EFFECTIVE OPERATION AND MAINTENANCE
PROCEDURES FOR CONTROL OF EMISSIONS
FROM WET-COAL CHARGING, TOPSIDE
LEAKS, AND DOOR LEAKS
PEDCo ENVIRONMENTAL
-------
EFFECTIVE OPERATION AND MAINTENANCE
PROCEDURES FOR CONTROL OF EMISSIONS
FROM WET-COAL CHARGING, TOPSIDE
LEAKS, AND DOOR LEAKS
by
PEDCo Environmental, Inc.
11499 Chester Road
Cincinnati, Ohio 45246
Contract No. 68-02-3546
Work Assignment No. 16
PN 3530-16
EPA Task Manager
Mr. Lee Beck
U.S. ENVIRONMENTAL PROTECTION AGENCY
EMISSION MEASUREMENT BRANCH
EMISSION STANDARDS AND ENGINEERING DIVISION
RESEARCH TRIANGLE PARK, NORTH CAROLINA 27711
March 1983
-------
CONTENTS
Page
Figures iii
Tables v
1. Introduction 1-1
2. Major Variables Affecting Emissions 2-1
2.1 Process description 2-1
2.2 Charging and topside 2-5
2.3 Doors 2-37
2.4 Recordkeeping 2-53
References for Section 2 2-63
3. Inspection Procedures 3-1
3.1 Preparing for inspection 3-1
3.2 Safety considerations 3-2
3.3 Emission observation 3-5
3.4 Onsite inspection 3-9
3.5 Inspection report 3-14
Appendix A - Stage Charging Procedures and Coke Oven Job Functions
and Written Maintenance Procedures for Charging and
Topside A-l
Appendix B - Effect of Stage Charging on Tar Quality B-l
Appendix C - Pressure Regulating Systems C-l
Appendix D - Coke Oven Job Functions for Doors D-l
Appendix E - Occupational Health and Safety Standards E-l
Appendix F - Method 109 Determination of Visible Emissions from Coke
Oven Batteries F-l
Appendix'G - Example Inspection Forms G-l
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FIGURES
Number Page
2-1 Major Design Variables in the Charging Process 2-3
2-2 Blocked Gas Passages Due to Excess Coal Charged from
Early Car Hoppers 2-10
2-3 Drop Sleeve Placement During Charging 2-11
2-4 Butterfly Damper Arrangement in Charging Hopper 2-13
2-5 Percent Air Flow vs. Percent Gooseneck Area Open 2-14
.2-6 Automatic Mechanical Gooseneck Cleaner 2-15
2-7 Automatic Gooseneck Cleaner Using High-Pressure Water
Sprays 2-16
2-8 Combination Jumper Pipe/Crossover Pipe and Jumper Pipe 2-18
2-9 Restricted Gas Passages Due to Improper Leveling, Excessive
Roof Carbon Buildup, and Overloading Coal Hoppers 2-21
2-10 Effect of Free-Space Temperature on Carbon Formation 2-24
2-11 Various Designs for Goosenecks and Steam Aspiration
Locations 2-26
2-12 Gas Flow Rates Associated with the Various Gooseneck Con-
figurations Presented in Figure 2-11 2-26
2-13 Nozzle Pressure vs. Aspiration Capacity for Single
Standpipe 2-27
2-14 Lid and Standpipe Cap Alternatives 2-34
2-15 Major Design Variables in Coke Oven Doors 2-38
2-16 Major Coke Oven Door Components 2-41
2-17 Major Chuck Door Components 2-42
m
-------
FIGURES (continued)
Number Page
2-18 Exaggerated Examples of Variations in Contours of Jambs and
Door Frames 2-46
2-19 General Arrangement of Door Cleaning Rack 2-47
2-20 Visible Coke Plant Emissions at 143-Oven Installation 2-55
2-21 Example Checklist for Battery Turn Foreman 2-56
2-22 Example of a Door Leak Report 2-58
2-23 Example Form for Monthly Battery Top Inspection 2-59
2-24 Example Form for Weekly Liquor Spray Inspection 2-60
2-25 Example Form for Monthly Gooseneck/Standpipe Inspection 2-61
2-26 Example Form for Quarterly Door Plug Inspections 2-62
3-1 Charging Time Study Form 3-6
3-2 Charging Emissions Data Form 3-7
3-3 Larry Car Inspection Form 3-8
iv
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TABLES
Number Page
2-1 Variables Affecting Charging Emissions 2-6
2-2 Variation in Coal Charge Weight 2-8
2-3 Collecting Main Pressures 2-19
2-4 Distance of Coal Charge from Oven Roof Measured from
Charging Holes 2-22
2-5 Variables Affecting Door Emissions 2-39
3-1 State and Alternative Regulations Governing Emissions from
Charging, Doors, and Topside of Coke Ovens 3-3
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SECTION 1
INTRODUCTION
The purpose of this document is to provide practical guidance to inspec-
tors charged with the responsibility of determining how well coke oven batter-
ies perform with regard to control of emissions from wet-coal charging, door
leaks, and topside leaks and evaluating the operation and maintenance (O&M)
procedures that coke oven batteries use to achieve emission control. Control
performance for these sources is indicated by visible emissions, which are
controlled by O&M practices. Because there are generally no equipment stan-
dards per se, and no mass emission standards, the inspector's job is far more
complicated than for most other emission sources.
This document is intended to enable the inspector not only to perform a
thorough inspection by proper use of visible emission observation methods, but
also to evaluate the various O&M practices at the battery to ascertain the
relationship between O&M variables and the observed emissions. The inspector
must also be able to determine if operating conditions during the inspection
are representative.
The EPA has developed information and data on alternative control tech-
niques for controlling coke oven emissions arising from wet coal charging,
door leaks, and topside leaks. A draft Background Information Document (BID)
that describes these control techniques and the achievable levels of control
has been developed.* This document thoroughly describes the emission sources,
the character of the emissions, the control technologies, and the costs of
control. Some of the levels of achievable emissions and formats in which
these levels are written are similar to existing emission limits in consent
decrees and State Implementation Plans (SIP's).
* Coke Oven Emissions from By-Product Coke Oven Charging, Door Leaks, and
Topside Leaks on Wet-Coal Charged Batteries - Background Information for
Proposed Standards. Draft. U.S. Environmental Protection Agency. July
1981.
1-1
-------
This document borrows from the BID where appropriate, but is generally
intended to supplement the BID in the particular area of coke oven inspection
and evaluation. It is recommended that the reader become familiar with the
BID prior to using this current document, because it contains much valuable
background information that cannot be repeated here.
This document has three basic components: Section 2 is intended to help
the inspector understand the O&M variables affecting emissions and to become
aware of general plant recordkeeping procedures; Section 3 provides guidance
for conducting the actual inspection; the appendices present typical coke oven
job descriptions, specific visible emission methods, and OSHA safety procedures
required around coke ovens.
1-2
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SECTION 2
MAJOR VARIABLES AFFECTING EMISSIONS
Many variables affect emissions from coke oven charging, topside sources,
and coke oven doors. These include design variables, operating practices, and
maintenance practices. After a brief process description (Subsection 2.1),
this section presents the major variables affecting charging and topside
emissions (Subsection 2.2) and door emissions (Subsection 2.3). Coke oven
operation and maintenance recordkeeping is discussed in Subsection 2.4.
2.1 PROCESS DESCRIPTION
Nearly all metallurgical and foundry (merchant) coke is made in byproduct
ovens. Coal is heated in the absence of air, which drives off most of the
volatile matter, part of the sulfur, and the contained moisture. The outgoing
gases from this process are collected as byproduct gas. About 90 percent of
the residue is carbon, and the remainder is ash and sulfur. After it is
screened, this metallurgical coke is either sent to the blast furnace or
shipped to end users (e.g., cupola operations).
Older ovens are generally 9 to 12 meters (30 to 40 feet) long, 1.8 to 4.3
meters (6 to 14 feet) high, and 0.28 to 0.56 meter (11 to 22 inches) wide.
More recent ovens are 17 meters (55 feet) long, 4 to 6 meters (13 to 20 feet)
high, and about 0.46 meter (18 inches) wide. As many as 70 to 100 ovens may
be grouped together in a battery to facilitate charging the coal into the
ovens and pushing out the coke produced when the coking process is complete.
The coal is charged through three or four charging holes situated in a
row on top of each oven. The coal is carbonized in a reducing atmosphere for
15 to 18 hours to produce coke for the blast furnace. The coal for this
application typically is a blend of coals with an average volatile content
(not counting moisture) of around 30 percent. Flue temperatures run about
2200° to 2400°F. Foundry coke is produced in the same general fashion, but
with coal blends averaging about 2:5 percent volatile matter, flue temperatures
2-1
-------
of 1800° to 2200°F, and longer coking times (24 to 36 hours). The ovens are
heated indirectly by burning cleaned coke oven gas in the combustion chambers
on both sides of the oven. Combustion air is preheated by passing it through
a brick regenerator located under the battery.
The gases released during carbonization are ducted to the byproduct
plant, where useful byproducts such as tar, ammonia, and light oil are recov-
ered from the gas. This cleaned gas is used for combustion in the coke ovens
and in other fuel-burning units in the steel plant.
When the coke is ready, the doors on both sides of the oven are removed
and a ram mounted on a pusher machine pushes the hot coke into a receiving
quench car. The quench car takes the coke to a quench tower, where it is
cooled with water sprays.
This document is specifically concerned with the battery operation, which
generates charging, topside, and door emissions. Other emission sources
within the coke plant that are addressed in proposed or existing regulations
are coke pushing, battery stacks, quenching, coal and coke handling, various
byproduct operations, hydrogen sulfide (hUS) in coke oven gas, and fugitive
emissions from roadways and storage piles.
A more complete description of coke plant operations may be found in the
BID.
2.1.1 Emissions and Process Variables
Charging, topside, and door emissions all occur for the same fundamental
reason—a coke oven battery must be operated under positive pressure (however
slight) to prevent the infiltration of oxygen. If the battery could be oper-
ated under sufficiently high vacuum, no emissions would occur. The central
theme in control, therefore, is 1) maintaining the seal of all openings, and
2) balancing the pressure at various points in the battery. Although this
becomes complicated in practice, these are the dominant factors to be consid-
ered.
First-level process variables are those dealing with differences between
plants. Although a given inspector probably will not be confronted with the
full variety of plants, it is helpful to be aware of the major differences.
Figure 2-1 depicts the major design variables in charging processes throughout
the coke oven industry. The shaded topics are not covered in this manual.
2-2
-------
ro
i
CO
CHARGING
WET
STAGE CHARGING
(SEQUENTIAL
-3 HOPPER CARS
r4 HOPPER CARS
-SINGLE COLLECTING MAIN
-DOUBLE COLLECTING MAIN
CHARGING)--SHORT OVENS (3-4 M)
-TALL OVENS (5-6 M)
-3 HOLE OVENS
L4 HOLE OVENS
CAR SCRUBBERS^
;TOP ENTRY PIPELINE ^
^SIDE ENTRY PIPELINED
LARRY CAR
Figure 2-1. Major design variables in the charginq process.
-------
Design variables are defined as factors that can vary from one battery to
another; on a given battery, such factors are fixed. Oven height is the only
design variable that the draft BID for charging takes into account. Statis-
tical analysis of emission data revealed that other design variables do not
significantly affect performance.
Successful control of emissions from charging is more dependent on
adherence to specified operating procedures than on equipment design. The
proper O&M procedures for control of charging and topside emissions are de-
scribed in Section 2.2, O&M procedures for control of door emissions are
described in Section 2.3, and plant recordkeeping procedures are presented in
Section 2.4.
2.1.2 Level of Operation
The level of operation can alter the effectiveness of emission control
in several important ways:
0 High-capacity operation, i.e., coking time at or near the minimum,
simply allows less time for conducting the meticulous procedures of
stage charging, door inspection, and repair.
0 High-capacity operation allows less time for maintenance of doors
and other equipment, which is required for continued effectiveness.
0 High-capacity operation requires higher oven temperatures, which
result in higher gas evolution rates.
0 Increasing the level of operation means there will be more new or
junior employees who are not as skilled either in control procedures
or maintenance. Additional staffing during high production levels
can only partially compensate for faster coking times.
0 Demand for coke may cause the operators to increase coal charge
weights, which decreases the tunnelhead in the oven and makes
control of charging emissions more difficult.
0 Higher operating temperatures cause greater gas decomposition,
increase the time required for door sealing, and result in more and
harder deposits. Lower temperatures decrease sealing time and
result in softer tar deposits.
As these factors indicate, effective emission control is made more difficult
at high operating rates. An effective O&M plan should provide for maintaining
control at high operating rates.
2-4
-------
2.2 CHARGING AND TOPSIDE
The emissions from charging and topside operations and the control of
these emissions are highly dependent on the coordinated activities of the
topside crew. These factors will be discussed with respect to charging in
Section 2.2.1 and to topside emissions in Section 2.2.2.
2.2.1 Charging Emissions
Discussion in this document is limited to the control of charging emis-
sions by the practice of stage charging. The key elements of stage charging
are the controlled discharge of coal into the oven from one hopper at a time
(or with some overlap, from two hoppers) and steam aspiration to draw the
gases into the collecting main. A detailed example of the steps involved in
stage charging is given in Appendix A. This section focuses on the most
important variables that influence emissions and how an inspector can evaluate
these variables.
