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1、PrefaceNRCCProjectisacementproductionlinewiththecapacityof6000TPDclinkerconstructedbyCNBMinTheKingdomofSaudiArabic.Thesafetyoperationmanualisformakingsurethesafetytrailproduction,handingovertoOwnersuccessfully,meanwhile,insuringsafetyforpersonnelandequipment.Thesafetymanualiscompliedbycombiningthepr
2、ocessofNRCCcementproductionline(6000tpdclinker)aswellascharactersandtechnologyofmechanicalandelectricalequipmentinconformityofanactualsituationinNorthRegionofKSA.Alldepartmentandtechniciansshouldrefertoexecuteandplayasupervisedroleintrailproductionandproductioninthefuture.November,2007NRCC6000th(cli
3、nker)CementProductionlineSafetyOperationManualTableofContentChapter1 General4Chapter2 GeneralInstructionsforInjuryProtectio51. GravityInjuryProtection(injurybyfallingdown,injurybyhitting)52. MechanicalInjuryProtection(injurybycrushing,injurybywringing)63. ElectricalInjuryProtection(injurybyelectrici
4、ty,injurybyburning)84. ThermalInjuryProtection(scald,injurybyburning)95. ChemicalInjuryProtection(ignition,asphyxia)106. WindInjuryProtection(injurybyhitting,injurybyfallingdown)107. MagneticForceInjuryProtection10Chapter3PostSafetyOperationInstructions131. .SafetyOperationInstructionsforCentralCont
5、rolOperator132. SafetyOperationInstructionsforApronFeeder133. SafetyOperationInstructionsforCrusher144. SafetyOperationInstructionsforBeltConveyor155. SafetyOperationInstructionsforbucketelevator166. SafetyOperationInstructionsforScrewconveyor,chainconveyor,chainbucketconveyor177. SafetyOperationIns
6、tructionsforStackerandReclaimer188. SafetyOperationInstructionsforRawMaterialVerticalRollerMill189. SafetyOperationInstructionsforEnteringintoRawMaterialVerticalRollerMill2010. SafetyOperationInstructionsforFuelOilSupplyingSystem2011. SafetyOperationInstructionsforPreheater(CaIciner)2112. SafetyOper
7、ationInstructionsforBypassSystem2513. SafetyOperationInstructionsforKiln2514. SafetyOperationInstructionsforCoolerandClinkerconveying2715. SafetyOperationInstructionsforAirBlastSystem2916. SafetyOperationInstructionsforHydraulicGiant3017. SafetyOperationInstructionsforCementMill3118. SafetyOperation
8、InstructionsforSeparatormaintenance3219. SafetyOperationInstructionsforEquipmentunderthesilo3320. SafetyOperationInstructionsforCleaningCement(rawmeal)Silo3321. SafetyOperationInstructionsforElectrostaticPrecipitator3422. SafetyOperationInstructionsforPacker3523. SafetyOperationInstructionsforBagFil
9、ter3624. SafetyOperationInstructionsforBulkLoadingMachine3725. SafetyOperationInstructionsforAirCompressor3726. SafetyOperationInstructionsforFan3927. SafetyOperationInstructionsforAirSlide3928. SafetyOperationInstructionsforMaterialBinandvibrationscreen4029. SafetyOperationInstructionsforSupervisio
10、nofWaterPumpRoom4030. SafetyOperationInstructionsforWeigh-bridge4131. SafetyOperationInstructionsforElevator4232. SafetyOperationInstructionsforLiftingOperator4233. SafetyOperationInstructionsforElectricalEquipment4334. SafetyOperationInstructionsforElectricalMaintenance4535. SafetyOperationInstruct
11、ionsforMechanicalMaintenance4736. SafetyOperationInstructionsforLaboratory48NRCC6000th(clinker)CementProductionlineSafetyOperationManualChapter 1 General1. Workerhastocomplywithlabordisciplinewhentheyareonduty,remembertheprincipleofThreeNon-Injury，concentrateontheworkandhaveastableemotion.Whentheshi
12、ftchanges,staffwhoisinchargeoftheworkhastocheckthepsychosisofworker.Iftheyarenotinagoodemotion,theyshouldbeleavetheworkandcannotdootherworks.2. Whenmanagerofdifferentdepartmentsassignproductiontask,theyhavealsotoinformthespecificsafetyrequirementrelatedtoproductiontaskbywritten(ororal).Staffreceived
