GB 43049-2023 PDF in English
GB 43049-2023 (GB43049-2023) PDF English
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Safety technical conditions for continuous casting machines
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GB 43049-2023: PDF in English GB 43049-2023
GB
NATIONAL STANDARD OF THE
PEOPLE’S REPUBLIC OF CHINA
ICS 77.180
CCS H 93
Safety technical conditions for continuous casting machines
ISSUED ON: SEPTEMBER 08, 2023
IMPLEMENTED ON: OCTOBER 01, 2024
Issued by: State Administration for Market Regulation;
National Standardization Administration.
Table of Contents
Foreword ... 3
Introduction ... 4
1 Scope ... 5
2 Normative references ... 5
3 Terms and definitions ... 9
4 Classification of continuous casting equipment and major hazards ... 12
4.1 Classification of continuous casting equipment ... 12
4.2 Major hazards ... 15
5 Safety requirements and safety measures ... 16
5.1 Overview ... 16
5.2 Major hazards, hazardous conditions, safety requirements and/or measures list ... 38
5.3 Special safety requirements or measures ... 51
5.4 Noise requirements ... 52
6 Verification requirements for safety requirements and safety measures ... 54
7 Usage information ... 54
7.1 Signs and alarm devices ... 54
7.2 Documents delivered with the continuous casting machine ... 54
7.3 Minimum required markings ... 59
7.4 Personnel training ... 60
Appendix A (Normative) Safety requirements and measures for electrical equipment
and control devices ... 61
A.1 General requirements ... 61
A.2 Special requirements for control devices ... 61
A.3 Special requirements for equipment shutdown ... 62
Appendix B (Normative) Noise test specification ... 68
B.1 Basic requirements ... 68
B.2 Determination of sound power level ... 69
B.3 Determination of emission sound pressure level ... 69
B.4 Measurement uncertainty ... 75
B.5 Operating conditions ... 75
B.6 Information to be recorded and reported ... 76
B.7 Publication and verification of noise emission values ... 76
References ... 78
Safety technical conditions for continuous casting machines
1 Scope
This document specifies the safety requirements, safety measures, verification
requirements for continuous casting equipment, during design, manufacturing,
assembly, transportation, installation, adjustment, commissioning, operation,
maintenance, shutdown. It also specifies the key use information of signs, alarms,
delivery and other steps of continuous casting equipment, during transportation,
assembly, operation, maintenance.
This document is applicable to continuous casting machines such as slab billets, square
billets, rectangular billets, special-shaped billets, round billets, and other similar
equipment (such as horizontal continuous casting machines, continuous casting
machines for headless rolling production lines, etc.).
2 Normative references
The contents of the following documents constitute the essential terms of this document
through normative references in the text. Among them, for dated references, only the
version corresponding to that date applies to this standard; for undated references, the
latest version (including all amendments) applies to this document.
GB 2893 Safety colors
GB 2894 Safety signs and guideline for the use
GB 3096 Environmental quality standard for noise
GB 4053.1 Safety requirements for fixed steel ladders and platform - Part 1: Steel
vertical ladders
GB 4053.2 Safety requirements for fixed steel ladders and platform - Part 2: Steel
inclined ladders
GB 4053.3 Safety requirements for fixed steel ladders and platform - Part 3:
Industrial guardrails and steel platform
GB 4943.1 Information technology equipment - Safety - Part 1: General
requirements
GB 5083 General rules for designing the production facilities in accordance with
safety and health requirements
5 Safety requirements and safety measures
5.1 Overview
5.1.1 General requirements
5.1.1.1 Basic conditions
The basic conditions for safety requirements are as follows.
a) This document requires that the continuous casting machine is operated in the
design environment of GB 50010, GB 50016, GB 50116. The lighting of the
continuous casting workshop shall comply with the provisions of 5.4 of GB
50034-2013; the indoor lighting shall refer to GB/T 26189. The ventilation, dust
removal and harmful gas purification, noise reduction and vibration isolation,
insulation and corrosion protection of the continuous casting workshop shall
comply with the provisions of Chapter 6, Chapter 7, Chapter 12, Chapter 13,
Appendix of GB 50019-2015.
b) The supplier of the continuous casting machine shall design and manufacture the
continuous casting production equipment safely, in accordance with this
document, GB 5083, relevant mechanical safety standards such as GB/T 20850.
