Confined space safety in foundries.
CCI S.p.A.

CCI SpA (Colata Continua Italiana) is a leading company in the national and international market of semi-finished copper products. Operating in high-risk environments, it chose to rely on Genesi Protection to secure the foundry’s confined spaces, in particular, the cooling tower shutdown, a very delicate activity that takes place only twice a year.

Izziv je bil zaščititi vzdrževalce pred boleznimi ali poškodbami med čiščenjem in vzdrževanjem opreme v tovarni za predelavo bakrenih kovin.

Postopek in vprašanja

Glavna kritična področja in z njimi povezana tveganja, ugotovljena za upravljavce v tovarni CCI SpA, vključujejo:

Talilna peč: surov baker se naloži v peč in pri visokih temperaturah stopi.
Tveganje: vdihavanje škodljivega drobnega prahu.

Kolo za litje: Nato se staljena kovina z livnim kolesom usmeri v ustrezne oblike. S pomočjo livnega kolesa se razporedi in nadzoruje pretok staljene kovine.
“Območje dostave” je del kolesa, kjer se staljena kovina usmerja v določena območja litja. V nekaterih sistemih je lahko prisotna voda za hlajenje nekaterih sestavnih delov samega kolesa ali za zmanjšanje oprijema staljene kovine na površine.
Na drugi strani je“povratno območje” namenjeno pridobivanju kovine, ki se ne uporabi takoj ali se zavrže med litjem. Ta kovina se zbere in ponovno vključi v postopek litja, da se ponovno uporabi.
Nevarnost: opekline zaradi stika z ostanki kovine, nevarnost padca, izpostavljenost plinom ali hlapom.

Hladilni stolp za polizdelke: Po taljenju je treba polizdelke hitro ohladiti, da se prepreči deformacija ali poškodba materiala. Stolp zniža temperaturo staljenega bakra, preden se uporabi v nadaljnjih fazah obdelave.
Tveganje: padci z višine, zdrsi, izpostavljenost bakterijam zaradi slabo razkuženih sistemov.

Bag filter: During processing, fumes and fine dust are generated. The bag filter purifies the air by removing these particles to ensure a safe working environment. It draws in polluted air by retaining the dust and releases the purified air into the environment.
Risk: exposure to hazardous dust and risk of falling.

Pickling tank: Semi-finished copper products may need chemical cleaning to remove oxides and impurities. For this, they are immersed in an acid solution that cleans them.
Risk: exposure to hazardous chemicals and risk of chemical poisoning.

Izparilni stolp s toplotnimi izmenjevalniki: Ta naprava z izhlapevanjem ohlaja vroče tekočine iz drugih stopenj predelave. Izmenjevalniki ohranjajo varno delovno temperaturo.
Tveganje: padci z višine, zdrsi in izpostavljenost bakterijam.

Rešitve, nameščene v livarni CCI SpA

Varnost upravljavcev med vzdrževalnimi deli je bila glavna prednostna naloga projekta.
V tovarni CCI Spa je bila izvedena ocena tveganja, da bi se preučila možna tveganja, ki bi jim lahko bili operaterji izpostavljeni med običajnimi vzdrževalnimi dejavnostmi.
Izvedeno je bilo tudi poglobljeno kartiranje zaprtih prostorov in delovnih območij s kritičnimi rešitvami v primeru nesreče. Ta analiza je omogočila opredelitev najnevarnejših območij in zasnovo najprimernejših rešitev za vsako kritično območje.

• Melting furnace: given the impossibility of permanent installations in the area adjacent to the melting furnace, Genesi SCPH double hoist installations have been provided. This solution allows safe access for operators inside the furnaces for specialized maintenance to restore the linings, which are subjected to high thermal stress. 

• Območje vračanja livnega kolesa : v bližini rezervoarjev so na voljo talni podstavki za namestitev naprave Genesi SC12NW.

• Casting wheel delivery zone: given the presence of water in this area and heights of up to 4 meters, the area can be dangerous for maintenance operations. To address this risk, wall-mounted bases were installed under the grates to support the Genesi SC12NW, which is equipped with specific equipment for confined space management.
  Bases were identified to provide a safe and stable anchor, even in a humid environment and in the presence of water. 

• Hladilni stolp za polizdelke: zaradi pomanjkanja zaščite po obodu konstrukcije in potrebe po varnem dostopu do notranjih rezervoarjev so bile za hitro in zanesljivo reševanje v primeru nesreče nameščene ravne talne ograje SK-21, sidrišča ALU12 in dvigalo Genesi SCPH.

• Pickling tank: EAR12 anchor points and the Genesi SCPH hoist were installed to ensure effective horizontal extraction in the event of a medical emergency.

• Boldrocchi bag filter (air filtration system): access at height has been made safer thanks to the Vertical X lifeline and ALUXRAIL rail, installed under the existing steel structure.
  This system was designed to facilitate rescue operations from floor-level hatches and evacuations from vertical accesses.

• Evaporative tower with heat exchangers: the fan, positioned at the top of the evaporative tower with water tanks underneath, requires daily maintenance to ensure correct operation. To protect the operators during normal inspection activities, an ALUXRAIL rail was installed under the existing carpentry, combined with a rescue device in case of an emergency.
  In addition, a gangway was constructed to facilitate safe access to the fan area, improving operations and reducing risks to personnel.

• Držanje: za zagotovitev vodoravnega izvleka v primeru nesreče in varnega sidranja je bila pod potujočim nosilcem nameščena sidrna točka ALU12 v kombinaciji z dvigalom Genesi SCPH z obeskom za sidranje pod nosilcem.
  
  

Usposabljanje in treniranje z Genesi Academy

In addition to the installation of the safety solutions, Genesi Academy carried out field training sessions, training the operators during a normal maintenance activity. The goal was to make staff self-sufficient in managing the different systems. and their configurations.
This investment in staff training proved to be essential in ensuring the effectiveness of the installed solutions with correct use and greater awareness of emergency protocols.

Are you aware of all the potential hazards in your foundry?

Podjetje Genesi Protection vam lahko pomaga pri spremljanju vseh morebitnih tveganj in pripravi učinkovit načrt za zavarovanje vaše livarne.

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