The Die Casting Plant Emergency Plan Of Leakage Liquefied Petroleum Gas And Molten Aluminum

Publish Time: 06/09 2021 Author: Site Editor Visit: 11723

1.Event Simulation And Scheduling

1.0 Purpose:In order to prevent the occurrence of fire and explosion accidents caused by the leakage of liquefied gas from the melting furnace, the gas holding furnace, and the leakage of high-temperature aluminum liquid, when the accident occurs, the rescue and disaster relief work can be carried out in an organized and smooth manner to minimize the casualties and property losses. The normal working order ensures that emergency rescue measures can be taken in time when an emergency dangerous situation occurs, to avoid casualties and minimize losses.
2.0 scope:Major accidents in the die-casting department mainly include: gas leaks, poisoning, liquid aluminum leaks, fires, and explosions
3.0 Responsibilities for handling emergency and dangerous situations
3.1 The department manager is fully responsible for the emergency rescue of emergencies and the commander-in-chief of emergency response measures;
3.2 The departmental security officer is responsible for the specific implementation and organization of emergency and dangerous emergency actions;
3.3 After an accident occurs, the personnel found should immediately report to the on-site management personnel (squad leader or dispatcher), the on-site management personnel (squad leader or dispatcher) should immediately notify the department manager and safety officer, and at the same time, organize the evacuation of personnel according to the situation of the on-site accident . The department manager or safety officer informs and directs each emergency team to carry out relevant rescue and accident handling work. When there is a fire alarm, the company’s security fire brigade must be notified to participate in the accident rescue work, and each emergency team must follow the command and dispatch.
3.4 In the event of an emergency, every employee has the obligation to report to the police.
3.5 On-site personnel of emergencies are responsible for emergency notification and actively participate in rescue work under the conditions of ensuring their own safety.
4.0 Organization: need to have strict control personnel
5.0 Hazard source and risk analysis:The melting furnace and gas holding furnace in the die-casting department use liquefied petroleum gas as fuel. During use, if the pipelines, joints are damaged, illegal operations, and paralyzed negligence, it will cause the leakage of liquefied gas. If it is not handled in time, it will cause gas poisoning. , Equipment explosion accidents have caused significant personal and property losses. Such vicious accidents must be prevented.;Aluminum alloy becomes liquid after being melted at high temperature. It is called molten aluminum. The temperature of molten aluminum is as high as 600-750℃. Water splashing into molten aluminum may cause molten aluminum to splash and explode, and oil splashing into molten aluminum may cause fire. Improper management of high-temperature molten aluminum can cause equipment damage and personal injury. During the production process of melting furnace and holding furnace, and the transfer process of molten aluminum forklift, due to equipment failures, operating errors, and illegal operations will cause molten aluminum leakage, splashing, and even explosions. Failure to handle them in time will cause significant personal and property losses. This must be prevented. The occurrence of such accidents.
6.0 Basic Principles of Emergency Response:When an accident occurs, the relevant personnel shall take necessary rescue measures in accordance with the requirements of the rescue plan and the on-site situation. At the same time, they should promptly report to the higher-level person in charge. The on-site commander will immediately formulate a preliminary rescue plan and notify the fire security and company rescue team (involving Liquefied petroleum gas related incidents), immediately went to the scene of the accident, and at the same time notified relevant units to rush to the scene of the accident to assist in the rescue;While carrying out emergency rescue work quickly and striving to minimize the loss, the personal safety of the on-site personnel should be considered first. For example, when an explosion and fire accident may break out again and endanger the lives of personnel, the rescue should be stopped and evacuate quickly. Safe zone, wait for the flame to go out naturally.

