pulverized coal preparation workshop: 1. Operators must receive specialized training and work with a valid certificate after passing the training. 2. Strictly follow the operating procedures. One must achieve the “three understandings and three abilities” (understanding the fire hazards associated with one’s own position, knowing the measures to prevent fires, and understanding how to extinguish fires in their early stages) ； Know how to use fire extinguishing equipment, handle emergencies that arise, and call the police). 3. Formulate and implement various post responsibility systems and safety regulations. 4. Equip or install smoke and dust prevention as well as spark extinguishing devices to prevent the spread of flying sparks. 5. In coal-fired burners, it is necessary to carefully inspect and remove items such as *pipes from within the coal pile at the time of feeding coal. And submit it to the security department in a timely manner. 6. Large combustion furnaces that use coal powder – the coal powder handling area is a place with explosion hazards, and its electrical equipment must meet fire and explosion prevention requirements ； During the preparation and transportation of coal powder, it is necessary to control its temperature, and steam or spray water fire extinguishing equipment should be installed in the workshop. 7. Before ignition, the coal dust in the furnace of a pulverized coal boiler should be removed, and it is necessary to check whether the explosion relief valve is reliable ； After ignition, the coal powder amount, as well as the air volume and wind speed, need to be adjusted appropriately. 8. In the inlet pipe ahead of the coal-burning nozzle, a pressure gauge should be installed. During operation, the speed at which fuel is ejected from the nozzle must be greater than its flow velocity, in order to maintain positive pressure in the furnace and prevent backflow ； When the gas pressure drops to the minimum level, the fuel gas inlet pipe should be closed immediately to stop usage. 9. Before igniting the combustion furnace, check the pressure in the intake pipe; only when the pressure is within the required range should a blower be used to purge the furnace chamber and remove any explosive mixtures present there. It is essential to strictly follow the procedure of lighting the furnace first and then supplying gas. 10. Conduct regular maintenance; scale and dirt inside the boiler should be removed promptly. 11. After the combustion furnace is put into operation, various technical performance tests, pressure tests, and calibrations should be carried out regularly as specified. Only those who pass can continue to use it. Purpose of the Pulverized Coal Preparation Workshop Management System: The following management system is established in order to maintain good production order, improve labor productivity, and ensure the smooth progress of production activities. Scope: Applicable to all staff in the production workshop. 1.0 Leave Policy 1.1 If there are special circumstances that require personal handling, a written request for leave must be submitted 24 hours in advance. The leave will only take effect after it is signed by the relevant supervisor; it is not allowed to ask someone else to submit the request on one’s behalf or to apply for leave after the fact (in cases such as illness, a medical certificate must be provided if leave is applied for later). Otherwise, it will be treated as absenteeism. 1.2 Except in cases of illness or special circumstances requiring leave, no leave is permitted under any other circumstances. 1.3 Private requests for leave or approvals for leave outside working hours are strictly prohibited; those who violate this rule will be fined at least 10 yuan. 2.0 Cleaning and Hygiene Regulations 2.1 Each shift is responsible for maintaining the cleanliness of its own area, and everyone must be responsible for keeping the area assigned to them clean. 2.2 Cleaning must be done every day after work, and a thorough cleaning is required on Wednesdays and Sundays (the doors, windows, production lines, parts tables, etc. in the workshop must all be cleaned). 2.3 Garbage and waste cardboard from Workshop 2.3 must be disposed of in the designated garbage area; it is not allowed to discard them anywhere else. Those who violate this rule will be fined 20 yuan per incident. 2.4 Waste tools and broken glass must be removed promptly, and items in the workshop should be placed neatly in their designated locations; they must not be left scattered around. 2.5 After use, cleaning tools must be thoroughly washed and placed in designated areas; they should be kept under the responsibility of designated personnel, and must not be discarded carelessly, turned upside down, or damaged. 2.6 The workshop must be kept clean and tidy; spitting, discarding paper scraps, cigarette butts, or other debris is prohibited. Those who violate this rule will be fined 10 yuan per incident. 2.7 Employees must keep their work areas clean, and team leaders must keep their desks tidy and clean ； A fine of 10 yuan per violation will be imposed. 2.8 Do not write or post anything randomly in the workshop; a fine of 20 yuan will be imposed for each instance detected. 3.0 Workshop Production Order Management System 3.1 During working hours, it is prohibited to talk about or do anything unrelated to work; those who violate this rule will be fined between 5 and 30 yuan per incident, depending on the severity of the offense, while those with a particularly bad attitude will be dismissed. 