Emergency Response Plan for Gas Fired Glass Furnace Melting

1. Glass leakage
1) When it is found that glass water leaks from the bottom of the pool and the amount is not large, compressed air can be used for cooling; If it cannot be effectively controlled, emergency water pipes shall be used for cooling.
2) Glass water leakage at the pool wall:
When the amount is not large, an iron rake can be used to plug the leaking glass, blow it to cool, and notify the bricklayer to handle the pool wall bricks that have leaked glass. After treatment, strengthen air cooling to prevent glass water leakage again.
In case of serious glass leakage, the following procedures shall be followed:
A. Immediately notify relevant leaders, managers of the Tank Kiln Department, Mechanical and Electrical Department, relevant engineers, and bricklayers
B. Use an iron rake to plug the leaking glass liquid and pour water to cool and solidify it
C. Properly reduce the pulling amount
D. With the consent of the leader, the glass level height and melting temperature can be reduced
E. After the bricklayer has treated the pool wall bricks that have leaked glass liquid
F. Gradually increase the melting temperature and add the liquid level to the normal state as required. When adding the liquid level, it should be slow and uniform. If the liquid level drops within 5mm, it can be added at a speed of 2mm/h; If the liquid level drops between 5 and 10 mm, add at a speed of 1 mm/h; If the liquid level drops by more than 10mm, it shall be determined based on the study of the situation in the kiln.
G. Strengthen air blowing, cooling, and patrol inspection of the pool wall bricks that leak glass liquid to avoid leakage of glass water again.
2. Handling of combustion air interruption due to shutdown of combustion air fan
Once the combustion air is stopped, combustion in the kiln will not proceed normally, and the following procedures can be followed:
1) Press the natural gas emergency stop switch in the central control room to turn off the gas supply.
2) Immediately start the standby fan and restore the combustion air supply. When starting the standby combustion fan, pay attention to:
First, turn the standby fan start button from the MCC room to "local".
B. Manually close the outlet valves of the two fans on site.
C. Press the standby fan start button on site to start the fan.
D. After the fan operates smoothly and the rotational speed reaches normal, manually open its outlet air valve to 90 °;.
3) Start the natural gas to resume normal combustion according to the following procedure:
Determine the combustion direction to ensure that the natural gas and combustion air are in the same direction
B. Change the natural gas control of each small furnace to manual control of the upper computer
C. Set the position of the natural gas control valve for each small furnace according to the output opening of the natural gas control valve before stopping the combustion air
D. Open the block valve of the natural gas main in the workshop to supply gas.
3) Notify the maintenance personnel to inspect and handle the fan.
3. Neck water bag leaking
1) Less water leakage: pay close attention to water leakage, notify relevant personnel, and organize personnel to replace water bags
2) When there is a large amount of water leakage:
A. First inform the molding to avoid falling off the edge due to a decrease in flow caused by a decrease in the temperature of the working part
B. Turn down the inlet circulating water valve (but not too small to prevent personal injury due to steam) and organize the replacement of the water bag
3) When replacing the water bag, follow the following procedure:
A. Clean up the debris on both sides of the water scooter track and prepare to exit the water scooter
B. Clean the sealing material in the insertion hole of the water bag
C. At the same time, shake both handles of the water ladle truck to raise the water ladle (at the same time, appropriately turn off the water supply to prevent attachments near the water ladle from falling into the kiln), so that its bottom is higher than the pool wall brick by more than 20mm.
D. Exit the water bag truck, replace the water bag with a new one, connect the inlet and outlet pipes, and adjust the water flow for use.
E. Mark the installation position on the water bag. Ensure that the gap between two water bags is between 30mm and 40mm, and the gap between the water bag and the pool wall is between 20mm and 30mm, with symmetrical arrangement on both sides.
F. Clean the upper edge of the pool wall.
G. Push the water bag truck into the predetermined position, while uniformly shaking the water bag truck takeoff and landing handle to slowly lower the water bag. Pay attention to the position of the water bag and do not contact the pool wall brick and the opposite water bag.
H. Seal the water bag insertion hole.
Adjust the outlet water temperature as required, and the temperature difference on both sides must be less than 2 ℃. Observe for more than 5 minutes and the temperature should remain stable.
4. Shutdown due to failure (or maintenance) of one feeder
1) The speed of another feeder can be accelerated in a short time, or the feeding amount can be increased to keep the liquid level stable
2) Frequently observe the changes in the position of the material pile and bubble boundary in the kiln to ensure that they are within the process control indicators.
