JB/T 6055-1992 Guidelines for environmental protection of forging workshops
Some standard content:
Machinery Industry Standards of the People's Republic of China
Guidelines for Environmental Protection of Forging Workshops
Subject Content and Scope of Application
This standard specifies the basic principles and requirements, general provisions and Method, JB/T6055..92
This standard is applicable to forging workshops (or professional forging plants, sections, teams, the same below). Its operation scope includes material preparation, book heating, forging heat treatment, cleaning, correction, Inspection, painting and other processes as well as corresponding auxiliary work. This standard also applies to the environmental protection design of newly built, renovated, expanded forging workshops and technical recovery forging workshops in industrial enterprises. 2 Reference Standards
Urban Area Environmental Noise Standards
GB 3096
GB3222
Urban Area Environmental Noise Measurement Methods
GB5748 Determination of Dust in the Air at Workplaces Method GB6881 Determination of sound power level of acoustic noise source Reverberation chamber precision method and engineering method GB 6921
Method for determination of atmospheric dust concentration
GB10070 Standard for urban regional environmental vibration
Urban regional environmental vibration Determination method
GB 10071
GBJ40 Power Machine Basic Design Specification
Industrial Circulating Water Cooling Design Specification
GB J102
ZBJ62006 Forging Machinery Noise Limit| |tt||TJ231 Mechanical Equipment Installation Engineering Construction and Inspection Specifications 3 Basic Principles and Requirements
3.1 The purpose is to protect the environment inside and outside the workshop. Protect the environment outside the workshop, prevent and limit pollution and damage to the surrounding environment to the greatest extent: protect and improve the environment inside the workshop, create a safe and suitable workplace for workers as much as possible, and protect the physical and mental health of workers. 3.2 Actively adopt effective pollution-free or low-pollution new processes, new equipment, new materials, and new technologies to eliminate pollution in production or limit pollution values ??to the minimum level and scope. When the pollution value does not meet the requirements, corresponding control measures should be taken to achieve the standard. Pollution prevention and control facilities must be designed, constructed, and put into operation at the same time as the main project. 3.3 The content, depth, format, and requirements of the environmental impact report (form) must be prepared and reviewed for new forging workshops that are newly built, renovated, expanded, or technically transformed. The content, depth, format, and requirements of the environmental impact report (form) should comply with the relevant regulations of the environmental protection department. . 3.4 For forging workshops with large pollution sources, they should be set up in industrial concentration areas or away from crowds and important facilities in accordance with specialized production source rules.
3.5 Workshop pollution treatment devices and protective facilities should be complete, with excellent performance, significant effects, safe and reliable, easy to install, economical and reasonable, and easy to maintain.
3.6 While taking comprehensive management measures to prevent and control pollution, on-site workers should take personal protective measures in accordance with national and industry regulations on labor protection.
3.7 Plant trees and lay lawns in suitable areas of workshops or factory areas, expand the green area as much as possible, and purify and beautify the environment. Approved by the Ministry of Machinery and Electronics Industry of the People's Republic of China on 1992-05-05 and implemented on 1993-07-01| |tt||30
4 Noise and vibration control
JB/T6055- -92
4.1 The location of the workshop on the general plan should be arranged downwind of the local wind direction all year round, away from Places with precision equipment and molding departments that require anti-vibration. The design of the wide room should be reasonable to minimize the impact of noise and vibration on the surrounding environment. Corresponding noise reduction measures should be taken against non-stop noise sources, and closed operations should be implemented when conditions permit. 4.2 Use pressure instead of forging, use low-noise and non-impact processes to replace high-noise processes and impact processes, and try to use extrusion, press die forging, rotary processing and other processes to replace the hammer die forging process. 4.3 Forging equipment with good body rigidity, low noise, small vibration and hydraulic transmission should be used. 4.4 Use forging hammers as little or as little as possible. When selecting forging hammer equipment, measures such as vibration reduction, anti-vibration, and isolation must be taken (spring foundation, adding dampers, rubber buffers, and anti-vibration trenches, etc.). When the energy is below 10\J, an anvilless hammer can be used. 4.5 For forgings that reach a certain economic batch size, the forging production line should be organized to reduce the number of storage and storage times of semi-finished forgings and the number of collisions between forgings.