3.2 During working hours, the team leader must remain at their post; leaving the post requires the approval of the factory manager. 3.3 During working hours, the team leader should provide patient guidance to the employees in their team; they must not lose their temper at them, nor ignore them. 3.4 During working hours, the material handler must promptly prepare the materials for the production line and follow the established procedures strictly, so as not to disrupt the smooth progress of work. 3.5 During commuting to and from work, personnel in various positions within the workshop must abide by the factory’s rules and regulations as well as the workshop’s management policies; those who violate these rules will be subject to penalties in accordance with the relevant provisions. 3.6 During working hours, one must stay at one’s post and not wander around; one should take the initiative to cooperate in tasks rather than waiting passively or observing without doing anything. 3.7 Each processing step must be subject to inspection and supervision by the workshop’s quality control team; it is not allowed to pass checks by deception or to report false quantities. Workers must cooperate with quality inspection efforts and must not resist or insult the inspectors. Those who fail to improve after being reprimanded will be fined between 20 and 50 yuan, depending on the severity of the offense. 3.8 Tools are to be used by designated persons only and must not be lost; those who violate this rule shall compensate for the loss at its value. Those who take them without the owner’s consent will be fined 10 yuan. 3.9 Be mindful of conserving water and electricity at work; turn off the water and electricity whenever work stops. Those who are found to be wasting water or electricity, or who fail to turn them off after working hours, will be fined 5–10 yuan each, regardless of whether it is the individual responsible or the entire team involved. 3.10 Items in the workshop must be placed neatly in designated locations; they must not be piled up randomly. Those who fail to comply with these rules will be fined 5 yuan. 3.11 Employees in the workshop must operate within the designated work areas; no miscellaneous items shall be piled up in the passageways, otherwise a fine of 5 yuan will be imposed for each incident detected. 3.12 Be vigilant at all times during commuting hours to check for any instances of theft at the work site; those who commit theft in the workshop should be dismissed immediately, and criminal liability should be pursued against them. 3.13 Employees must not deliberately damage materials during the production process, nor cause damage to glass semi-finished products or finished products; those who violate this rule shall compensate at the original price. 3.14 During the operation, unauthorized personnel are not allowed to approach or talk to the employees, as this may interfere with their work; those who violate this rule will be fined 10 yuan each time. 3.15 Employees are not allowed to approach the desks, sit on the office chairs, take office supplies, browse documents, or use the phones without permission; those who violate this rule will be fined 10 yuan each time. 3.16 All employees must operate in accordance with the operating procedures; those who violate these rules will be punished depending on the severity of the offense. 3.17 This workshop encourages employees to propose good improvements, and rewards will be given based on their practical value once they are adopted. 3.18 Employees must supervise one another; those who cover up or conceal misconduct will be severely punished upon discovery, while those who make reports and whose claims prove true will be given appropriate rewards. 3.19 Tools and equipment with functional impairments must not be used; their responsible persons must fill out a \"Maintenance Request Form\" to request repairs, and a \"Suspension of Use\" label must be applied. A \"Maintenance Report\" must be prepared after the repairs are completed. 3.20 Those who are lazy, careless, or have a poor work attitude, thereby affecting the working morale of others or failing to complete tasks on time, will be subject to disciplinary action. 3.21 During working hours, when the team leader is away, the deputy team leader must make every effort to complete the assigned tasks. 3.22 For any meetings and training sessions, those who are late, leave early, or are absent without permission will be subject to certain disciplinary action. 3.23 Before starting work at each shift, the personnel involved must arrive at the workshop 20 minutes in advance to carry out the work handover procedures. Responsibilities for Pulverized Coal Preparation I. Responsibilities for Roots blowers and screw conveyors used in pulverized coal preparation 1. Fulfill the general responsibilities of operators ； 2. Stay at one’s post to ensure the supply of coal to the intermediate warehouse ； 3 Be responsible for coordinating with the air compressor to supply air; after stopping coal feeding, blow air through the system for 3–5 minutes to remove any remaining coal from the pipes. 