In recent years, as the output of feed mills continues to increase, feed mills tend to focus on production, ignoring the importance of safety precautions; although some feed mills do not currently meet full-load requirements, they still do not take safety seriously. Frequent accidents. These accidents not only caused great economic losses to the company and were sanctioned by the law, but also led to the death of a beautiful family. I have been engaged in the feed business for more than 20 years. Since 2002, I have experienced more than 20 major accidents in feed safety and more than 50 casualties. In June 2015, a warehouse in Linyi, Shandong Province, saw a warehouse worker mistakenly entered the batching warehouse, resulting in death of suffocation; in May 2016, he visited the market, and another feed factory had a major safety accident-dust explosion, causing more than 10 people to be seriously injured. The cause of the explosion was initially identified as a result of dust exposure to an open flame.
These painful accidents have sounded a safety alarm for our feed production and processing industry, and safety production is more important than everything else. Now I have integrated, summarized and sorted out many hidden dangers in the feed factory. I hope to be able to sound alarms for all feed enterprises, always remembering safety and preventing problems before they happen.
Fire
In 2007, a woven bag warehouse of a feed mill in Shouguang suddenly caught fire. In 2008, a feed mill in Changle crushed palm sputum, causing smog burning in the pulverizer; on April 15, 2014, a warehouse of a feed mill in Donghai County, Jiangsu Province Suddenly the fire burned and a large amount of feed piled up in the warehouse was ignited.
There are three main conditions for fire:
First, there are combustibles (packaging materials, raw materials, finished products, acetylene, gas, dust, etc.);
Second, the aerobic state;
Third, there is input energy (fire source, circuit short circuit, etc.).
Precautionary measures:
1. Division, isolation and strengthening of 6S (finishing, rectification, cleaning, cleaning, literacy, safety) management of flammable materials; no flammable materials are stored in the workshop, the bags are cleared, the daily knots are not retained, and the waste is timely cleared and transported. Takeaway, paint, thinner, diesel, alcohol, and petrol are not allowed in the workshop.
Second, the production area is strictly prohibited fireworks, regular inspection of electrical appliances, lines, cables, anti-aging, loose, broken, damp, short circuit, overload, heat; not allowed to do hot work in the workshop, if you need to fire, do everything Preparation, after the on-site inspection and confirmation by the supervisor, the hot work can be carried out, and the surrounding and downstairs debris should be cleaned up in advance.
Third, the rainy season check the lightning protection system is intact, to prevent lightning strikes;
Fourth, to prevent spontaneous combustion of special raw materials. For example: fishmeal, meat and bone meal, rice bran, sugar residue, chemical reagents and other special raw materials should be properly kept; oxygen acetylene bottles are required to belong to pressure vessels, tempering devices and other accessories should be complete, placed away from pedestrians, away from the operating area.
5. Ensure that the fire protection facilities are in good condition. Maintain adequate and effective fire extinguishers within the plant area, and place them in an obvious position. It is convenient to use and cannot be blocked. The method of use is posted on the site and everyone will use it (regular drills). The fire extinguishers that fail will not be stored on site. Causing confusion. The dormitory and the concentrated parts of the building should have escape routes, and the escape route cannot be blocked. If it is locked, it must leave a tool for shackles.
Dust explosion
Dust explosion is a kind of ignitable solid dust or flammable liquid mist droplets dispersed in air or other combustion-supporting gas in a relatively closed environment. When the concentration reaches the explosion limit, a certain amount of ignition energy is inevitable. Explosion phenomenon. Can cause huge damage, such as a feed mill in Feicheng in 2002, a welding slip on the fifth floor of a feed mill in Qingyun in 2003, an explosion in the welding of a feed mill in Shouguang, an explosion in a finished product warehouse in Dezhou, Laiyang A dust explosion occurred in the crushing system of a feed mill. According to statistics, dust explosions accounted for 48% of accidents in the feed mill.
There are three necessary conditions for dust explosion:
First, there is a burning agent (dust);
The second is aerobic conditions;
The third is the input energy.