13、tasksmustsign(ororal)foracceptingtoworkbasedontherequirement.3. Forsafetyworkprotectionproductsprovidingtoindividual,workershavetowearwhentheyareworking.Forthosepublicorspecialsafetyworkprotectionproducts,workershavetohandoverandtakeovercompletely.Otherwisetheycannottakeovertheworkwhileoff-dutyandle
14、avetheirpositionwhileon-duty.4. Allworkershavetherighttorefusesuchworkslikebreakingcommend.Allworkershavetherighttorefuseexecutingunfulfilledsafetymeasurement.Foranyoperationbrokesafetyoperationmanual,allworkershavetherighttodeterexecutionandinformtheaboveeventstosafetyoperatoruntilmanagerinsafetyco
15、mmitment,andthenwillbepraisedpublicly.5. Differentsafetymanagementdepartmentshavenrightandresponsibilitytotestworkersasdifferentmethodsregardingtosafetyoperationknowledge.Disqualifiedworkershastounderstandinalimitperiod,otherwisewillleavethecurrentpositionforstudyinguntilbequalifiedtheposition.Chapt
16、er 2 InjuryProtectionGeneralIntroduction1. GravityInjuryProtection(injurybyfallingdown,injurybyhitting)I、InjurybyfallingdownProtection：2. Workersworkingatheight(3maboveworkingplatform)shouldnothaveCardiovascularetc,waresafetybelt,fastenandhangonthefixedbuildingorimmobilepartofequipmentandaresupervis
17、edunderside.Moreover,theycannotworkatheightwhilelightingstormandraining.3. Workingabovelevel2ofbuildinghastohaverailprotection.Unknownholeofshieldorcoveredcannotbeappearedonthefloor.Workershavetocheckthereliabilityofrailandholecovinginadvanceandthenbegintowork.Cuttingrailorremovingcovingduetoworkrea
18、sonshavetorevertafterfinishingtheworkandarecheckedandacceptedbysafetyoperator.Donotlyingon,havearestandchattingonrailofhighrisebuilding.4. Stairwayshouldsethandrailandillumination.Donotrunandjumpwhilewalkingonstairway.Handsdonotputintopocket.5. Donotwalkreverselywhilewalkingintheplantsite.Anycoverof
19、channelandwellshouldbecoveredwell.INrouteway,thereshouldnothavereinforcedsteelheadetconthegroundandsprinkleeasy-to-fallingdown,suchasclinkergrainetc.6. Donotwalk(includingimmobileequipment)ontheequipmentwithoutprotection.7. Whenworkersworkinsideoflarge-scalecontainere.g.preheateretc,thereshouldsetup
20、all-roundscaffoldandsetsafetynetifnecessary.8. Thoseareaneededworkinginnighttimeshouldhavesufficientilluminationfacility.IIInjurybyhittingmeansworkersareinjuredbyfallingdownofheavyproducts:1. Donotthrowdownanymaterialfromhighaltitude.Toolsandaccessoriesshouldputintokit.Ifitisinaspecialcondition,itha
21、stobeenapprovedbysafetyoperatorandarrangessomeonetosuperviseintheareaoffallingdown.Scaffoldingshouldsetupsafetynet.Anythingputtingonhighrisebuildingshouldbeplacedontheareawhichcannotbeeasytofalldown.2. Donotconcurrentlyworkatthesamesideandabove/belowdifferentstoryheightofuncoveredthing.3. Workerssho
22、uldobserveifanydangerisgoingtofalldownbeforepassinganyroutewaywhichhasequipmentconstructiononthetop4. Doputsafetyhelmetwhilewalkingorworkingatplantsite.5. Doappointoutspecialpersontosuperintendtogetherwhilemorethantwoworkersconveyheavyetc.6. Douseliftingequipmentwhileconveyingheavyproductmorethan10O
23、KG.Liftingheavyproductshouldhaveoperationcertificateofrigger.Docheckcarefullyforelectricalhoistbrakefacingandsteelcable.Donotusebrokenliftingequipment.Donotstandbelowliftingproductandrunningarm.Liftingequipmentcannotbeoverloadinguse.7. Furnacemaintenanceworksinsideofkilnshouldnoticeupperkilncoatinga
24、ndlinermaterial,prepareforprotectionandcomplywithoperationmanual.Changinglinerinsideofkilnshouldtakestrictprecautionsagainstthefallingoffofupperlinerandsteelball.8. Dochecknothingmaterialisinsideoffeedingslidebeforeenteringintoverticalrollermill.9. Doobservematerialinhighaltitudewhileexcavatingordis