Specific Emergency Plan

Source of accident: 1. Leakage of liquefied gas from melting furnace and holding furnace, and the fire and explosion caused by it

Preventive measures:

It is not allowed to work without aluminum tapping training.
During the production process, pay attention to checking the aluminum tapping device (including electric and gas switches and manual locking devices) for flexible movement and accurate alignment. If abnormalities are found, they should be reported to the Ministry of Mobility for repair and notify the equipment supervisor immediately, and stop production and wait for repair;
There are enough plugs (not less than 10) for the aluminum tapping hole on site, check that the plugs are not damaged and stored in the specified area;
The spare manual aluminum outlet plug is installed with the plug head, placed in the specified area, and marked;
When opening the aluminum tap plug, first install the tap plug head and confirm that it is securely installed before tapping aluminum. When tapping aluminum, you must carefully clean the aluminum around the tap with steel fiber to ensure that the periphery is tightly plugged;
Every time after closing the aluminum outlet plug, it is necessary to check that the aluminum outlet plug is tight and there is no aluminum leakage before other operations can be carried out;
After closing the aluminum outlet plug, if there is a small amount of aluminizing around the plug head, immediately open the aluminum outlet plug and reinstall the plug head to close; if there is a small amount of aluminizing on the plug head again, manually plug the aluminum outlet plug. The aluminum outlet, after the turnover package is replaced, clean the aluminum outlet and then block it;
When the aluminum outlet brick of the equipment is chipped or cracked, it must be reported to the equipment supervisor in time for handling;

Emergency Countermeasures

When the aluminum outlet plug device suddenly fails to be closed due to a large amount of molten aluminum flowing out, the operator must immediately block the aluminum outlet with a manual aluminum outlet plug and fix it, and report to the equipment supervisor and the mobile department to maintain the equipment at the same time;
After the forklift driver removes the turnover package filled with molten aluminum, forklift the empty turnover package to the aluminum outlet;
If the aluminum outlet bricks of the equipment are chipped and cracked, causing a large amount of aluminum leakage and unable to block the aluminum outlet with the aluminum outlet plug device, you must immediately block the aluminum outlet with a manual aluminum outlet plug and stop feeding at the same time , Notify the equipment supervisor to carry out continuous aluminum tapping operations until the molten aluminum in the furnace is emptied, and the furnace is cleaned and the furnace is stopped after the furnace charge in the melting zone is melted.

2.The General Principles Of Plan For Liquid Aluminum Leakage

Preventive Measures

Tools and auxiliary tools are not preheated and dried, and it is strictly forbidden to contact molten aluminum, otherwise it will cause molten aluminum to explode;
Any employee who operates on molten aluminum must wear labor protection equipment;
Water splashing into molten aluminum may cause molten aluminum to splash and explode, and splashing oil into molten aluminum may cause fire. Improper management of high-temperature molten aluminum can cause equipment and personal injury.
Store dry sand at a designated place on the workshop site for backup in case of liquid aluminum leakage.

Emergency Response

It is found that any equipment aluminum liquid leakage cannot use water as the fire extinguishing medium, otherwise it will cause the water to meet the high temperature aluminum liquid to rapidly accumulate and vaporize, causing an explosion and injury. Only dry powder fire extinguishers or dry sand can be used to remedy the fire;
When the molten aluminum leaks, you must first ensure the safety of yourself and the personnel, and do not clean up the scene, rescue property and equipment under the premise that your personal safety is not guaranteed.
When molten aluminum is found to be flowing on the ground, dry sand can be poured immediately to block and extinguish the fire. To avoid further expansion of the harm of molten aluminum;
When a person is scalded by molten aluminum, the on-site management personnel (squad leader or dispatcher) should be notified as soon as they are found, and the on-site management personnel should urgently notify the department safety officer, call 120 if necessary, and send the injured to the hospital for examination and treatment in time .

3. Leakage Of Molten Aluminum In The Melting Furnace

Source of accident: A. Overflow of molten aluminum in the heat preservation area

Preventive Measures:

Make the position monitoring tooling of the liquid level detection rod (picture), and check the position and wiring of the liquid level detection rod every shift to ensure that the liquid level detection rod is safe and effective;
When the equipment is working, it is strictly forbidden for the operator to pull out the liquid level detecting rod at will. If the liquid level detecting rod is not put into the specified position in the furnace in time, it will cause the aluminum liquid level to lose control;
When the height of the molten aluminum in the heat preservation area is found to be abnormal, and there is a hidden danger of molten aluminum overflow, immediately notify the equipment supervisor, close the melting burner at the same time, and prepare to turn off the aluminum to lower the liquid level.
It is found that the door of the furnace in the holding area is broken, and report to the supervisor in time for handling;
The slag truck is placed in the slag discharge chamber to prepare for receiving materials when a small amount of molten aluminum overflows.