The concentration of dust that is highly prone to explosion is 10-200 μm; the limit of dust explosion concentration: the lower limit is 20-60 g/m3; the upper limit is 2-6 kg/m3. The higher the relative concentration, the greater the explosive force.
The environment that easily causes dust explosion mainly includes silos, silos, distributors, slide pipes, hoists, crushers, dust removal equipment, workshop basements, and crushing machine rooms.
Precautionary measures:
First, control the dust concentration, eliminate the generation of dust, strengthen the equipment to prevent the dust from ;
Second, the appropriate suction and dust removal device; timely cleaning, cleaning, eliminating and preventing dust accumulation;
3. Fires are forbidden in the fire-prohibition area. For example, strictly prohibit the fireworks system in the factory area; prohibit the area from requiring fire work in accordance with the safety production management system, and take necessary protective measures before operating;
Fourth, the workshop cleaning section must be equipped with sufficient magnetic separation equipment, regularly cleaned and inspected to prevent metal objects from falling into the high-speed operation of the equipment to produce sparks;
5. Check the tightness of the connecting parts frequently to prevent the connecting parts from falling off and the transmission parts from off, causing friction and heat to generate sparks;
Sixth, the lighting equipment of the workshop and warehouse is explosion-proof;
7. For equipment that is prone to static electricity, protective grounding should be used to eliminate static electricity;
8. Dust environment Resolutely pay attention to the open environment, set ventilation, explosion-proof and so on.
Boiler accident
On July 25th, 2011, Yunnan Guangde Feed Co., Ltd. made a loud noise. A steam boiler that was being commissioned in the factory suddenly exploded, and the clay and insulating cotton in the boiler were blown up. Feed mills often use boilers, and must use the boiler safely and correctly, especially for unlicensed operations.
Precautionary measures:
1. The water quality test is carried out in each shift. The laboratory report and the boiler operation record are reported to the production department for review every day. Hard water or unqualified boiler water is not allowed.
Second, the boiler workers are certified to work, loyal to their duties, not allowed to leave during the operation, not allowed to sleep;
3. The attachments are kept in good condition at all times (especially the safety valve, which should be manually discharged once a week, including the safety valve in the pipe network system). If there is any problem, it should be inspected and repaired immediately, and the problem is not allowed to be forced to start;
Fourth, according to the regulations for annual inspection, every two years must be carried out an internal inspection, is not allowed to require the inspection of the pot inspection ;
5. Leakage or other serious problems must be reported to the company's supervisor and repaired;
Sixth, the boilers to be stopped should be treated with protection (both dry and wet), eliminating oxidation, strictly implementing the water quality management system, taking necessary maintenance measures when stopping the furnace, timely cleaning and preventing corrosion of the furnace Causing an accident;
Seven, to prevent overheating: pay attention to the correct use of water level and water level gauge, often check whether the boiler water quality meets the requirements, pay attention to the boiler often draining, descaling, to prevent boiler water shortage (boiler water shortage to stop fire, to be replenished after the boiler cools) , fouling caused by boiler overheating caused accidents;
Eight, early detection, it is necessary to timely and properly handle the phenomenon of sudden heat and cold, load fluctuations, to avoid accidents.
Electrical circuit accident
Feed mills should also pay attention to the correct use of electrical appliances, including the inadvertent use of electrical appliances; non-licensed electricians are not allowed to enter the high and low pressure rooms, and unrelated personnel are not allowed to enter the central control room (main control room, substation room to lay insulation board) ), it is not allowed to watch the electrician's maintenance of electrical lines (extremely dangerous); it is not allowed to use unqualified electrical materials (electrical materials are used for fixed-point procurement), wire aging should be replaced in time; special effective fire extinguishers, central control room, high and low pressure are available. The room is not allowed to be littered; the electrical equipment needs to be de-dusted once every three months; check whether the cable in operation is overheated, and find the problem in time; check the terminal of the large motor every three months to keep the contact good; Always use power tools (such as manual sewing machines) to ensure good grounding.