25、charginghigh-stackmaterial.Oncethematerialispossibletoslipadown,workersmustretreatquickly.10. MechanicalInjuryProtection(injurybycrushing,injurybywringing)1. Fortherunningpartofrunningequipment,donottouchbyhandoranytool,especiallypayingmoreattentiontothoserunningequipmentwithslowspeed.Forsuchequipme
26、ntlikeallowinglubricating,coolingandcleaningoradjustingduringrunning,workersshouldexecuteinanimmobileplaceandhaveprotectionmeasurewithouttouchingrunningpart,suchassafetycover,net,etc.2. Uniformandsafetyhelmetshouldallbewornandtidiedupe.g.cuff,inordertorollinofclothandhair.3. Forthemaintenanceofrunni
27、ngpart,especiallyenteringintokilnandmillequipment,equipmenthastoshutdown.Operatormustcutpowerbypropercut-offprocedure.Forthoseequipmentcanbestartupbycentralcontrol,operatorshouldexecuteaftermakingsurewithstaffwhoisresponsibleforcontrolcentral.Staffresponsibleforcentralcontrolhastocontactwithworkerat
28、sitebeforestartinguptheequipment,inordertomakesurenobodyinnerandoutertheequipmentandcanstartupafterfinishingprocedureofshut-downandcut-off.4. Onlymorethantwopeoplecanenterintoequipments,likekiln,mill,bagfilter,etcformaintenanceandmakesuresomeonearesupervisingoutsidetheequipment.5. Nobodyallowsspanni
29、ngequipmentintheplaceofnorouteway,includingbeltconveyor,rimer,andchainmachineetc.Nobodyallowswalkingonthecoverofequipment.Routewayforspanningequipmentshouldbewithspanladderwithrailandplatform.6. Doappointoutuniformofficersformaintenanceofsameequipment(up,down,front,rear,inner,andouter).Theyneedtocon
30、tactclosely,cooperateanddonotinfluencewitheachother.7. Forcleaningoutjammedmaterialduringequipmentrunning,workersneedtocontactwithcentralcontrolandcannotstart/stoptheequipmentatsitewithoutauthorization,meanwhile,cannotenterintoinequipmentbytheirown.8. .Forthoseequipmentofoverhaulingorfinishingexamin
31、ing,relatedmanholes,coveretcneedtobeenclosedandtighten.Afterthat,itcannoticetostarttheequipmentup.9. Duringtheperiodofmaintenance,nobodyallowsstandingorwalkingonanyrotationalpartofequipment.10. Operationandcleaningsideofbeltconveyorshouldbedoneafterstoppingofbelt.Adjustingforbeltdeviationshouldbedon
32、ebyexperiencedoperatorduringrunning.Safetypullswitchofbeltconveyorshouldlearnhowtocheckanduse.Donotdealwithbypedalingonfoot,pullingbyhand,pressingpoleetcwhilebeltskit.11. Donotstandandsitontheequipmentduringmaintenance.12. Usinglathe,drillpress,grindingwheelmachine,portableelectrictool(percussiondri
33、ll,squirtgun,nailgun,brickcutter)etcequipmentshouldcomplywithrelatedoperationmanual.Donotallowlotsofpeopleworkingatthesametime.Shootingdirectionshouldnotaimatpeople.Usingtheabovemachineshouldforceequally.Ifanyabnormalsituationappears,operatorshouldshut-downthemachinerightnow,inordertopreventthefollo
34、wingaccidents:wringinguniform,drillhand,andwheelflyingetc.Donotcleanupmaterialonthehandoftoolduringrunning.13. Workershouldusequalifiedgrindingwheelmachine.Newgrindingwheelafterassemblingshouldspend30minutesforanover-speedtest.Grindingwheelcannothavecrackbeforeusing.Grindingwheelsteeringshouldnotaim
35、atpeoplewhileusing.Operatorshouldstandonthesideofgrindingwheel,cannotuseforcuttingandgrindingbigandflexiblematerial,andcannotgrindbyusingthesideofgrindingwheel.14. Usingtoolswithhandle(handhammer,filecutter,scraperetc)shouldcheckinadvancewhethertheinstallationofhandlefixesupornot.15. Donotrestandsle
36、epatproductionsite,especiallyonimmobileequipment,thesideofequipmentwithhightemperature,androuteway.16. Safetyvalveofpressurevesselshouldbereliableandcheckaccordingtorelatedregulation.17. Driveratsite(includingforklift,wheelloader,crane)shouldhavedrivinglicensewiththespeedofnomorethan5Km/h.18. Elevat
37、orcannotoverloadduringrunning.Oncethecontrolsystemisoutofcontrol,donotuseelevatorandstrapcontrolcircuitwithoutpermission.Whenworkeroverhaulsonthetopofcaroflift,theyhavetotakeacut-offprocedure.3ElectricalInjuryProtection(injurybyelectricity,injurybyburning)1. .Operatorofliveworkingforelectricalequipm