Emergency Response:

When a small amount of molten aluminum is found at the door of the furnace in the holding area, the melting burner should be closed with the furnace door in the holding area closed, and the turnover package should be prepared to lower the liquid level and notify the equipment supervisor at the same time;
When a large amount of molten aluminum overflows at the furnace door in the holding area, immediately close the furnace door in the holding area, turn off the main power switch of the equipment, and immediately evacuate unrelated persons near the aluminum outlet. And prepare to turn the aluminum out of the turnaround to lower the liquid level, and notify the department safety officer and equipment supervisor at the same time;
Under the condition of ensuring personal safety, the monitor will arrange to clean up the molten aluminum in the slag discharge chamber in time. Try to pull out the slag trolley before the molten aluminum is completely solidified to disperse the aluminum blocks, so that the aluminum blocks can be cleaned and returned to the furnace afterwards.

The source of the accident: B. The furnace door of the melting zone leaked aluminum

Preventive measures:

Open the furnace door of the melting zone for inspection 1 to 2 times per shift. If aluminum deposits at the door are found, and there is a tendency to leak aluminum, clean the aluminum deposits at the furnace door in time
If the furnace door and furnace door are found to be broken in the melting zone, report in time Supervisor processing
Place a material truck on the floor of the furnace door in the melting zone to prepare for receiving materials when aluminum is leaked

Emergency response

When the molten aluminum is found to overflow, open the furnace door slowly under the premise of ensuring personal safety, and use a slag rake to push the aluminum deposit at the furnace door into the furnace
If a large amount of aluminum leakage is found, keep away from it immediately to ensure personal safety Clean up the aluminum deposit at the door of the furnace afterwards;
If aluminum leakage is found, the equipment supervisor must be notified in time; 4. The monitor arranges for the site to be cleaned in time.

Source of accident: C. Leakage of aluminum outlet

Preventive measures:

It is not allowed to work without aluminum tapping training.
During the production process, pay attention to checking the aluminum tapping device (including electric and gas switches and manual locking devices) for flexible movement and accurate alignment. If abnormalities are found, they should be reported to the Ministry of Mobility for repair and notify the equipment supervisor immediately, stop production and wait for repair;
On-site aluminum tapping plugs are sufficient (not less than 10), check that the plugs are not damaged and stored in the specified area;
The spare manual aluminum outlet plug is installed with the plug head, placed in the specified area, and marked;
When opening the aluminum tap plug, first install the tap plug head and confirm that it is securely installed before tapping aluminum. When tapping aluminum, you must carefully clean the aluminum around the tap with steel fiber to ensure that the periphery is tightly plugged;
Every time after closing the aluminum outlet plug, it is necessary to check that the aluminum outlet plug is tight and there is no aluminum leakage before other operations can be carried out;
After closing the aluminum outlet plug, if there is a small amount of aluminizing around the plug head, immediately open the aluminum outlet plug and reinstall the plug head to close; if there is a small amount of aluminizing on the plug head again, manually plug the aluminum outlet plug. The aluminum outlet, after the turnover package is replaced, clean the aluminum outlet and then block it;
When the aluminum outlet brick of the equipment is chipped or cracked, it must be reported to the equipment supervisor in time for handling

Emergency response

When the aluminum outlet plug device suddenly fails to close due to a large amount of molten aluminum flowing out, the operator must immediately block the aluminum outlet with a manual aluminum outlet plug and fix it, and report to the equipment supervisor and the mobile department to repair the equipment at the same time;
After the forklift driver removes the turnover package filled with molten aluminum, forklift the empty turnover package to the aluminum outlet;
If the aluminum outlet bricks of the equipment are chipped and cracked, causing a large amount of aluminum leakage and unable to block the aluminum outlet with the aluminum outlet plug device, you must immediately block the aluminum outlet with a manual aluminum outlet plug and stop feeding at the same time , Notify the equipment supervisor to carry out continuous aluminum tapping operations until the molten aluminum in the furnace is emptied, and the furnace is cleaned and the furnace is stopped after the furnace charge in the melting zone is melted.