As shown in Table 2-1, the effectiveness of stage charging in minimizing
charging emissions depends on many variables. The most important parameters
are as follows:
0 Aspiration steam pressure
0 Coal discharge rate
o
o
o
Standpipe open area
Lid removal and replacement procedure
Chuck door sealing (leveling bar opening in oven door)
Aspiration steam controls suction, and it is equivalent to fan capacity
in a conventional evacuation system. Coal discharge rate controls the gas
generation rate, and it cannot exceed suction capacity or smoke will escape
through other available openings, taking the path of least resistance. The
Standpipe open area directly affects the gas-carrying capacity of the stand-
pipe. As an integral part of the exhaust duct, the Standpipe, gooseneck, and
oven tunnel head* must all be kept clean of tarry deposits.
The last two variables in the list, the lid opening and the chuck door
opening, control the tightness of the evacuation system. Any openings other
than the one through which coal is being charged allow tramp air to enter the
oven and overload the gas withdrawal system. The chuck door opening is most
* Space at the top of the oven between the top surface of coal and the oven
roof, i.e., free space.
2-5
-------
TABLE 2-1. VARIABLES AFFECTING CHARGING EMISSIONS
Design Variables
Larry car design
Single or double collecting main
Standpipe, gooseneck design
Oven height
Number of charging holes
Flushing liquor spray nozzle design
Steam aspiration nozzle design
Automatic goosneck cleaning device
Leveling bar smoke seal (boot) -
Coal Variables
0 Coal moisture
0 Coal bulk density
0 Coal volatile matter
0 Coal grind
Operating Variables
Coal discharge rate -
Oven temperature
Steam aspiration pressure -
Collecting main pressure
Leveling procedure
Roof carbon buildup
Level of operation
Human Variables
Lid removal/replacement -
0 Coal dumping sequence
0 Coordination of larry car operator, lidsmen, and pusher
operator
o
Standpipe cleaning - Standpipe open area -
2-6
-------
critical on a battery with a single collecting main, especially when the
collecting main is on the pusher side. In this case, there is a direct "short
circuit" from the chuck door opening into the standpipe.
In the following sections, these five variables and the interrelated
variables in Table 2-1 will be discussed as to their effect on charging emis-
sions. In evaluating O&M practices at a given battery, the inspector must
keep in mind that there is no best single method. Many plants have developed
specific procedures that they find effective for their particular circumstanc-
es. In every case, however, a systematic approach must be used to evaluate
the effectiveness of charging control on emissions.
Larry Car Design--
Larry cars have either three or four hoppers. Three hopper cars are used
in two situations: on ovens with three charging holes and on ovens where one
hopper has been removed to accommodate a jumper pipe. Whether three or four
are used, hoppers must be designed to hold varying portions of the charge so
as to avoid blocking the gas passageway at the top of the oven when the coal
is discharged. The exact proportion in each hopper depends on the angle of
repose of the coal, the specific dimensions of the oven, and the charging
sequence used. On most batteries, the bulk of the coal is placed in the outer
two hoppers. The third or middle two hoppers are used for topping off the
charge.
Plants must experiment to find the right proportions of coal for each
hopper. The hoppers must have coal level measuring rings to enable the oper-
ator to achieve the proper coal level in each hopper when loading. The rings
must be adjustable to account for minor changes in relative proportions as
coal bulk density changes with the use of different coals or changes occur in
the plant's density control. Table 2-2 presents the variation in coal charge
weights reported at one plant as an example. Typical proportions of coal
in each hopper for a four-hopper car are 33.5 percent in Hoppers 1 and 4, 20
percent in Hopper 2, and 13 percent in Hopper 3. (Hoppers are typically
numbered from pusher side to coke side.) In a three-hopper car, typical
proportions are 50, 35, and 15 percent.
The inspector cannot accurately check the actual proportions of coal, but
he/she should observe the coal level in the hoppers on several charges to
determine both proper level and consistency from charge to charge.
2-7
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TABLE 2-2. VARIATION IN COAL CHARGE WEIGHT'
Month
January
February
March
April
May
June
July
August
September
October
November
December
Coal charge weight,
tons/oven
14.0
14.7
14.5
14.1
14.0
13.8
NAb
13.9
14.8
15.2
15.2
15.2
Reference 1.
NA = not available.
2-8
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Figure 2-2 illustrates blockage of the gas passage due to excess coal in
Hopper 1. The problem is exacerbated if both Hoppers 1 and 4 are overloaded,
for then there is no escape for the gases except through the Number 2 and 3
charging ports.
Whether three or four hoppers are used, the essential features of a larry
car are as follows:
0 Drop sleeves that can be raised and lowered independently of one
another
0 Stainless steel hoppers, and/or hopper agitators to effect coal
discharge
0 A reaming device for cleaning tar deposits from the gooseneck and
standpipe
0 An arrangement to effect double drafting (on a single collecting
main battery), i.e., a jumper pipe
Drop Sleeves--
Drop sleeves on each hopper provide containment between the bottom of the
hopper and the battery top. The drop sleeves must be raised while the larry
car is in motion so they don't drag on the battery top. If they are not in a
full up position during travel, they may be damaged. They also may catch on
the lids and dislodge them. Once in position, the drop sleeves should align
perfectly with the charging holes;. Although this seems simple enough, various
problems can occur, as illustrated in Figure 2-3.
Proper larry car alignment is a function of operator skill and attention.
Better larry cars are equipped with electrical controls that enable the car to
creep and spot very accurately.
The condition of the battery top can also affect alignment. Warpage and
shifting of top brick and the rails on which the larry car rides can cause
various alignment problems on one or more ovens. This condition can also
cause the lid frame to distort. Oversized drop sleeves can be used in this
situation to minimize emissions due to drop sleeve and lid frame misalignment.
As shown in Figure 2-3, a flexible "donut" or gasket also can be used on the
bottom of the drop sleeve to accommodate misalignment. These gaskets are
relatively fragile and must be replaced when torn or damaged. A survey con-
ducted by the Association of Iron and Steel Engineers in 1978 indicated that
most drop sleeves are hydraulically operated and are not, in themselves, a
2
high maintenance item.
2-9
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STANDPIPE
BLOCKED GAS
PASSAGE
STANDPIPE
EMISSIONS
.1 I,
Figure 2-2. Blocked gas passages due to excess coal
charged from early car hoppers.
2-10
-------
DROP SLEEVE
CHARGING HOLE
RING CASTING
OVEN TOP
CORRECT ALIGNMENT
DROP SLEEVE GASKET
TO AID IN SEALING
OVERSIZED DROP SLEEVE
TO COMPENSATE FOR
MISALIGNMENT OR WARPAGE
CORRECT
ro
i
COAL SPILLAGE AND
-EXTENDED DISCHARGE TIME
GAP
GAP
MISALIGNED DROP SLEEVE
DUE TO INDIVIDUAL HOLE
MISALIGNMENT OR IMPROPER
SPOTTING OF LARRY CAR
FAILURE OF DROP
SLEEVE TO LOWER
COMPLETELY
TOPSIDE BRICK
SHIFTING
INCORRECT
Figure 2-3. Drop sleeve placement during charging.
-------
Independent operation of drop sleeves enables each sleeve to be raised
for lid replacement while the other sleeves remain seated. An alternative is
the use of a butterfly damper in the hopper discharge. If a small amount of
coal is left on the damper, this, in effect, provides a second "lid"; this is
illustrated in Figure 2-4.
To evaluate alignment, the inspector must closely observe each drop
sleeve as it is seated over the charging hole. After the larry car pulls off,
there should be very minimal coal spillage (less than a few handfuls). As
discussed more fully later, the lidsmen should sweep this coal into the oven
while the aspiration steam is still on. Coal spillage left on top of the oven
can eventually get hot enough to smolder and generate emissions. Some larry
3
cars are equipped with vacuum cleaners to pick up coal spillage.
Coal Discharge--
Coal discharge from the hoppers should be smooth, rapid (15 to 25 sec-
onds), and uniform. If coal hangs up, it lengthens overall charging time,
thus increasing the likelihood of emissions. Two types of discharging, gravi-
ty and screw feeding, are utilized; either is acceptable. Stainless steel
hoppers provide a smoother surface for coal discharge. The hoppers can also
be equipped with vibrators or other types of agitators to move the coal if
necessary.
Gooseneck and Standpipe Cleaning--
The standpipe and gooseneck assembly is essentially the duct for exhaust-
ing the gases generated during charging. As such, deposits that reduce the
effective diameter of this "duct" will increase resistance to flow and cause
the charging gases to seek other paths of escape, i.e., lids and doors.
Figure 2-5 illustrates the effect of deposits on the reduction of gas
flow. Cleaning must be done before every charge to maintain a clear opening.
Cleaning the standpipe and gooseneck is usually accomplished from the larry
car.
The longer the deposits remain, the more difficult they are to remove.
Figure 2-6 illustrates a mechanical gooseneck cleaner and Figure 2-7 illus-
trates a high-pressure-water gooseneck cleaner. In addition to an automatic
device, the larry car operator should clean deposits from the standpipe cap
and seat with a cutting tool. When observing manual standpipe cleaning, the
inspector should note whether the operator is thorough and spends sufficient
2-12
-------
CHARGING HOPPER
COAL ACTING AS SECOND LID
CHARGING HOLE RING CASTING
DISCHARGE HOPPER
OVEN TOP
Figure 2-4. Butterfly damper arrangement in charging hopper.
2-13
-------
ro
100
90
80
i 70
<:
UJ
£ 60
CJ
50
o
S 40
30
20
10
0
I
I
L
0 10 20 30 40 50 60 70
% OF MAXIMUM AIR FLOW
80
90
100
Figure 2-5. Percent air flow vs. percent gooseneck area open.
-------
.CLEANING TIP
ANCHORED TO LARRY CAR
Figure 2-6. Automatic mechanical gooseneck cleaner.
2-15
-------
SPIN JET CARRIAGE
IN RETRACTED f"
POSITION— JLf
I I
U
II
'I
II
II
|l
il
SPIN JET CARRIAGE IN
POSITION FOR CLEANING
VERTICAL STAND PIPES
SPIN JET CARRIAGE
IN RETRACTED
POSITION-
NOZZLES IN
CLEANING
POSITION
•SPIN JET CARRIAGE IN
EXTENDED POSITION FOR
CLEANING GOOSENECKS
Figure 2-7. Automatic gooseneck cleaner using
high-pressure water sprays.
(National Liquid Blasting Corporation)
2-16
-------
time to clean both the standpipe and the seating surface. After cleaning is
completed, the lid should be closed, tamped to ensure seating, and luted with
an effective luting compound. All the required cleaning and tamping tools and
the luting compound must be on the car at all times. One plant has also built
a raised platform on the car to permit the operator to make a better examina-
5
tion of the gooseneck.
Double Drafting--
Batteries with two collecting mains inherently have double drafting. The
jumper pipe, or fifth hole, was devised to simulate double drafting on single
main batteries. A crossover pipe can be used with a jumper pipe to add an
additional passageway for gases to reach the collecting main. Two of the
various schemes currently in use are illustrated in Figure 2-8. All the ap-
proaches require the larry car operator to follow a set procedure for their
proper utilization. Jumper pipes must be aligned over the charging holes and
seated tightly.
Even with a jumper pipe, drafting or pressure control on the battery is a
complex process. Several coke plants use a common exhauster for multiple
batteries. The distance of each battery (and each oven within the battery)
from the source of suction influences the pressure at various locations. The
points farthest from the exhauster tend to have a higher oven pressure and
consequently are more difficult to control from the standpoint of emissions.
Some plants try to maintain collector main pressures at essentially zero, but
most operate in the range of 5 to 12 mm H^O. Table 2-3 presents data show-
ing acceptable variations taken at a relatively new (1977) coke plant with a
double collecting main and 6-meter batteries. The inspector should observe
and evaluate the uniformity of oven pressure in conjunction with observing the
charging.
Other Larry Car Features--
Other features of larry cars beyond the basic requirements already de-
scribed can be added to improve performance. These include:
0 Magnetic lid lifters
0 Interlocks to control sequence of charging
0 Butterfly valves in the hoppers to maintain a coal seal after hopper
discharge
2-17
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ASCENSION PIPES
NO.3
NO.5
LARRY HOPPERS 4
STEAM ON
CROSSOVER PIPE r.«.
O
OJUMPER PIPE
O
O
LEVEL
DOORS
OVEN
DOORS
COMBINATION JUMPER PIPE/CROSSOVER PIPE
COLLECTOR MAIN
ASCENSION PIPES
NO.3
NO.5
LARRY HOPPERS 4
STEAM
LEVEL
DOORS
OVEN
DOORS
JUMPER PIPE
Figure 2-8. Combination jumper pipe/crossover pipe and jumper pipe.
-------
TABLE 2-3. COLLECTING MAIN PRESSURES'
Date
(1981)
10/27
10/27
10/28
10/28
10/29
10/29
10/30
10/30
Time
09:10 - 11:14 a.m.
01:55 - 04:24 p.m.
09:47 - 11:58 a.m.
02:35 - 05:18 p.m.
