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REGULATION of the Gosgortekhnadzor of the Russian Federation dated April 24, 2003 22 ON THE APPROVAL OF SAFETY RULES IN THE COKE PRODUCTION (2020) Relevant in 2018

Chapter IV. MAINTENANCE, INSPECTION, REPAIR AND CLEANING OF TECHNOLOGICAL EQUIPMENT

4.1. Operation and maintenance (inspection, repair and cleaning) technical devices coke chemical industries must be carried out in accordance with the requirements of the technological instruction approved by the technical head of the organization and taking into account the requirements of the OPBM.

4.2. Technical devices are subject to inspection and repair within the time frame stipulated by the schedules approved by the technical head of the organization.

4.3. In coke production, lists of technical devices should be drawn up, the repair of which should be carried out using the tag system, the issuance of work permits and the development of a work organization project (POR).

4.4. The main technical devices of the coke production, subject to industrial safety expertise (survey), after a major overhaul or reconstruction, can be put into operation only after they are accepted by a commission with the participation of a representative of the territorial bodies of the Gosgortekhnadzor of Russia. The results of acceptance must be documented.

4.5. The thickness of the walls of vessels, apparatuses and pipelines containing explosive and flammable substances, as well as acids or alkalis, should be periodically checked with an appropriate entry in the log. The frequency, methods and place of control should be determined by the instruction approved by the technical manager of the organization.

4.6. All safety fittings must be adjusted to the set pressure and checked for tightness before commissioning.

The safety valves must be inspected each time the unit is stopped for inspection, cleaning or repair in accordance with the instructions approved by the technical manager of the organization, but at least once a year.

When testing safety valves for explosive and aggressive hazardous environments, registration (in the act of adjusting and checking the safety valve) of their operation pressure (opening and closing) using self-recording recording devices should be provided. The safety valve test chart must be kept for 3 years.

4.7. Shut-off valves for apparatuses and pipelines before their installation and after each repair must be subjected to a hydraulic test for strength and density. The test results are documented in an act.

4.8. Vessels, apparatus and pipelines subject to opening for internal inspection or repair must be freed from the working substance, disconnected from the operating equipment by locking devices and plugs. Depending on the properties of the working substances and the design, they must be purged with an inert gas, steamed or washed with water, purged with air.

Opening, cleaning, inspection, repair and testing of technical devices and communications containing harmful and explosive substances in the operating mode should be carried out according to the plan for the organization and conduct of gas hazardous and hazardous work (Appendix 3), with the issuance of a work permit (Appendix 1) and in the presence of a responsible work manager.

4.9. Vessels, apparatus and pipelines with LBZH intended for repair, after being freed from the working substance, must be disconnected from all existing pipelines with shutoff valves and removable plugs.

The procedure for purging with steam, opening vessels, apparatuses and gas pipelines for coke oven and blast-furnace gases, as well as the procedure for cleaning their internal surfaces must comply with the requirements of the technological instruction approved by the technical director of the organization.

4.10. All technological devices that are in reserve must be disconnected from the working devices with shut-off valves and metal plugs.

4.11. Removable plugs used to disconnect devices, gas pipelines and product pipelines must comply with the requirements of the OPBM.

4.12. Repair work must be terminated if:

there is a threat to the life and health of workers;

a violation of the conditions for disconnecting technical devices was detected;

a discrepancy between the state of the work area and the requirements of the POR, work permit and safety requirements was found;

the scope and nature of work has been changed, requiring a change in equipment shutdown schemes or conditions for their safe implementation;

V industrial premises an alarm has been given.

4.13. All work on shutting down existing devices, vessels and pipelines, as well as work on the removal of technological products, purging and steaming must be carried out by the production staff of the shop.

Equipment operated in various industries, as well as special equipment, need regular cleaning. It is necessary for continuity technological process, ensuring the necessary performance and extending the life of the equipment.

Until recently, this problem was solved in several ways, depending on the specifics of production. For this, strong chemical solvents, sandblasting and hydrotreating were used.

Disadvantages of chemical treatment technologies

1. toxicity chemical substances;
2. the toxicity of sand containing silicon dioxide and has long been banned for use in most developed countries;
3. the need to collect and dispose of consumables after completion of work; the need to suspend production for the period of technological maintenance (cleaning);
4. the need to protect certain parts of the equipment from the ingress of aggressive substances, sand or water;
5. high costs time and labor resources;
6. high cost of work performed.

Industrial equipment cleaning with soda blasting technology

The advanced technology of soda blasting solves the above problems with ease. It not only saves money and time for customers, but also provides an order of magnitude top quality works.

Soft blasting technology has become an ideal way to perform such types of work:

Removing the old layer of paint and dirt

Removal of old paint from equipment using a special abrasive Armex is carried out quickly, efficiently and at minimal cost. The basis of abrasive particles is sodium bicarbonate - simple soda, which is mixed with chalk. These natural, environmentally friendly components guarantee complete safety of work.

The composition of Armex is sprayed with special compact devices onto the surface to be cleaned. During the collision of the granules with the surface, they are destroyed with the simultaneous destruction of the surface layer of pollution.