Source of accident: D. Leakage of aluminum on furnace wall and bottom

Preventive measures:

If the furnace wall loses a block, it must be reported to the equipment supervisor in time for handling;
If smoke is found on the furnace wall and bottom, and the paint on the furnace shell is black at high temperature, immediately notify the equipment supervisor for inspection and confirmation. When there is a hidden danger of aluminum leakage, immediately arrange for shutdown of the furnace for maintenance;

Emergency response

Stop feeding, turn off the melting and heat-preserving combustion burner, and immediately prepare the turnover package for aluminum output to reduce the liquid level, and immediately notify the equipment supervisor;
Turn off the main power supply and the switch of the liquefier;
When a small amount of aluminum leaks, use a slag box to connect Aluminum;
When there is a large amount of aluminum leakage, evacuate the crowd and stay away from the source of danger;
Under the condition of ensuring personal safety, the monitor will arrange for the site to be cleaned in time;

Source of accident: E. Overflow of molten aluminum in the turnover package

Preventive measures:

When tapping aluminum, the operator must concentrate on monitoring the tapping liquid level, not leaving the tapping site, and not doing work that has nothing to do with tapping;
When the aluminum tapping device is abnormal, aluminum is not allowed to be tapped, and aluminum can be tapped only after the fault is confirmed and eliminated;
The liquid level of the liquid aluminum of the turnover package is not less than 100mm from the mouth of the turnover package, and the liquid aluminum level limit mark line shall be made on the shell of the turnover package, and a special liquid level marking device shall be used;
Make a fixed marking line for the turnover package on the ground at the aluminum outlet, mark the area where the aluminum outlet of the turnover package is placed and the direction of the inverted aluminum outlet, so as to prevent the molten aluminum in the package from flowing onto the operating platform and endangering the safety of the operator.
Water is not allowed on the ground of the aluminum outlet;
Before the cold turnaround package is used, it must be dried with anhydrous steam (each continuous heating time is at least 60min, to 200℃);
If the inner wall of the turnover package is broken, it must be reported to the supervisor in time. If smoke is found from the outer shell and bottom of the turnover package, or the paint is hot and black, immediately notify the equipment supervisor for inspection and confirmation. When there is a hidden danger of aluminum leakage, stop using it for maintenance.

Emergency response

When the molten aluminum in the turnover package overflows, immediately close the aluminum outlet clogging device (if it cannot be closed, use manual aluminum outlet plug);
Under the condition of ensuring personal safety (there is no molten aluminum overflow in the bag, the molten aluminum on the ground is basically solidified), clean up the molten aluminum that overflows the ground;
Use a dry empty turnover bag or slag box to scoop out the molten aluminum in the turnover bag. After reaching a safe level (the liquid level is 100mm from the turnover bag opening plane), the molten aluminum can be transferred;

Source of accident: F. Fire accident caused by aluminum slag dumping

Preventive measures:

Check the slag discharging trolley before shift, and strictly prohibit the use of slag discharging trolleys with damaged wheels, leaking aluminum in the aluminum box, etc.
Before using the slag trolley, check whether the aluminum box is in place and whether the slag trolley is aligned with the slag outlet of the melting furnace;
When slagging out of the melting furnace, the slag must be carefully removed to minimize the aluminum content of the slag and reduce the aluminum liquid carried out;
The slag loading volume of the slag discharging truck is not allowed to exceed the roof plane. When the amount of slag is large, change the car in time;
Under normal circumstances, the slag discharging truck can be pulled out after being loaded with slag in the slag removal chamber to cool to room temperature. If the aluminum slag is pulled out of the slag discharge truck at high temperature, it must be transported by a forklift to the designated slag discharge storage area and covered with a special slag truck cover;
When the forklift transports the slag, the forklift must be stable, the forklift should be in place, and slow down to prevent the aluminum slag from dumping during the forklift.
Obvious warning signs should be made in the aluminum slag storage area, and it is strictly forbidden to place flammable and explosive materials around. To prevent burns and fires;