Among them, the steel straight ladder, steel inclined ladder, industrial protective
railing and steel platform shall comply with GB 4053.1, GB 4053.2, GB 4053.3,
respectively.
c) This document shall take into account local regulations on lighting, which may
differ from the requirements of some local regulations.
d) The factory where the continuous casting machine is located shall establish the
safety production rules, implementation rules, operating procedures for the
continuous casting machine, in accordance with this document, the supplier's
equipment manual, GB 4943.1, with reference to GB/T 30574, GB/T 33000,
GB/T 33222, etc. Conduct standardized safety production education, training and
quantitative assessment for all employees involved in the operation and
maintenance of the continuous casting machine, technology development, test
and research, logistics operation, marketing, factory management, etc.
e) Implement the safety production responsibility system; clarify the responsible
personnel, scope of responsibility, assessment criteria, supervision measures of
each position.
f) Establish a safety officer system. The safety officer of the continuous casting plant
shall be familiar with this document; be proficient in the safety production
implementation rules of the continuous casting machine formulated according to
this document, the supplier's equipment manual and other safety production
standards; conduct a full process investigation of safety risks during the
production and maintenance of the continuous casting machine; pay attention to
discovering and collecting and summarizing safety incidents not covered by
various safety regulations.
g) Safety education shall be conducted for all types of personnel who temporarily
enter the continuous casting plant; precautions and safety responsibilities shall be
clarified.
h) This document assumes that the continuous casting equipment is operated and
maintained by trained and competent personnel, as shown in 7.4. Manual
intervention for setting, adjustment and maintenance is part of the intended use
of the continuous casting equipment.
i) Strengthen the scientific and technological research on the safe production of
continuous casting machines and the promotion and application of advanced safe
production technologies; continuously improve the safe production level of
continuous casting machines.
5.1.1.2 Summary of this document
The continuous casting machine that complies with this document shall comply with
the safety requirements and safety measures specified in this document.
In the use information, the supplier shall provide all the detailed information necessary
for the safe operation process of the continuous casting machine under normal operating
conditions. The supplier shall also describe specific safety measures under special
operating modes (such as maintenance and commissioning work).
The subsequent clauses point out the safety requirements for the continuous casting
machine plant design, overall design, equipment design, production operation,
equipment maintenance, etc.; put forward the relevance of special safety requirements
or safety measures to its major hazards and dangerous conditions.
5.1.2 Layout and on-site inspection of continuous casting machine
The supplier shall conduct a full inspection on site, to ensure the following items of
continuous casting machine are well arranged and operate safely:
a) Barrier-free environment;
b) Equipment maintenance and equipment cleaning and cleaning space;
c) Transportation and storage of mechanical equipment and materials;
hydrogen system is referred to GB/T 34542.1. In addition, it shall also meet the
requirements of Table 1.
c) In areas prone to fire, the hydraulic system shall use fatty acid ester (vinegar) fire-
resistant hydraulic fluid (HFDU) or water-ethylene glycol fire-resistant hydraulic
fluid. Fire-resistant hydraulic fluid complies with ISO 7745:2010 and ISO
12922:2012. Water-ethylene glycol fire-resistant hydraulic fluid refers to GB/T
21449.
d) If there are signs of dangerous hydraulic fluid leakage, the operator shall be
promptly provided with an audible and visual alarm to stop the leakage.
e) For equipment supported by hydraulic cylinders, especially when supporting
containers with steel liquid, a hose rupture protection device shall be installed at
the hydraulic cylinder to quickly stop the flow of fluid.
f) Hydraulic accumulators shall be designed in accordance with national pressure
vessel standards.
g) Hydraulic stations and lubricating oil stations (depots) shall not be connected to
cable tunnels (corridors) and underground electrical rooms. If they must be
connected, firewalls and fire doors shall be installed. The design of fire doors
shall comply with GB 12955-2008, category A thermal insulation fire doors A3.0
shall be selected.
h) The rooms of the hydraulic station shall be equipped with escape doors in different
directions; the hydraulic tunnel shall be equipped with at least one escape exit at
both ends.
i) The rooms and water valve stations of the hydraulic station shall be equipped with
oil drainage grooves to ensure smooth drainage.