4 Be responsible for reminding or preventing persons carrying open flames (including those who smoke) from entering the operation area. 5 Responsible for the maintenance of cleanliness and order in the single-screw conveyor pump room. 6 Single-screw pump – Intermediate tank. One long whistle at Changling – stop coal supply. Two long whistles at Changling – resume coal supply. Three long whistles at Changling – stop coal supply but keep the wind running. Four long whistles at Changling – abnormal wind pressure. Five long whistles – pause operation. If the other party receives the signal, they will respond with the same ringtone. II. Responsibilities of the Team Leader 1. Be responsible for the overall management of the team and bear overall responsibility for the work of the team. 2 Be responsible for safety, environmental protection, and quality education; foster the mindset that safety and quality come first, and actively carry out activities related to safety, environmental protection, and quality management. 3 Responsible for ensuring compliance with factory rules and regulations as well as the three key procedures; overseeing process quality and safety and environmental protection activities, and being accountable for safety in production processes as well as environmental and quality standards. 4 Responsible for organizing on-the-job training to improve the technical skills of team members. 5 Responsible for organizing the completion of tasks and work plans assigned by the workshop, as well as for reviewing and summarizing the work done by the team. 6 Responsible for organizing team labor competitions, team safety activities, safety training, accident analysis, as well as team corrective and preventive actions and the rectification of potential hazards. 7 Is responsible for organizing and improving cultural and environmental hygiene, holding regular meetings of the organizing committee to conduct work reviews and distribute bonuses. 8 Be responsible for the management of equipment, tools, and materials in the team, as well as for filling out and archiving the team’s original records. 9 Complete the temporary task assigned by the workshop. III. Responsibilities of the Control Room Operator for Pulverized Coal Preparation 1. Perform the general responsibilities assigned to operators. 2 Be responsible for controlling the process conditions of the entire coal powder preparation system, and promptly provide feedback on the control status to the operators on duty. 3 Operate the equipment according to the instructions of the operators in each position; do not operate it arbitrarily. 4. Responsible for reminding or preventing persons carrying open flames (including those who smoke) from entering the operation area. 5 Responsible for maintaining cleanliness and order in the control room and power distribution room. IV. Responsibilities for the Ball Mill and Combustion Chamber in Coal Powder Preparation 1. Perform the general responsibilities of operators. 2. Be responsible for all operations of the ball mill, and add steel balls as required. 3 Regularly check the condition of the ball mill and the operation of the equipment, and issue appropriate instructions to the control room as needed. 4 Be responsible for reminding or preventing persons carrying open flames (including those who smoke) from entering the operation area. 5. The maximum operating temperature of the combustion chamber furnace shall not exceed 900 ℃; any consequences resulting from violation of this rule are the user’s own responsibility (use in special cases requires approval from the supervising manager). 6 Before ignition, the coal dust in the combustion furnace should be removed, and it is necessary to check whether the explosion-proof door is reliable ； After ignition, the coal powder amount, as well as the air volume and wind speed, need to be adjusted appropriately. 7 Responsible for maintaining cleanliness and order around the combustion area in the ball mill room. V. Responsibilities of the powder blower and exhaust fan operators in coal powder preparation 1. Fulfill the general responsibilities of operators. 2 Is responsible for all maintenance tasks related to the two turbines, as well as for regular inspections and cleaning of the impellers. 3 Be responsible for reminding or preventing persons carrying open flames (including those who smoke) from entering the operation area. 4 Be responsible for maintaining the cleanliness and order of the two fans and the surrounding area (including the stairs). VI. Responsibilities of the Operator for the Pulverized Coal Disk Feeder 1. Perform the general responsibilities applicable to operators. 2 When the equipment is started, it is necessary to carefully inspect and maintain the equipment, stay at the site, and ensure a steady supply of raw coal to the ball mill. 3 Be responsible for reminding or preventing individuals who carry open flames (including those who smoke) from entering the operation area. 4 Be responsible for maintaining the cleanliness and order of the disc feeder and the area (including the stairs). Technical Operating Procedures for Pulverized Coal Preparation Workshop (I) Control Room Position 1. Control of key technical parameters ⑴ Temperature ① Furnace temperature during combustion: 600–1000°C ② Temperature at the exit of the flame arrester: 200–400°C ③ Temperature at the inlet of the ball mill: 200–300°C ④ Temperature at the outlet of the ball mill: 60–90°C ⑤ Temperature at the inlet after dust collection by filter bags: <90°C ⑥ Temperature at the outlet after dust collection by filter bags: <70°C ⑦ Temperature of the ball mill bearings: <50°C ⑧ Oil temperature in the thin oil station tank: 30–45°C ⑨ Temperature of the bearing shells of the induced draft fan: <65°C ⑩ Temperature of the bearing shells of