Emergency response

When aluminum slag dumps and causes aluminum slag to catch fire and smoke, ground cement may burst. If there is water on the ground, it will cause water vaporization. People who are found should stay away from the accident site to avoid personal injury.
When a small amount of aluminum slag smokes, no fire extinguishing measures are required, and let it cool naturally;
When the dumping of a large amount of aluminum slag causes aluminum slag to catch fire and thick smoke, the personnel found should immediately notify the on-site management personnel (squad leader or dispatcher), and the on-site management personnel should evacuate the personnel immediately to prevent smoke poisoning and high-temperature cement explosion on the ground. When it is confirmed that the ground will not burst, and on the premise of ensuring personal safety, the on-site management personnel shall organize personnel to use dry powder fire extinguishers to extinguish the fire;
When the aluminum slag dumps and causes the aluminum slag to catch fire and smoke, if there are flammable and explosive materials or liquefied gas pipelines around, under the premise of ensuring the safety of personnel, the main liquefied gas valve of related equipment should be closed first, and the flammable and explosive gas should be removed. article. Allow the aluminum slag to burn and cool naturally. When dense smoke or flames are large, personnel should not approach the scene to prevent suffocation and injury caused by dense smoke.
When it is confirmed that the aluminum slag has no open flame and explosion hazard, clean up the scene.

4. Liquid Aluminum Transfer Pperations

Source of accident: a. Personnel safety reminder

Preventive measures:

The sign prompts: "Special channel for molten aluminum, unrelated personnel and vehicles are prohibited", "When the forklift is filled with molten aluminum, unrelated personnel are prohibited from entering within 3 meters."
When the forklift is filled with molten aluminum, the voice prompt will be played: "Please pay attention to the molten aluminum, please avoid irrelevant personnel within 3 meters", "Please pay attention to reverse" to remind personnel and vehicles to avoid;

Emergency countermeasures:

When a person is scalded by molten aluminum or hit by a forklift, the on-site management (squad leader or dispatcher) should be notified as soon as possible, and emergency call should be called if necessary, and the injured should be sent to the hospital for examination and treatment in time;

Source of accident: b. Aluminum liquid forklift operation

Preventive measures:Unlicensed operation is not allowed, and no work is allowed without the training of molten aluminum forklift operation.

Emergency countermeasures:When a person is scalded by molten aluminum or hit by a forklift, the on-site management (squad leader or dispatcher) should be notified as soon as possible, and emergency call should be called if necessary, and the injured should be sent to the hospital for examination and treatment in time;

The source of the accident: c. The aluminum liquid forklift dumped

Preventive measures:

Liquid aluminum forklift tires are solid tires (explosion-proof).
Check the tires and fastening screws of liquid aluminum forklift trucks every shift. If the tires are broken, damaged, worn out, lack of screws, or loose, the aluminum is not allowed to be transported and must be repaired and replaced immediately;
When transferring molten aluminum, the forklift speed is controlled within 3km/h. It is strictly forbidden to drive the forklift at excessive speed. After seeing the road conditions, drive slowly to prevent sudden braking, run smoothly, and drive carefully when turning;
It is strictly forbidden to drive when the ground is slippery (with water or oil)

Emergency countermeasures:

When a large amount of molten aluminum is dumped, the forklift driver must immediately evacuate from the dangerous area, and the surrounding people should evacuate quickly, and at the same time notify the equipment supervisor and department safety personnel;
Cut off the main power supply of the relevant die-casting machine and holding furnace equipment in the area, and turn off the gas and water source switches.
On the premise of ensuring personal safety, use a dry powder fire extinguisher to extinguish the surrounding fire. When the molten aluminum is solidified, disperse the overflowed aluminum into aluminum blocks and clean up the site.