38、entmusthaverelatedcertificatedandcomplywiththeregulationof,oneworkeroperateswhileoneworkersupervisesn.2. Anyworkersworkingnearbyequipmentorlinewithelectricityshouldkeepasafetydistancewithelectrifiedbody.3. Donotexecuteliveworkinginnormalsituation.Forsomespecialconditionneedingliveworking,itshouldbes
39、ignedandapprovedbyelectricchiefengineerandsafetyoperatorandcanbeexecutedafterreliableonsafetymeasure.Thefirstoperatoraftercut-offshouldcheckelectricity,hang-onnoticeboard,andsetupfenceetc.Operatingequipmentwithhighvoltage,handmustkeepdryingandwearinsulatedglove.4. Inthesituationoftemporarypower-off,
40、itshouldcutpowerswitchoffimmediately,inordertoavoidsuddenstart-upafterhavingpower.5. Electriciansshouldwearinsulatedshoes.Itshouldpaveinsulatedrubberboard.Staffhastocheckthepressurizationdegreeofsafetyprotectiontool(safetybelt,insulatedoperationstick,highvoltagetestingpen)everyyearandmusttochangefor
41、disqualifiedtool.6. Buildingwithhighvoltagemustinstalllightingprotectionfacilityandshouldbecheckedoncethereliableofgroundinglinebeforelightingstormseason.Groundingresistanceshouldnotgreaterthan10.Groundingprotectionresistanceforcaseofelectricalequipmentshouldlessthan4.7. Donotchangesafetyinsurancede
42、greeofeachelectriccabinetofequipmentwithoutpermission.Donotconnectpowerlineandelectricalequipmentforprivateusewithoutpermission.Donotshortconnectforline.8. Groundwireofelectricweldingmachinecannotputuptheoilpipe,cablepipe,andsteelwireetcwithoutpermission.Workshopshouldsetupspecialgroundwire.Connecti
43、onheadofelectricweldinglinecannotexposure.Electricweldingmachineshouldhaverainprotectionfacilityandbeenlocatedatdryarea.9. Allelectriccabinetshouldcloseafterfinishingtheoperation.10. Temporaryilluminationworkinginsideofmetalequipmentslikekilnandmillshouldusesafetyvoltagewith24Vor36V.Powertemporaryli
44、necannothavetheareaofelectricleakageandwillberemovedandreturnedafterfinishing.11. DonotopenanymanholeduringrunningofEP.Manbodyhastokeepadistanceabove1.5mwithhighvoltagepart.Dosuchworksascut-offanddischargebeforemaintenance.12. Usingportableelectrictoolmustinstallprotectiondeviceforelectricconnecting
45、andleakage.Wiremustbeinsulatedrubberflexiblewireandcannothaveelectricleakage.Operatorshouldwearinsulatedgloveandinsulatedprotectionproducts.13. Anychangingforequipmentandtechnologycannotusetemporarywireandshouldspanpowerlineaccordingtolinerequirement.4 ThermalInjuryProtection(scald,injurybyburning)1
46、. Duringpokingandblockingforpreheater,workershouldwearprofessionalandwellprotectionproductsandnoticeCCRsystemtokeepanegativepressure.Itcanventilateandconnectwaterafterplugginginblowtorch.Workershouldstandonuptakeofpreheater.Aboveandbelowsystemcannotworkatthesametime.2. Whilecheckinginsideofkilnandco
47、oler,workerhastowaituntiltemperaturebelow40(includingenteringintootherequipmentlikemilletc)andcanenteraftermakingsurethatthereisnothingmaterialinpreheater.Workerscannotworkatthesametime.Dealingwithbigmaterialofcoolerbymanualshouldstoptherunningofcrusherandcutoffwindpowerofairblast.3. Donotstorediese
48、landHFOatanyplaceofsiteforalongtime.Workershouldrunoutofoiltankbeforelong-time(above20days)stoppingtousekiln.Stoppingusingkilnwithoutplanningshouldblowtermlyforcoolingtowardsoiltankandobservetermlythetemperaturechange.Donotstorefuelateachdeadangel.Oiloverflowingequipmentshouldcleanupsoon.CO2gascylinderforfuelsystemshouldchangeandtop-upwhilecloserunningout.4. Outlettemperatureoffuelshouldlessthan65insummerand70inwinter.5. Duringfiringandfeedingofkilnhead,donotobserveclosetokilnhead,sothatavoidingburningfromfirereturn.6. Docutofftheentrancechannelofkilnexhaustgasbeforeenter