the exhaust fan: <65°C Temperature of the pulverized coal storage bin: <70°C ⑵ System negative pressure (unit: Pa) ① Pressure difference between the inlet and outlet of the ball mill: 600–1200 MPa ② Inlet pressure of the ball mill: –1200––2200 MPa ③ Outlet pressure of the ball mill: –1800––3000 MPa ④ Inlet pressure of the coarse powder separator: –2400––4000 MPa ⑤ Outlet pressure of the fine powder separator: –2600––4500 MPa ⑥ Inlet pressure after dust collection by filter bags: >–250 MPa ⑦ Outlet pressure after dust collection by filter bags: –1500––2000 MPa ⑶ Current (A) ① Current of the ball mill: 180–220 MPa (under current load) ② Current of the induced draft fan: 85–90 MPa ③ Current of the exhaust fan: <30 MPa ④ Current of the single-screw pump: <40 MPa ⑷ Quality of raw coal ① Water content: <12% ② Fixed carbon content: >45% ③ Particle size: <50 mm ④ Volatile matter content: >15% ⑤ Calorific value: >4000 calories 2. Operational procedures for this position ⑴ Preparations before starting up the system ① Conduct a thorough inspection of all electrical devices, temperature meters, negative pressure meters, etc.; the readings of these instruments should be within the specified technical parameters. ② Turn off the power to the instruments, coordinate with all relevant stations, and supply power to them. In case of any abnormalities, immediately inform the shift supervisor in the workshop; the equipment can only be started after the issue has been resolved. ③ Check whether there is enough raw coal in the raw coal bin. ④ Inform the ball mill operator to start the oil pump for the ball mill; when the oil temperature is below 35°C, start the oil temperature heater to raise it to 35–45°C. ⑤ Notify the hot blast stove operator to start heating up. ⑥ The team leader is required to conduct a thorough inspection of the system’s explosion-proof facilities and ensure they are in order before turning the system on. ⑵ System startup procedures: ① Wait until the temperature at the outlet of the hot air furnace reaches above 600°C. Contact the personnel in charge of the intake and exhaust fans, start the exhaust fan, then start the air compressor. Once they are operating properly, open the butterfly valve at the inlet of the exhaust fan. ② Start the exhaust fan; once it is operating normally, open the inlet butterfly valve of the exhaust fan to adjust the negative pressure in the system. ③ Notify the ball mill operator to start the ball mill. ④ Close the cold air butterfly valve, vent valve, and bottom valve of the flame arrester in the hot air furnace, and open the hot air valve. ⑤ Once the temperature at the outlet of the ball mill exceeds 60°C, the disk feeder is started to feed coal. During operation, the coal feeding rate is controlled by adjusting the speed of the disk feeder, thereby keeping the temperature at the outlet of the ball mill between 60°C and 80°C. ⑥ If any abnormal issues are detected during operation, report them to the team leader immediately for handling. ⑶ Shutting down the machine: When the pulverized coal bin is full, the machine must be shut down and the following actions taken: ① Open the cold air butterfly valve, the vent valve, and the valve at the bottom of the spark catcher of the hot air stove; close the hot air valve to cool down the hot air stove. ② Reduce the speed of the disk feeder to lower the coal feed rate, and stop the disk feeder when the temperature at the outlet of the ball mill is <60°C. ③ After vacuuming the ball mill for 15 minutes, if the outlet temperature is <55°C, and when there is little coal remaining in the mill (as indicated by the sound of the steel balls inside), the mill should be stopped. ④ Close the inlet butterfly valve of the exhaust fan to stop it. ⑤ Close the butterfly valve at the exhaust fan inlet to stop the exhaust fan. ⑥ Stop the bag filter dust collector air compressor and screw after 15 minutes. ⑦ After the entire system is shut down, the furnace temperature is maintained at 300–400°C through insulation control of the hot air furnace. (II) Ball mill position: (1) Check that the water and oil pipelines are unobstructed, that the switches operate smoothly, and that there are no leaks. ⑵ Check the lubrication of all rotating parts. ① There is sufficient oil in the tank; the inlet and outlet valves of the oil filter should be open, as well as the pressure gauge and pipeline valves. The large bearings of the ball mill and the valves for the lubricating oil circuit should also be opened. ② The lubricating oil pressure in the ball mill should be maintained between 0.147 and 0.294 MPa. ③ The large gears of the ball mill must have sufficient gear oil. ⑶ The couplings, bearings, screws, and all foot screws must not be loose; the protective covers must be in place and not loose as well. Start-up: ⑴ Upon receiving the start-up signal from the control room, start the oil pump and adjust the pressure in the oil circuit to 0.147–0.294 MPa. ⑵ Wait until the oil pump is operating properly and the oil supply is stable; only after 10–15 minutes can the ball mill be started. The power current of the ball mill should return to normal within 10 seconds. When operating manually, first press the “Start” button, then the “Run” button. Release the buttons once the ball mill is rotating properly and its operating current has returned to normal. (3) The ball mill shall not be started continuously more than three times; if it fails to start on the first attempt, it is necessary to report to the