Source of accident: d. Overflow of molten aluminum in turnover package

Preventive measures:

When the molten aluminum in the turnover package is too full and affects the safe transportation of aluminum, the molten aluminum must not be cross-lifted. The ultra-high molten aluminum in the bag must be scooped out to a safe level before the transfer;
When the surface of the molten aluminum channel is uneven, drive on a detour and promptly report to repair the road surface;
Control the vehicle speed, drive carefully, see the road conditions clearly, turn slowly, and prevent sudden braking

Emergency countermeasures:

When a small amount of overflow occurs, clean up the site after the aluminum liquid has solidified;
When a large amount of overflow occurs, the forklift driver should quickly leave the accident area, retreat to a safe area, immediately notify the evacuation of the surrounding people, and immediately notify the equipment supervisor and the department safety officer;
Cut off the main power supply of the relevant die-casting machine and holding furnace equipment in the area, and turn off the gas and water source switches.
When the molten aluminum is solidified, disperse the overflowed aluminum into aluminum blocks and clean the site.

The source of the accident: e. The rotating fork is faulty and the molten aluminum is dumped.

Preventive measures:

Inspect the rotating forks, lifting chains, loose chains, abnormal noises, and cracks in the rotating forks in each shift, and notify the equipment supervisor in time for maintenance. Operation with faults is strictly prohibited.
It is strictly forbidden to overload forklifts;
Long-distance transportation after raising the turnover package is strictly prohibited;
It is strictly forbidden to work when the single lifting chain is broken

Emergency countermeasures:

The forklift driver must immediately evacuate from the danger zone, evacuate the surrounding people immediately, and immediately notify the department safety officer;
Cut off the main power supply of the relevant die-casting machine and holding furnace equipment in the area, and turn off the gas and water source switches.
On the premise of ensuring personal safety, use a dry powder fire extinguisher to extinguish the surrounding fire. When the molten aluminum is solidified, disperse the overflowed aluminum into aluminum blocks and clean up the site.

The source of the accident: f. The molten aluminum was poured out of the holding furnace

Preventive measures:

Forklift drivers must concentrate when pouring molten aluminum and improve their operating skills. Independent work is not allowed if they are unskilled.
Adjust the clearance between the forklift's rotating fork and the turnover package fork foot, and repair it in time if it is unreasonable;
Regularly clean the feeding port of the holding furnace to prevent slagging and solidification of molten aluminum at the feeding port, causing blockage of the feeding port;
Pay attention to the structure and size of the package when repairing the turnover package to avoid the uncontrollable flow of aluminum liquid

Emergency countermeasures:

When a small amount of overflow occurs, clean up the site after the aluminum liquid has solidified;
When a large amount of overflow occurs, cut off the main power supply of the die-casting machine and holding furnace equipment, and turn off the gas and water source switches.
On the premise of ensuring personal safety, use dry powder fire extinguishers or dry sand to extinguish the surrounding fire. When the molten aluminum is solidified, disperse the overflowed aluminum into aluminum blocks and clean up the site

Source of accident: g. Liquid aluminum turnover package dropped out

Preventive measures:

Control the speed of the vehicle, drive carefully, see the road conditions, turn slowly, and prevent sudden braking.
Increase the turnover package anti-falling safety pin and lock it firmly;

Emergency countermeasures:

When there is a small amount of overflow in the bag, the forklift will stop slowly, put the turnover bag on the ground and fork it again, and clean up the site after the molten aluminum overflowing on the ground has solidified;
When the turnover package comes out and a large amount of molten aluminum is poured out, the forklift driver must immediately evacuate from the dangerous area, immediately evacuate the surrounding people, and immediately notify the equipment supervisor and the department safety officer;
Cut off the main power supply of the relevant die-casting machine and holding furnace equipment in the area, and turn off the gas and water source switches.
On the premise of ensuring personal safety, use dry powder fire extinguishers or dry sand to extinguish the surrounding fire. When the molten aluminum is solidified, disperse the overflowed aluminum into aluminum blocks and clean the site.