09:40 - 11:37 a.m.,
01:50 - 03:54 p.m.,
09:30 - 11:35 a.m..
02:'38 - 04:41 p.m..
Push side,
mm HpO
7.5
7.0
8.0
8.0
8.0
8.0
8.0
8.0
Coke side,
mm H20
7.5
8.0
7.0
10.0
7.5
7.0
7.0
7.5
2-19
-------
Magnetic lid lifters reduce the lidsman's workload, allow the larry car
operator to control the entire operation of charging, and permit the use of
heavier lids with less warpage and better sealing. Generally, magnetic lid
lifters have not received wide acceptance, however, because they increase the
maintenance workload. Where used, luting must be applied carefully so as not
to spill luting compound on the lid itself because it can interfere with the
magnetic grip required to manipulate the lids.
Interlocks and butterfly valves can also improve charging performance.
Interlocks on larry cars can prevent more than one hopper from being dis-
charged at one time or control the sequence of coal flow from the hoppers.
Butterfly valves in the coal discharge hopper are useful to seal the hopper
opening after discharging and prevent emissions. A typical arrangement was
shown previously.
Leveling Procedures--
The leveling procedure is critical to avoiding emissions during charging.
If the leveling practice is faulty, emissions usually occur as the last hopper
is dropped, which indicates loss of the tunnel head. Leveling should start as
the last hopper is charged to maintain a gas passageway. The inspector should
note both the start of leveling and the uniformity of the leveling procedure
from one charge to another. Charging and leveling procedures should not vary
from charge to charge unless major changes have been made such as different
coal mixes or bulk density changes. Figure 2-9 depicts some problems caused
by improper leveling. Table 2-4 shows the effect of leveling and the limited
distance the operator has to work with between the coal peaks and the top of
the oven roof. Both the coal volume in each hopper and the leveling procedure
must be maintained in a very narrow range to avoid puffing at the end of the
charge. The proper procedure, mainly number and length of leveling strokes,
must be developed by trial and error at each plant. Many plants use scale
models of the oven to aid in this procedure.
When the chuck door is opened for leveling, it allows tramp air to aspi-
rate into the oven, which causes a higher load on the aspiration system. The
leveler bar on the chuck door should be outfitted with a seal (or "boot") to
seal the chuck door opening. This boot should latch onto the door or have
some other arrangement to keep it in place as the bar is moved back and forth.
The inspector must check this operation either from the ground or the pushing
machine. If emissions escape from the chuck door, the gas may ignite, which
2-20
-------
pz!4
vin vni v/n-a:
CORRECT TUNNEL HEAD
INCOMPLETE LEVELING OR
IMBALANCE IN COAL DISTRIBUTION
V//A
21 t'yj
EXCESSIVE ROOF CARBON BUILDUP
OVERLOADING COAL HOPPERS
Figure 2-9. Restricted cias passages due to improper leveling,
excessive roof carbon buildup, and overloading coal hoppers.
2-21
-------
TABLE 2-4. DISTANCE OF COAL CHARGE FROM OVEN ROOF MEASURED FROM
CHARGING HOLES1
(inches)
Charging hole designation3
After dropping No. 3 hopper
After leveling
No. 1
-
17
No. 2
107
21
No. 3
3
19
Smoke hole
-
28
The Number 1 charging hole is closest to the pusher side of the battery,
and the smoke hole is next to the coke side of the battery.
Hole to which jumper pipe is connected.
2-22
-------
eventually can create further problems with chuck door sealing by warping or
cracking the chuck door or jamb.
Roof Carbon--
As hydrocarbons evolve during the coking process, they deposit on the
roof of the oven. Because these deposits diminish the area of the gas passage-
way, they increase resistance to flow of the gas into the standpipe(s). This
is illustrated in Figure 2-9. Consequently, the likelihood of door emissions
and lid emissions increases. The formation of roof carbon buildup has been
studied to determine the rate of formation. Figure 2-10 shows the effect of
o
free space temperature on carbon formation. The formation of carbon on the
test probe used to determine the rate of roof carbon buildup is expressed in
equivalent inches of carbon. This; unit expresses the nonuniform (varying
thickness) buildup of carbon as a perfectly uniform (constant thickness) de-
posit of carbon on the test probe. Higher free space (tunnel head) tempera-
tures are caused either by higher flue temperatures or underfilling of the
oven (which exposes additional hot. wall area). Good operating and maintenance
practice for the oven heating system can reduce carbon buildup. The O&M plan
should provide for regular cleaning of gas guns, checks on flue gas tempera-
ture and excess air, daily checks of oven flue temperatures, and observation
of ovens when empty for cold spots. In practice it is relatively simple to
maintain an adequate level of control on excessive buildup by the use of roof
carbon scrapers and compressed-air jets mounted on the pusher ram. As the
coke is pushed, these devices remove the buildup prior to the next charge.
Maintenance of this equipment and inspection of the oven prior to door replace-
ment is necessary for good performance. A survey of coke plant operators in
1978 indicated that decarbonizing air pressure and flow varied from 80 to 140
p
psi and 54 to 230 scfm, respectively. It is not necessary for the inspector
to obtain these values at a plant. Rather, he/she should determine that air
is being used and that the equipment is in working order. The oven should be
observed while the doors are off to detect excessive roof carbon buildup.
Aspiration Steam Pressure—
Aspiration is provided by injecting either high-pressure steam or waste
ammonia liquor into the gooseneck. The use of steam predominates in the
United States. This practice essentially converts the gooseneck into a crude
2-23
-------
ro
ro
to
0,5
0.70
0.60
0.50
0.40
>
'5 0.30
£> 0.20
0.10
I
HOLE 1
HOLE 2
I HOLE 3
'HOLE 5
I
I
I
I
1300 1400 1500 1600 1700 1800
AVERAGE FREE SPACE TEMPERATURE AT HOLE, °F
1900
Figure 2-10. Effect of free-space temperature on carbon formation.8
-------
hogging ejector utilizing the Bernoulli effect to create a vacuum. Figure
2-11 illustrates several gooseneck designs showing the location of the steam
jets used for aspiration and the liquor sprays used to cool the raw oven gas.
Figure 2-12 illustrates the gas flow rates associated with the different
configurations.
The major variables associated with aspiration are:
0 Steam nozzle placement and nozzle diameter
0 Steam aspiration pressure
Once the location and number of jets have been selected, it is expensive
to relocate the nozzles because the standpipe or gooseneck would have to be
modified. Nozzle diameter, which is relatively easy to change, is determined
by experiment. Figure 2-13 illustrates the effect of nozzle diameter on
aspiration capacity at a given steam pressure. Most plants have determined
the most effective nozzle diameter and placement for their batteries.
Steam pressure must be monitored continually to maintain the pressure
determined to be necessary for smokeless charging. Most plants find a pres-
sure of 90 to 125 psi necessary for effective stage charging. This pressure
should be measured in the steam header on top of the battery, not at some
distant point in the steam supply line. Obviously, too low a pressure will
reduce aspiration capacity and increase emissions. Too high a pressure is
undesirable because it results in excessive carryover of coal fines into the
collecting main. This in turn impairs tar quality and its value as a by-
product. Excessive steam also creates high moisture content in the tar, which
is undesirable. The quantitative effect of stage charging on tar quality
and moisture based on a survey of coke plants is given in Appendix B.
Static pressure in the offtake during charging should be in the range of
-1.0 in. H90 to -4.5 in. H90 to avoid puffing during the
7
charge. Pressure is not usually monitored in the offtake, however, but
rather in the collecting main. Pressure in the collecting main is kept close
to zero, just slightly positive.
Steam nozzles must be checked at least once a week for plugging and
erosion. This is normally done by a pipefitter who removes, inspects, and
replaces defective nozzles. On every charge, the lidsman can make a quali-
tative check by listening to the steam as it is turned on; a defective nozzle
will have a different sound. One plant has installed a positive method for
2-25
-------
STEAM
STEAM
in
STEAM
Figure 2-11. Various designs for goosenecks and steam
aspiration locations.
2000
1800
1600
1400
1200
1000
800
600
400
200
0
T T
J I
STEAM TEMPERATURE
500°F AT 200 PSIG
J I
22 30 38 46 54 62 70 THRUST LBr
0 20 40 60 80 100 120 140 160 180 PRESSURE PSIG
STEAM
Figure 2-12. Gas flow rates associated with the various
gooseneck configurations presented in Figure 2-11.
2-26
-------
o
to
1300
1200
1100
1000
900
£ 800
700
O-
•X.
* 600
ex.
500
400
300
200
I I
I
I
I I I I I I
3/4 inch
NOZZLE DIAMETER
I
I
I
I
10 20 30
40 50 60 70 80
NOZZLE PRESSURE, psig
90 100 110 120
Figure 2-13. Nozzle pressure vs. aspiration capacity for single standpipe.4
2-27
-------
ensuring steam flow detection. It consists of a tap on each line that allows
both a visible and audible steam jet to be observed. This method not only
indicates that the steam is on for charging but also helps the operator remem-
ber to turn the steam off after charging. Failure to turn the steam off
increases pressure variation in the collecting main(s), which can degrade
charging control.
In practice, a defect in the aspiration system for a single oven probably
cannot be corrected for the charge on which it is detected; however, it should
be corrected prior to the next charge. No defect should be permitted to
affect two charges in a row on the same oven.
Steam should be on an oven at any time one of the ports is open during
coking. This includes the charging period itself and post charging activities
including opening of lids to sweep coal into the oven and/or opening of the
chuck door for releveling.
Lid Removal/Replacement--
Lid handling is simple but extremely important because the openings
provide both a large escape port for emissions and an aspiration port for
tramp air to enter the system. The latter not only overloads the aspiration
system, but also causes higher oxygen content in the coke oven, which dilutes
heating value.
The procedure for removing and replacing the lids is an integral part of
the stage charging procedure. Two practices are used. In one case, all four
lids are removed and the drop sleeves are lowered to provide a seal. The
stage charging procedure is followed, and the lids are replaced as each hopper
is emptied. In the other practice, one lid is removed at a time, the drop
sleeve is lowered, and the lid is replaced after the drop sleeve is raised.
In either case, the primary factors of importance are:
o
Coordination of the lidsman and larry car operator
0 Efficient and timely execution by the lidsman
The lid should be pulled far enough away from the hole so that it does
not interfere with the drop sleeve. When the lid is replaced, it should be
seated firmly and squarely. If the lidsman does not get the lid in place the
first time, he/she should work with the lid until it is seated properly.
After the charge is completed the lid should be promptly and thoroughly
luted.
2-28
-------
Oven Pressure Control--
Because oven pressure control is such a critical factor for both oven
operation and emission control, a complete discussion is provided here.
Oven pressure during the coking cycle-- Coke oven gas pressure is not
uniform at all points or at all times. At the start of coking, the gas
evolves rapidly as the coal comes in contact with the hot brickwork, and the
gas pressure in the oven is at its maximum. The rate of evolution of the gas
(and hence the pressure) decreases rapidly for a short period and continues to
decrease gradually until the end of the coking period.
At the start of the coking period the pressure is higher at the bottom of
the oven than at the top because of the resistance the charge of coal offers
to the copious flow of gas. Toward the end of the coking period it is lower
because more free space is available for flow of the reduced volume of gas,
and the stack effect of the heated gas then becomes a controlling factor in
determining the pressure. Regulating the gas pressure individually in each
oven throughout the coking period would be impractical. Control is exercised
by maintaining a constant pressure on the collecting main, which ensures the
same pressure cycle in each oven throughout its coking period. The pressure
in the collecting main is usually held at a point that will provide a neutral
or slightly higher than atmospheric pressure in the bottom of the oven at the
end of the coking period.
The above conditions exist in either a single or double collecting main;
however, where double collecting mains are installed, one on each side of the
battery, the gas is removed from both ends of the ovens simultaneously. This
arrangement provides a more uniform gas pressure in the ovens throughout the
coking period, and lessened exposure of the gas to the high temperatures in
the space at the top of the ovens..
Control pressure valves used—The gas must be withdrawn from the oven as
rapidly as it is produced. Gas under pressure in an oven leaks through joints
in the brickwork into the combustion system and interferes with control of
heating. Conversely, when the pressure in an oven is reduced below that in
the flues, inleakage of air or waste gas affects the quality of the coke-oven
gas. It is therefore desirable to effect a balance between the pressure in
the ovens and the pressure in the combustion system.
2-29
-------
The pressure in the main must be controlled to provide the 1 mm pressure
*
at the bottom of the oven at the end of the coking cycle.
Collecting main pressures vary between 5 and 12 mm H^O, depending on
the height of the ovens. Taller ovens require higher pressures to overcome
the stack effect at the end of the cycle.
As a general rule of thumb, the collecting main pressure (in millimeters
of water) is usually one-third the value of the height of the ovens plus the
collecting main height (in feet). Example: If the combined height of the
ovens and collecting main is 19 feet, the back pressure is usually 1/3 of 19
or 6.3 mm H?0. If the combined height is 30 feet, the collecting main pres-
sure should be around 10 mm HpO.
