Monitoring the safety of industrial operations production of

Monitoring the safety of industrial operations production of galvanized wire. prepared by: student gr. 3 TBm-03 -11 op NS Matyushev 1

Objective APS Internal audit process safety consists of: analysis of process documentation, analysis of manufacturing operations. Objective APS - identification of the operations are not actually prescribed in the technical documentation. During APS auditor comes into place, conducts supervision of a worker, makes notes, prepares the report. Regarded documentation: - processing instructions (TI), routings (TC); - labor safety instructions; - job descriptions. 2

APS of hot-dip galvanized wire unit number 1 The process of manufacturing galvanizing wire on the unit number 1 includes: • unwinding; • annealing ; • hydrochloric acid etching; • washing ; • fluxing; • drying ; • metallic coating (galvanized); • waxing ; • winding. 3

The unwinding Labor operations: • Inspection of equipment, tools and work place; • Preparation of the coil for installation on the figure; • Slinging of the coil using a crane girders; • Installation of the coil on the figure. 4

The Furnace of the annealing Designed for wire heat treatment imparting plasticity. Labor operations: • Broaching wire to the welding machine or to the annealing furnace; • Welding wire or broaching thread the wire through the furnace; • Broaching thread wire through the furnace. 5

The bath cooling It is intended for cooling the wire before broaching through the etching bath. Labor operations: • threading wire 6

The etching bath Designed for descaling: Labor operation - threading wire in a bath of hydrochloric etching Bath closed. 7

Bath wash Designed to remove the acid from the wire service water. Labor operations: • threading wire through a bath washing; • threading wire through separating comb; • installation the hemp cord. 8

Bath fluxing Designed to improve adhesion to the zinc coating (used ammonia chloride). Labor operations: • threading wire through a bath fluxing; • Installation the hemp cord. 9

The dryer Designed for drying and heating the wire prior to galvanizing (minimum temperature of 150 C optimal 250 C) Labor operations: • threading the wire in the dryer; • threading wire through separating comb dryer. 10

The galvanizing bath Intended to cover the wire surface of molten zinc. Labor operations: • threading wire in the galvanizing bath; • Installation the hemp cord; • Installation of cooling tubes; • cleaning the work area from the galvanizing bath of zinc dross. Bath closed, equipped with aspiration system. 11

The bath of waxing Designed to protect the surface of the wire from corrosion. Labor operations: • threading wire through a bath waxing razor sagging zinc; • installation the hemp cord. Machine open, equipped with aspiration. 12

The winding Designed winding wire: Labor operations: • Broaching and threading wire winding on the block; • installing anchors on winding unit; • certification of products. 13

Results APS According to the results of the internal audit it was found that the main risks affecting the safe production process of galvanized wire are: • the human factor - the lack operations in technical documentation; • technical factor - the absence of guard between the winding and the furnace of annealing. 14