shift leader. Attempt a second start after 15 minutes; if it still fails to start, it is necessary to report to the workshop, and only after appropriate measures have been taken can a third start be attempted. Maintenance during operation: (1) Check the water supply to the ball mill and the operation of the oil supply equipment every 20 minutes; any oil leaks in the lubrication system should be addressed promptly, with the oil pressure maintained at 0.147–0.294 MPa. (2) The temperature of the large bearings in the ball mill must not exceed 50°C, while the oil temperature in the oil tank should be kept between 30–45°C. (3) There should be no abnormal noises in the transmission components. ⑷ Steel balls should be replenished in a timely manner. The ball mill grinds 4 tons of coal per hour; based on the fact that the equipment consumes 200–250 grams of steel balls per ton of coal per hour, 1 kilogram of steel balls needs to be added per hour. It is specified that steel balls should be replenished once a week, with one Ф100mm steel ball being added for each hour of operation. (5) Clean the fuel tank filter once every Monday. Shut down: Stop the ball mill upon receiving a shutdown command from the control room, and stop the oil pump after 30 minutes. (III) Single-screw pump position: (1) Before operation, check that there is sufficient lubricating oil at all lubrication points, that the oil seals and oil cups contain enough oil; the connection bolts must be tightened, the weight and gate mechanisms must operate smoothly, and the pipeline pressure must be normal. The bolt shaft should rotate freely when turned by hand. (2) Open the intake valve; use compressed air, with the air pressure not exceeding 0.343 MPa, and open the valve that allows compressed air to enter the sealed chamber. (3) Start the motor until it operates normally, and check whether the pipes are unobstructed. (4) Slowly open the feed valve to start feeding. (5) During operation, regular inspections should be carried out to ensure proper lubrication; the seals must not allow air or coal leakage, and the bearing temperature must not exceed 35°C. (6) The outlet pressure of the wind-powder mixture should be controlled between 0.049 and 0.078 MPa. (7) If the pressure during feeding exceeds the normal value, feeding should be stopped; feeding can resume only once the pressure returns to normal. (8) The operating pressure must not be lower than 0.147 MPa; a low pressure indicates that the amount of air supplied is insufficient. (9) If the pressure increases and fails to return to normal even after stopping the feed, it indicates that the pipeline is blocked; the coal transport pipeline must be cleaned using air until it is completely unobstructed. (10) When shutting down, feeding must be stopped first; wait until all the pulverized coal in the pump has been discharged (approximately 10 minutes) and all pipelines have been purged, then listen to the motor, and finally close the main compressed air valve. (IV) Hot blast stove position: (1) Before starting up, check whether the stove and the ducts at the fan outlet are in good condition; close the cold air valve and the ash discharge valve at the bottom of the spark catcher, cover the inspection holes, and then increase the temperature. (2) When heating the furnace, pay attention to whether there is ** in the raw coal; address any issues found promptly. (3) Make sure to keep the furnace temperature above 600°C, and the outlet hot air temperature between 300 and 400°C. (4) Regularly check the temperature at the outlet of the ball mill, and adjust the temperature of the hot air at the outlet of the combustion chamber as required and in response to changes there. (5) When the ball mill is in operation, coal should be added frequently to the combustion chamber and slag removed regularly to maintain the furnace temperature. (6) Upon receiving the notification to stop system coal grinding, cease coal feeding and open the cold air valve as well as the valve at the bottom of the vortex dust collector to carry out cooling. (7) After the ball mill stops operating, reduce the coal supply to the combustion chamber to maintain the furnace temperature above 300°C. (5) Hopper conveyor post: (1) Before starting up, check whether the hopper conveyor, belt conveyor, electric feeder, and associated motors are in good condition, as well as whether the hopper conveyor is blocked. (2) There should be no coal accumulation or debris on the grid screen, and no water accumulation at the bottom of the bucket elevator; if water accumulation is detected, it must be pumped out using a submersible pump. (3) Upon receiving the start-up signal, activate the bucket elevator, belt conveyor, and electric vibrating feeder, and check to ensure they are functioning properly. (4) After verification, notify the grab crane to prepare for coal loading. (5) The coal feeding sequence is: bucket elevator → belt conveyor → electric vibrating feeder → coal grabbing to grid screen. (6) When feeding coal, ensure that it passes evenly through the belt conveyor into the bucket elevator. (7) Regularly check the raw coal bin; once it is full, notify to stop feeding coal. (8) Once the coal on the waiting screen is exhausted, shut down the vibratory feeder and the belt conveyor; then, once there is no more coal in the bucket elevator, shut down that elevator as well. (VI) Induction fan and exhaust fan positions: (1) Upon receiving the start-up instruction from the shift leader or