5.1.6 Fluid systems for transporting or carrying fluids
The safety requirements for fluid systems for transporting or carrying fluids are as
follows.
a) In the fluid system, the supplier of the continuous casting machine shall consider
the protection against temperature and fire for all equipment and parts for
transporting or carrying fluids.
b) Hydraulic stations, valve platforms, accumulators, hydraulic pipelines, hydraulic
actuators shall be equipped with safety valves, pressure reducing valves, stop
valves in accordance with safety requirements. Emergency locking devices shall
be installed between accumulators and pipelines and inspected regularly.
c) The connecting parts of cable tunnels (corridors) and cable interlayers with
inspection laboratories shall be fireproofed.
d) Prevent the leakage of toxic gases used in operations such as drying, preheating
of tundish, cutting of ingots, accidental cutting, flame cleaning.
e) In permanent workplaces, flanges, fittings, hoses shall be covered if there is a risk
of fluid leakage. If pneumatic, hydraulic, oxygen, gas, steam, cable pipelines are
found to be damaged or broken, they shall be replaced immediately.
f) When designing hydraulic, oxygen and gas systems, quick-cut devices shall be
installed. Flame arresters shall be added to gas pipelines to prevent the spread of
flames after flammable gases are accidentally ignited. Quick-cut devices and
flame arresters shall ensure:
1) They are installed outside the danger zone;
2) They are easy to access;
3) Their locations are clearly marked.
g) When inspecting the gas system pipeline, the quick-cut valve or blind plate valve
shall be closed; the residual gas in the pipeline shall be cleaned up by effective
measures, such as replacing the gas in the pipeline with nitrogen and other flame-
retardant gases.
h) The emission of pollutants generated by billet cutting, billet flame cleaning and
grinding by billet mechanical grinding wheel shall comply with the specific
provisions of GB 28664.
i) Operators are prohibited from wearing oily gloves or wearing oily work clothes,
work hats and work shoes to contact oxygen and gas equipment.
j) It is forbidden for workers to rest near dangerous sources such as oxygen, gas,
steam, high-pressure containers and their pipelines; it is forbidden for unrelated
personnel to stay near dangerous sources.
k) It is strictly forbidden to use flammable materials such as gasoline and kerosene
to clean equipment in the hydraulic room.
l) When inspecting and repairing pressure pipelines, flammable and explosive gas,
liquid transmission pipelines and nearby equipment, strictly implement the
relevant safety regulations in the equipment manual; formulate specific fire
prevention and explosion prevention safety measures. If hot work is required, it
shall be completed in accordance with the hot work grading and basic
requirements specified in Chapter 5 of GB 30871-2022.
m) When equipment and pipelines are frozen, it is strictly forbidden to bake them
5.1.10 Right of access
5.1.10.1 Conditions of access
It is strictly forbidden to enter dangerous areas and dangerous parts without
authorization. Physical barriers specified in GB/T 8196-2018 are used to isolate
dangerous areas and dangerous parts. When accessing, the safety conditions for
approaching mechanical fixed facilities are as follows:
a) The positioning of safety protection devices related to the approach speed of
human parts is shown in GB/T 19876;
b) The selection and approach of fixed facilities is shown in GB/T 17888.1;
c) Working platforms and passages are shown in GB/T 17888.2;
d) Stairs, steps, guardrails are shown in GB/T 17888.3;
e) Fixed vertical ladders are shown in GB/T 17888.4.
The exceptions are as follows:
1) Casting platform area: See 5.2.3.1a) for other safety measures;
2) Flame cutting area: See 5.2.5.2 for other safety measures;
3) Non-safe passages in the run-out-area are prohibited for personnel to pass
through, see 5.2.6.
These passages shall be protected from heat radiation and high-pressure liquid or gas
spray; have the conditions and functions for moving materials and tools.