Pressure charts—The pressure pattern on a collecting main pressure chart
should be relatively smooth, with a variation of only 1 or 2 mm hLO. A saw-
tooth pattern indicates imbalances in the gas system; for example, the valve
settings on the crossover main may not be quite correct or sluggish operation
of the butterfly valve may not allow the gas to be removed from the collecting
main fast enough.
Other factors that contribute to higher pressure in the collecting main
and prevent smooth butterfly valve operation are as follows:
0 Whenever steam is opened up on the gooseneck the steam pressure
causes an imbalance in the collecting main and pressure usually
rises 1 to 2 mm during each charge. During stage charging, the
steam is also on in the adjacent oven; this sometimes makes it
difficult to maintain stability on the collecting main.
0 Any control problems that occur in the exhauster affect all the bat-
teries; the pressure rises and drops according to the operation of
the exhauster. This variation in pressure is usually wide. The
exhauster suction must be balanced with the removal of gas through
the collecting main, and the butterfly valve on the collecting main
must be in harmony with the valve settings at the end of the cross-
over mains. In other words, the back pressure in the main must
dictate how much the crossover valves are to be opened and also how
much suction has to be maintained on the exhauster. The position of
the butterfly valves on the collecting main should be such that (if
necessary) the valve could open up wide or close down completely,
depending on conditions. The gate valves on the crossover must be
balanced so that the butterfly valves function freely in a relative-
ly narrow range about their midpoint; gate valves are usually in a
position of at least 1/2 to 3/4 open. The exhauster suction is then
altered to yield the above.
2-30
-------
0 After the oven is charged, a higher pressure will sometimes be noted
(about 2 to 3 mm H^O) on the collecting main for a longer than
normal period, say 5 minutes or so, and will then gradually return
to normal. This indicates a condition in which the butterfly is
open wide but the gas is restricted in the crossover main because
the gate valves are not open wide enough.
0 On the other hand, if the pressure is barely okay (at the set point),
but the butterfly is just about in a closed position, this indicates
that the gate valve is open too much or the exhauster is pulling too
much. The gate valves on the crossover mains are not all wide open,
they are staggered open; the one crossover valve closest to the ex- •
hauster is open only a small portion whereas the crossover valves on
the battery farthest away are open much more. The farther the
valves are from the exhauster, the more open they are.
In general, the valves are set so that the butterfly operates about
midway between fully open and fully closed. Looking at the extension on the
butterfly handle, the normal operating position of a butterfly valve is in a
45 degree position from the horizontal. The inspector should observe the
operation of the butterfly valves; they should operate smoothly and respond
quickly to pressure variations. The collecting main pressure recorder charts
should also be examined for uniformity and fast response time. It should be
noted that if a pressure surge occurs in a battery because of exhauster upset
or other pressure control failure, this may disturb the seal on self-sealing
doors or the luting compound on luted doors and lids and cause the doors and
lids to leak, even after pressure control is restored.
Operator procedures for controlling the back pressure—The oven heater is
the operator responsible for checking and making corrections on the collect-
ing main back pressure control. The control of the back pressure is normally
automatic, but the control is sometimes very ragged. The heater observes the
high-line (collecting main and crossover mains) on all batteries several times
a shift. If the ovens are pushing on schedule no adjustments are necessary.
If the ovens are seriously delayed because of a mechanical failure, to hold
back pressure on the main at the designated point, the heater would have to
cut back on the gate valve on the crossover main so that the butterfly can
operate in its range and not be in the fully closed position. If the delay
should continue, further reductions would be made on the crossover valve, and
the exhauster suction would be dropped by 10 to 15 mm. Again, the system is
converted so that it is maintained in balance.
2-31
-------
When the problem has been rectified and oven charging is resumed, perhaps
at a faster rate than normal, the heater and the byproduct exhauster engineer
work together to increase suction to compensate for this extra gas by increas-
ing valve openings and suction by the exhauster. Further details on the
operation of pressure regulating systems are given in Appendix C.
2.2.2 Topside
The major sources of topside emissions are as follows:
0 Piping leaks - Leaks from cracks or defects in the standpipe.
0 Flange leaks - Leaks from the junction of any two pipes, including
the final junction with the main.
0 Base leaks - Leaks coming from the standpipe base.
0 Cap leaks - Leaks coming from the standpipe cap.
0 Other leaks - Leaks from the offtake piping assembly that are not
within one of the above categories, such as leaks from the flushing
liquor fittings. High oven pressure (i.e., greater than 10 mm FLO)
can also aggravate emissions from topside sources. This high
pressure can be caused by a malfunctioning pressure regulator or
clogged standpipes or goosenecks.
The emissions from these sources are basically controlled by operation
and maintenance procedures. The topside crew's O&M activities for managing
these emissions include:
0 Seating of charging port and standpipe lids.
0 Luting of charging port and standpipe lids.
0 Cleaning of standpipe and goosenecks.
0 Effective patching of cracks in standpipe and goosenecks.
0 Handling of coal spillage.
0 Continuous monitoring of equipment that regulates oven pressure and
making repairs when necessary.
In general, the effectiveness of the emissions control from topside sources is
directly related to the labor used for maintaining the lids, luting, and
pressure system.
Some charging lids are designed with a beveled seat, and others are
designed to seal through a shouldered metal-to-metal joint. Newer designs
2-32
-------
incorporate a threaded lid and lid ring, which permit the lid to be turned
into place. In this arrangement, coal spillage and excess luting material
should be kept out of the threads.
Standpipe lids are designed to seat against the metal standpipe for a
metal-to-metal contact seal. The s;eal design can be simply a flat surface of
the lid mating with a flat surface on the standpipe, or it may involve the use
of a beveled or a shouldered seat. Furthermore, standpipe lids may be verti-
cally or horizontally oriented with respect to the standpipe, as shown in
Figure 2-14. The horizontal standpipe lids permit the use of water seals.
Leakage from charging lids is generally attributed to one of the follow-
ing: 1) improper cover positioning, (2) failure to clean and lute seating
areas properly, or 3) distortion of the lid/seat system. Cover positioning
can be improved by emphasizing the importance of lid positioning to emission
control during the training of topside personnel. Even if the lids seat prop-
erly, the absence or deformation of lid handles can make removal and replace-
ment difficult and lengthen the time that emissions can escape. Designing
lids for ease of handling and properly maintaining the lifting features (see
Figure 2-14) of the lids should also minimize positioning problems. In gen-
eral, oven designers indicate that seals will not leak or allow emissions if
q
they are properly cleaned and maintained. Most plants, however, use some
kind of lut.ing material or slurry to seal the lids. The luting material is
applied to the lid/frame interface; when it dries, the luting mud or slurry
provides an effective sealant. Good operating practice dictates that the
sealing material not be applied to the metal-metal contact area below the oven
top surface. The mud/slurry used to seal lids should be inexpensive and
readily available and have a consistency that makes it easy to apply. It is
also important that the dried material break cleanly from the lid/frame inter-
Q
face when the lid is removed for the next coal charging. Containers of
luting material should be spaced along the battery top so the lidsmen don't
have to walk back and forth continually.
One plant sealed its charging lids with a slurry consisting of a mixture
of clean-up materials (such as coke breeze and old mud from the luting of
q
end-closure doors), clay from a local source, and water. Another slurry
used to seal charging lids in U.S. plants consists of lime (CaO), alumina
CO, and silica (SiOp) mixed with water. There are apparently a
2-33
-------
LIFTING HANDLE
LIFTING RIM
HANDLE
SIDE VIEW
SIDE VIEW
SIDE VIEW SIDE VIEW
OVERVIEW
SHOULDERED
OVERVIEW
BEVELED
OVERVIEW
SHOULDERED
BEVELED
STANDPIPE CAP
STEAM
ASPIRATOR
STANDPIPE-
STANDPIPE CAP
STEAM
ASPIRATOP
TO
COLLECTING
MAIN
'FLANGE
STANDPIPE-
.TOP OF OVEN
TO
COLLECTING
MAIN
kFLANGE
TOP OF OVEN
VERTICLE STANDPIPE CAP
HORIZONTAL STANDPIPE CAP
Figure 2-14. Lid and standpipe cap alternatives.
2-34
-------
wide variety of slurry mixtures in use, some based on clays, some on silica
g
flour, and some on other materials. Lids or the frame into which the lid
seats may distort during service. The distortion of the lid-frame system is a
major factor contributing to the occurrence of topside'emissions. Increased
repair and replacement should decrease emissions resulting from this problem.
Luting of standpipe lids follows the same procedures as those for oven
lid luting. Some plants use a sodium silicate (water glass) solution that is
effective. Regardless of the material used for luting, it is necessary to
relute each time a lid or cap is opened or disturbed.
2.2.3 Charging and Topside Emission Control Planning
It is one thing to describe the procedures required for stage charging
and topside emission control; it is quite another to implement these proce-
dures on every charge day in and day out. Unlike most pollution control
systems, these procedures require meticulous and constant attention to detail
by many people. This entails such things as detailed job descriptions, con-
tinuous training programs, written maintenance procedures, and some type of
monitoring system. Regulations do not prescribe the exact ways for a given
plant to accomplish emission control; they only indicate the expected results.
The inspector, however, should be familiar with the detailed procedures to
evaluate the possible reasons for noncompliance and distinguish between short-
term upsets and longer-term faults in a given program.
Specific procedures vary from one plant to another, but certain basic
elements are found in almost every plan. As a minimum, a complete plan should
include at least the following:
General Work Practice Controls —
0 Inspect goosenecks, stemdpipes, and charging hole lids for cracks,
warpage, misalignment, and other defects and make the necessary
repairs.
0 Remove tar and carbon buildups from goosenecks and standpipes to
assure an adequate gas passage.
0 Remove roof carbon buildup to provide an adequate gas channel at the
top of each oven.
0 Clean and inspect liquor sprays before every charge to assure ade-
quate flushing liquor at all times.
2-35
-------
0 Inspect aspiration system to assure optimum pressure.
0 Clean steam nozzles regularly.
0 Fill larry car hoppers to predetermined levels established for each
hopper with mechanical volumetric controls.
0 Align the larry car so that drop sleeves fit tightly over the charg-
ing holes.
0 Inspect and repair the joint between the gooseneck and the collect-
ing main and the joint between the standpipe and battery top to
prevent topside emissions from these sources.
0 Carry out charging in accordance with a specific written procedure
to minimize emissions.
0 Turn off the aspiration system only after the charging hole lids
have been replaced.
0 Maintain procedures for checking oven back pressure controls to
maintain uniform pressure conditions in the collecting main.
0 Check the condition of the charging holes before each charge to
ensure a free flow of coal into the ovens.
In addition, written maintenance procedures and schedules should be
developed to accomplish the following:
0 Preserve alignment of charging hole castings and larry car drop
sleeves
0 Preserve alignment of off-take equipment
0 Maintain battery and machinery in good working order by making
repairs as needed for effective emission control.
0 Institute a training program for all coke oven employees and for all
new employees before they begin work on the coke ovens.
These procedures must be translated into specific job responsibilities for
each member of the battery crew involved in the operation and maintenance
procedures for charging and topside emissions control. Typical job functions
for these personnel are described in detail in Appendix A. Naturally, not
every plant will have the same job descriptions but the inspector can use this
appendix as a gauge for evaluating the completeness of the job descriptions 'at
a given plant.
2-36
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2.3 DOORS
Controlling emissions from coke oven doors has proven to be the most
difficult task for most coke oven operations. The prevention of door emis-
sions requires containing pressurized gas within an oven despite substantial
opportunities for leakage through the mating surface between the door and the
oven. Figure 2-15 illustrates the; major variations in coke oven door param-
eters. Luted doors are used on older, shorter batteries. Newer ovens use
self-sealing doors, which were invented to eliminate the need for luting,
especially on taller doors. Table 2-5 shows the variables that can affect
emissions from luted and self-sealing doors. Leakage at a given door can be
outward near the beginning of the cycle and inward later. Because inward
leakage of air affects the utility of the coke oven gas and the quality of the
coke (because of oxidation), coke oven operators are concerned with leaks from
both a process and an emissions viewpoint.
The major items that cause visible door emissions are:
0 High oven pressure
0 Damaged door seals
0 Improper cleaning
0 Damaged jamb
0 Poor luting
0 Poor door repair and replacement policies
Self-sealing doors on ovens that have just been charged typically release
visible emissions because the oven pressure is at its highest point. The
pressure is high because the freshly charged coal is releasing moisture and
volatile matter and the pressure control system has not reached equilibrium.
Leakage from self-sealing doors is exacerbated during this initial period
because the sealing effect of tar condensation and the filling of the small
defects in the sealing surface have not had time to occur. Double collecting
mains allow the generated gases to be exhausted more effectively during this
early period of the coking cycle. The doors should seal in less than one
hour. Any longer time usually indicates that the seal is defective or that
the door and jamb have not been cleaned properly.
A number of approaches are available for controlling door emissions. The
most common alternatives are as follows:
0 Self-sealing doors with adjustable seals
0 Luted doors
2-37
-------
DOORS
LUTED
ro
i
co
oo
SELF/SEALING
SPACE
3M
4M
4M
5M
6M
LUTING COMPOUNDS
TYPE OF SEAL
— VENTED DOOR PLUGS
— GASKETS
-LATCHING MECHANISM
L—REPAIR FACILITIES
Figure 2-15. Major design variables in coke oven doors.