the control room, check whether the foot bolts of the induction fan and exhaust fan, as well as the couplings, are secure; address any looseness promptly. (2) Check whether the lubricating oil in the induced draft fan and exhaust fan is at the specified level; if the oil is insufficient, it needs to be added. (3) Turn on the cooling water for the induced draft fan and adjust the water flow to an appropriate level. (4) Check that the inlet butterfly valves of the induced draft fan and exhaust fan are in the closed position. (5) After verification, notify to start the exhaust fan; once the fan is running properly, open the inlet butterfly valve of the exhaust fan to the desired air volume. (6) Once the exhaust fan is operating properly, notify the start of the induced draft fan. After the induced draft fan starts correctly, manually open the inlet butterfly valve, and adjust the opening degree of this valve according to the negative pressure in the system’s dust collection chamber, so as to maintain a negative pressure condition in that chamber. (7) Regularly check the cooling and lubrication of the induced draft fan during operation, and address any issues found promptly. (7) Disk feeder position: (1) Upon receiving the start-up signal from the control room, check whether the disk feeder and the coal discharge opening are in good condition, and whether there is any blockage or jamming. (2) Check the lubrication of the disc feeder; apply sufficient butter to ensure its proper operation. (3) Check whether there is sufficient raw coal in the raw coal bin; notify the coal feeder to supply more coal if necessary. (4) After verification, start the disc coal feeder to supply coal. (5) Regularly inspect the coal inlet to prevent blockages and jams caused by excessive moisture or large particle size of the coal. (6) When the coal feeding amount from the disc coal feeder is insufficient, activate the vibrator in the raw coal bin to shake it; stop the vibration once the coal feeding amount becomes sufficient. (7) Upon receiving a shutdown signal from the control room, the control room shall first stop the disc coal feeder; coal feeding shall be halted once all the coal has been supplied to the inlet of the ball mill. (8) After the entire shift is over, clean the area of the post, and shovel any spilled coal into the coal hopper. (8) Air compressor station (1) Preparations before starting up ① Open the main cooling water inlet valve (or start the circulation water pump) to supply cooling water to the main unit and the cooler. ② Check whether the oil level inside the engine body and the oil level in the filler is sufficient; if not, top them up. Also, manually inject an appropriate amount of lubricating oil into the cylinders to facilitate starting. ③ Check that the unloading valve is properly closed to ensure start-up under no load conditions. ④ Check whether the valve of the main exhaust pipeline is open to ensure an air supply condition. ⑤ Turn off the power switch and check whether all meters and indicator signals are normal. ⑥ Ensure that there are no debris or tools around the host and motor, and that the transmission system is in good working order and safe. (2) Driving operation ① Since electrically driven motors have various starting methods such as Y-△ starting, reduced-voltage starting, and resistance-changing starting, the operator must carry out the operation correctly according to the starting method specified for the product. ② The air compressor must be able to start under no-load conditions. It is necessary to carefully check whether the pointer on the oil pump pressure gauge rises immediately, whether oil is dripping from the transparent covers of each oil reservoir in the oil filler, whether the sounds of the motor and the air compressor are normal, and to feel the temperature of various operating parts to ensure it is within normal limits. The compressor should run without load for about 10 minutes. ③ Gradually turn the handwheel of the pressure relief valve open; the air compressor begins to load, and the pressure gauges for the first and second cylinders start to rise in pressure until they reach the specified values. ④ By feeling it, the water temperature should be no lower than 30°C and no higher than 40°C. ⑤ The sewage discharge valves at various locations should be opened 1-2 times per shift to remove the waste liquid. (3) Parking operation ① The air compressor must be stopped with the load removed. Before stopping, the pressure relief valve must be closed first to cease air supply, allowing the compressor to run idly for a few minutes. If there is no vent valve in the exhaust pipe, that valve should also be opened for ventilation. ② Then the power is cut off, and the equipment stops working. ③ About 15 minutes after shutting down the machine, wait until each cylinder has cooled down sufficiently, then close the cooling water valve to stop the supply of water, and drain any water remaining inside the machine to prevent freezing. ④ The condensed oil and water residues in the intercooler, air storage tank, and aftercooler should be drained. ⑤ For normal shutdowns after each shift of operation, the above procedures are sufficient. If the machine is to be shut down for more than 10 days, sufficient lubricant should be applied to all moving and friction surfaces after the machine has cooled down fully to prevent rust. (10) 475m2 Bag Filter Dust Collection Post (1) Preparation work: ① Regularly monitor the changes in