Emergency plans that production technicians in the coking workshop need to prepare

Of course, the technical skills must be excellent, and management capabilities must be in place. There are many plans, accident plans for spills from each storage tank. Such as coal tar, sulfuric acid, and crude benzene. Plans for shutting off water, electricity, and gas, such as those related to blowers; plans for dealing with failures in critical equipment, such as tubular furnaces, etc. These are the elements that plans generally include. . .

Reply to 2# gaoyan123: It’s not possible to take care of everything at once; let’s start with the coke ovens first, and find technicians who are skilled in recycling； For example, if the vent pipe on the gas collection pipe of a coke oven is rusted and cannot be used for venting, how should it be handled? If it cannot be cleared, is there a backup plan?

It’s unheard of for the coke oven gas collection pipe to become rusted shut and unable to be opened, but we have replaced the valve body; it’s very dangerous.

Gas pipeline rupture: On Wednesday, March 9, 2011, in the early hours of the morning, a fault occurred in the flow meter of the mixed gas pipeline on the coke side of furnace No. 8, resulting in a measured flow rate that was more than 10,000 units higher than the actual value. The gas pressure in the basement area on the coke side reached 2000 Pa. Due to the lack of timely intervention, an excess amount of gas accumulated; this gas could not be completely burned in the combustion chamber and ended up entering the flue ducts. As a result of the high gas pressure, leaks occurred in the main walls of regenerator chambers No. 54 and 55 on the coke side, as well as in chambers No. 52 and 53. There were also leaks in the small flue duct No. 44. The explosions in these flue ducts caused several small metal plates covering the air inlets on the coke side to fall off, and several similar metal plates on the air inlets for exhaust gases on the machine side also came loose. In the morning, upon inspection of the top of Furnace No. 8, it was found that the temperature on the coke side was low, there was an excess of gas, the positive pressure at the viewing ports was high, and the positive pressure at several ports on the machine side was also elevated. Therefore, it was instructed to the control room to reduce the pressure in the coal gas pipeline on the furnace side to 1500 Pa and the suction pressure to 260 Pa; meanwhile, the personnel in charge of measurement and control were asked to come and check the flow meters. The flame adjustment team used U-tube gauges to verify the pipeline pressure at the sampling pipe of the mixed coal gas pipeline in Furnace No. 8. Due to corrosion at the base of the sampling tube, whose wall was extremely thin, the tube broke during opening, and the coal gas pipeline at the base of the sampling tube ruptured. Thereafter, the switch was moved to the manual position to reduce the pressure in the mixed coal gas pipeline on the coke side to 500 Pa; the controls for the coal gas flow rate and the suction force in the flue ducts were also set to manual mode. Timber clamps, rags, lead paint, a hammer, a file, a respirator, an alarm, and a flashlight were prepared. Seal the leak site, and once it is confirmed that no more air leakage occurs, gradually restore the exchange rate as well as the pressure in the branch pipes. Apply sealing filler around the gap, and secure it by tying the clip with asbestos rope. Summary of shortcomings: 1. The instruments for the gas pipelines in the basement have not been calibrated for a long time ； 2. The thickness of the coal gas pipeline walls was not checked ； 3. The root of this sampling tube remains wet due to water droplets for a long time; therefore, a water barrier needs to be installed on it ； 4. No equipment inspections were carried out on the other condensate cocks, sampling pipes, and instrument switches in the basement ； 5. Insufficient preparation in advance; no readiness to deal with pipe ruptures, and various equipment could not be put into use immediately ； 6. The emergency response capabilities of the gas team need to be improved, and emergency plans must be in place. Gas pipeline rupture plan: If the rupture is small: 1. Reduce the pipeline pressure to 500 Pa; under these conditions, switching is strictly prohibited, the switch should be set to manual mode, and the control room must be informed ； 2. Prepare yellow clay, sealing filler, rags, lead paint, log clamps, hammer, file, respirator, explosion-proof lamp, CO detector ； 3. Put on the respirator, ensure it is working properly, then go to the site with the necessary tools. Seal the damaged area tightly; once there is no air leakage, restore normal pressure in the pipeline by activating the switch. If the rupture is large and difficult to handle: 1. Immediately change the switch’s automatic mode to manual ； 1. Reduce the pressure in the gas pipeline to 500 Pa, switch the controller to manual mode, put on a respirator, close all condensate valves, introduce steam, and open the vent pipes for release ； 3. Reduce the machine’s operation level, close the flaps on the coke side flue to decrease suction, and switch the machine to manual mode ； 4. Report the situation to the factory management and the shift supervisor on duty to coordinate efforts ； 5. Put on the respirator, close the heating gas control valves, and gradually shut down the coke oven gas valve and the blast furnace gas valve ； 6. Reduce the suction in the smoke duct to 120–140 Pa; if this reduction is not possible, slightly open the access cover on the side of the chimney, and set all regulators in the heating system to their fixed positions ； 7. Stop the coke pushing operation, cover the air inlet of the exhaust gas tray with asbestos board, leaving a 10mm gap ； 8. Contact the gauge operator to close the switches on all instruments (except those for the main pressure pipe). 9. Replace the exhaust weight and air cover manually every 30 minutes as usual, but it is strictly prohibited to move them to the middle position ； 10. Stop heating for more than two hours to maintain a collector pipe pressure that is 20–30 Pa higher than normal ； 10. The gas engineer personally checks the status of handling in various areas ； 11. After no gas or explosive vapors are escaping from the pipe to be vented, shut off the steam and carry out repair work (clean the damaged area and weld it together; for long cracks, cover them with iron plates before welding) ； 11. After the fault is resolved and the pressure in the main gas pipeline rises above 4000 Pa, obtain approval from the control room before preparing to supply gas. Gas supply emergency plan: 1. Introduce steam to purge the gas pipelines, until the steam is discharged from the vent pipes ； 2. Open the gate valve of the blast furnace gas pipeline on the machine side to start supplying gas ； 3. Gradually reduce the steam supply until it is completely shut off; take samples at the vent pipe to conduct explosion tests. If the tests are successful three times or more, reduce the vent pipe’s opening to 1/2, and then shut it off completely once the gas supply is restored ； 4. Restore the small iron plate of the air inlet to its normal size, and then restore the suction force in the flue ； 5. Move the switch to its normal operating position, then open the gas control valves one by one. Stay in close contact with the gas team to adjust the pressure in the main gas pipeline as needed; it is also possible to open the valves only to 1/2 of their capacity first ； 6. Open both of the swapped gas valves fully; when swapping, introduce gas slowly ； 7. After restoring Coke and carrying out the exchange, the coke oven gas blending gate valve can be opened ； 7. When heating is stopped for an extended period, temperature measurements should be taken; once gas supply is resumed, the heating regime should be determined and the coke pushing schedule reorganized ； 8. Restore the normal pressure in the gas collection pipe. Safety measures: 1. Ventilate the basement to prevent the accumulation of explosive gases ； 2. The operator must wear a respirator and an alarm device, and pay attention to the operation time ； 3. Open flames are prohibited in the basement before gas is cut off and when gas is supplied ； 3. For gas delivery, an explosion test must be passed three times or more, and the oxygen content in the gas emitted from the vent pipe must be below 3%.