3) If a longer maintenance time is required, the following procedures should be followed:
A. Notify the Manager of the Tank and Kiln Department, the Melting Engineer, and the Tin Return Engineer.
B. Inform the molding department to make preparations for appropriately reducing the pulling amount. The pulling amount can only be reduced with the approval of the manager of the tank and kiln department.
Adjust the melting temperature as required.
D. Organize personnel to pull out the feeder: first close the screw ram at the outlet of the kiln head silo corresponding to the feeder, then adjust the lower edge of the feeder push plate to be more than 5mm above the top surface of the tank wall, and clean it up; Then separate the intermediate clutch and slowly push out the feeder.
E. Manually shovel the mixture into the kiln with a shovel.
F. Pay attention to adjusting the direction of the material hill with a push rake.
After the feeding machine is processed, position it according to the predetermined position and close the clutch.
H. Start the feeder after confirmation by electrical and mechanical personnel.
After starting the feeder, pay attention to observing the rotational speed of the feeder, which should not be higher than 10% of the normal operating rotational speed, to avoid excessive feeding and outward displacement of the pile position.
J. Restore the normal process system.
5. Water leakage from agitator
1) Less water leakage: pay close attention to the water leakage, notify the manager of the tank and kiln department, relevant engineers, and organize personnel to replace the mixer.
2) When there is a large amount of water leakage:
A. First inform the molding to avoid falling off the edge due to a decrease in flow caused by a decrease in the temperature of the working part.
B. Turn down the inlet circulating water valve (but not too small to prevent personal injury due to steam) and organize replacement.
C. Notify the manager of the tank and kiln department and relevant engineers.
3) When replacing the mixer, follow the following procedure:
A. Remove the sealing material from the agitator hole.
B. Loosen the fastening bolts on the mixing rod, and turn the mixing rod over 90°, And fix it.
C. Withdraw the mixer from a suitable position outside the kiln.
D. Clean the glass liquid on the pool wall with a shovel and hook.
E. Close the water inlet valve of the mixer, and remove the mixing rod and water inlet and outlet pipes.
F. Install a new mixing rod, determine the position of the mixing rod according to the neck size, and connect the inlet and outlet water pipes.
Open the water inlet valve, check the water volume of the mixer, and observe whether there is water leakage in the mixer.
H. Rotate the mixing rod to keep the mixing blades horizontal.
I. Clean up the rust and other debris on the surface of the new mixing rod.
J. Send the mixer into the kiln, return the mixing rod to the last position, and check the gap between the mixing paddle and the tank wall, which should be around 80mm; Inch the mixer motor to move the mixing rod to the most forward position. Observe the distance between the two mixing rods, which should be more than 50mm.
K. Loosen the fastening bolts on the mixing rod, and turn the mixer over 90°, And fixed with fastening bolts.
Start the agitator and adjust the phase of the agitators on both sides.
M. Check the water outlet temperature of the mixer, adjust the water inlet valve, and make the water outlet temperature meet the specified requirements.
N. Seal the agitator hole properly.
O. Clean up the site for hygiene.

6. Agitator shutdown
1) Notify the maintenance personnel to check and handle, and restart in a timely manner.
2) If it cannot be started immediately, proceed as follows:
A. Rotate the mixing rods on both sides by 90 ℃ to disengage from the liquid level.
B. Take the mixer out of the kiln, clean the glass and condensate on the mixing rod, and submit it to the maintenance personnel for treatment.
C. Reinstall the agitator after handling it.
Note: Both steps B and C are carried out according to the operating requirements for replacing the mixer.
7. Furnace water shutdown occurs
1) Immediately notify the relevant departments (department managers of the Mechanical and Electrical Department and the Tank Kiln Department, relevant engineers, maintenance personnel, and company leaders).
2) Organize personnel to remove water consuming equipment such as neck water bags and agitators from the kiln; Close the corresponding water supply valve to avoid steam injury after sudden water supply.
3) Remove the instrument cooled with water immediately to prevent burning out; And close the corresponding water supply valve.
4) After water supply, check the water bag and agitator for water leakage and deformation. If necessary, replace the water bag and agitator with a new one.
5) To reinstall the water bag and agitator, follow the replacement steps when the agitator leaks or the water bag leaks.
8. Furnace shutdown of compressed air
1) Inform the air compression station and maintenance personnel to inspect and handle, and notify the managers of the Tank Kiln Department, the Mechanical and Electrical Department, and relevant engineers.
2) According to the opening of the control valve for the combustion air branch pipe of each small furnace during normal operation, open each branch pipe valve on site for air supply through the control valve handwheel.
3) Open the main pipe bypass valve according to the pressure during normal operation.
4) According to the pressure of the natural gas branch pipe of each small furnace during normal operation, open the bypass valve of each small furnace control valve to supply gas, and close the butterfly valve in front of the reversing valve.
