BLAST FURNACE

STANDARD OPERATING PROCEDURES OF BLAST FURNACE DEPARTMENT

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TITLE:

TOP LIGHT UP

RE NO : !! AMD NO : !! EFF" DATE : Pa#e: $ o% &

STANDARD OPERATING PROCEDURES FOR TOP FIRING

CONTENTS SR.NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Introduction Description of activities Personal hazards Risks to environment and plant Safety requirement - Training, isolations, PP , Special equipment mergency preparedness Safety quipment required Pre-conditions for Top firing! Sequential description of activities "ompletion checks Important telephone nos! #ist of documents to $e maintained %onitoring the data - &requency and corrective actions to $e taken! ngineering "hange notes Training records of the employees "ali$ration records Documents 'ould $e revie'ed and authorization DESCRIPTION PAGE NO 2 3 3 4 4 4 5 5 5 5 6 6 6 6 7 7 7

1. Introd

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In a planned maintenance shutdown it is normal to open the furnace top and ignite the burden surface. ISSUED B' : APPRO ED B' : ISSUED DATE :

BLAST FURNACE
STANDARD OPERATING PROCEDURES OF BLAST FURNACE DEPARTMENT

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A positive a++itude

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TOP LIGHT UP

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This will allow venting of the furnace top and raw gas system, enabling access to the BLT and dust catcher. Top Firing is a safe practice for maintenance job at furnace top and gas line.

Prepared by

!hec"ed by In charge

#pproved by $ead of the department

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2.

D$%!r"&t"on o' (!t")"t*#

R$%&on%"+","t* o' %-"'t "n.!-(r/$ ISSUED B' : ISSUED DATE : APPRO ED B' :

BLAST FURNACE
STANDARD OPERATING PROCEDURES OF BLAST FURNACE DEPARTMENT

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A positive a++itude

TITLE:

TOP LIGHT UP

RE NO : !! AMD NO : !! EFF" DATE : Pa#e: ) o% &

&nsure that the materials re'uired for top firing li"e wood, cotton waste, match bo(, L)* and prepare torch should be shifted to furnace top prior to shut down. #fter shut down "eep open the relief valve, bleeder valves, bac" draft valve, +%,, +-.. !lose the primary / secondary e'uali0ation valves, L-., L%, and dust catcher cut off valves. #ll tuyeres must be plugged with hydrous clay e(cept one tuyere. 1itrogen !ooling of BLT gear bo( to be stopped. &nsure all bolts from the access manhole are removed. This process may start after the furnace has been shut down, leaving 2 of bolt firmly in place. Turn off the 13 purging at the furnace top and open the door. 1o personnel should stand directly in front of the door or in a position to be struc" by the door in the event of an e(plosion. Throw a torch made with wood /cotton through the door to ignite the burden surface. &(ercise with great care, to see if the burden has ignited, if not, then throw in another torch. If the burden still does not light, throw in torches till there is definite ignition of gas ta"ing place. )raft the furnace, dust catcher and down comer. This process will remove nitrogen from these vessels and allow entry for maintenance purposes. 1ote 4 the atmosphere should be tested for o(ygen depletion before entry into any vessel or confined space. Safety Considerations Top Firing can be a ha0ardous process, with potential for flames from openings in the top and projection of material from tuyeres. #ll non5essential personnel should be cleared from the top area. Those involved in the process should be well protected by safety e'uipment and have a monitor capable of detecting both !* and *3 gasses. #ll personnel should be cleared from the tuyere area and loo"outs 6 barricades erected to "eep people out until the top firing is complete. &nsure ade'uate supply of torches is available. # minimum of 7 torches may be re'uired.

3.

P$r%on(, -(0(rd% . "n or (ro nd t-$ 1or2:

a8 b8 c8 d8 e8 !* content in BF5gas is Poisonous9 permissible limit of !* gas is 7: ppm. Fire and e(plosion. &lectricity $a0ards. $a0ards with !ompressed #ir613, steam and o(ygen. -aterial handling ha0ards.

4.

R"%2% to $n)"ron3$nt (nd &,(nt . A%%o!"(t$d 1"t- t-$ 1or2 #

a8 1oise generation from Blast Furnace.

ISSUED B' : ISSUED DATE :

APPRO ED B' :

BLAST FURNACE
STANDARD OPERATING PROCEDURES OF BLAST FURNACE DEPARTMENT

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5.

TITLE:

TOP LIGHT UP

RE NO : !! AMD NO : !! EFF" DATE : Pa#e: * o% &

BF .as lea"age in to the atmosphere Fire and e(plosion. )ust pollution. $eat.

S('$t* r$4 "r$3$nt . Tr("n"n/5 I%o,(t"on%5 PPE5 S&$!"(, $4 "&3$nt #

a8 b8 c8 d8 First aid training for Top Firing. Training on .as safety. Training on usage of fire e(tinguishers. &nsure that all operators are wearing helmet with face guard, safety shoes, leather hand gloves, #luminium aprons, %afety goggles, during normal operation. e8 Portable gas lea" monitor for detecting !arbon mono(ide f8 Breathing apparatus ;B# set8 for attending gas lea"ages. g8 !linical *(ygen cylinders h8 !hilled water showers. i8 &ar muff6plug

6.