For shutdown maintenance, production is suspended for one shift in advance. Once the coke cakes are ready, all rise pipes are opened, the exhaust gas is ignited, the negative pressure pipes are gradually closed, and all collection pipes (the front negative pressure pipes) are opened to inspect the cleaning holes; only then can oxy-acetylene welding or gas cutting be used for maintenance work.

Technological innovation requires the replacement of the rising pipe. Replacement options: 1. Make plans in advance so that at the time of replacement, the furnace is in the late stage of coking, with coal carts and coke pushers not operating in that area, and ensure that the bolts of the rising pipe and bridge pipe can be replaced； 2. Prepare new rising pipes and bridge pipes, arrange cranes of appropriate capacity, a temporary chimney, high-temperature asphalt, water glass, and asbestos blind plates ； 3. Before replacement, open the high-pressure ammonia water for that furnace number to remove the asphalt from the socket joints of the bridge tube and the flap seat; loosen the connection bolts of the rising tube, bridge tube, and other components; cut off the water supply to the water seal on the rising tube cover. The rising tube and bridge tube must be tied securely to the crane’s steel cables ； 4. Close the water seal flap for that furnace number, open the cover of the rising pipe; at the same time, open one of the furnace covers on the coke side and align it using a temporary chimney. Use compressed air to suppress the flame in the rising pipe, shut off the high- and low-pressure ammonia water supplies for that furnace so as to disconnect the ammonia water pipes from the bridge pipe. Use a crane to remove the rising pipe and the bridge pipe, and seal the water seal flap with industrial water ； 5. Immediately cover the rising pipe opening with an asbestos blind plate, and clean the flange connections and socket joints ； 6. Install the rising pipe and bridge pipe in sequence, connect the water pipes and ammonia pipes, adjust the direction of ammonia spray, remove the asbestos blind plates; do not close the cover of the rising pipe, take away the temporary chimney, cover the furnace lid, move the crane away, and place the old rising pipe and bridge pipe in their proper positions ； 7. Cover the furnace, push out the coke and load coal; once raw gas begins to emerge from the rising pipe opening, open the water seal flap, cover the rising pipe, spray high-pressure ammonia water, and resume normal production.