-------
TABLE 2-5. VARIABLES AFFECTING DOOR EMISSIONS
Design variables
0 Door design
0 Oven height.
0 Cleaning system
Seals
0 Door lining
0 Material of construction
0 Door weight (i.e., massiveness)
Latching mechanism
00 Seal adjustment mechanism
o
Coal variables
Coal volatile matter
Coal bulk density
Operating variables
Oven pressure
Repair policy
Oven temperature
Luting practice
Human variables
Door handling
Door cleaning
Door maintenance
- Self-sealing doors only.
- Luted or self-sealing doors,
2-39
-------
0 Additional manpower for maintenance
0 New materials of construction
° Vented door plugs
0 Door hoods and sheds
o
Inert gas seals (foreign technology)
The criteria used to evaluate these alternatives include the following:
1) Promise of substantial results, i.e., leakage reduction.
2) Consistency with the design and arrangement of existing plant (i.e.,
can be retrofitted).
3) Minimal energy and maintenance requirements.
4) Creation of new environmental demands, i.e., water treatment or gas
cleaning.
5) Use of equipment or techniques already demonstrated and proven.
6) Possess flexibility, i.e., the ability to be modified to take advan-
tage of new developments.
7) Reasonable levels of labor or workmanship required.
8) Installation and implementation in shortest possible time with
minimum disruption to oven operations. Door hoods and sheds capture
door emissions; they are not discussed in this document, however.
A double collecting main offers definite improvement in emission control,
but it is difficult to retrofit to existing batteries.
The use of new door designs and new materials of construction has been
implemented at several plants. ' The objective is to find designs and
materials which are less subject to warpage and distortion. Regardless of the
specific designs or materials used, however, the O&M procedures discussed in
this section are necessary for effective door emission control. Vented door
plugs reduce emissions by providing an open vent for the gases coming from
within the coal mass itself, which in turn reduces gas pressure against the
joints of the door. The operating and maintenance features of these and other
door variables are described in the following sections.
2.3.1 Door Design
Figure 2-16 illustrates the basic components of a coke oven door and
Figure 2-17 shows a similar diagram of the chuck door configuration. The
major components are as follows:
2-40
-------
, GUIDE LUG
KNIFE
EDGE SEAL'
(EXTENDS AROUND
DOOR CIRCUMFERENCE)
SEAL
COMPRESSION
SPRING
LATCH BAR
DOOR BODY
SCREW LATCH
COKE OVEN DOOR CROSS SECTION
GAS CHANNEL,
gs-^.v^i'ttiri'il^sS
GUIDE LUGS
DOOR FRONT VIEW
JAMB CASTING
t
*
*
:CED^
t
4
»
t-
t
r
f
f
»
+
r
f _
- **"" ^Ol """
; — &sl
: D
f
•*• ^ * * 4-
>«-TOP LATCH
SEAL ADJUSTABLE
SCREWS
'
>— BOTTOM LATCH
DOOR BODY
— SCREW LATCH
LATCH HOOK
CROSS SECTION OF DOOR IN COKE OVEN
Figure 2-16. Major coke oven door components.
2-41
12
-------
COKE OVEN DOOR
CHUCK DOOR
OPEN POSITION
GUIDE LUG
LATCH
CHUCK DOOR
SLOT IN DOOR
CASTING FOR
SEAL STRIP
LATCH
CHUCK DOOR CASTING
CLOSED POSITION
SECTION THROUGH OVEN DOOR AT CHUCK DOOR
COMPRESSION SPRING
PLAIN CARBON OR
STAINLESS STEEL
SEAL STRIP
SEAL ADJUSTABLE
SCREWS
GUIDE LUGS
GENERAL LOCATION
OF CHUCK DOOR
ON COKE OVEN DOOR
Figure 2-17. Major chuck door components.
12
2-42
-------
0 Door seal - A metal knife edge that fits against the jamb sealing
surface. It must be flexible enough to conform to variations in the
surface but strong enough to cut through light tar deposits.
0 Door frame (or body) - The backbone of the end door. Its main
function is to provide a straight surface for mounting other com-
ponents.
0 Refractory door plug (door lining) - An insulator that shields the
metal door frame from the oven heat and maintains the coal in proper
position with the end heating flue.
0 Latching mechanism - The device that holds the door onto the jamb
and provides the main force that holds the door seal tightly against
the jamb sealing surface. Springs or screws may be used to provide
tension against the jamb. Most doors use a top and bottom latch to
provide more uniform tension.
0 Door jamb - The cast frame at both ends of the coke oven in which
the door is placed.
0 Guide lugs - Protrusions at the top and bottom of the coke oven door
that mate with similar fittings on the door jamb to insure proper
door positioning.
0 Seal compression springs - Springs that provide tension between the
knife-edge seal and the jamb.
0 Gas channel - The space between the refractory door plug and the
oven jamb and wall that allows gases to flow freely from the bottom
to the top of the oven and minimizes pressure at the bottom of the
oven. Some door linings have a vent area through the plug from top
to bottom for gas to pass.
Door Seals--
There are two basic types of door seals—luted and self-sealing. A luted
seal is one in which a water-based dispersion of clay and other materials is
used as plaster to seal the door. The oven heat evaporates the water, and the
luting composition dries in position. The slurry used for luting is generally
inexpensive, based on either clay or silica flour, and has a consistency that
can be applied easily to achieve a seal. It is also important that the dried
material break cleanly from the door/jamb when the door is removed for the
push. It is important for the luterman to lute thoroughly, particularly in
the difficult to reach space behind the latches, in the corners of the doors,
and at the top of the door. A useful design feature on luted doors is a
beveled area between the jamb and the door, which permits more luting mud to
be placed. Such a bevel also provides a key to hold the mud in place.
2-43
-------
On self-sealing doors, a knife-edge seal is used, which is essentially a
metal strip attached around the circumference of the door that presses against
the jamb to create the seal (see Figure 2-16). To obtain a uniform pressure
against the jamb, the metallic strip has adjustable screws, springs, or cams,
as indicated in Figure 2-16. Self-sealing doors rely on the condensation of
tars in the spaces created by small defects in the sealing surface. The time
required for self-sealing varies with oven pressure and the size of the gap.
Research has shown that for sealing within 1 hour, the gap between the knife-
edge seal and the jamb must be less than 0.008 inch.
One way knife edges become damaged is by hitting the latch hooks when the
pusher machine or door machine is not lined up properly for door replacement.
One company developed a guiding system to help resolve this problem. In
the absence of a mechanical system, the pusher machine (and door machine) op-
erator must exercise care when replacing doors. No door system will consist-
ently seal satisfactorily unless maintenance and operation practices are
continuously good.
Refractory door plug--
The door plug is the refractory section of the door inside the oven.
This plug prevents the hot coke from damaging the metal door structure, as-
sures containment of the coal in the hot section at the ends of the oven so it
will be coked, and most importantly, provides a channel through which the gas
can pass from the bottom of the coal charge to the top of the oven and into
the collecting main. Some plants have tried a vented plug (i.e., a plug
containing a special passage for the gas from the bottom to the top of the
oven) to provide an additional gas escape. By lessening the pressure buildup
at the base of the oven door, this arrangement reduces leaks. A more detailed
description of the door plugs can be found in the BID. Vented plugs can be
effective but they have a tendency to become blocked with coal and deposits.
When a conventional door plug is used, the gas channel pressure peaks
shortly after charging begins. Pressures reach 180 mm f-LO at the bottom of
a coke-side door and can remain as high as 30 to 40 mm H90 for up to 30 min
11
after charging is completed. The occurrence of high gas pressure can be
minimized by the use of a vented door plug. A vented plug will reduce both
the peak pressure that occurs just after charging and the average pressure
throughout the cycle. Pressure reductions as great as 20 to 1 have been
obtained at the beginning of the cycle, from 180 mm to 10 mm HpO.
2-44
-------
The door frame, jamb, and latching mechanism are important in door de-
sign, but once installed, little can be done to modify them. Bowing or hour-
glassing (see Figure 2-18) of the door frame or jamb will inhibit proper seal-
ing of the door and increase emissions. These conditions can be minimized if
temperature differences across the jamb are not excessive. For example, one
plant incorporates expansion slots in the highest temperature portion of the
jamb to minimize bowing and hourglassing. Others use heavier castings for
the door frame and jamb and select materials having lower coefficients of ex-
pansion. Once door deformation gets beyond narrow limits, the only option is
to replace the door. Luted doors have a greater tolerance for warpage because
the luting operation, if practiced aggressively, can accommodate larger defor-
mation than can the metal sealing strip used on self-sealing doors. This is
not to say that warpage can be ignored on luted doors, however.
Most doors have latches at the top and bottom, and some have only one
latch in the middle. It is important that all latches be securely in place in
the latch hook (or keeper) for the door to be held firmly in place and to have
uniform latching pressure.
2.3.2 Operating Variables
Cleaning--
Cleaning the oven doors, the chuck door, the oven door jamb face, and the
gas channel of the sealing edge are the most important operating practices for
minimizing emissions from self-sealing doors. Both cleaning and luting prac-
tices are important for luted doors. When the door is removed from the oven,
either high-pressure water sprays, chain-driven cutters, or chipping bars can
be used to clean the door surfaces. If not cleaned, the buildup of carbon
between the knife edge and the jamb will inhibit proper sealing.
Several plants use high-pressure water to clean coke oven doors and
jambs. Both mounted equipment and hand-held sprayers are used. Figure 2-19
shows one type of high pressure spray system. This system remains stationary
at the end of the coke battery, and the doors are carried to it for cleaning.
Doors and jambs should be inspected and cleaned after each cycle. Hand-held
sprayers can be made available near the point of door removal. These sprayers
can be used to remove tarry deposits as necessary as well as to clean jambs.
2-45
-------
Away from Oven
Door
Jtmb
Seal
UunolcA. Horizontal dolmen
bHwc«fl i*mb and doot
are «• the MOW.
Door
Seal
Example I. Dooc lui Im curvature
tfun |amb. |ai*b com«n «
dotcf lo tout tfu* M the
SM!
h«apl*C Door b curved biwjrd md
b Ucing cillwr * tfuighl
|*mb of difUnce bMiMrffi
|nnb *nd doer b (rcilct
SM!
tumafeD. fjmb and door bow toward*
cacholhct.
Figure 2-18. Exaggerated examples of variations in
contours of jambs and door frames.
2-46
-------
HORIZONTAL
SPRAY HEAD
HORIZONTAL
SPRAY HEAD
(SIDE
MOVEMENT)
DOOR OUTLINE
TWO VERTICAL
SPRAY HEADS
(IP AND DOWN
MOVEMENT)
FRONT ELEVATION
SIDE VIEW
Figure 2-19. General arrangement of door cleaning rack.
12
2-47
-------
The primary variables that need to be optimized for spray cleaning are
water pressure and flow rate, carriage drive speed, nozzle selection, and the
13
positioning of the nozzle relative to the door.
One British plant has found that a water spray at 18 gal/min and 7000
13
psig will remove tar deposits very effectively. This plant leaves a thin
layer of tar on the knife edge to improve sealing. Later on, pressure and
water consumption can be reduced for routine washing down of the door. Test-
ing at this plant also indicated that two rapid passes are better than one
slow pass; for a door 6.2 meters (20 ft) high, two cycles of 35 to 40 seconds
13
each give the best results.
Some plants clean by using chipping bars with chisel heads or mechanical
pneumatic chisels. When either of these systems are used, extreme care must
be taken when cleaning the knife edges or damage will occur and result in poor
sealing. One plant that uses chisels rarely cleans the knife edges because
they believe that having tar on the knife edge is better than the risk of
14
damaging the knife edge during its removal.
As coking temperature increases, the cleaning necessary to assure ade-
quate sealing also increases because the deposits that occur at higher temper-
atures are harder (essentially carbon) and do not condense as quickly. These
harder deposits make it necessary to clean the door thoroughly after each
cycle to obtain a smooth surface for the knife edge to press against. At
lower temperatures, the tars condense faster around the seals, and because
there is less gas decomposition, the deposits are of higher order hydrocar-
bons, which are softer and form a better seal. Cleaning to bare metal is not
necessary after each cycle, because the soft tar deposits form a good sealing
surface for the knife edge.
When door leakage is encountered, the escaping gases will sometimes
ignite and cause a door fire. Door fires should be extinguished to avoid
excess heat and subsequent warpage and deformation.
Door Handling and Replacement--
Leakage from the oven doors often results from physical damage to the
sealing edge. The basic cause of physical damage is typically improper han-
dling during the replacement of doors on ovens, improper tightening of door
latch screws, and improper adjustment of knife edge adjusting plugs. The
obvious way to reduce emissions caused by physical damage is to remove the
2-48
-------
door and replace it with a rebuilt door, but steps should be taken to minimize
the frequency and magnitude of such damage.
Damage to the knife edges, for example, can be caused by the application
of excessive torque to latch screws. This problem can be corrected by first
ensuring that the latch screws are properly lubricated. If not, the normally
correct wrench torque will be inadequate, and the door will leak. As the
number of leaking doors increases, the torque is often increased to compensate
for the loose doors, and this increased torque could then cause damage to some
of the now properly lubricated doors. Instituting a routine lubrication
schedule for the latch screws and routine verification of wrench torque has
eliminated this damage at one plant.