4.6 Various low-noise transmission devices should be used for the transmission and transportation of small and medium-sized forgings. Avoid high drop and rolling during transportation. 4.7 The hydraulic press and the high-pressure pumping station should be connected with sound and light signals; for larger water pumping stations that supply multiple hydraulic presses, a separate factory building should be built, and sound absorption and noise reduction measures should be taken, such as hanging space sound absorbers and setting up sound insulation barriers. Soundproof doors and windows. 4.8 When using a bar shearing machine to cut materials, the shearing process and tooling should be included to reduce shearing noise. The exhaust hole of the pneumatic pressing device on the automatic feeding system should use a damping or impedance composite muffler. 4.9 The fan with centralized air supply should be installed in a separate soundproof room hung with sound-absorbing material, and a silencer should be used on the fan inlet and exhaust duct. For fans that disperse the air, a silencer cover should be installed. Large blowers should be installed underground if conditions permit, and damping or impedance composite mufflers should be used. The fan and the foundation are elastically connected, and an anti-vibration foundation is designed or a shock absorber is installed. 4.10 Power pipelines, especially high-temperature, high-pressure, and high-speed power pipelines, should generally be buried underground. Pipes transporting high-speed gases should be damped. Asphalt soft rubber and other polymer materials should be used to coat the pipe walls and tightly cover them with a layer of linoleum. Damping to reduce noise. Pipes and perturbation equipment should be flexibly connected.
4.11 Small mobile air compressors should be placed in a separate soundproof room outside the workshop. 4.12 For pneumatic components on various types of equipment, the exhaust part should use Newy or impedance muffler compounders, small hole injection mufflers, throttling and pressure reducing mufflers, or small hole injection-throttle and pressure reducing mufflers. 4.13 The exhaust pipe of the air hammer should be equipped with a muffler. For forging die replacement, a hydraulic ejection (personnel) device should be used. Adjustable vibration damping plates should be installed at workers’ operating points
4.14 The noise limits of various shearing machines, bending machines, hydraulic presses, automatic rutting machines, air hammers, mechanical presses, etc. in forging machinery should be Comply with the relevant regulations in ZBJ62006.
4.15 For noise limits that are exposed to noise for 8 hours or less per day, please refer to Table 1. Table 1 Noise level limits in forging workplaces
Exposure time to noise per shift, h
8
4
2
1
The maximum shall not exceed
noise limit
90
93
96
99
115
4.16 workshop noise radiation The environmental noise limits in areas outside the factory boundary should comply with GB3096. 4.17 The installation and construction of forging equipment must comply with the relevant regulations in TJ231. dB(A)
4.18 The basic design of the forging hammer must comply with the provisions of Articles 109, 112 and 113 of GB40. Those that do not meet the requirements should be modified or remedial measures should be taken. | |tt | The vibration parameters of the "ergonomic limit" of work efficiency should not exceed the values ??in Figure 1. The effective acceleration values ??of the vibration allowable standards are shown in Appendix A (Supplement) 8.0
6.3
5.0||tt. ||4.07
3.15
2.5
25/（）
2.0
1.6
1.25
1.0|| tt||0.8
0.63
0.50
0.40
0.315
0. 25
0.20
0.16| |tt||0.125
0.10
Imin
416min
25min
1h
[2.5h
4h| |tt||Bh
16h
24h
x
X
vertical vibration 1g peak
130
Iin
16min
25min
Ih
2.5h
4h
Bh
16h
24h| |tt||1.0 1.25 1.6 2.02.5 3.15 4.0 5.0 6.3 8.010 12.5Jti
Vertical vibration
Horizontal vibration
272531.54506380
Frequency or 1/3 octave center frequency, Hz
Figure 1 Vertical and horizontal vibration The limit allows contact time to ensure the health and safety of the operator. The acceleration value is allowed to be 6d3 higher than the "ergonomics limit". 4.21
20
19
fir
Guaranteed The vibration parameters of the "comfort limit" for operator comfort and pleasure must be 10dB lower than the "ergonomic limit" acceleration level4.22
Noise measurement
4.23
SIP·||tt ||Regional noise shall be in accordance with Articles 4.1.2.1 and 4.1.2.2 of GB3222, and workshop noise shall be in accordance with Articles 7.2~7.7, 8.1 and 8.2 of GB6881