Precautionary measures:
First, the electrical circuit installation must meet the electrical industry standards, complete supporting facilities;
Second, electrical equipment to do ventilation and heat dissipation device;
Third, regular inspection to prevent electrical and cable aging, loose, broken, damp, short circuit;
Fourth, often remove the deposition of dust on electrical equipment;
5. Ensure that there is no grounding wire or reliable grounding to avoid causing the equipment to be charged;
6. It is strictly forbidden to operate in violation of regulations, such as: frequent start, load start with load, more fuel, etc.;
Seven, the correct use of safety protection facilities;
8. The distribution room, control room, and cabinet are strictly prohibited from being placed indiscriminately or randomly;
Nine, the correct use of sensor protection devices.
Personal injury and death accident
100% of personal safety accidents in feed mills are caused by illegal operations. In May 2006, I personally handled an illegal operation and died. The scene is still fresh in my memory (unforgettable in my life), and the lessons are painful. In 2008, a corn delivery truck of a feed mill in the Shandong Plain collapsed the loading and unloading personnel during the reversing; in 2014, a feed mill in Yantai fell off the head of the car and hit the road along the stone, causing a vegetative accident. Therefore, the biggest safety hazard of feed mills at present is to let untrained employees go directly to work. If there are no well-trained employees, they will not understand the production site, and their personal safety awareness will not be strong. They will not deal with abnormal situations. They are important drivers of safety hazards. Therefore, it is hoped that the company will pay attention to the three-level safety education, the post-change staff and the safety training of the employees before the new employees are employed, so that they can truly understand and master the safe operation procedures in their posts, and at the same time understand the positions that have been taken. In the event of a safety accident, learn to discover the safety hazards on the spot during your own work, and rectify it in time. Take necessary precautions against the probable safety accidents, so as to effectively prevent or avoid the occurrence of safety accidents.
Precautionary measures:
First, the maintenance and cleaning equipment must be listed for operation;
Second, special operations personnel must be certified to work, comply with the operating procedures;
Third, the annual inspection of the body, participate in the necessary accidental injury insurance;
Fourth, the production site, canteens, dormitories, etc. must be sanitized and disinfected; (the canteen personnel have also suffered from arm involvement and facial disability;)
Fifth, to ensure the health of employees' diet and prevent food poisoning;
6. For safety hazards, there must be safety facilities such as warnings and ;
Seven, the warehouse top observation port must be set up to prevent people from falling;
Eight, high-speed operation equipment must be equipped with a protective cover;
Nine, regular inspection and maintenance of safety facilities;
Ten, the workshop hanging system (lifter, electric hoist) should be operated in accordance with the safe operating procedures, special equipment boiler pressure vessel in accordance with the safe operation of the national special equipment;
XI. For high temperature pipelines and equipment, it is necessary to keep warm and prevent hot (including heating equipment);
Twelve, the factory maintains smooth flow, speed limit of 5 km / h, to prevent traffic accidents, door posts to strengthen the management of vehicles and personnel;
Thirteen, ensure lightning protection, fire protection facilities are effective;
14. Safety facilities such as safety valves must be regularly tested and tested in accordance with the requirements of the State.
Special equipment accident
The safe use of mechanical equipment should be noted: ensure that the equipment guards are intact; the operators are away from moving parts (regardless of whether the equipment is running); the red card is indicated during partial maintenance, and the listing is not allowed to leave; the operator must pass the third level before taking up the post. Training (with training records), especially the production supervisors should personally carry out one-on-one training; new employees who are engaged in this position for less than three months must have special personnel guidance; if using forklift operation, if customers enter the warehouse, storage and handling Workers must stop at the first time (especially forbidden children); production supervisors should strengthen their training on equipment structure, preferably on-site anatomy.
