Design points for environmental protection and safety of process equipment

[Abstract] By fully identifying the impacts of environmental and hazardous factors before designing the process equipment, and designing the right medicine for these factors, we will establish control measures to fully guarantee the safety and environmental protection of the process equipment. This paper systematically discusses the identification and measures of the impact of environmental and hazard hazards of these process equipment, and carries out the effect analysis and the prospect of green and healthy process equipment application.

I. Overview

At present, in order to meet the requirements of production characteristics such as variety and frequent production of railway wagons, Qiqihar Railway Vehicles (Group) Co., Ltd. (hereinafter referred to as Qiqi Group) needs to design and manufacture a large number of process equipment every year, only to export in recent years. In Brazil, for example, the number of crafts and equipment is 272. With the increasingly tight and busy production situation, and the stricter production requirements of environmental protection and occupational health and safety systems, the requirements for safety and environmental protection of various technological equipments are increasing under the premise of satisfying the functions of use. Therefore, in combination with the environmental impacts and hazard hazards that may arise after the process equipment is put into use, the requirements for safety and environmental protection in the design of process equipment are increasingly prominent and important.

Second, the environmental impact of process equipment and the main performance of dangerous hazards

At present, in Qiqi Company, the environmental impacts and dangerous hazards that may occur after the process equipment is put into use mainly include the following aspects:

1. Environmental impact

(1) Noise-causing pollution If equipped with a pneumatic system consisting of a cylinder, a gas valve, etc., if no appropriate measures are taken, the pneumatic components often emit large noise when performing the action.

(2) Contamination caused by oil leakage in hydraulic system If equipped with hydraulic equipment consisting of hydraulic cylinders, control valves and other components, if hydraulic fluid components are not properly taken, hydraulic fluids often leak hydraulic oil when performing operations.

(3) Dust emission in welding and other operations When some important equipments are used in conjunction with welding, shot blasting, etc., if improper measures are taken, it will cause disorderly discharge of soot and dust.

(4) Discharge of Chips Some important equipments, when working with cutting and other operations, may cause disorderly discharge of chips and accumulation on site if appropriate measures are not taken.

2. Hazardous aspects

(1) Noise causes damage Strong noise can cause deafness on the spot.

(2) Improper protection of moving parts There are devices with high speed rotation or transmission, which are easy to get caught or twisted into the body of the site and cause injury.

(3) 穃-transfer lock and limit failure cause the swivel part to squat - causing injury or scratching on the spot.

(4) Lifting and transmission brake failure The drop of the lifting member or the inability of the traction member to stop may cause injury or scratching on the site personnel.

(5) The walking platform and the guardrail do not comply with the relevant regulations, which may cause the field personnel to fall and damage.

Third, design points based on environmental impacts and hazard factors

The following types of measures are mainly taken for the environmental impacts and dangerous hazards that may occur after the process equipment is put into use:

1. Control welding fume emissions

Welding fume emissions are important environmental impact factors for railway wagon manufacturing enterprises, and it is necessary to formulate correspondingly perfect environmental management plans.

To this end, the company will focus on this aspect, develop environmental management programs, establish scientific goals, prepare meticulous implementation plans, implement effective monitoring methods, and conduct strict inspections and timely dynamic monitoring. Especially with the wide application of materials such as stainless steel in railway wagons, the impact of welding fume emissions on the environment is more prominent. Although the field operators are equipped with protective tools such as welding caps, masks, glasses, etc., there are often smoke and dust that strongly stimulate the operators. Occupational hazards such as the eyes and upper respiratory tract have occurred, and some welders have requested to transfer to their current positions. This is the short-term phenomenon, and the long-term consequences are even more unimaginable. To this end, in recent years, in the truck operating parts such as welding robots, all the dust-removing hoods have been removed, and replaced with new welding fume purification devices imported from foreign and domestic professional manufacturers in Harbin and Tangshan. During operation, the welding fumes are sucked into the purifier by the negative pressure of the fan, and the large particles of dust are filtered and deposited by the equalizing plate and the primary filter. The micro-scale fumes and exhaust gases entering the purification device are filtered and decomposed through the interior of the exhaust device, and then discharged to the standard. Gas, welding fumes can be collected, sputum-ring cleaned, and cleaned regularly. Through the monitoring of the environmental protection department, the discharge of the standard has been achieved, and the on-site welder is also very satisfied, achieving clean and civilized production, and embodying the people-oriented environmental protection concept of “cherishing the health and safety of employees”.

Combined with the seasonal characteristics of production, especially the climate characteristics of enterprises located in the north, we must fully consider the requirements for energy conservation. To this end, when working with professional manufacturers to formulate technical discussions, the equipment can be as far as possible to achieve "self-裓-ring", such as electric welding fume purifiers, through its own internal 裓-ring utilization, to avoid unnecessary discharge of energy outside.

2. Welding special fixture

For the 穃-transfer locking and limit failure, it is easy to produce the swaying part of the slewing part, which causes the injury or scratching of the field personnel. The main selection is the worm gear drive, safety pin and other mechanisms or components with self-locking function. . For the process equipment with pneumatic system, such as the special fixture for the K6 bogie support, since the workpiece of the process equipment is driven by wind pressure in the three coordinate axes, the pneumatic control system is specially configured (see below) The figure shows that the system uses a pressure of 0.4 MPa. In order to make the positioning and clamping action of the side frame smooth and slow, and the clamping force is suitable, the KLJ type throttle valve is installed to control the movement speed of the cylinder to control the movement speed of each clamping mechanism, and the QP type pressure regulating valve is installed to control each clamp. The clamping force of the actuator of the tensioning mechanism. In order to make the clamping of the side frame safe and reliable, that is, it will not fall from the clamp under any circumstances, the gas path is controlled by a KLA type check valve, and the circuit is controlled by the power failure clamping method. In this way, during the working process of the fixture, the side frame will be firmly clamped on the fixture regardless of the power failure, thus ensuring the absolute safety of the man-machine during the welding operation of the robot. It is fully programmed during operation and has an interlock function. The operator does not need to enter the welding work area, and the 穃-turn clamp does not interfere with the robot action and cause damage, thus achieving man-machine safety.

This achievement won the first prize of 2006 Heilongjiang-Mechanical-Celebrity Science and Technology Progress Award, and has been promoted and applied in several large enterprises inside and outside the railway system.

Transfer K6 and other bogie support seat welding special fixture pneumatic diagnosis - map

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