Power outage across the entire plant – contingency plan for the coking workshop

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I. Positions in the workshop where problems are likely to occur after a power outage include: 1. Coke oven switch. 2. Coke oven pusher, quench car, coke stopper car, coal car, coke conveyor belt. 3. Coke oven rising pipe II. Steps to take in the event of a power outage 1. The operator must immediately report to higher-level management and explain the status of each piece of equipment in use. 2. The duty supervisor shall contact the electrical staff to go to the site to find out the cause. 3. Emergency measures after a power outage in various positions. 1. Coke oven switchgear: ㈠ In the event of a power outage with no switching in place, it is necessary to set all indoor actuator switches to the manual position, as well as the actuators controlling the suction force in the coke oven flue and the gas flow. This is done to prevent the DCS system from restarting once power is restored, which could cause the actuators to return to their initial settings and result in fluctuations in oven temperature and suction force; it might even lead to the shutdown of heating and potential explosions. (ii) Power outage during switching: I. In addition to taking the measures required in the event of a power outage without switching, specific action steps should also be taken based on the particular circumstances. Ⅱ. When burning blast furnace gas, a hand pump should be used immediately to convert the blast furnace gas into coke oven gas for heating. Ⅲ. When heating coke oven gas, manual pumps are used to facilitate the exchange process. When operating these manual pumps, attention must be paid to the limits of movement of the cylinders, in order to prevent overstraining or insufficient movement. 2. Coke oven pusher car: I. In the event of a power outage during the pushing process, return the main control lever to its zero position, start the diesel engine according to the specified steps, and lift the pusher brake while it is in neutral position. Connect the gear that links the diesel engine to the coke pushing rod, and secure it with a pin. Shift the diesel engine into gear, adjust the throttle, and pull the coke pusher out of the furnace. When the pusher is nearly out, use a low throttle setting to reduce its pulling speed. Assign a dedicated person to monitor the process to prevent the pusher from being pulled back into the furnace. Once it has reached the desired position, immediately shift the diesel engine into neutral. Lower the brake, move the coupling gear to its proper position and insert the pin, stop the diesel engine from running, and arrange to clean off the carbon buildup from the burner. Use the hand pump to press the solenoid valve and close the furnace door in the order specified for closing it. The flip valve on the rising pipe above the furnace is lifted, and the rising pipe cover is closed. II. Power outage during coal leveling: Set the main control device for coal leveling to the zero position, remove the locking pin from the manual operation device for the coal leveling rod or coke pushing rod, move it to the location where it connects with the reducer, insert the locking pin in place, attach the manual crank, lift the brake used for coal leveling, and then manually operate the rod to move it aside. Be careful of the direction of movement to avoid moving it in the wrong direction. After shaking it out, reset the manual positioning device and insert the latch properly. It also organized the use of a hand pump along with solenoid valves to push the flat coal chute back into place, manually closed and secured the small furnace door, and waited for power to be restored. 3. Power outage when there is red coke in the coke oven car. I. Turn off the main power supply inside the car and reset the traveling controller to its zero position. Ⅱ. Check whether the wind pressure gauge shows pressure. The old furnace brake train locks the brakes of the train, with the wheels pressing together to prevent slipping. Ⅲ. Inform the shift supervisor, call the fire department, and cooperate with them to extinguish the red flames inside the carriage as soon as possible. Ⅳ. During fire suppression, pay attention to the air pressure on the doors to prevent the carriage from opening and red-hot debris from falling and injuring people. 4. Power outage during the coke pushing process by the coke car in the coke oven: I. Immediately inform the shift supervisor, and ask the fire department to send someone to pour water into the coke chute to extinguish the fire. Ⅱ. If the coke has been completely pushed into the coke guide channel, wait until the large rod is retracted into the furnace, then use a hand pump to open the lock on the coke guide channel, pull it out, close the furnace door, and pour water into the coke guide channel from a vehicle to extinguish the fire. 5. Power outage during coal loading into the coke oven car Ⅰ. Open the rising pipe cover of the coal loading furnace. Ⅱ. Utilize the coal car accumulator. First, use an iron rod to press on the solenoid valve located on the coal car’s guide sleeve, then press on the solenoid valve of the accumulator. Once it can be observed that the furnace lid can be closed over the coal car, immediately release the solenoid valve of the accumulator. Then, using the same method, lift guide sleeves 2–4 one by one and cover the furnace lid. Ⅲ. Then use an iron rod to press the dust collection sleeve to retract the solenoid valve, followed by pressing the accumulator solenoid valve to pull back the dust collection sleeve; the dust collection push rod can be retracted in the same manner. 6. Power outage during coal leakage from the coke oven coal car: I. Set the control switch for the coal tower’s leakage outlet to the zero position. Ⅱ. Remove the hydraulic cylinder and tie it securely with wire. Ⅲ. Use a crowbar to tightly close the leak outlet of the coal tower. 7.. Positions involved in coke transportation Ⅰ. Set the belt start control box to zero. Ⅱ. Check for burning on the belt; for those cases where it is not clear, apply an appropriate amount of water to the belt to prevent it from being damaged by burning. Ⅲ. Unload the coke before starting; it is strictly prohibited to operate the machine under load. 8. Coke oven rising pipe I. Set the regulator to manual mode. II. When the pressure exceeds 250 Pa, open the vent pipe for release. Ⅲ. If the circulation of ammonia water in the pipeline stops, immediately close the main ammonia water circulation valve on the furnace, and then open the make-up cooling water pipes at both ends of the rising pipe to reduce the temperature. If the temperature of the gas collection pipe is too high, the cover of the rising pipe of the furnace in service can be opened, but care must be taken to prevent the rising pipe from catching fire; any such occurrence should be extinguished immediately. III. Resuming production: ① Switches and rising pipes ⅰ. Rising pipe: Turn off the cold water supply, gradually open the valve for circulating ammonia water, close the vent pipe and the cover of the rising pipe, manually adjust the flap to maintain the normal operating pressure, and contact the switch to switch to automatic operation. ⅱ. Switches: Once all measurement parameters have stabilized, switch each meter from manual to automatic control, and set each actuator to automatic mode. After the switch is powered on, manual switching is used for the first exchange, and it is checked whether all parameter settings are normal. ② After checking that all movements of the coke pusher, coke stopper, coal car, and coke quencher are functioning properly, the coke that has not been pushed out is removed, and normal production resumes. ③ Belt: Start the belt, thoroughly inspect the interlock switches; once everything is normal, notify them to load the goods.