5. Leakage Of Molten Aluminum In The Holding Furnace

The source of the accident: a. Alcan overflow

Preventive measures:

The melter must concentrate on monitoring the aluminum level, cannot leave the site, and cannot do irrelevant work;
The reversing speed of the forklift must be slow and steady, and follow the instructions of the melter;
The liquid level of the scooping hole must be greater than 50mm from the plane of the furnace platform of the holding furnace, draw the aluminum liquid limit height scale mark on the outer wall of the holding furnace, and make a special tool for inspection;
If the scoop opening and the furnace lining are found to be broken, report to the equipment supervisor in time;
Regularly clean the slagging and scum of the holding furnace to prevent the liquid level from being unstable when adding aluminum;
Leave a safe passage near the holding furnace

Emergency countermeasures:

The forklift driver stopped dumping materials, and the surrounding personnel immediately evacuated, cut off the water, electricity, and gas switches of the equipment (including the die-casting machine and the holding furnace), and reported to the supervisor at the same time;
Under the condition of ensuring personal safety (there is no molten aluminum overflow in the scoop mouth, the molten aluminum on the ground basically solidifies), clean up the molten aluminum overflowing the ground, and clean up the site.
Use the preheated aluminum spoon to scoop out the molten aluminum from the scooping port to a safe level, and check that the electrical operation of the equipment is normal before it can be turned on for normal production.

Source of accident: b. Leakage of aluminum on furnace wall and bottom

Preventive measures:

If the furnace wall loses a block, report to the equipment supervisor in time;
If smoke is found on the furnace wall and bottom, and the paint on the furnace shell is blackened and smoked at high temperature, immediately notify the equipment supervisor for inspection and confirmation. When there is a hidden danger of aluminum leakage, stop the furnace immediately, scoop out the molten aluminum and wait for repair;
After the oven is completed, the first time the aluminum liquid is added is 1/3 of the furnace capacity. After observing that the furnace body is normal, the feeding can be performed normally.

Emergency countermeasures:

Under the condition of ensuring safety, immediately use tools to push the dry slag box to the place where the aluminum leaks, and report to the supervisor for disposal;
Cut off the water, electricity and gas switches of the equipment (including die casting machine and holding furnace); use dry powder fire extinguisher or dry sand to extinguish the surrounding fire. When the molten aluminum is solidified, disperse the leaked aluminum into aluminum blocks
Open the furnace cover by crane, forklift the empty turnover package, scoop the molten aluminum to the turnover package and transfer it to other holding furnaces, and stop the furnace for maintenance;
Under the condition of ensuring personal safety, clean up the molten aluminum spilling on the ground.

6. Splash Of Molten Aluminum

Source of accident: a. Splashing of molten aluminum caused by explosion of water pipes and oil pipes of die-casting machine

Preventive measures:

Check the water pipes and pipe joints of the die-casting machine every shift. If water or oil seepage is found in the water pipes, oil pipes, and pipe joints, report for repairs in time.
When water pipes and oil pipes are found to be leaking, turn off the equipment water valve and main power switch in time, and shut down for maintenance.

Emergency countermeasures:

Immediately turn off the main water source switch of a single die-casting machine. When the oil pipe bursts, immediately shut down and turn off the equipment's main power switch.
Water splashing into molten aluminum may cause molten aluminum to splash and explode, and oil leakage may cause fire. In the case of a small amount of splashing, the cover of the holding furnace can be covered under the prerequisite of ensuring personal safety, but when the water has splashed into the molten aluminum, it should not be near the holding furnace or ladle. Prevent molten aluminum from splashing and hurting people. 2. The personnel should immediately evacuate and evacuate, and immediately notify the equipment supervisor and department security personnel;
After the water pipes and oil pipes are closed, the molten aluminum can enter the accident area without splashing and no explosion hazard.