current and voltage of the main fan motor, keep records of these values, and stop the machine immediately in case of any abnormal conditions to identify the cause and take appropriate action. ② Regularly check whether all operating equipment is functioning properly, and apply lubricant to the parts that require it on a regular basis. ③ Regularly check the connections of all electrical circuits for any sparks or unusual odors, and address them promptly. ④ Regularly check the sealing of the compressed air pipelines, monitor the changes in the readings on the gauge attached to the pressure reducing valve, and periodically remove any water accumulated within the pressure reducing valve and the pulse tank. ⑤ Regularly or continuously remove the ash accumulated in the ash hopper. ⑥ Regularly check the sealing performance of the blast relief doors and manway doors. ⑦ Regularly check the operation of the pulse valve. ⑧ Pay regular attention to other aspects of the exhaust gases from the fan chimney. ⑨ In the event of an abnormality during operation, the dust collector can have its PLC powered off directly. Maintenance and troubleshooting ⑴ Preventing spontaneous combustion and explosions in coal powder preparation ① Regularly check for accumulated coal and coal powder within the system. ② If the shutdown duration is long, the coal in the pulverized coal bunker should be used up. ③ Strictly control the coal mill outlet temperature at 60~90°C. ④ Maintain the coal powder particle size and moisture within specified ranges. ⑤ Eliminate air leakage from the coal powder silo. ⑥ Prevent external sources of fire. ⑵ Handling of spontaneous combustion in the coal powder system: ① Stop the operation of the system, eliminate all sources of fire in various areas, and only after confirming that there are no sources of fire inside is it permissible to repair the explosion-proof doors. ② A thorough inspection of the equipment should be carried out before the system is restarted. ⑶ Treatment of blockage in the coal powder transfer pipeline from the single-screw pump to the intermediate bin. ① Stop feeding coal. ② Open and close the air supply valve for pulse air supply. ③ Identify the pipeline blockage location based on the pipeline temperature. ④ Pulse air supply while knocking on the blocked areas. ⑤ Pulse backwashing is performed by blowing air through the duct from the point closest to the blockage. ⑥ Since the previous method failed, the only option is to remove or cut the pipeline for cleaning, and then use air to blow away the coal accumulation in the pipeline. ⑷ Treatment for water jacket leakage in the furnace body: ① In the case of leakage on the outer wall and no steam coming from the water jacket outlet pipes, welding repairs can be carried out after slag removal during melting. ② Check regularly; if steam is observed coming from the furnace seams and slag removal becomes difficult, it should be suspected that the inner wall of the water jacket is starting to leak. ③ When there is significant leakage from the inner wall, increase the heating intensity, remove the slag immediately, and try to avoid a dead furnace. ④ After slag removal, the furnace chamber is cooled forcibly, and welding repairs are carried out under safe conditions. ⑤ If the water jacket is found to be unusable after inspection, it should be replaced immediately. ⑸ Treatment of coal leakage from the furnace seams: ① Before starting the furnace, the furnace seams must be sealed off with asbestos rope. ② Adjust the coal feed rate and intensify temperature-raising blowing. ③ Check whether the air supply volume adjustment is sufficient and if there are any issues with the airflow. ④ Check whether there is any leakage on the inner wall of the water jacket; if found, it should be welded and repaired promptly. ⑤ Maintain the cooling water at a stable and appropriate level. ⑹ Treatment for high inlet temperature of the bag dust collector: ① Properly control the coal feeding amount at the tertiary air nozzles. ② Increase the cooling water flow rate of the spray cooler. ③ If the above measures are ineffective, force cooling by blowing air. ⑺ Solutions for insufficient negative pressure at the furnace top: ① Increase the air extraction volume of the dust collection system fans. ② Clean the ash and water accumulation in the flue ducts and ash hoppers in a timely manner. ③ Check whether the explosion-proof doors, inspection doors, and ash cleaning doors of the flue are properly closed. ④ Check whether there is excessive slag accumulation on the furnace top, and clean it up promptly. ⑤ The coal feed rate is appropriate. (8) Check the water supply to the ball mill and the operation of the oil supply equipment every 20 minutes; any oil leaks detected in the lubrication system must be addressed promptly, with the oil pressure in the oil circuits maintained at 0.147–0.294 MPa. (9) The temperature of the large bearings in the ball mill shall not exceed 50°C, while the oil temperature in the oil tank should be kept between 30–45°C. There should be no abnormal noises in the transmission parts. (10) Steel balls should be replenished in a timely manner. The ball mill grinds 4 tons of coal per hour; based on the fact that the equipment consumes 200–250 grams of steel balls per ton of coal per hour, 1 kilogram of steel balls is required per hour. It is specified that steel balls should be replenished once a week, with one Ф100mm steel ball being added for every hour of operation. (11) Clean the fuel tank filter once every Monday. Operating Procedures for Pulverized Coal Preparation Equipment: 1. The operator must pass an examination and hold a ‘Equipment Operation Certificate’ specific to this equipment before being allowed to operate it. II. Before starting work, it is necessary to do the following carefully: 1. Read the shift handover report thoroughly to understand the work carried out by the previous shift. 