Emergency shutdown plan for quartz sand production line
In the production process of quartz sand, the stable operation of the
production line is directly related to the production efficiency, product
quality and personnel safety. However, it is difficult to completely avoid
emergency shutdown due to equipment failure, power interruption, abnormal
materials and other factors. This emergency plan is formulated to ensure quick
response and scientific disposal during emergency shutdown, minimize losses, and
ensure personnel safety and equipment integrity.
1、 Classification and identification of emergency shutdown causes
There are various reasons for emergency shutdown of quartz sand production
line. Common types and identification methods are as follows:
(1) Equipment failure
Crushing equipment (such as jaw crusher and cone crusher) may be shut down
due to abnormal vibration, abnormal sound or material jam; Sudden rise of
bearing temperature and motor overload of sand making equipment (such as impact
sand machine) are also important signals for shutdown; The conveying equipment
(such as belt conveyor) deviates, slips or breaks, which will directly interrupt
the material conveying and cause shutdown. Operators shall always pay attention
to the operating parameters of the equipment and find out the abnormality in
time by listening, watching, measuring, etc.
(2) Interruption of power
Sudden power failure is a common cause of emergency shutdown of the
production line, which may be caused by external power supply system failure or
internal circuit problems. At this time, all equipment will stop running, and
the workshop lighting may be off, which can be quickly judged by observing the
equipment shutdown state and lighting condition.
(3) Material problems
Interruption of raw material supply, such as empty bin, will make the
subsequent equipment have no material to process, and then shutdown; Large
foreign matters or impurities with abnormal hardness mixed in materials may
cause equipment blocking and shutdown. The operator shall closely monitor the
material level and material transportation of the silo to find out the material
abnormality in time.
(4) Safety accident
In case of equipment leakage, fire and other safety accidents, emergency
shutdown is required to ensure personnel safety. In case of emergency, the
operator shall immediately take shutdown measures and start corresponding safety
rescue procedures.
2、 Emergency organization structure and responsibilities
(1) Emergency command group
The production plant manager serves as the group leader and is responsible
for unified command of emergency disposal, formulation of emergency strategies,
coordination of resources of all departments and decision making on major
issues.
(2) Technical support group
Equipment engineer and technical personnel are responsible for analyzing
shutdown reasons, formulating equipment maintenance plan, guiding maintenance
personnel to carry out emergency repair and ensuring that equipment returns to
normal as soon as possible.
(3) Site Disposal Team
The team leader and operator shall be responsible for site emergency
treatment, such as cutting off power supply, stopping material supply, setting
warning signs, etc., to prevent accident expansion.
(4) Logistic support group
It is composed of administrative and logistics personnel, responsible for
emergency material supply, medical aid coordination and other work to ensure the
smooth implementation of emergency disposal.
3、 Emergency shutdown emergency treatment process
(1) Shutdown discovery and report
When the operator finds an emergency shutdown of the production line, he/she
shall immediately report to the team leader to explain the shutdown time,
phenomenon and possible causes. Upon receiving the report, the team leader shall
report to the leader of the emergency command group.
(2) Emergency response start
The leader of the emergency command group shall judge whether to start the
emergency plan according to the situation after receiving the report. If it is
started, immediately notify each emergency team to enter the working state.
(3) Disposal on site
Upon receiving the instruction, the site disposal group shall quickly arrive
at the site, cut off the power supply of relevant equipment, stop the material
delivery, check whether there is any personal injury or equipment damage on the
site, and set warning signs to prevent irrelevant personnel from entering.
(4) Cause analysis and treatment
When the technical support group arrives at the site, it shall communicate
with the operators and analyze the shutdown reasons in combination with the
equipment operation records. In case of equipment failure, formulate maintenance
plan and organize maintenance personnel to carry out emergency repair; If the
power is interrupted, contact the power supply department to learn about the
situation, check the internal circuit and prepare for power restoration; In case
of material problem, clean foreign matters or supplement raw materials in time;
In case of safety accident, cooperate with relevant departments for
handling.
(5) Equipment recovery and test run
Upon troubleshooting, the technical support group shall check the equipment
and inform the site disposal group to recover the power supply and material
supply after confirmation. The operator shall carry out test run and observe the
operation of the equipment. If everything is normal, report it to the team
leader and the emergency command group.
(6) End of emergency
The leader of the emergency command group shall declare the end of the
emergency after confirming that the production line returns to normal operation
and there is no potential safety hazard, and each group returns to normal
work.
4、 Preventive measures
(1) Equipment maintenance and repair
Formulate perfect equipment maintenance plan, regularly check, clean,
lubricate and repair crushing equipment, sand making equipment and conveying
equipment, and timely replace vulnerable parts to ensure that the equipment is
in good operating condition.
(2) Power supply guarantee
Provide standby power supply (such as generator), conduct regular maintenance
and test run to ensure timely power supply in case of power failure. At the same
time, strengthen the internal circuit inspection to prevent the shutdown caused
by circuit failure.
(3) Material management
Strengthen the purchase and inspection of raw materials to ensure that the
quality of raw materials meets the requirements and avoid impurities. Establish
a bin level monitoring system to timely master the bin level and prevent the
interruption of raw material supply.
(4) Personnel training
The operators shall be trained regularly to improve their operation skills
and emergency handling capacity, so that they can accurately judge the abnormal
conditions of the equipment and master the emergency shutdown operation
process.
(5) Regular drill
Organize emergency shutdown drill regularly, inspect the feasibility of
emergency plan and the cooperation ability of each group, and timely modify and
perfect the plan in case of any problem.
5、 Notes to note
During emergency shutdown, the operator shall keep calm and operate according
to the operating procedures to avoid secondary accidents caused by improper
operation.
The maintenance personnel must cut off the power supply when carrying out
rush repair, and set the sign of "Maintenance in progress, no closing" at the
power switch to prevent misoperation.
In the process of emergency disposal, each group shall closely cooperate and
obey the command to ensure that the emergency work is carried out in an orderly
manner.
Upon the end of the emergency, the emergency shutdown situation shall be
timely summarized and analyzed to find out the reasons and formulate improvement
measures to prevent similar situations from happening again.
The emergency plan shall be reviewed and revised regularly according to the
actual situation of the production line and the change of the external
environment to ensure its applicability and effectiveness.