Asphalt Plant Gas Supply - Piping, Drawings

Contents

1. Project Executors

2. General part

3. Gas consumption system. Gas-equipment

4. Automation

5. Electrical part

6. Technical and economic indicators

7. List of operating personnel for maintenance of ABU

8. Requirements for officials and maintenance personnel

9. Occupational safety

10. Environmental protection

11. Safety Requirements for Gas Pipeline Operation

12. Measures to prevent accidents and localize their consequences

2. General part

The project was developed on the basis of contract No. 29/08 dated 01.07.2008, Engineering Specification, in accordance with the technical regulations:

- on the safety of buildings and structures No. 384FZ of December 30, 2009;

- fire safety 69 FZ dated December 21, 1994

rule sets:

- SP 62.13330.2011 "Gas distribution systems. Updated revision. SNiP 42012002;

- SP 4.13130.2009 "Fire protection systems. Limitation of fire spread at protection facilities. Requirements for space-planning and structural solutions ";

- PB 1252903 "Safety rules for gas distribution and gas consumption systems."

- "Rules for the protection of gas distribution networks" utv. Decree of the Government of the Russian Federation of November 20, 2000 No. 878.

The design documentation is executed in accordance with the state standards of the design documentation system for construction (SPDS), as well as the state standards of the unified design documentation system (ESKD) and other valid technical documents.

The project was developed on the basis of TU No. 811 dated 24.05.2011 of the Samaragaz branch of SVGK LLC.

The design documentation provides for the technical re-equipment of the medium pressure gas pipeline with the connection of the ABU (DS185) located at:

to the existing medium pressure gas distribution network and made on a topographic plan (M1: 500) developed in 2011 by LLC.

Gas consumption within the allotted limit.

ABU (DS185) is located on an open area and is designed to produce asphalt. The production of asphalt and its laying on the roads is carried out in the warm period of the year at positive external temperatures. Gas equipment is serviced from a special site by permanent maintenance personnel. The use of flue gas heat is not economically feasible in view of the fact that the asphalt concrete installation is not a permanent installation, works only in the summer and is remote from possible consumers.

The ABU consists of the following main process components:

- open storage of gravel or crushed stone;

- open storage of sand;

- closed warehouse for storage of mineral powder;

- drying drum with gas burner GSAU200 for sand, crushed stone and dolomite heating;

- loose material dispenser;

- drying drum gas dust cleaning unit;

- mixing unit (asphalt mixer);

- silos of finished asphalt concrete mixture;

- bitumen storage with equipment for heating and pumping;

- bitumen heating plant with gas burner GBG0,34;

- fuel oil storage tanks.

The project provides for:

- gas supply of drying drum with gas burner GSAU200;

- gas supply of bitumen heating plant with gas burner GBG0,34;

- comprehensive automation of ABU.

The dryer drum is designed for drying and heating mineral materials to the required temperature (180200˚S) and is a horizontally located rotating furnace with a burner GSAU200 manufactured by Polytechnic LLC (Russia).

The bitumen heating plant is a continuous heating device and is designed for dewatering bitumen and its subsequent heating to the required temperature. The plant consists of a boiler divided into two compartments - in the first there is previously dehydrated bitumen, and in the second - evaporated and heated to operating temperature. The plant is equipped with a block gas burner GBG0.34 manufactured by OJSC Brestselmash. Heating is performed in accordance with Job Instruction.

To protect the gas burner GBG0.34 from atmospheric precipitation, a canopy should be provided.

For fire-fighting purposes, a fire shield with a bucket, shovel, luggage and nightmare, as well as a box with dry sand (capacity 0.5 m3) is provided near the oil heating plant.

Perform piling around the oil heating plant and bitumen tanks with a height of at least 0.3 m.

4. Automation

Set of automation and control systems is intended for automatic control and regulation of heat-technical parameters of GSAU200 burner operation, as well as safety of ignition and operation of gas-burner device with BUS12 control unit.

BUS12 control unit provides automatic stop of gaseous fuel supply to the burner in the following emergency situations:

- ignition of burner flame;

- reducing the pressure of gaseous fuel upstream the burner below the minimum (0.013 MPa);

- increase of gas fuel pressure upstream the burner above maximum (0.02 MPa);

- reduction of air pressure upstream the burner (60 mm. waters. article);

- reduction of rarefaction (-2 mm. waters. article);

- lack of electricity.

Control of gas throttle and air dampers is performed by means of electric drive of MEW type.

Power supply of automation equipment and emergency light signalling of process parameters are performed on switching board and control unit of BUS12.

Block gas burner GBG0,34 is fully automated and provides automatic stop of gaseous fuel supply in the following emergency situations:

- reducing the pressure of the gaseous fuel upstream the burner below the minimum (0.01 MPa);

- increase of gas fuel pressure upstream the burner above maximum (0.023 MPa);

- reduction of air pressure upstream the burner (60 mm. waters. article);

- reduction of rarefaction (-2 mm. waters. article);

- lack of electricity.