5.1.10.2 Warning signs
Warning signs comply with 5.1.9.
5.1.10.3 Avoid squeezing of various parts of the human body
The spacing (see GB/T 12265.3) to avoid squeezing of various parts of the human body
(possible contact due to being constrained by a small space) near control consoles,
pulpits, underground places, maintenance yards, etc. shall follow the provisions of GB
23821 and meet the conditions listed in 5.1.10.1. Safety requirements for machinery,
electrical equipment, control systems are listed in GB/T 5226.1-2019, GB/T 16855.1-
2018, GB/T 16855.2, GB/T 19876.
5.1.10.4 Railings
Railings shall not be used as the sole measure to protect hazardous areas, except to
prevent slips, trips, falls. Railings may be used in conjunction with other means (such
as warning signs) to exclude unauthorized persons from hazardous areas.
5.1.10.5 Anti-slip
The surfaces of walkways, stairs, platforms shall be anti-slip and protected, to avoid or
minimize slips or falls caused by scale, oil, emulsions, lubricants.
5.1.10.6 Protective devices
The type of protective devices (fixed or movable protective devices, adjustable
protective devices, interlocking protective devices, etc.) used to prevent entry into
hazardous areas shall be selected, according to the permitted degree of entry in
accordance with Chapter 6 of GB/T 8196-2018. The protective devices specified in
Table 1 shall be selected according to the actual situation.
For the design and manufacture of protective devices, refer to the provisions of Chapter
5 of GB/T 8196-2018.
5.1.10.7 Entering the equipment during equipment operation or maintenance
The relevant safety systems required for entering the equipment during equipment
operation or maintenance selected according to A.2 shall comply with the relevant
requirements of GB/T 16754-2021, GB/T 18831, GB/T 19670-2005.
5.1.11 Escape route
The escape route shall meet the following requirements at a minimum:
a) It shall have two emergency exits; the distance between the two emergency exits
shall be as far as possible;
b) It shall have an outward opening door;
c) It shall have an escape sign; the sign shall indicate the escape route under any
conditions;
d) It shall be free of obstacles;
e) The floor (slab) shall not be slippery;
f) Guardrails shall be installed in some places; handrails shall be installed where
there are steps.
5.1.12 Automation equipment
Automation equipment shall comply with the provisions of GB 7247.1 and GB 28526.
It shall be designed with reference to GB/T 5226.1-2019, GB/T 15706, GB/T 16855.1,
for use;
b) When lifting heavy parts with eyebolts or similar auxiliary devices, handles,
handrails or grips with non-slip surfaces (such as knurled surfaces) shall also be
provided;
c) There shall be no obstacles in the work area where objects are manually moved,
to ensure that the operator will not be hindered when working. The working area
shall be spacious, so that the operator can carry items close to the body;
d) Use non-slip surface, see 5.1.10.5;
e) Ventilation and air conditioning vibration protection shall comply with the
relevant provisions of GB 50019-2015;
f) Heat insulation is as shown in 5.1.14, which shall comply with the relevant
provisions of GB 50019-2015;
g) The line nodes, fluid power nodes, connections between electrical equipment shall
be as high as possible 400 mm ~ 2000 mm above the plane where the personnel
stand, so that the equipment installation, operation, inspection, maintenance can
be carried out safely;
h) For the lighting of the working area, refer to GB/T 28780, which shall complies
with the provisions of Table 5.4.1 "7 Iron and steel industry, steelmaking and
continuous casting" of GB 50034-2013. For the design of human-computer
interaction environment, refer to GB/T 14776, GB/T 15241.2, GB/T 16251, GB/T
18717.1, GB/T 18717.2, GB/T 18717.3, GB/T 22188.1 on human ergonomics, to
optimize the operation and maintenance environment of the continuous casting
machine and effectively protect human health.