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In case of problem in top firing a8 Inform to %hift in charge. b) )on<t give any clearance to start the shut down jobs .as lea"age / Fire a8 Inform to fire and safety control room and see" for assistance. b8 Inform to %hift in charge and all concern c8 Ta"e following actions to control and mitigate the fire Press the emergency push button ;if re'uired8 =emove all personnel from the lea"age area. &nsure breathing apparatus / other rescue devices are in reach. &nsure the area is of no to(ic gas before entering into the area of lea" for investigation.

! #8

B8

A,%o &,$(%$ r$'$r t-$ EPP 'or t-$ /(% ,$(2% (nd '"r$ Prepare fire incident report and send it to fire control room for detail investigation to avoid such type of fire in future.

7.

S('$t* E4 "&3$nt R$4 "r$d. S('$t* (&&,"(n!$%

Portable !* gas monitor. APPRO ED B' :

ISSUED B' : ISSUED DATE :

BLAST FURNACE
STANDARD OPERATING PROCEDURES OF BLAST FURNACE DEPARTMENT

REF NO

A positive a++itude
8.

TITLE:

TOP LIGHT UP

RE NO : !! AMD NO : !! EFF" DATE : Pa#e: + o% &

*(ygen gas -onitor. $eat resistant hand gloves. &ar plugs. )ust mas". Breathing apparatus ;B#8 set. $elmet. %afety shoes. !hilled water showers.

Pr$.!ond"t"on% 'or %t(rt o' To& 6"/-t U&.

#vailability of total 'uantity of purging 13. #ppro(imate flow rate to each purge point. Time re'uired to re5fill 13 storage tan"s and from where it has to refill. Plant set up prior to top firing:Furnace stopped and on bac" draft as per normal shutdown procedure. .oggle valve downstream from the dust catcher closed. This isolation is established purging of the clean gas system may commence. &nsure 13 purging is *1 to the furnace top and dust catcher 6 down comer. =e'uirement to plug the tuyeres to be determined 4 it is possible that too much gas may be produced if tuyeres are not plugged prior to top firing.

9. S$4 $nt"(, d$%!r"&t"on o' (!t")"t"$%

10.

Inform to all concerned departments Ta"e safety preparation in every aspect.

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a8 b8 c8 d8 &nsure sufficient firing is there. &nsure there is no 136%team purging in the Furnace top and dust catcher. &nsure the opening of safety bleeders. &nsure the o(ygen availability for safe wor"ing of personnel.

. Responsible person# 1. *peration shift in charge. 2. -echanical In charge 3. &lectrical in charge. ISSUED B' : ISSUED DATE : APPRO ED B' :

BLAST FURNACE
STANDARD OPERATING PROCEDURES OF BLAST FURNACE DEPARTMENT

REF NO

A positive a++itude

TITLE:

TOP LIGHT UP

RE NO : !! AMD NO : !! EFF" DATE : Pa#e: , o% &

11. I3&ort(nt t$,$&-on$ no%.

a8 b8 c8 d8 e8 Blast Furnace operation control room 5 >>>>>>>>>>> $ead of the department contact no 5 ?@2@AB@2:::3C Fire and safety control room 533336DDDD. !are hospital 6#mbulance 4 72::6D333. %ecurity control room 53E::6D:C:.

12.

6"%t o' do! 3$nt% to +$ 3("nt("n$d . A% ( +(!2 &. a8 *peration log boo" ;%hut down trend6graphs and log boo"8. b8 %*Ps. c8 %hift -anger and %hift In charge log boo" ;*peration, -echanical, &lectrical and Instrumentation8.

13. 7on"tor"n/ t-$ d(t(

The shift in5charge shall observe and monitor the following during operation 5 )epute one person continuously to monitor the top firing. If it got off immediately light it again. The presence of !* gas is to be monitored continuously, if it e(ceeds 7:ppm purge the system again. For the time being remove all persons involved in the job till gas level becomes low<

14.

En/"n$$r"n/ C-(n/$ not$% . R$!ord% to +$ 3("nt("n$d 1"t- &ro&$r (&&ro)(,% (nd 'or3(t% . a) #ll the engineering changes shall be approved on prescribed format from $*) with proper reasons for changes9 P / I) s shall be revised and documented. b) #fter changes being made, rewrite the %*Ps and revised documents shall be issued to respective control rooms.

15. Tr("n"n/ r$!ord% o' t-$ $3&,o*$$%

a) Trainings attended by all e(ecutives of the Furnace and the Tuyere platform6!ast $ouse shall be recorded in monthly / annual dept report.

ISSUED B' : ISSUED DATE :

APPRO ED B' :

BLAST FURNACE
STANDARD OPERATING PROCEDURES OF BLAST FURNACE DEPARTMENT

REF NO

A positive a++itude

TITLE:

TOP LIGHT UP

RE NO : !! AMD NO : !! EFF" DATE : Pa#e: & o% &

16. C(,"+r(t"on r$!ord% 8 For (,, t-$ 3$(% r"n/ "n%tr 3$nt%
#8 !ontinuous monitoring at control room, fault signal is generated if any problem occurs with instruments. b8 Field instruments monitored regularly ;shift wise8, replaced or calibrated if any problem is noticed.

17.

Do! 3$nt% 1o ,d +$ r$)"$1$d (nd ( t-or"%$d &$r%on 'or t-$ !-(n/$ "n SOP% .

a8 $ead of the department 6 Blast Furnace *peration In charge. b8 %*P %hall be reviewed every 3 years and record shall be maintained.

ISSUED B' : ISSUED DATE :

APPRO ED B' :