Most knife-edge-seal (self-sealing) doors have spring-loaded adjustment
screws about the perimeter, which assure that the proper contact pressure is
maintained between the knife edge and surface of the oven jamb. Excessive
tightening of these screws to compensate for dirty jambs or misalignment of
the door can result in permanent distortion of the knife edge and loss of
15
effectiveness in containing emissions. When a rebuilt door is placed into
service, the adjusting plugs should be tightened or loosened only by properly
trained personnel.
Seals can also be damaged when the latch hooks (keepers) are hit. One
plant designed a guiding system that virtually eliminated seal hit damage.
In addition to preventing seal damage, this system reportedly always positions
the door in the same place on the jamb, thereby producing better door sealing.
This guiding system acts as a spotting aid to help the door-machine operator
align the door with the jamb as a stop to prevent overcompression of the seal
in the event of excessively large: latch forces. Also, it is reportedly a good
indicator of whether or not the door is going far enough into the oven to
achieve good sealing. Whether or not a guiding system is used, the pusher-
machine and door-machine operators must exercise care when replacing doors to
avoid physical damage.
Chuck Door Leakage--
Chuck doors present a different set of problems. Coal buildup between
the casting and the chuck door results from the leveling operation, and this
small buildup combined with the rigidness of the sealing mechanism prevents
the door from closing properly; thus emissions occur. Untrue chuck door cast-
ing surfaces also cause leakage and present a more difficult problem. When a
2-49
-------
casting becomes warped, the mating surface is lost. One solution is to remove
the casting and refinish the surface. Other solutions are similar to those
described for main door problems; i.e., selection of better materials, careful
handling, proper cleaning of deposits, and prevention of chuck door fires.
When the metal-to-metal contact seal of the chuck door becomes ineffec-
tive because of distortion or excessive carbonaceous deposits on the sealing
surface, some plants lute the door or apply gaskets to effect a seal. The
luting material is made of the same mixtures of materials as those used for
the charging lid slurries, but contains less water. The luting material is
either applied to the flat contact surface of the end-closure door (so that
the sealing edge becomes encased in the luting) or troweled (or laid) along
the outside of the chuck door end-closure contact line.
Chuck door gaskets are usually used as a temporary corrective measure
until the chuck door can be repaired. The following kinds of gaskets are
used: cardboard, tar paper, Esscolator*, and Fiberfrax.** The use of gaskets
has been somewhat limited, but the latter two have reportedly provided a
generally successful temporary control measure. Chuck door design and pre-
ventive maintenance are considered better approaches to leakage problems.
To evaluate door O&M practices at a plant, the inspector should discuss
the program with operating supervision. The effectiveness of each practice
used should be discussed, as well as any practices that have been used in the
past and any new procedures that are planned. This information should be
documented in the inspection report to supplement the visible emissions data.
2.3.3 Door Maintenance and Repair
This section describes the door repair facilities and job responsibili-
ties of the various members of the coke plant team with regard to door main-
tenance. These descriptions are detailed because of the critical and direct
relationship between door maintenance and emission control. Appendix D pre-
sents typical job descriptions of the coke oven operators responsible for door
maintenance, inspection, and cleaning.
*
Esscolator gaskets are a lamination of steel foil and compressible refrac-
tory paper produced and marketed by Esscolator Mfg. Co., 727 Pennsylvania
Avenue, Pittsburg, Pennsylvania 15221
**
Trademark, The Carborundum Company.
2-50
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Door Inspection--
Although not required by regulations, it is a useful practice for the
battery foreman to conduct a door inspection on every shift. The inspection
should include checking for leaking doors, broken latches, bent keepers,
cracked or warped chuck doors, very dirty doors, and doors that do not seat
properly even after cleaning. He/she should make out a door leak report
noting the number of the oven door, the location of the door (coke side or
pusher side), the battery number, and the specific source of the emissions
(the door proper or the chuck door assembly). The report should also indicate
whether the door begins to leak upon charging and eventually stops or if it
continues to leak well into the carbonization cycle. An example door leak
report is shown in Section 2.4.
In many cases, the door is stamped with a serial number for identifica-
tion purposes. This is done to monitor frequency of repair such as door
linings, door seals, chuck doors, latching mechanisms, etc. Frequent door
repairs could indicate a faulty spotting device, which would necessitate a
thorough inspection. Recordkeeping of all door repair can be used to estab-
lish the history of repairs and total cost for each door.
Because door inspections are made by the operators several times a shift,
it should be evident if a door stops leaking later on in the shift. If a door
continues to leak, the nature and cause of the leak must be determined, e.g.,
a slightly damaged door seal, an adjustment problem, or a more serious jamb
problem. The foreman should see that the door is tagged, and the door repair-
man may be able to work on it on the following day shift. If the problem is
minor, such as an adjustment, the repairman may be able to do something imme-
diately. If the door continues to leak when the oven is pushed and charged
again, the door should be replaced at the end of the next cycle and put into
the door repair station for general maintenance. The repair station is usual-
ly located at one end of a battery or between two batteries.
Repair or Replacement of Chuck Doors, Castings, and Latches--
Luted doors are constructed with two sections on the pusher side, the
main door section and the top casting, which contains the chuck door assembly.
The two are bolted together. The chuck door is usually made of an iron cast-
ing, whereas the top casting is made of fabricated steel or cast iron.
2-51
-------
The damaged door is placed in the door rack. A cracked chuck door cast-
ing is changed by securing the door casting with a chain block and removing
two courses of brick lining to expose the connecting bolts that attach the
chuck door casting to the door. New bolts are used to attach a new chuck door
casting to the door. The two courses of lining brick are replaced and grouted.
Replacing a chuck door simply involves removing the hinge pin, taking out
the old door, and replacing it with a new door.
Self-sealing doors may or may not have a top casting that bolts to the
main door section. Some doors on the pusher side have the two sections bolted
together and some have an integral door with the chuck door assembly attached.
Minor Straightening of Door Seals—
Minor dents in doors can be straightened with or without heating the
door. Sometimes the seal is built up with weld and then ground or filed to
conform with the adjacent section of seal.
It may be possible to replace only damaged sections of seal by welding in
a new piece and grinding down to the size of the adjacent sections. Most door
seals, however, come in one piece.
Replacement of the Knife Edge—
Some doors are mishandled when they are removed or replaced on the door
jamb, sometimes because of operator error, and sometimes, because the equip-
ment spotting device is not functioning properly or the door seal is struck on
the buckstay, etc. The door seal can become so badly bent that the entire
door seal must be replaced. Some type of mechanical aid should be used to
ensure that the seal is straight. This can be a jig, a taut wire, or some
other arrangement. When the seal is replaced, adjusting screws and feeler
gauges are used to determine the space between the door seal and straight
edge. The screws are adjusted so that the door seal is straight and level in
all areas. In general, the screws are pre-adjusted to a certain degree, and
final adjustment is made when the door is placed on the oven.
In general, most door work is done in the designated door repair area;
however, another area away from the batteries may be available where mainte-
nance work such as installation of refractory door plugs, preparing or making
up new doors, and painting can be performed.
2-52
-------
Keeping Doors and Jambs Together--
Most plants attempt to keep matching doors and jambs together because
they tend to curve or expand and contract together. The door seals have a
certain amount of resilience and conform to a certain joint configuration.
When a new door seal has been installed and the adjustment screws have
been preadjusted, the door is placed on the oven for one cycle for observa-
tion. Some leakage may occur, and final adjustments are made on the adjust-
ment screws at that point. Usually more pressure has to be exerted on the top
and bottom of the door than in other areas. Because these adjustments are
made for a particular jamb and conform to that jamb, it is beneficial to keep
that jamb and door together, if possible. If the door is removed and placed
on another jamb, leakage is very likely to occur.
The Effect of Coking Time on Door Life—
In general, short coking times cause door linings to fail sooner because
of the higher temperature differential. Also, door seals tend to become
damaged as a result of the frequency of removing and replacing the doors. The
faster cycles cause the operator to hurry, which normally means less care is
taken in handling the doors.
Shorter coking times and higher temperatures also result in higher evolu-
tion of gas, which causes higher pressures and more door leaks, and increases
the possibility of fire.
2.4 RECORDKEEPING
Many plants have found recordkeeping to be an essential part of the
emission control plan. This section presents examples of recordkeeping proce-
dures and some typical forms for maintaining records on charging, topside, and
door inspections. Although every plant will have its own procedures and
forms, they all must include certain basic elements to be effective. The
importance and value of recordkeeping in a stage charging program has been
demonstrated; in fact, some regulations (e.g., the Pennsylvania SIP and OSHA
regulations) require recordkeeping.
The inspector should review the records maintained by the plant and be
aware of who is responsible for recording the data. The inspector should make
this review before going on top of the battery so he/she can compare the
recordkeeping plan with the observed practice. This also gives the inspector
2-53
-------
the opportunity to interview the individuals, both foremen and operating
personnel, who actually maintain the records.
One plant has reported on the value of maintaining graphical records of
emission performance as a means of monitoring long-term trends and detecting
shortcomings in the emission control program. Figure 2-20 presents an
example of such a performance graph.
Records fall into the following three general categories:
1) Emission observations conducted by the plant.
2) Checklists maintained by operating personnel to track compliance
with the O&M plan.
3) Preventive maintenance inspections and records to audit condition of
key equipment items.
Many plants are required to perform self-monitoring. Pennsylvania regu-
lations, for example, provide for continuous monitoring of visible emissions
by a qualified smoke reader. Even those plants not required to self-monitor
find it a valuable part of their plans to control emissions from charging,
lids, standpipes, and doors. These plants monitor on every shift or at least
periodically. The forms used for such observations can vary according to
preference, but it would be sensible for the plant to use the same forms as
their local control agency. Emission observation forms are important; it can
be somewhat distracting for example, if a form does not contain enough lines
on which to record the data. Alternative forms are presented and discussed in
Section 3.
The collection of emission data in an organized and consistent manner
allows the plant to correlate emissions with various control practices and
evaluate changes in control variables (e.g., steam aspiration pressure, level-
ing sequence, coal percentages by hopper, luting compounds, and door mainte-
nance).
Figure 2-21 is an example of a checklist that a battery foreman might use
on a shift basis to monitor compliance with overall control procedures. Many
different variations of such a checklist are possible, but the continued
effective implementation of an emission control plan requires some type of
formal monitoring and recordkeeping.
As was indicated earlier, inspection of doors is advisable on each shift
and should be the responsibility of the foreman. Leaky doors should be noted
2-54
-------
>-
CO
I/)
o
I/O
UJ
CO
o
et
o:
180
160
140
120
100
80
60
40
20
0
CHARGING LID EMISSIONS
I I
TOTAL TOP SIDE EMISSIONS
OFFTAKE PIPING SYSTEM
i WMISSIONS i
1976
1977
1978
1979
Figure 2-20. Visible coke plant emissions at 143-oven installation.5
2-55
-------
Name Date Shift
Pollution Control Items: Yes No Comments
Cut doors and jambs
Doors fit properly after
being cut
Door fires
Lids sealed
Proper lids pulled for
decarb
Stage charging
Sealing standpipe caps
Full charges in larry car
Goosenecks cleaned
Pushermen leveling
properly
Stacks smoking excessively
Dirty pushes
Green push indicators
prior to push:
Green ends
Lids burning on decarb
Standpipes smoking
Steamjets cleaned
Pusherside platform clean
Coke side benches clean
Figure 2-21. Example checklist for battery turn foreman.
2-56
-------
on a door leak report, such as shown in Figure 2-7.2. Doors on ovens that have
been charged within the last 10 minutes should be noted separately, as tempo-
rary leaking is normal. These doors should be rechecked later during the
charge to see if a problem exists.
Figures 2-23 through 2-26 are examples of preventive maintenance inspec-
tion forms for lids, liquor sprays, goosenecks, and doors, respectively. The
application of this relatively simple but organized approach to monitoring
equipment conditions on a regular basis is intended to supplement the normal
inspections performed on each shift. It provides an audit of shift perform-
ance and helps to detect malfunctions before they get out of hand. Again,
each plant can vary the frequency and exact nature of the auditing, depending
on individual needs.
2-57
-------
DOOR LEAK REPORT
Battery
Date
Turn
Foreman
Oven
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
ID of
leak*
PS
CS
Oven
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
60
ID of
leak*
PS
CS
* D = Door
C = Chuck door
B = Both door and chuck door
Figure 2-22. Example of a door leak report.
2-58
-------
MONTHLY BATTERY TOP INSPECTION DAT*
No.
INSPECTOR
OVCN No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
LIDS
No. 1
No. 2
No. 3
No. 4
5oo»c
NECK
STANDPIPE
OVEN
No.
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
61
62
Cooc: C= CRACKED
W-= WARPED
M M MISALIGNED
LIDS
No.1
No. 2
No.3
No. 4
JOOSE
NECK
3TANDPIPC
Figure 2-23. Example form for monthly battery top inspection.