4.24 Vibration measurement||tt ||Follow the provisions of Chapters 4 and 5 of GB10071. 5 Wastewater Control
5.1 The cooling water of heating equipment and tool and mold cooling water should be recycled to minimize the amount of fresh water and reduce the discharge of industrial wastewater. Industrial wastewater and domestic sewage should be discharged separately, and the clear and turbid water should be separated. The cooling circulating water should comply with the provisions of Articles 1.0.2 and 1.0.1 of GBJ102
5.2 When using clean gas, a supporting gas tank should be set up according to regulations. , to treat phenol-containing wastewater; when using hot gas, the phenol-containing wastewater should be used for as long as possible, and should not be arbitrarily overflowed. When it needs to be replaced, it should be concentrated and treated with chemical oxidation or adsorption methods. Water with an oil content of 5.3 in the workshop must not be discharged at will. It must be injected into the oil trap, and the heavy oil and floating oil must be removed by gravity separation and flotation. After the purification treatment reaches the standard, the oily wastewater will be transported to the discharge port through pipelines or open ditches. Oil traps, air flotation, oil-water separation devices, etc. are used to separate oil and water and discharge them after meeting the standards. 307
JB/T6055--92
5.4 According to the materials, shapes and sizes of different forgings, select the ones with the lowest pollution. Small oil-free smokeless forging die lubricant, reduce the amount of lubricant as much as possible.
5.5 Forgings should be cleaned without pickling process as much as possible. When using pickling process, the pickling waste liquid is strictly prohibited to be discharged freely, which is valuable. The waste acid should be concentrated and recovered, and the pickling residue should be neutralized before being discharged, and should comply with the discharge standards. 5.6 Acid-containing wastewater can be treated by alkaline waste, lime neutralization, and filtration and lime neutralization. There should be a mixing and sedimentation tank, and the treated waste residue should be transported away in time after dehydration and solidification. 5. Extend the use time of the cleaning solution and reduce the alkali concentration when there is both alkali-containing wastewater and acid-containing wastewater. Attached, wastewater and waste residues should be used to neutralize each other to achieve comprehensive management. 5.8 For hydraulic transmission devices and equipment that use oil and emulsified coatings, special pipe ditches should be set up. An oil collection pit and oil collection device should be set up at the bottom of the ditch. Liquid must not be discharged directly into sewer pipes. 5.9 The lubrication systems of various types of equipment should be reliably sealed. Pipes, valves, and burners in the oil system should not leak oil. The foundation floor and pipe trench of the hydraulic press should be coated with anti-seepage paint.
5.10 Separate emulsion wastewater from other wastewater. Set up a separate treatment system. The wastewater should use air flotation, electric flotation, and coagulation sedimentation. After slag removal, emulsion breaking, oil removal, and purification, it should be discharged into the sewer. 5.11 Wastewater that exceeds the standard in the workshop must be discharged into the designated ditch. It must not be discharged directly outside the workshop before treatment. Wastewater whose water quality exceeds the discharge standard shall not be discharged by dilution to reduce its concentration. 5.12 It is prohibited to use seepage pits, seepage wells or overflow methods to discharge wastewater. Pipelines and open channels leading to the discharge outlet should have anti-seepage measures. 5.13 When wastewater is discharged into urban sewers, it is strictly prohibited to mix flammable and explosive substances (gasoline, heavy oil, lubricating oil, etc.) and harmful substances. 5.14 The temperature of discharged wastewater shall not be higher than 40C. 5.15 The maximum allowable emission concentration of pollutants in vehicle wastewater should comply with the provisions of Table 2. Table 2 Forging workshop wastewater pollutants maximum allowable concentration sequence
1
3
5
6
7
No.||tt ||Pollution
PH value
Oils
Suspended solids
Hydrochemicals
Volatile phenols
Staining
Steel and its compounds
Things
Lead and its inorganic compounds
mg/m
Maximum allowable concentration
6.0~~9.0||tt| |10
500
1.0
0.