Since the density of the abrasive is low, it removes only those substances that have the same or lower density, without damaging the surface being cleaned.

Blasting industrial equipment

Soft blasting has a number of advantages when cleaning equipment:

1. no need to use harmful chemicals;
2. cleaning is easy to carry out;
3. the remains of abrasive granules are easily dissolved in water, which makes it possible to simply wash them off without additional cleaning and disposal of materials after cleaning;
4. no additional preparatory work, for example, protection of equipment from abrasive ingress into mechanisms;
5. you can clean chrome, nickel, galvanized and aluminum surfaces without fear of damaging them;
6. allows cleaning engines and other parts of mechanisms without dismantling and disassembly;
7. consumable residues do not accumulate inside the mechanisms, as they are easily removed with water;
8. in case of unwanted dust formation, the abrasive can be used together with water;
9. significantly reduces the time spent on cleaning and its cost.

Armex blasting technology

Due to its versatility and simplicity, the technology can be applied to any modern enterprise, ensuring the excellent condition of the equipment, saving time and money.

Since Soviet times, we remember calls from propaganda posters - “Contain workplace clean." The modern industrial enterprise needs cleanliness more than ever. High quality standards, harsh sanitary norms and finally, the demands of management and owners, make it necessary to fight for the cleanliness of equipment and the workplace everywhere.

However, the peculiarities of the production process inevitably lead to the formation of various dirt, in Food Industry these are surpluses of food mass and drinks, in the industrial - production wastes, oils and technical liquids. Such pollution accumulates over time and can lead to very deplorable consequences both for the enterprise itself - breakdowns, failure of expensive equipment and various sanctions of regulatory authorities, and for the end user who received the product of inadequate quality or declared characteristics.

Workers of a small, handicraft workshop may well manage on their own to clean equipment from dust and dirt, but what about in-line, conveyor production, where every minute counts? Distracting personnel from the main activity of the enterprise and periodically sending them to cleaning - such a practice will inevitably lead to a drop in productivity and losses. Introducing separate staff units to maintain order is also not an option. Cleaning equipment from dust and dirt is a task for a specialized cleaning company.

cleaning technological equipment.

Which enterprises first of all need to take care of professional cleaning of the surface of the equipment and workspace:

• food industry enterprises require cleaning of process equipment due to increased standards of sanitary requirements;
• pharmaceutical and cosmetic companies whose waste may contain substances that threaten health;
• manufacturing enterprises using expensive machinery and equipment require constant cleaning of equipment surfaces;
• manufacturers who certify their products in accordance with international quality management;
• manufacturers of electronic and high-tech products urgently need to clean equipment from dust;
• enterprises whose technology contains potentially hazardous production processes, such as cleaning gas equipment;
• after reconstruction construction works or before putting the plant into operation.

Features of washing and cleaning enterprises

The cleaning process in manufacturing enterprises has its own subtleties:

• machines and lines, in high-tech and food industries, is an extremely complex surface. Cleaning equipment from dust and dirt requires a careful approach;
• pollution in the manufacturing industry is very difficult to remove with conventional household products.

Our cleaning company is equipped with the most modern equipment, an extensive fleet of various washing machines, industrial vacuum cleaners, high-pressure cleaners and hand tool allows you to remove dirt, taking into account the characteristics of the enterprise itself.

Regular/periodic cleaning of heat exchange equipment is a determining factor in improving the economic efficiency of the plant as a whole and increasing the service life of the equipment being cleaned.

The ALVIGO group of companies provides cleaning services for the existing heat exchange equipment in the production of ammonia - methanol, as well as nitrogen, hydrocyanic acid and hydroxylamine sulfate from sludge. Constantly improving the technology of work, "ALVIGO" is a leader in the market for cleaning equipment of chemical production, in order to extract metals containing platinum group metals (PGM).

The following cleaning methods are used to clean process equipment:

• Mechanical

Depending on the design features equipment to be cleaned The ALVIGO Group of Companies can carry out mechanical cleaning. Mechanical cleaning is successfully used in gas-tube boilers. Mechanical cleaning also includes cleaning the bottoms of storages, the inner walls of gas ducts and linings.

This type of cleaning is carried out using a special cleaning tool - a cutter that removes only a thin layer of rust and scale, which contains almost all the PGMs in the apparatus. The material of the cleaned equipment is not affected.

• Chemical

To extract PGM, the method of chemical cleaning of process equipment with inhibited aqueous solutions of sulfuric and phosphoric acids is also successfully used. This method of cleaning is the only way to clean apparatuses, in the heat exchange packages of which nitrous gas passes in the annulus. For aqueous solutions of sulfuric acid, such purification is carried out in optimal mode in terms of concentrations, temperature and time required for cleaning.

The technology of non-destructive/destructive physical-chemical cleaning is based on the process of acid etching of the surfaces to be cleaned. Conventionally, it can be divided into 4 stages:

1. Preliminary mechanical cleaning (dismantling of the equipment to be cleaned and its processing by physical and mechanical methods to remove sludge from the accessible surface).
2. Acid etching (the equipment is placed in pools with sulfuric acid, which, reacting with both the surface layer of rust and scale, the sludge falls to the bottom of the pool in the form of sediment).
3. Washing with water (remaining sludge is washed off with water, carried out over the pool).
4. Neutralization of solutions and collection of sludge (the resulting sludge is dried and homogenized).