2-59
-------
WEEKLY
LIOUOR SPRAY INSPECTION
Tu"M
INCPCCTOH
LIME BCINC PU»MIO
DATE
DVEN
1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
19
21
22
23
24
25
26
27
28
29
31
NORTH
SOUTH
OVEN
32
33
34
35
36
37
38
39
41
42
43
44
45
46
47
48
49
51
52
53
54
55
56
57
58
59
61
62
NORTH
SOUTH
OVEN
1
2
3
4
5
6
7
8
9
11
12
13
14
IS
16
17
18
19
21
22
23
24
25
26
27
26
29
31
NORTH
SOUTH 1 OVEN
32
33
34
35
36
37
36
39
41
42
43
44
45
46
47
46
49
51
52
53
54
55
56
57
58
59
61
62
NORTH
SOUTH
P ™
O.K.
Figure 2-24. Example form for weekly liquor spray inspection.
2-60
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MONTHLY
GOOSENECK INSPECTION
TuHN
OATC
IVEN
1
2
3
4
5
6
7
8
9
11
12
13
14
IS
16
17
18
19
21
22
23
24
25
26
27
28
29
31
OVEN
}2
33
34
35
36
37
38
39
41
42
43
44
45
46
47
48
49
51
52
53
54
55
56
57
58
59
61
62
E'
C-
too*
90*
OVEN
1
2
3
4
5
6
7
8
9
ll
12
13
14
15
16
17
18
19
21
22
23
24
25
26
27
28
29
31
OVEN
4
32
33
34
35
36
37
38
39
41
42
43
44
45
46
47
48
49
51
52
S3
54
55
56
57
58
59
61
62
OPBN
P
VP
• 50} Ml
MM
Figure 2-25. Example form for monthly gooseneck/standpipe inspection,
2-61
-------
DOOR PLUG INSPECTION
QUARTERLY
TURN
INSPECTOR
DATE
BATTERY
OVEN
1
2
3
4
5
6
7
8
9
11
12
13
14
15
16
17
18
19
21
22
23
24
25
26
27
28
29
31
PUSHER SIDE
OVEN
32
33
34
35
36
37
38
39
41
42
43
44
45
46
47
48
49
51
52
53
54
55
56
57
58
59
61
.
Q = Good
C = Check monthly
R = Rebrick
Figure 2-26.
OVEN
1
2
3
4
5
6
7
8
9
If
12
13
14
15
16
17
18
19
21
22
23
24
25
26
27
28
29
31
COKE SIDE
OVEN
32
33
34
35
36
37
38
39
41
42
43
44
45
46
47
48
49
51
52
53
54
55
56
57
58
59
61
f
Example form for quarterly door plug inspections.
2-62
-------
REFERENCES FOR SECTION 2
1. Case, E. R., and S. T. Penclergrass. The Use of a Scale Model for Coke
Oven Charging Practice Development. Ironmaking Proceedings, Vol. 41.
American Institute of Mining, Metallurgical, and Petroleum Engineers.
pp. 285-288.
2. Coke and Byproduct Maintenance Problems—A Survey of the Industry.
Iron and Steel Engineers, December 1978. pp. 65-69.
3.
Samways, N. L. Steel Producing Facilities at Republic's Chicago
District Plant. Iron and Steel Engineer, September 1982.
4. Munson, J. G., et al. Emission Control in Coking Operations by Use of
Stage Charging. JAPCA, 24(11):1059-1062, 1974.
5. Oliver, J. F., and J. T. Le,ne. Control of Visible Emissions at CF&I's
Coke Plant - Pueblo, Colorado. In: Ironmaking Proceedings, Vol. 39.
American Institute of Mining, Metallurgical, and Petroleum Engineers.
pp. 217-225. 1980.
6. Clark, F. M. Stage Charging on a Single Collector Main Battery - A
Total System Concept. In: Ironmaking Proceedings, Volume 34.
Toronto, 1975. pp. 350-361.
7. PEDCo Environmental, Inc. Summary Test Report: Method Development
and Testing for the Coke SCU Industry, Wheeling-Pittsburgh Steel
Corp., Follansbee, West Virginia. May 1982.
8. Bauer, E. G. Measurement of Roof Carbon Buildup During the Coking
Cycle. Ironmaking Proceedings, Vol. 39. American Institute of
Mining, Metallurgical, and Petroleum, pp. 289-295. March 23-26,
1980. Washington.
9. Mobley, C. E., et al. Sealing Coke Oven Charging Lids, Chuck Doors,
and Standpipe Elbow Covers. EPA-600/2-77-058. Prepared by
Battelle-Columbus Laboratories, Columbus, Ohio. February 1977.
10. Giunta, J. S., and R. G. Anderson. U.S. Steel Development of Coke
Oven Door System Technology. Proceedings: Air Emissions from Coke
Plants. Air Pollution Control Association. April 1979. pp. 105-113.
11. Barchfield, F. I., et al. New Developments at J&L Drastically Cut
Coke Oven Door Emissions. 33 Metal Producing, May 1978.
2-63
-------
12.
13.
14.
Robinson, A. C. High Pressure Cleaning of Coke Oven Doors. The
Algoma Steel Corporation Limited, Sault Ste. Marie, Ontario.
Goddard, H. Water-Jet Cleaning of Coke Oven Doors.
Engineers, April 1981. pp. 65-66.
Iron and Steel
U.S. Environmental Protection Agency. Coke Battery Survey Procedures,
Description and Data Presentation, USS Fairfield Works. Office of
Enforcement. Denver, Colorado. EPA-330/1-77-012, 1977.
2-64
-------
SECTION 3
INSPECTION PROCEDURES
Careful preparation and planning are vital to a successful inspection and
evaluation of coke oven doors and charging and topside operations. An inspec-
tion will be meaningful only if the inspector knows what information he/she
wants to collect and is familiar with the equipment at the site. Time invest-
ed in a file review will reduce the inspector's field time and that of the
source representative. Also, if all the required data can be obtained during
the inspection, the inspector will avoid later time-consuming efforts to
secure missing data. Furthermore, the performance of homework will result in
the plant personnel viewing the inspector as a professional, and they are more
likely to provide the complete information and cooperation the agency needs to
meet clean-air objectives. The guidelines outlined below will help the inspec-
tor conduct a successful inspection and prepare an informative and useful
inspection.
3.1 PREPARING FOR INSPECTION
Inspection of coke oven operations requires the recording of data on site
for later use in evaluating compliance practices. The following items will
help to ensure that the inspection is complete and that the pertinent informa-
tion is obtained while the inspector is on site:
Plot Plan
The plot plan should show entrances, major buildings, and the coke oven
area to scale. Other appropriate details should be included to provide
orientation.
Equipment Drawings
Photographs or sketches of the coke oven configuration are useful for
reference or comparison when a coke oven is evaluated. Traffic flow,
major process equipment, and control equipment should be shown to allow
for easy reference at a later date.
3-1
-------
Process Flowsheet and Equipment Checklist
An inspector should have a clear idea of the coke plant operating proce-
dures, factors affecting emissions, necessary data to collect for deter-
mining compliance, and data collection methodology.
Individual Process Worksheets and Observation Forms
Individual worksheets should be used during the inspection to collect
pertinent process information. These worksheets are particularly im-
portant in coke oven inspections because of the complexity of the opera-
tion and general difficulty faced by the observer in documenting the
emissions. Some examples of forms that have been used are discussed in
Section 3.3. Specific example forms used by various states and in spe-
cial studies are included in Appendix D.
Most of these items can be obtained during the file review at the appropriate
EPA Regional and local offices. Most EPA offices in steel producing states
also have worksheets already developed for coke oven inspections.
Prior to the inspection, the inspector should review the worksheets and
process flows with the plant's representative at the plant to assure that the
information obtained during the file review is accurate and up to date. This
procedure also makes the plant representative aware of the inspection proce-
dures so that he/she can assist the inspector in collecting information.
Organizing these items prior to the actual inspection helps ensure that all
necessary data are obtained.
Because inspectors generally are responsible for compliance inspections
for several kinds of facilities, which are subject to a variety of regula-
tions, a review of the coke oven regulations is necessary prior to an inspec-
tion. This review serves to refresh the inspector's memory of the regulations
as well as to indicate the necessary information to be obtained. Table 3-1
summarizes the regulations for those states with operating byproduct coke
ovens.
3.2 SAFETY CONSIDERATIONS
In the course of conducting a thorough inspection of a coke oven battery,
the inspector is exposed to many potential hazards. To avoid injury, the
inspector must:
0 Wear the requisite safety equipment
0 Be aware of the safety hazards
0 Respect the company's safety procedures
0 Never become overconfident
3-2
-------
TABLE 3-1. STATE AND ALTERNATIVE REGULATIONS GOVERNING EMISSIONS
FROM CHARGING, DOORS, AND TOPSIDE OF COKE OVENS
Coking operation
Charging (wet)
seconds/charges
Doors, % leaks
Topside
Standpipes, %
leaks
Lids. % leaks
Jefferson
Alabama
125/5b
15
10
5
vania
75/4
10b
5
I
Allegheny
Pennsylvania
75/4
10
5
2
Virginia
100/4
10
10
2
Michigan
80/4
10
4
4
Ohio
125/5
16
10
5
Lake
Indiana
125/5b
10b
10
3
Tennessee
75/4
10
10
2
Illinois
170/5
10
10
5
York
150/5
10
10
2
Alternative
in BID3
I
c
c
c
c
II
16/ld
12
6
3
III
8/ld
7d
4
1
co
co
Coke Oven Emissions from By-Product Coke Oven Charging, Door Leaks, and Topside Leaks on Wet-Coal Charging Batteries - Background Information
for Proposed Standards. Draft. U.S. Environmental Protection Agency. July 1981.
Exclusions permitted.
c State regulations apply.
Log average of 10 charges.
-------
The last point is particularly important. It is human nature, especially in
the case of the relatively new inspector or engineer, to feel like an "oldtim-
er" after the first few trips to the plant. This attitude puts the inspector
at high risk. The inspector always should follow all the company's safety
procedures and stay with the plant escort.
3.2.1 Safety Equipment
For proper fit, the inspector should have his/her own safety equipment.
Although most plants will provide some equipment items, it is an imposition
for the agency to expect them to do so. The recommended equipment for a safe
inspection is as follows:
Hard hat
0 Safety glasses with side shields or full-cover goggles
o
o
o
o
0 Wooden shoe sole attachments
Steel-toed safety shoes
Fire-resistant pants and jacket
OSHA-approved respirator (fit tested)
Heavy-duty gloves
Appendix E contains a full description of the special safety procedures
OSHA requires around coke ovens. These procedures are necessary because of
the hazardous nature of coke oven emissions. The key elements include wearing
a properly fitted and clean respirator when on the battery topside or benches
and not smoking, eating, or chewing gum in the area of emissions. Beards or
facial hair that interfere with proper respirator fit are not permitted. A
medical examination is recommended for those who spend more than 30 days a
year on a coke oven battery. The top of a coke"oven battery is sufficiently
hot to cause discomfort if the inspector spends enough time there. Most
plants will provide "wooden shoes" used to insulate the inspector's regular
safety shoes.
Other physical hazards that are not uncommon at coke oven batteries
include the following:
0 Falling from the benches
0 Being struck by the pusher machine larry car or hot car
0 Being struck by the door machine
0 Touching the hot rail from electrically driven equipment
0 Stepping on a lid that is not firmly seated
0 Slipping on ladders or stairs
0 Coal or coke particles blowing into eyes
0 Striking head on low-hanging pipes or structures
0 Tripping on rails, lids, or items on bench or battery top
0 Standing too near an oven being pushed
0 Fire flares from lids and standpipes
3-4
-------
Although these incidents may seem unlikely, the inspector's attention is
often focused on observing emissions and/or operating procedures, ahd there-
fore, it is easy for him/her to become unmindful of the hazards that exist.
In preparing for any of the observation procedures, the inspector must review
where the observation point will be, what movements may be necessary, what
activities will be going on in the immediate vicinity, and what escape route
is available. It is generally advisable to stay as far away from moving
equipment as possible.
Unfortunately, a thorough inspection entails some risk. Respect for the
hazards, familiarity with battery operations, and constant concern for safety
will minimize the chance of an unpleasant or fatal accident.
3.3 EMISSION OBSERVATION
EPA reference procedures for the determination of visible emissions from
coke oven batteries are currently under consideration. A draft version of
these procedures is presented in Appendix F.
A coke oven inspection can be performed at various levels of detail,
depending on the time allotted for each inspection, regulatory requirements,
the depth of the inspector's knowledge, and the latitude the plant grants the
inspector. By establishing the goals of the inspection before entering the
plant, the inspector can be better prepared and have the proper equipment and
forms to achieve these goals.
Appendix G presents a variety of forms that regulatory agencies have used
for inspections at different levels of detail. Because these forms are from
various sources, some are very similar. They are intended to be examples of
forms in use, not to represent the "ideal" set of data sheets.
Figures 3-1 through 3-3 present examples of the three generic forms
(one for operating data, one for emissions data, and one for equipment data)
that can be used in a charging inspection. Figure 3-1 provides space to
record the process variables such as charging time, cleaning and luting prac-
tices, and aspiration. Figure 2-2 is a particularly thorough example of a
form for recording visible emissions because it provides a larry car schematic
that makes it easy for the observer to indicate the emission points during
each charge. The larry car inspector can use a form such as that shown in
Figure 3-3 to record the coal volume settings in the larry car, the specific
3-5
-------
Page
of
CHARGING TIME STUDY
Larry car inspector
Topside Inspector
COMPANY
LOCATION
INSPECTOR
DATE
BATTERY
i-
C4
X
1.
c
Cv"EN CHARGED
-^^_^ Timinp
Process Operation ^~~
Remove oven lids.