0.5
.0
5.16 Wastewater pollutants are always in the workshop or workshop When sampling the discharge outlet of the treatment facility, the water samples taken must represent the true status of water quality and quantity. The measurement of its pollutants should be carried out in accordance with the standards promulgated by the state (including sampling methods and measurement standards for pollutants). 6 Exhaust gas control
6.1 Cleaning equipment and pickling equipment should be arranged on the downwind side of the prevailing wind all year round. The pickling room should be built independently. If it must be set up inside the joint workshop, it should be separated by a partition wall to prevent corrosion. Metal doors and windows must not be used in the pickling room. 6.2 Various types of heating equipment should be arranged on the downwind side of the shed or the dominant wind direction as much as possible, and effective heat insulation and dust removal measures should be taken. The waste gas from its fuel burning shop must be exported out of the workshop through a flue or a smoke exhaust device 3 to 5 meters higher than the nearby factory building, and must not be directly discharged in the workshop; for waste gas with utilization value, heat exchange technology should be used as much as possible , make full use of the waste heat of the exhaust gas and achieve segmented utilization. 6.3 Change the energy structure and improve the heating process. Develop coal gasification heating technology and promote electric heating technology where possible. For industrial furnaces that use coal as fuel, the combustion method should be improved to eliminate black smoke. Renovate old-style furnaces with serious pollution and adopt new ones that are both energy-saving and low-pollution:
308
JB/T 6055-·92
6.4 Coal-fired industrial furnace door A smoke exhaust hood should be installed, and a cyclone dust collector should be installed in the smoke exhaust system. The blackness of the smoke at the outlet of the smoke exhaust system should not be greater than Ringelmann blackness level 2
6.5 Cleaning drums and shot peening equipment must be equipped with local exhaust dust removal The dust removal efficiency of the equipment should be above 90%, and isolation should be set up where conditions permit to carry out closed operations.
6.6 When large forgings of carbon steel and low alloy steel are flame cut and cleaned, they should be carried out on the wind side of the air circulation in the designated working area, and mechanical ventilation should be used to accelerate the airflow in the working area. circulation. 6.7 The use of grinding wheels to grind various types of forging burrs or surface defects should be carried out in the working area. Local ventilation and cattle removal devices must be installed in the work area, and wet dust removal should be used.
6.8 The exhaust gas generated by the lubricating mold should be exported out of the workshop through a local air insertion device when conditions permit. 6.9 A ventilation and smoke exhaust device must be installed in the manual welding workplace. 6.10 The pickling room must be equipped with a device to handle acid mist. There should be exhaust hoods above and on both sides of the pickling tank to prevent the acid mist from spreading randomly. At the same time, the level of mechanization of operations will be improved.
6.11 When using the bar cutting machine to cut materials in the material preparation section, reduce the dust concentration in the air as much as possible. Where possible and within production conditions, install a vacuum cleaner.
6.12 For various production equipment that emit dust, dust removal measures such as gravity, filtration, washing, and electrostatics must be taken based on process characteristics and the nature of the dust to prevent dust from flying freely and strictly limit the transfer of pollution. 6.13 The maximum allowable concentration of harmful gases in the workshop should comply with the requirements in Table 3. Table 3 The order of the maximum allowable concentration of harmful gases in the forging workshop
2
3
4
6
8
9||tt| |No.
Hazardous substance name
Dioxide bowl
Carbon dioxide
Carbon monoxide
Fluorine diammide
Hydrogen sulfide||tt| |Hydrogen cyanide
Volatile phenol
Smoke
Dust
6.14 The maximum allowable concentration of harmful gases in the pickling room should comply with the requirements in Table 4. Table 4 Maximum allowable concentration of harmful gases in the pickling room Liquid name
Sulfuric acid and hydrochloric acid
Sulfuric acid
Hydrochloric acid
Nitric acid
Gas name
Harmful
Arsenic
Sulfuric acid vapor and sulfur oxides
Hydrogen sulfide
Hydrogen chloride vapor
Nitric acid vapor and nitrogen oxides||tt ||mg/m
Maximum allowable concentration
15
10
30
5
10
0.3| |tt||5
10
mg/m
most
high theft
0.5 | |The provisions of Articles 3.3.2~-3.3.6 in GB5748 are implemented. 6.16 The production dust sampling port should be located at the outlet of the dust removal device. If the dust removal device is not installed, the sampling port should be located at the furnace mouth or the maximum concentration emission of the dust source.