Source of accident: b. Leakage on the roof of the factory

Preventive measures:

Regularly inspect and repair the roof. If a small amount of rain is found to leak, report to the Infrastructure Department for repair in time.
The molten aluminum transfer forklift is prohibited from driving on leaky roads.
When the top of the holding furnace and melting furnace leaks, please take measures to avoid rain and water in time. Do not allow water to enter the molten aluminum in the furnace.

Emergency countermeasures:

When the roof leaks, the ground on which the aluminum liquid forklift is driving is immediately isolated as a no-go sign, and the forklift is driven in a detour;
When the roof leaks in the exposed parts of the holding furnace and melting furnace, the work must be stopped immediately. Under the premise of ensuring personal safety, rain-proof measures shall be taken after the cover is covered. When necessary, if possible (with adequate rain protection) When taking measures), use a driving vehicle to move the holding furnace to a safe area with no rain leakage;
When rainwater leaks into the molten aluminum and splashes, personnel should quickly avoid it;
Report to the Infrastructure Department to repair the leaky roof.

The source of the accident: c. The tool is operated with water

Preventive measures:

Tools and accessories are not allowed to contact molten aluminum without preheating and drying, so as to avoid explosion of molten aluminum:

The melting tools and auxiliary tools must be fully preheated and dried before use. Before use, cold tools and painted tools should be placed 50-100mm above the molten aluminum level for more than 2 minutes, or placed on high-temperature hot slag for more than 10 minutes, and only when there is no moisture or steam coming out, can they be contacted slowly Aluminum liquid.
The preheating operation must be performed only when the tools and auxiliary devices are free of dripping water. It is strictly forbidden to bake over the molten aluminum when the tool is dripping.
When there is no high-temperature aluminum liquid or high-temperature aluminum slag preheating, a liquefied gas torch can be used for preheating operation, the operating tool is preheated for about 5 minutes, and the ladle is preheated for 1 hour.

Emergency countermeasures:

Take the tool away quickly, make an emergency escape, report to the supervisor, and deal with it after the molten aluminum has stopped;
People around leave the accident area quickly.

Source of accident: d. Equipment maintenance water splash

Preventive measures:During equipment maintenance, it is not allowed to rinse the equipment with water to prevent water from splashing into the molten aluminum of the holding furnace and causing the molten aluminum to explode.

Emergency countermeasures:

Quickly turn off the water main switch of the relevant die-casting machine, make emergency avoidance, and notify the department safety officer in time, and deal with it after the molten aluminum is stationary.
People around leave the accident area quickly.

Please keep the source and address of this article for reprinting: The Die Casting Plant Emergency Plan Of Leakage Liquefied Petroleum Gas And Molten Aluminum

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Zinc die casting design assistance/concurrent engineering services. Custom manufacturer of precision zinc die castings. Miniature castings, high pressure die castings, multi-slide mold castings, conventional mold castings, unit die and independent die castings and cavity sealed castings can be manufactured. Castings can be manufactured in lengths and widths up to 24 in. in +/-0.0005 in. tolerance.

ISO 9001 2015 certified manufacturer of die cast magnesium and mold manufacturing

ISO 9001: 2015 certified manufacturer of die cast magnesium, Capabilities include high-pressure magnesium die casting up to 200 ton hot chamber & 3000 ton cold chamber, tooling design, polishing, molding, machining, powder & liquid painting, full QA with CMM capabilities, assembly, packaging & delivery.

Minghe Casting Additional Casting Service-investment casting etc

ITAF16949 certified. Additional Casting Service Include investment casting,sand casting,Gravity Casting, Lost Foam Casting,Centrifugal Casting,Vacuum Casting,Permanent Mold Casting,.Capabilities include EDI, engineering assistance, solid modeling and secondary processing.

Casting Industries Parts Case Studies for: Cars, Bikes, Aircraft, Musical instruments, Watercraft, Optical devices, Sensors, Models, Electronic devices, Enclosures, Clocks, Machinery, Engines, Furniture, Jewelry, Jigs, Telecom, Lighting, Medical devices, Photographic devices, Robots, Sculptures, Sound equipment, Sporting equipment, Tooling, Toys and more.