5.1.16 Fire protection
Equip fire alarm devices and establish fire protection systems in specific rooms such as
the main pulpit, hydraulic station, electrical room of the continuous casting machine,
or in the exposed areas in the workshop and the tunnels (corridors) of hydraulic
equipment. Fire protection follows the following rules:
a) Fire protection of continuous casting machine shall comply with GB 50414;
b) In continuous casting machine equipment, if a gas fire extinguishing system is
used, its design shall comply with GB 50370. Use heptafluoropropane
(HFC227ea) fire extinguishing agent, as shown in GB 18614; gas fire
extinguishing system and components shall comply with GB 25972;
c) The design of automatic sprinkler fire extinguishing system shall comply with GB
50084;
d) Fire water supply and fire hydrant system shall comply with GB 50974;
e) Hydraulic system exposed to molten steel shall be equipped with separate fire
alarm and firefighting system (such as protective shield, small storage tank,
flame-retardant fluid, etc.), or take other measures to reduce fire risk;
f) In case of fire, in addition to cutting off gas and oil sources, the power supply shall
be cut off for fire extinguishing.
5.1.17 Continuous casting machine operating position
5.1.17.1 Overview
The setting of the operating position shall comply with the following provisions.
a) The setting of the operator's operating position shall be close to the frequently
operated control device, to ensure the operator's comfortable operation. For
control devices used occasionally, they shall be placed within the reach of the
operator, see GB/T 21935.
b) The visual display is arranged to ensure that it is non-reflective and clearly visible.
c) Ensure that the operator can directly see the operation process from his position.
If it is not possible to see all the operation process areas, visual aids such as
industrial televisions, reflectors, etc. shall be provided.
5.1.17.2 Pulpit
When designing the pulpit, refer to GB/T 22188.1. The pulpit shall have:
a) Automatic control air conditioning system;
b) Heat insulation function;
c) Sound insulation function (see 5.4);
d) If necessary, install heat reflective windows;
e) If necessary, configure special color glass areas to protect the operator's eyes from
radiation injury;
f) Not affected by external factors such as slag and molten steel splashing.
5.1.17.3 Local control stand
The local control stand shall be protected to avoid external factors such as slag and
molten steel splashing.
5.1.17.4 Human cooling fan
The cooling water system shall comply with the following requirements.
a) The operation of the cooling water system of the continuous casting machine shall
comply with GB 13456, 13.5 of AQ 2001-2018, Chapter 8 of GB 50580-2010,
with reference to GB/T 50050.
b) The cooling water system shall be equipped with monitoring functions and fault
alarms. Once any fault occurs during the production process of the continuous
casting machine, an alarm shall be issued through the alarm system (see 5.1.9).
c) An emergency cooling water system independent of the main water supply system
shall be established, to supply cooling water through gravity (accident water
tower) or emergency power supply (including diesel/gasoline engine). The
emergency cooling water supply volume and supply time shall be sufficient, to
avoid personnel and related equipment from falling into dangerous conditions.
d) When a crystallizer leaks or a low flow (including no flow) alarm is issued by the
pipeline, the continuous casting machine shall stop operating immediately, to
avoid burning the crystallizer or even causing an explosion.
e) The return water flow and temperature difference of the equipment cooling water
shall be mastered in a timely manner, to avoid insufficient cooling water, causing
the radiant heat of the high-temperature ingot burning the bearings and equipment.
f) Check the blockage of the secondary cooling nozzle regularly and replace it in
time if it is found to be blocked, so as not to affect the cooling effect and cooling
uniformity, which may cause cracks in the casting and even cause steel leakage
accidents.
g) Necessary safety response measures shall be taken for sudden water outages and
other dangerous signs.
h) In the equipment manual, special instructions shall be given for the measures to
be taken in case of emergency in the cooling water system.
5.1.22 Radioactive source
When using radioactive sources to control the liquid level of the crystallizer, refer to
GB/T 19661.1 and GB/T 19661.2. Pay special attention to the following matters:
a) Use radioactive sources with low radiation intensity;
b) The installation and replacement of radioactive sources can only be carried out in
a safe location;
c) Radioactive sources shall be stored in special containers and rooms; special
radiation protection measures shall be taken;
......
Source: Above contents are excerpted from the PDF -- translated/reviewed by: www.chinesestandard.net / Wayne Zheng et al.
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