309
JB/T 6055--92
6.17 Continuous and stable emission sources, sampled under normal production conditions, intermittent or fluctuating emission sources, emission at peak period sampling. 7 Waste slag and other pollution control
7.1 The slag produced by industrial furnaces using coal as fuel must be piled up in a centralized manner, processed uniformly, and try to make use of it as much as possible. According to the process requirements and the nature of the coal, the combustion technology is improved by mechanical coal addition, pulverized coal combustion, and increasing the temperature of the combustion air to ensure full combustion.
7.2 Asbestos wool, slag wool, glass wool and other thermal insulation materials used in industrial furnaces must not be exposed on surfaces that may be touched by operators. The above-mentioned waste materials must be collected and properly disposed of and must not be discarded randomly. 7.3 Production waste shall not be dumped randomly. Establish a waste dump site. When conditions permit, the iron oxide scale in production should be concentrated separately and used as secondary raw materials.
7.4 Clean up the dust-removed waste residue from rolling mills and shot peening equipment, determine its treatment method after technical and economic analysis, and deal with it in a timely manner. It must not be allowed to cause secondary pollution by dust. Where conditions permit, take Curing treatment. The cleaning process should consider wet operations. 7.5 The location, structural type, and internal process layout of the room should be reasonable. The factory building must use wind-shielding skylights, make full use of natural ventilation, and discharge as much heat and dust inside the workshop as possible in a timely manner. 7.6 For heating furnaces that use coal, gas, or fuel oil as fuel, cooling measures should be taken at the entrance of the furnace, such as using a spray water curtain. After taking out the bad materials, the furnace door should be closed in time and should not be left open for burning. 7. Heat shields should be installed between the hammer operator and the heating furnace, and between the operator and the hot forgings stacking area. When hydraulic press forging, fixed or movable heat shields should be installed without hindering the operator's work. 7.8 In operating areas where the thermal radiation illumination is above 350W/m2, a heat shield must be installed between the heat source and the operator, and mechanical ventilation must be used to dissipate heat and reduce overflow.
7.9 For all operations that can be replaced by machinery and electricity, try to use machinery and electricity equipment to operate, lift and transport hot forgings, and improve the mechanization and automation level of the operation. The hot forgings storage area should be arranged at the end of the workshop, away from operators and equipment, and should be transported out of the workshop in a timely manner.
31.60
A1
Vertical vibration
Vertical vibration Ruixu standard is based on the frequency specified in Table A1 or 1/3 times the frequency
Process center frequency| |tt||Hz
1.0
1.25
1.6
2. 0
2.5
3.15
4.0| |tt||5.0