• Hydrodynamic

One of the most popular and effective modern technologies from the point of view of economics and ecology is hydrodynamic cleaning. Cleaning takes place inside the waste heat boiler.

The essence of this method is that the contaminated surfaces are treated with water at a pressure of 2500 bar. Flushing of the heat exchanger pipe is carried out by supplying water through a flexible hose ending with a special nozzle. For greater efficiency, nozzles of various modifications are used, allowing you to adjust the required pressure and angle of distribution of the jet.

Advantages of hydrodynamic cleaning:

• High efficiency: 90 – 99% of pgm deposits are collected
• Environmentally friendly
• Guarantees of safety of the customer's equipment
• Specialized complex equipment
• No loss of PGMs in the form of dust.

Usage different methods cleaning, as well as reagents of our own design, ultimately provides a high degree of cleaning while providing a full guarantee for maintaining the residual life of the cleaned equipment.

To carry out work on the cleaning of technological equipment, the ALVIGO Group of Companies developed and built unique mobile production complexes (MPCs), which have no analogues in any of the competing companies.

We also carry out:

primary treatment of sludge obtained during cleaning of equipment, namely: preliminary sorting from foreign objects, drying, grinding, homogenization, packaging, etc.

We guarantee:

1. Preservation of the residual resource of the cleaned equipment. To confirm the safety, in the standard, before and after cleaning, hydrotesting is carried out.
2. Preservation of the technological modes of operation of the boiler.
3. Perhaps, but not necessarily, there will be some improvement in modes. In particular, an increase in steam production and a decrease in the gas temperature at the boiler outlet.

You can send a request for the inspection of the unit, a preliminary assessment for the collection of PGMs and the preparation of TCH for cleaning work by

• Hydrodynamic cleaning - cleaning with high water pressure (jet cleaning with water) using industrial high pressure installations. It is one of the main technologies currently used for cleaning industrial facilities. The company has a resource in the form of technological equipment, hydrodynamic installations operating from 350 to 2800 bar, with a capacity of 12 to 200 l/min. High-pressure installations in such a range of operating pressures make it possible to remove almost any type of dirt, deposits, coatings on various types equipment and engineering systems.
• Sandblasting (abrasive blasting) is a classic jet cleaning technology with an abrasive in the form of quartz sand, cupro slag, nickel slag, crushed shot. As part of cleaning and preparation metal surfaces for painting in accordance with ISO 8501, is the main one. The most simple to organize and effective in terms of the speed of work. However, it can not be used everywhere due to high dust formation, the formation of a large amount of secondary waste, and the creation of roughness on the surface to be cleaned (which is not always acceptable).
• Soda cleaning (soda blasting) - jet cleaning with sodium bicarbonate and calcium bicarbonate. A special technology and special sets of equipment that allow cleaning surfaces without the formation of roughness, while effectively removing various kinds of pollution.
• Hydroabrasive cleaning - jet cleaning with a water-abrasive mixture. It is used in order to remove various contaminants, coatings, deposits from surfaces with a jet of a mixture of air, abrasive and water. Effective for a range of different cleaning tasks, as well as tasks that exclude the possibility of dust formation in the work area.
• Dry ice cleaning - blast cleaning with dry ice pellets. The technology is used to remove dirt and coatings of medium complexity at facilities where the presence of water or any abrasive in the form of secondary waste is unacceptable. The effectiveness of the technology lies in the fact that the cleaning takes place without the formation of roughness on the surface of the cleaning, and also without any secondary waste: ice evaporates upon impact from the surface.

• Chemical cleaning - cleaning using alkaline, acidic and neutral reagents. The technology is used to clean engineering systems by creating a circuit for circulating a reagent for cleaning purposes. For these purposes, we use professional chemicals and special pumping units with a capacity of up to 150 m3/hour. The technology is also used to clean various surfaces by spraying and applying chemicals, followed by their removal along with contaminants.

Industries in which we implement industrial cleaning technologies:

• Petrochemical.
• Chemical.
• Oil and gas production.
• Oil refinery.
• Pulp and paper.
• Coal.
• Oil and gas production.
• Energy.

• Metallurgical.
• Food.
• Transport.
• shipbuilding

Typical contaminants that have to be removed during technological cleaning:

• Scale deposits.
• Various kinds of soot and soot (burning results).
• Various products of chemical synthesis.
• Oil and grease contamination.
• Rust.
• old polymer coatings(paint, insulation).
• polymer deposits.
• Oil sludge deposits.
• Deposits of a biological nature.

If it is necessary to clean the process equipment at your enterprise, please contact our company. Experts will advise you on possible solutions existing problems regarding the maintenance of equipment, will carry out a site visit for the purpose of inspection and evaluation, and calculate the cost of work. We are one of the best in this segment, which confirms real experience! Call!