2. Check whether the equipment and work area are clean and wiped down properly ； There should be no obstacles, impurities, or new scratches, abrasions, or dents on the equipment’s bed, work surface, guide rails, and other major sliding surfaces. In the event of the above situations, it must be removed, and the equipment should be wiped clean ； In the event of new scratches, abrasions, or bruises, the equipment operator or team leader should be called in to inspect them and keep a record of it. 3. Check that the handles, valves, rods of various operating mechanisms, as well as all the main components (sliders, hammers, tool holders, etc.), are in the non-operational positions specified in the manual. 4. Check that all safety protection devices (protective covers, limit switches, limit stops, electrical grounding, fuses, etc.) are complete and in good condition, and installed correctly and reliably ； The doors of the distribution boxes (cabinets), fuel tanks (reservoirs), and gearboxes should be closed. 5. Check that the lubrication areas (oil sumps, oil tanks, oil cups, guide rails, and other sliding surfaces) have sufficient oil levels, and add oil according to the lubrication guidelines. 6. Check all major components and fasteners for any signs of abnormal loosening. 7. Open the gas (steam) line valves, check that the pipeline valves and other devices are in good condition with no leaks, ensure that the gas (steam) pressure is within specified limits, and drain any water accumulated in the pipes. 8. Conduct a no-load test run; start the machine in short bursts. Check that all operating devices and safety protection devices (brakes, commutators, interlocks, limit switches, fuses, etc.) as well as all indicating devices (indicators, lights, etc.) function in a sensitive, accurate, and reliable manner ； The movements of various parts should be coordinated ； The oil supply should be normal, and the lubrication should be good ； The machine tool operates without any abnormal noises, vibrations, temperature increases, odors, smoke, or other such issues. Work can only begin after confirming that everything is normal. For equipment that operates on a shift basis, the person handing over the shift shall conduct a joint inspection in accordance with the provisions mentioned in item (8) before the handover ； For equipment that operates on a shift rotation basis, if serious violations of operating procedures are detected during the previous shift, the equipment operator or shift leader should be asked to conduct an inspection and record such incidents; otherwise, any equipment problems that arise will be attributed to violations of operating procedures by the current shift. After the equipment has been adjusted or repaired, the operator must also inspect it in accordance with the aforementioned (8) requirements and steps to ensure that everything is in order before starting work. III. In one’s work, it is essential to: 1. Stay at one’s post, operate the equipment carefully, and avoid doing anything unrelated to the work. When leaving the equipment for some reason, it must be shut down, and the power and gas supplies must be turned off. 2. Use the equipment in accordance with the technical specifications specified in the manual; do not use it beyond these specifications or under excessive load. 3. Pay close attention to the lubrication status of all parts of the equipment, and apply oil during shifts as specified in the lubrication schedule to ensure proper lubrication of all components. 4. Pay close attention to the operation of all parts of the equipment; if there are any abnormal sounds, vibrations, temperature increases, unusual odors, smoke, uncoordinated movements, or malfunctions, stop the machine immediately for inspection, and resume operation only after the issues have been resolved. 5. When adjusting the speed, replacing molds or cutting tools, or cleaning and maintaining the equipment, it is necessary to shut down the machine first and turn off the electrical and pneumatic (steam) supplies. 6. During work, it is prohibited to remove safety protection devices without permission, or to open the doors of distribution boxes, oil tanks, or gearboxes in order to carry out work. 7. In the event of an accident with the equipment, it must be stopped immediately, the scene must be preserved, and the relevant departments must be informed for analysis and handling. The equipment can only be used again after ensuring that the three requirements are met. IV. After starting work, it is necessary to ensure that: 1. All operating devices, as well as sliders, hammers, tool holders, etc., are placed in their non-operational positions as specified in the instructions ； Turn off the electrical and gas (steam) supplies. 2. Organize tools, parts, and the work area. 3. Clean the work area and equipment of scraps, edges, scale, debris, etc ； Wipe all parts of the equipment clean and apply oil to all sliding surfaces for protection. 4. Fill in the shift handover log. This post was last edited by The distance to happiness on 2009-3-5 10:19.]