Precautionary measures:
First, the safety and maintenance management of the hanging system;
Second, strengthen the management of flammable products such as oxygen, acetylene and liquefied gas;
Third, strictly implement the safety management system for motor vehicles such as forklifts;
Fourth, regular pressure vessel inspection, experimental maintenance management;
5. check the working condition of the compressor to prevent leakage of the ammonia compressor;
Sixth, pay attention to the storage of special chemical products and corrosive products to prevent infringement and spontaneous combustion;
7. In accordance with the national electricity safety management regulations, professionals are required to carry out normal inspection and maintenance of the transformer and distribution system;
8. Regularly check the lightning protection and fire protection facilities to ensure that they are normal and effective.
Seven, quality accidents
With the improvement of living standards, people pay more and more attention to health and pay more and more attention to the safety and hygiene of food. The implementation of the national “Food Safety Law†will ultimately start from the source. Feed mills provide food for animals. Therefore, ensuring feed safety and hygiene is a must for every feed manufacturer. I think that as long as the feed production enterprises strictly implement the national laws and regulations on feed safety, the feed safety will be strongly guaranteed!
Matters needing attention:
I. Management of feed ingredients, finished products and label items (in December 2007, a silage of a feed mill in Qingzhou, Shandong Province, due to excessive moisture, steam and wine incidents);
Second, the mixer, warehouse top, slide pipe wall, hoist and base, pit, silo, pulverizer, cooler, dust collector, permanent magnet and other equipment should be cleaned regularly;
Third, often check whether the mixer, batching scale, ingredient warehouse and other key equipment leaks;
Fourth, weighing equipment, batching equipment, mixed uniformity regular inspection, testing;
5. Strengthen the regulation of quenching and tempering temperature, moisture, crushing size and steam pressure in the production process;
Sixth, pay attention to the preparation, delivery and recycling of small materials;
Seven, on-site management in accordance with 6S management requirements in place;
8. When the grease is added, the grease is atomized, the system is cleaned regularly, and the quality of the added grease should be monitored in time;
Nine, effective use of finished product inspection sieve;
Ten, pay attention to the standard use of ring molds, screens, hammers and other spare parts;
XI. Clarify job responsibilities and strengthen skills training so that safety operation procedures are in place.
Lifting and falling objects
Ensure that the lift door is in good condition and closed at any time; no personnel are allowed to take the lift; the lift and electric hoist area should be marked with obvious warning signs; the electric hoist of the lift should be inspected regularly (every month); the maximum lifting weight warning sign is produced, no Quasi-overloaded!
Flood
Regularly (monthly) check the drainage and falling water systems, and promptly divert them. Especially in the rainy days, the custodians should conduct high-frequency inspection of the warehouse, and pay attention to whether there is water leakage in the basement.
Material collapse
According to the standard code, the raw materials and finished products (including the forklift pallets) are not allowed to be skewed. Once found, the re-stacking is immediately pushed down; the non-operator and management personnel are not allowed to enter the warehouse and the workshop, and the custodian and the loader must stop the foreigners. Personnel entry; introduction of advanced company management experience, determination of the loading and unloading wage coefficient by stacking quality, custody has the right to grade the loader.
There have been many incidents of collapse of employees or deaths due to the collapse of raw materials and finished products; the collapse of silos.
The above-mentioned safety precautions must be strictly observed by a company in the course of its operations. In addition, there are no financial management directly related to personal safety. Many companies are not responsible for financial irresponsibility, unclear accounts or misappropriation of public funds. The long-term arrears of accounts, the failure to deal with quality accidents, and the disputes and compensations with customers have also become the safety precautions of the company's operations. In the current fierce market environment, in 2016 and even in the future, the competition of feed enterprises is an era of comprehensive cost competition. A small security accident will increase your costs. A major accident may lead to a business failure. Bankruptcy. Therefore, it is hoped that by understanding these dangerous points, it will be able to attract the attention of the industry, and always keep safety in the mouth, always speaking, talking every day, without safety, everything is empty. The most important business benefits, the first article of fire safety.
I would rather not have nothing to do with the day, and I can’t prevent it from happening in a day.
Grasp the foundation from the big picture, and prevent hidden dangers from starting small.
Safety is the guarantee of a happy family, and accidents are the bane of life's tragedy.
Safety and efficiency go hand in hand, and accidents and losses occur simultaneously.
Safety is the lifeline of employees, and employees are the responsible person of safety.
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