5) When reversing, use manual operation. Proceed as follows:
A. Close the bypass of the natural gas branch pipe of the 1 #~6 # small furnaces and stop supplying gas to the kiln. Notify the air handover operator after completion (note: it is prohibited to use walkie talkies, telephones, etc. in the control room).
B. Air delivery machine reversing: First, manually exchange the air delivery machine ram in place in the central control room. If manual operation in the central control room is not feasible, on-site manual operation is used. Remove the handle next to the drive motor of the air compressor and press the control button on the adjacent column to make the air compressor ram run in place. If the electric drive cannot operate, use the handle to place the switch ram in place. Notify the operators in the natural gas control room after the reversing of the 1 #~6 # air shuttles is completed.
C. Close the manual valve in front of the reversing valve, open the bypass of the natural gas branch pipes of the 1 #~6 # small furnaces according to the pressure of the natural gas branch pipes of each small furnace during normal operation, resume gas supply, and complete the reversing.
D. When reversing, pay attention to the direction of fire and ensure that the wind and fire are in the same direction.
9. L hanging wall fan shutdown
1) Start the standby fan immediately:
First, turn the standby fan start button from the MCC room to“ In Place”.
B. Go to the site and close the outlet air valves of the two fans.
C. Press the standby fan start button on site to start the fan.
D. After the fan operates smoothly and the rotational speed reaches normal, open its outlet air valve to the normal use opening.
2) Immediately notify the person in charge of electrical and equipment on duty in the Mechanical and Electrical Department to inspect and handle the situation on site, find out the reason for the shutdown of the fan, and keep it in a normal standby state.
3) If the fan stops for more than 5 minutes, open the outlet air valve by 30% after the fan starts, and then open the outlet air valve by 10% every 10 minutes until the opening is normal for use.
10. Shutdown of steel arch slag blower
1) Immediately start the standby fan in the MCC room.
2) Immediately notify the person in charge of electrical and equipment on duty in the Mechanical and Electrical Department to inspect and handle the situation on site, find out the reason for the shutdown of the fan, and keep it in a normal standby state.
11. Pool wall (U-shaped hanging wall) fan shutdown
1) Start the standby fan immediately:
First, turn the standby fan start button from the MCC room to“ In Place”.
B. Go to the site and close the outlet air valves of the two fans.
C. Press the standby fan start button on site to start the fan.
D. After the fan operates smoothly and the rotational speed reaches normal, open its outlet air valve to the normal use opening.
2) Immediately notify the person in charge of electrical and equipment on duty in the Mechanical and Electrical Department to inspect and handle the situation on site, find out the reason for the shutdown of the fan, and keep it in a normal standby state.
3) If the fan stops for more than 5 minutes, open the outlet air valve by 30% after the fan starts, and then open the outlet air valve by 5% every 10 minutes until the opening is normal.
12. Short time power failure of furnace
If a short power outage causes the shutdown of equipment such as fans, the following procedures shall be followed:
1) Combustion fan shutdown:
A. Notify the on-duty personnel of the Mechanical and Electrical Department to handle the situation on site.
B. Immediately close the main natural gas valve.
C. Start the combustion fan after the power is turned on.
D. Start up natural gas at about 50% of the normal dosage and gradually increase to the normal dosage.
2) Start the pool wall (U-shaped hanging wall) fan:
First, twist the fan start button from the MCC room to“ In Place”.
B. Go to the site and close the outlet air valves of the two fans.
Press the fan start button on site to start the fan.
D. After the fan operates smoothly and the rotational speed reaches normal, open its outlet air valve to the normal use opening.
E. If the fan stops for more than 5 minutes, open the outlet air valve by 30% after the fan starts, and then open the outlet air valve by 5% every 10 minutes until the opening is normal for use.
3) Start the L hanging wall fan:
First, twist the fan start button from the MCC room to“ In Place”.
B. Go to the site and close the outlet air valves of the two fans.
Press the fan start button on site to start the fan.
D. After the fan operates smoothly and the rotational speed reaches normal, open its outlet air valve to the normal use opening.
E. If the fan stops for more than 5 minutes, open the outlet air valve by 30% after the fan starts, and then open the outlet air valve by 10% every 10 minutes until the opening is normal for use.
4) Start the steel arch slag blower:
A. Immediately start the fan in the MCC room.
5) Start the dilution fan (pay attention to first closing the outlet valve to avoid sudden increase in kiln pressure affecting the flow.)
6) Start the feeding machine (control its rotation speed to be within 1.1 times of the normal rotation speed).
7) Start the agitator.
