Installation & Commissioning of Blast Furnace Iron Making Equipment
Installation of blast furnace iron making equipment is very big and complex project.It needs skilled engineer for the installation.All necessary materials and equipment should be prepared to done the installation and commissioning.The installation process includes but not limited to, unloading and positioning of the blast furnace vessel and other components, foundation work, erection of gas supply system, preheater and hot/cold stoves, setting of lining and tapping arch and other equipment.
At the same time necessary piping connection are being done together with the necessary electrical connections to ensure complete vacuum tight conditions.Installation and Leakage tests will also be carried out prior to commissioning.
A special emphasis is put on the Maintenance and Safety aspects relating to the operation of the blast furnace iron-making unit due to the high temperature and pressurized conditions.A comprehensive safety check ensures all necessary measures are taken against gas / dust explosions, high temperature and other safety hazards.
Commissioning of the Iron-Making unit is completed with a temperature stability test.Subsequent operational trials will also be performed to check and optimize the operational parameters of the blast furnace iron-making plant to ensure total operational reliability and product quality.
Installation Safety Measures
Safety is of paramount importance in an installation of blast furnace iron making equipment.Different machinery involved in the installation process require to be handled according to the manufacturers instructions. The manufacturer should supply the necessary safety instructions prior to installation.
The installation team should ensure that sufficient safety measures are taken for the installation and should make sure that the instructions are followed accordingly. Safety glasses and hard hats should be worn by all the personnel involved in the installation and the safety instructions should be listed in each Safety Manual to be updated regularly with learning from different installations.
The installations team should also ensure that proper grounding of the equipment is given in order to prevent electrocution hazards. It is advisable to wear insulated gloves and boots in order to avoid shocks from wires and pipes.
The installation area should be cleared from all obstructing obstacles. This will help to maintain the necessary gap between the working personnel and the equipment and protect them from getting crushed in case of any accidents during the installation.
No smoking, open flames or naked lights should be allowed in the area of installation. If the area of installation is near to the open flame, then it is the duty of the installation team to move the equipment to some other safer area.
Commissioning & Testing
Commissioning and testing is a critical part of the process. All systems/components must be tested to ensure they meet the manufacturers specifications before they are used. The tests include but not limited to, performance testing, pressure testing,flow testing and leak testing.
Performance testing is an important part of the commissioning process. It is necessary to ensure that the equipment is designed and operating as designed. The tests should be performed in accordance with the manufacturers specifications.
Pressure testing is also important to check the pressure with the control valves. The pressure testing should be done both before and after the installation. Any malfunctioning valves should be replaced with new ones.
Flow testing is another important test. The tests help to ensure that the flow of hot/cold gasses is as per the manufacturers specifications. This helps to maintain the desired performance of the furnace over its lifetime.
Finally, the leakage tests should be done to check for any leaks in the system. This will ensure that the equipment works efficiently and safe over the years.
Conclusion
The installation and commissioning of the blast furnace iron-making equipment is a complex task, requiring specialized skills and knowledge.It is important to ensure that all components and systems are tested for their performance, pressure, flow and leakage in order to have safe and reliable operation of the furnace.Safety should be taken utmost priority during the entire installation process.The proper safety measures should be taken in order to avoid any accidents or loss of life or property during the installation and commissioning process.