5. Electrical part

The current collectors of the newly installed equipment are powered from the existing power distribution board located in the operator's booth, the voltage of the 380/220 V network is not considered by this project.

Boiler house current collectors in terms of power supply reliability belong to category II.

Existing wiring is made three-wire: phase, zero working conductor and protective conductor.

8. Requirements for officials and maintenance personnel

Managers and specialists involved in the operation of hazardous production facilities of gas consumption systems shall be certified (verification of knowledge of industrial safety requirements, Safety Rules for gas distribution and gas consumption systems (PB 1252903) and other regulatory legal acts and regulatory and technical documents assigned to the competence of certified) to the extent corresponding to official duties and established competence.

Workers must be trained and tested on safe methods and methods of performing work within the scope of the requirements of the instructions assigned to their work duties.

9. Occupational safety

The project was developed taking into account the provision of the maintenance personnel of the asphalt concrete plant (ABU) with regulatory conditions for health and safety.

The following measures are provided for safe maintenance of the equipment:

- pipelines are marked by painting in accordance with the requirements of Gosgortekhnadzor.

- devices for protection of personnel from electric shock.

The plant is equipped in accordance with the current norms and regulations, necessary technological protections, including sound alarm at deviation of process parameters from the norm.

ABU is provided with automatic regulation and safety according to the requirements of SNI3576 and PB 1252903 with disconnection from the gas supply source.

10. Environmental protection

To reduce the concentration of harmful emissions into the atmosphere, the asphalt concrete plant is equipped with a dust collection and dust removal system.

Combustion products with dust from the mixer drum are supplied to the Cyclone dry cleaning system, where dust (solid particles) are separated and returned to the mixer drum. After pre-cleaning, wet cleaning is carried out by the Svetlana system.

Emissions of combustion products of natural gas are ensured by its qualitative combustion in furnace device of drying drum. High-quality combustion is achieved when adjusting the thermal mode of the asphalt mixer.

11. Safety Requirements for Gas Pipeline Operation

The project provides for measures to ensure safe operation of the gas pipeline, safety of maintenance personnel, buildings and structures located in the immediate vicinity of gas pipelines:

- disconnecting valves of the external gas pipeline are in conditions of restriction of access of unauthorized persons.

- construction and installation works shall be performed only according to the approved work execution project, which shall reflect the requirements of labor protection and safety including.

- "Safety rules for gas distribution and gas consumption systems."

- "Rules of technical operation and requirements for occupational safety in the gas industry of the Russian Federation."

- PUE 7.

- use of only certified gas equipment, components and materials.

During the operation of the gas farm, it is necessary to organize control over the serviceable state of gas networks .

Prevent the operation of gas supply systems, as well as the performance of any kind of repair and gas hazardous work, if further production is associated with a danger to the life of the workers.

Workers involved in the maintenance and repair of the gas farm and the performance of gas hazardous works should be trained in safe working methods in the gas farm.

Prevent employees who do not have certificates and rights to service the gas farm.

Maintenance and operation of gas networks is carried out according to the instructions approved in accordance with the established procedure.

The main attention of gas workers should be focused on preventing accidents and maintaining gas pipelines in good condition. What is achieved with the help of the planned preventive repair system, which provides for the performance of preventive work, current and major repairs.

Preventive work includes periodic inspections, as well as the elimination of minor malfunctions identified during the inspection. The current repair consists in the elimination of small faults and damage to gas pipelines, as well as in the revision of individual equipment. During overhaul, worn-out units and parts are changed, wear is eliminated and the original state of the gas pipeline is restored.

Emergency work is work that requires urgent action, emergency work is carried out by the emergency dispatch service of the gas farm. First of all, the emergency service carries out work that limits the spread and size of accidents, and the elimination of serious consequences is subsequently carried out by operational personnel on their own. Work to eliminate accidents is carried out without a warrant (until the direct threat to people's lives and material values ​ ​ is eliminated).

After elimination of this threat, work on gas pipelines and gas equipment in a technically serviceable state is carried out in the prescribed manner (along with).

All tools and accessories used in emergency operations shall be explosion-proof, made of non-ferrous metals and do not form sparks during operation.

All construction and installation works on the construction of gas pipelines, existing networks and structures on them should be carried out in full compliance with the requirements of existing regulatory documents.

12. Measures to prevent accidents and localize their consequences

In the area where the medium pressure gas pipeline is laid, there are no objects that pose a danger as a result of the accident on the gas pipeline. Along the route of the designed gas pipeline, a security zone is installed in the form of an area limited by conditional lines coming at a distance of two meters from each side of the gas pipeline.

In the event of an emergency (gas pipeline break, gas leak), the subscriber or witness of the incident calls the Samaragaz branch emergency service by tel. 04. The emergency service quickly leaves the place, localizes the accident, calls the head of the emergency recovery link from the operation service, which eliminates the problems.

The service has a plan for the interaction of the district center services (police, ambulance station, fire department). Depending on the degree of emergency, all these services are notified.

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