8) If the above-mentioned fan cannot be started normally, immediately start the standby fan according to the same procedure, notify the on-duty electrical and equipment responsible person of the Mechanical and Electrical Department to inspect and handle it on site, find out the cause, and put it in a normal standby state.
9) During the power outage, pay close attention to the temperature changes of the suspended wall and pool wall, try to avoid the sharp changes in the temperature of the suspended wall and pool wall bricks causing the suspended wall and pool wall bricks to burst, and prevent glass water leakage due to stopping the wind on the pool wall for too long
10) If the power outage lasts for more than 5 minutes, it is necessary to promptly notify the engineer and department manager of the Tank and Kiln Department, as well as the electrical and equipment responsible person of the Mechanical and Electrical Department.
13. Fires in the kiln caused by fire exchange failure
1) Due to the fire, the kiln body emits serious fire and the turbidity in the kiln is unclear. It is necessary to press the natural gas emergency button to turn off the natural gas. Meanwhile, notify the control engineer to check and handle the fault.
2) Distinguish the fire direction and manually switch the combustion air reversing shutter to the correct position on site to ensure the same direction of wind and fire.
3) According to 80% of the pressure of the natural gas branch pipe of each small furnace during normal production, open the bypass pipe of the small furnace at the fire inlet side on site, and close the manual valves in front of the reversing valves on both sides.
4) Open the main pipe block valve to supply air and resume combustion.
5) After troubleshooting, first perform a manual panel fire change, then restore semi-automatic fire change, and finally switch back to automatic fire change.
14. Furnace power failure for a long time
1) Notify the manager of the tank and kiln department, the electromechanical department, and relevant engineers.
2) After obtaining the consent of the leader, notify the molding department to appropriately reduce the pulling amount.
3) Turn down the amount of natural gas to about 2% during normal production, and change the direction to manual.
4) The regulating valve of the combustion air branch pipe of each small furnace is fully opened (manually operated on site).
5) Pull out the feeder and block the feeding port with a mixture.
6) Turn down the rotary shutter of the main flue to keep the kiln pressure at a slight negative pressure.
7) Pull out water cooling equipment such as agitators, neck water bags, etc.
8) Seal all holes for full thermal insulation.
9) Carefully inspect the kiln body and tighten the tie rod if necessary.
10) After calling, resume production according to the following procedure.
A. Resume combustion: Open the main flue rotary shutter to about 50% of the normal opening____- Start the combustion fan____ Gradually increase the amount of natural gas (first, drive to about 40% of the normal amount, then gradually increase, and ensure the same direction of wind and fire)____ Adjust the kiln pressure to normal level.
B. Reinstall the feeder, change the liquid level control to manual, and determine the feeding speed based on the temperature in the kiln.
C. Start the kiln protection fan as required: the air volume of the pool wall fan and the hanging wall fan increases gradually from small to large; The air volume of the steel arch slag blower can be fully turned on at one time.
Gradually adjust the melting temperature to normal as required.
E. Gradually restore the use of mixers, water bags, etc. according to production conditions.
15. Stop natural gas
1) Notify the person in charge of utilities in the Mechanical and Electrical Department, the manager of the Tank and Kiln Department, relevant engineers, and company leaders.
2) Turn off the combustion air to avoid temperature drop.
3) Close the rotary ram, maintain the pressure in the kiln, and avoid a rapid drop in temperature.
4) Stop feeding and inform the molding to reduce the drawing amount.
5) Remove neck water bags, blenders, etc. to reduce heat loss.
6) After restoring gas supply, resume production according to the following procedures:
A. Resume combustion: Open the main flue rotary shutter to about 50% of the normal opening____- Start the combustion fan (the air volume is controlled at about 50% of the normal consumption, and then gradually increase according to the natural gas volume)____ Gradually open up natural gas (first, open it to about 50% of the normal consumption, and ensure the same direction of wind and fire)____ Adjust the kiln pressure to normal level.
B. Start the feeder, change the liquid level control to manual, and determine the feeding speed based on the temperature in the kiln.
C. Gradually adjust the melting temperature to normal as required.
D. Reinstall the agitator, water bag, etc. gradually according to the production situation.
16. Furnace body fire penetration
1) Notify the kiln protection engineer and kiln workers to handle the situation on site in a timely manner.
2) If the fire penetration is large but does not reach the steel structure of the furnace, the operator on duty must temporarily cover the fire with refractory bricks or insulation cotton.
3) If the fire burns to the steel structure of the furnace, the operator on duty must immediately separate the fire from the steel structure with refractory bricks or insulation cotton (it is strictly prohibited to cover the flame and the steel structure together with insulation cotton).