6.3
8.0
10.0
12.5
16.0
20.0
25.0||tt ||31.5
40.0
50.0
63.0
80.0
A2
Horizontal vibration
Sh||tt| |0.63
0.56
0.50
0. 45
0.40
0.355
0.315
0.315||tt| |0.315
0.315
0.40
0.50
0.63
0.80
1.0
1.25
1.60
2.0
2.5
3.15
4h
1.06
0.95
0.85
0.75|| tt||0. 67
0.60
0.53
0.53
0.53
0.53
0.67
0. 85
1.06
1.32
1.70
2.12
2.65
3.35
4. 25
5 ,30
The horizontal vibration allowable standards are as specified in Table A2. JB/T6055---92
Appendix A
Vibration Allowable Standard
(Supplement)
Table Al
has
content
effect
Xu
2.5h
1.40
1.26
1.12
1.00
0.90| |tt||0.80
0.71
0.71
0.71
0. 71
0.90
1.12
1.40| |tt||1.80
2.24
2.80
3.55
4.50
5.60
7.10
Add||tt ||Connect
h
Speed
Touch
2.36
2.12
1.90
1.70
1.50
1.32
1.18
1.18
1.18
1.18
1.50bzxZ.net
1.90
2.36| |tt||3.00
3.75
4.75
6.00
7.50
9.50
11.8
degree||tt ||hour
value
time
25min
3.55
3.15
2.80
2.50
2.24
2.00
1.80
1.80
1.80
1.80)
2.24
2.80
3.55
4.50
5.60
7.10
9.00
11.2
14.0
18.8
16min|| tt||4.25
3.75
3.35
3.00
2.65
2.35
2.12
2.12||tt| |2.12
2.12
2.65
3.35
4,25
5.30
6.70
8.50||tt| |10.6
13.2
17.0
21.2
n/s
min
5, 60)
5.00| |tt||4.50
4.00
3.55
33.15
2.80
2.80
2.80
2.80||tt ||3.55
1.50
5.60
7.10
9.o0
11. 2
14.0
18.0| |tt||22. 4
23.0
311
frequency or 1/3 times frequency
range center frequency
112
1.0
.25
1.6
2.0
2.5
3.15
1.0
5.0
6.3
8. 0
10.0
12.5
16.0
20.t)
25.0
31.5
40.0
50.0
63.0
80.0||tt| |这些设计：
8h
0.224
0.224
0.224
0.224
0.280
0.355||tt| |0.450
0.560
0.710
0.900
1.12
1.40
1.80
2.24
2.80
3.55
4.50
5.60
7.10
9.00
4h
0.355
0.355|| tt||0.355
0.355
0.450
0.560
0.710
0.900
1.12
1.40||tt| |1.80
2.24
2.80
3.55
4.50
5.60
7.10
9.00
11.2
14.0
JB/T 6055-·9
92
表A2
有
容
数| |tt||许
2.5h
0.50
0.50
.50
0.50
0.63
0.80| |tt||1.00
1.25
1.60
2. 0
2.5
3.15
4.0
5.0
6.3
8.0
10.0
12.5| tt| ||0.85
0.85
C.85
. 85
1.06
1.32
1.70
2.12
2.65
3.35
4.25
5.30| |tt||6.70
8.50
10.6
13.2
17.0
21.3
26.5
33.5||tt ||度
时
值
间
25min
1.25
1.25
1.25
1.25
1.60
2.0
2.5
3.15
4.0
5.0
6.3
8.0| |tt||10.0
12.5
16.0
20.0
25.t
31.5
40.0
50.0| tt 1.50
1.50
1.50
1.50
1. 9
2.36
3.0
3.75
4.75
6. 0)
7.5
9.5
11.8
15.0
19.0
23.6
30.0
87.5
45.7
60.0
m/s
Imin
2.
2. 0)
2.0
2.0
2. 5
3.15
.(
5.0
6.3
8.0
10.t
12.5||tt| |16.0
20.03
25.0
31.5
40.0
50.0
63.0
80.
-- -
0
25.t
31.5
40.0
50.0
This standard is issued by the Ministry of Machinery and Electronics Industry - Design Research Institute and the Northern Design Research Institute. Drafting. The main drafters of this standard are Chen Zaizhu, Li Xianfu, Jing Shuang and Huang Xiaolin. 312
16mir
1.50
1.50
1.50
1.50
1. 9
2.36
3.0
3.75
4.75
6. 0)
7.5
9.5
11.8
15.0||tt| |19.0
23.6
30.0
87.5
45.7
60.0
m/s
Imin||tt| |2.
2. 0)
2.0
2.0
2. 5
3.15
.(
5.0
6.3
8.0
10.t
12.5
16.0
20.03
25.0
31.5
40.0
50.0
63.0
80.
-- -
0
25.t
31.5
40.0
50.0
This standard is issued by the Ministry of Machinery and Electronics Industry - Design Research Institute and the Northern Design Research Institute. Drafting. The main drafters of this standard are Chen Zaizhu, Li Xianfu, Jing Shuang and Huang Xiaolin. 312
16mir
1.50
1.50
1.50
1.50
1. 9
2.36
3.0
3.75
4.75
6. 0)
7.5
9.5
11.8
15.0||tt| |19.0
23.6
30.0
87.5
45.7
60.0
m/s
Imin||tt| |2.
2. 0)
2.0
2.0
2. 5
3.15
.(
5.0
6.3
8.0
10.t
12.5
16.0
20.03
25.0
31.5
40.0
50.0
63.0
80.
-- -
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