Fiil tarry car at coai bunker.
Hsve car to oven.
Spot car on oven, drop sleeves.
Clean goosenecks, CS
standpipe caps and seats. fS
Close Standpipe, damper oven, CS
turn on aspirating steam. PS
Charge coal to oven:
..«$;
#3
#2
Lute standpipe cap.
Replace oven lids.
Damper ovon, turn off steam.
Return car to bunker.
Time
Start
F,l2nc
Min.
°d
Sec.
Tine
Start
Elao.
Min..
;..d
Sec.
r.ommenc
Number
COMMENTS:
Figure 3-1. Charging time study form.
3-6
-------
CHARGING OBSERVATIONS
Company
Location
Company Rep.
Inspector _
Date
Sky Condition
Wind Speed _
Ambient Temp.
Background
Battery/Oven
Tine of Charge: Start_
End
T1re£ 20i (seconds)
Opacity
Charge period
Seal period
Total
i opacity
Indicate sun position, observation
position, and wind direction:
o
o
o
o
/
t \
3 /
\
Comments:
Hark dominant emission points:
v/v^W
B VS
Battery/Oven
Tine of Chargs: Start_
End
Tire 2 202 (secctxds)
0|)icity
Charge period
Seal period
Total
Maximum opacity
Comments:
Indicate sun position, observation
position, and wind direction:
Hark dominant emission ooints:
Battery/Oven
Tire of Charga: Stsrt_
Hue 220! (seconds)
Opacity
Charge period
Seal period
Total
Maximum opacity
Comments:
Indicate sun position, observation
position, and wind direction:
Mark dominant emission points:
I
Figure 3-2. Charging emissions data form.
3-7
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rage
of
PROCESS DATA
LARRY CAR INSPECTOR
COMPANY
LOCATION
INSPECTOR
DATE
BATTERY
Oven
Charged
Coal Hopper
Volume Setting;
Check Sheet - Indicate Yes (/) or No (Q)
Gooseneck Carbon I Comment
(Illustrate Carbon Buildup Number
after cleaning)
oo
00
1231
Steam on
(Both
ends for
dual
mains)
#4 and #
hoppers
dropped
first
83 and HZ
hoppers
dropped
individually
Slide gates
cl.oscd
after
discharging
hoppers
1234
Goosenecks
cleaned*
Pusher Side
PS ' CS
Coke Side
COMMENTS:
*M - machine •
H - hand tool
Figure 3-3. Larry car inspection form.
-------
charging procedure used, and the effectiveness of the gooseneck cleaning.
Equipment condition and recent maintenance can be entered in the comment
section.
3.4 ONSITE INSPECTION
Assuming the company has submitted the necessary information, the inspec-
tor should become familiar with the detailed procedures contained in the
plant's emission control plan and the job descriptions of the key employees
(i.e., larry car operator, pusher machine operator, door machine operator,
lidsman, jackman, and foreman) before visiting the plant. If such information
is not available ahead of time, the inspector should request it during his
introductory meeting and study it before inspecting battery operations.
A successful inspection hinges as much on the interaction between the
inspector and plant representative as it does on the efficient inspection of
the equipment and the observation of operation and maintenance procedures.
Upon entry to the plant, the inspector should be prepared to discuss the
following:
0 Authority for the inspection
0 Agency organization
0 Scope, timing, and organization of the inspection (preferred inspec-
tion agenda)
0 Treatment of confidential data
It is also important that the inspector ask plant officials about the
operational status of equipment within the scope of the inspection and the
kinds and frequencies of any malfunctions. If equipment is not operating at
or near normal conditions, the reasons should be noted, along with information
concerning when they will be operating normally (for use in scheduling follow-
up inspections). The inspector should observe coke oven operations for a time
before collecting any data. This orientation period allows the inspector to
check the conformity of operating procedures against those stated in the plan.
Deviations should be discussed with the battery foreman to determine the
reason.
If the inspector is denied entry to all or any part of the facility
within the scope of the inspection, the reasons for refusal should be noted
3-9
-------
and the name and title of the person responsible for the refusal. The inspec-
tor's supervisor should be notified immediately by telephone, but no attempt
should be made to summarize potential legal consequences of the company's
refusal to grant entry. The inspection does not have to be performed in any
particular sequence.
Visible emission observations during the inspection can be made by ob-
servers who are trained and qualified to measure plume opacity or to detect
visible emissions with the naked eye. The location of the observer should be
such that the sun is at his/her back and there is nothing to interfere with an
accurate reading. Because of the many visible emission sources at a coke
plant, emissions that appear to be from one source (such as lids) may actually
be from another (such as coke oven doors). This illusion results from the air
currents created by the heated battery or the angle of the observer with
respect to the source being read. Charging emissions may also flow from the
oven up through the larry car hoppers and exit from the larry car. The in-
spector should be aware of this possibility and be on the lookout for other
similar phenomena. When not certain of the emission source, the observer can
change positions or look for clues, such as cracks, warped lids, open stand-
pipes, normal door emissions from recently charged ovens, and open standpipes.
3.4.1 Inspection of Charging Operations
Although both charging and topside inspections are performed on top of
the coke battery, the inspector should complete the inspection of one of the
operations before proceeding to inspect the other. An attempt to inspect both
sources simultaneously will lead to confusion that could result in overlooking
important data or observations.
Regulations for charging generally involve an allowable total time for
visible emissions during a series of charges (Table 3-1). In Pennsylvania,
for example, a total of 75 seconds of visual emissions are allowed for a se-
ries of four charges. Using a stopwatch, the observer can measure the time of
the visible emissions over the interval from charging initiation until all the
covers have been firmly sealed after the removal of the larry car. If emis-
sions from more than one point are observed during a charge, the regulations
generally allow these multiple emissions to be considered as one emission
3-10
-------
point and they are not added individually to the total time. The observation
can be made from any point on top of the coke oven that has an unobstructed
view of the charging operation.
During the observation of visible emissions during charging, other items
may be noted that will assist in the process and O&M evaluation. The follow-
ing items are especially important:
Coal level in the hoppers
Cleaning of the standpipe and gooseneck
Lid removal and replacement
Turning on steam before dropping coal
Turning steam off after charging
Sequence of discharging hoppers
o
o
o
o
o
o
0 Leveling sequence
0 Condition of drop sleeves
0 Charging team efficiency
Because observation of these items requires the inspector to be involved
in the operations atop the battery, he/she is exposed to the full range of
safety hazards existing topside and must act accordingly.
The inspector should discuss the maintenance procedures for checking
liquor sprays and steam sprays with the battery foreman. Records should be
reviewed for completeness.
3.4.2 Inspection of Topside Operations
Topside emissions are observed from on top of the coke battery after
completion of the inspection of the charging operations. The major sources of
topside emissions are as follows:
0 Piping leaks—any leaks from cracks or defects in the piping itself.
0 Flange leaks—any leaks from the junction of any two pipes, includ-
ing the final junction with the main.
0 Base leaks—any leaks coming from the standpipe base.
0 Cap leaks—any leaks coming from the standpipe cap.
0 Other leaks—any leaks from the offtake piping assembly that are not
within one of the above categories, such as leaks from the flushing
liquor fittings.
The inspector can observe these sources while walking along the top of the
battery and noting any visible emissions. A description of the lid and stand-
pipe cap design should be recorded.
3-11
-------
State regulations for coke oven topside emissions generally limit the
percentage of lids and standpipes from which visible emissions emanate. In
Indiana, for example, State regulations do not permit visible emissions from
more than 3 percent of the total charge port lids or more than 10 percent of
the total offtake piping (standpipes and goosenecks). Indiana regulations
also limit the visible emissions from the gas collector main to three points.
These Indiana emission limitations do not include visible emissions resulting
from burning coal spilled on top of the oven or from a maximum of three ovens
that are open during the decarbonizing or charging period. Nor do they in-
clude emissions caused by maintenance work.
During the topside inspection, the inspector should note all sources of
visible emissions and their apparent cause. Causes of visible emissions
include improper sealing of charging port lids and standpipe lids as well as
poor structural condition of the charge port lids and casting and the stand-
pipes because of cracking or warping. The inspector should note apparent
causes for all visible emissions as he walks down the center of the coke oven.
If there are two collector mains, the inspector should traverse the length of
the coke oven twice, each time concentrating on only one of the collecting
mains.
The inspector also should observe the topside crew's efforts to minimize
emissions. Particularly important are the following:
0 Luting of charging port and standpipe lids
0 Seating of charging port and standpipe lids
0 Cleaning of standpipes and goosenecks
0 Effective patching of cracks in standpipe and goosenecks
° Handling of excess charging coal
The lids also should be inspected for proper handles. The maintenance
procedures for lid removal, repair, and replacement can be reviewed with the
battery foreman and a visual inspection can be made of the available lid
inventory.
3.4.3 Inspection of Doors
The door inspection can be made at ground level while walking along the
battery on each side to observe both pusher-side and coke-side door emissions.
3-12
-------
The inspector should walk at a comfortable distance away from the pusher
machine or hot car tracks and idemtify leaking doors by reading opacity at the
lintel (i.e., the top of the door frame).
State regulations for coke oven doors limit the percentage of total doors
that can leak. Visible emissions from the chuck door only or from both the
pusher door and the chuck door may count as only one leak or multiple leaks,
depending on the regulation. In Michigan, for example, each kind of door is
regulated separately. For doors 5 meters or shorter, the push-side doors,
coke-side doors, and chuck doors are each limited to leaks in 10 percent of
the doors in that category. Illinois, on the other hand, limits visible
emissions to emanate from no more than 10 percent of all doors in any one
battery. The regulations generally exclude the doors on ovens just charged or
that are obstructed from view. Some states also include a requirement for a
specified amount of coke oven door inventory. Alabama requires one door in
inventory for every 12 ovens operated and Michigan requires that the invento-
ries of the push-side, coke-side, and chuck doors each exceed 5 percent of the
number of those doors in service.
During the door inspection, the inspector should record visible emissions
from the push-side, coke-side, and chuck doors and sketch the leak location on
the inspection form. Potential or obvious causes of the emissions should be
noted, such as:
° High oven pressure
0 Damaged door seals
o
o
o
o
Improper cleaning
Damaged jamb
Poor luting
Poor door repair and replacement policies
Hand luting may be used to seal some coke oven doors. In these cases,
the inspector should observe the application of the luting material and judge
its effectiveness after the oven is charged.
The inspector should observe door handling during several removal and
replacement operations to note any improper or careless handling procedures.
Seal damage can occur either when cleaning with the chipping bars or pneumatic
chisels, or when the seal hits against the latch hooks or jamb during removal
or replacement.
3-13
-------
The availability of spare doors (door inventory) and door repair facili-
ties should be checked. As stated earlier, some states require a specified
number of spare doors, and all coke oven facilities should have at least two
or three spare doors at the coke oven for immediate availability and several
others at the plant maintenance and repair facility. After a walk-through
tour of the repair facility, the inspector should note the general activity
level and any coke-oven-related activities.
3.5 INSPECTION REPORT
The level of detail of an inspection report will depend on the purpose
and extent of the inspection. It is not necessary to incorporate all of the
information gathered during the inspection in the body of the report, but such
information should either be attached as an appendix or kept in the company's
compliance file. In general, the report should include the following:
0 Changes in plant status since last inspection
0 Current plant operating status and condition
0 Current plant compliance status, including any calculations and
justification for determining compliance
0 Plant activities and modifications expected to occur before the next
inspection
This section presents a brief discussion of specific items that can be
included in inspection reports, but no specific format is recommended. Al-
though they vary, the existing inspection report formats at the various state,
regional, and national EPA offices can all be used to develop a thorough coke
oven inspection report.
The changes in plant equipment and operating status should be reported to
keep the file up to date and to help determine which changes might have caused
an increase or decrease in emissions. These include changes in the following:
0 Process equipment
° Operating techniques
0 Control techniques
0 Personnel and job descriptions
0 Operating level
The operating level is particularly important because emissions are naturally
lower at lower operating levels than at higher operating levels.
3-14
-------
Reporting plant conditions on the day of the inspection is extremely
important—not only the operating level, but also maintenance activities,
absence of normal crew members, coal properties, and any other information
that might have an impact on coke oven emissions on that day. Any relevant
operating information reported by the plant foreman can be included in this
section of the report.
The plant's compliance status should be clearly stated in the report,
along with any supporting information. This can include:
0 Visible emission observations
0 Calculations determining compliance
0 Regulation, discussion, and comparison with inspector's observations
0 Comparison of the results of the latest inspection with those of
earlier inspections
0 Potential causes of noncompliance
The compliance section should specifically point out which regulations apply
and the compliance status of the plant with respect to each regulation.
The report should also include a summary of any planned equipment addi-
tions or modifications and changes in operating procedures that were disclosed
by the plant foreman during the inspection. This information will help the
inspector prepare for his next inspection.
In summary, report formats can vary, but the reports must contain certain
essential information to be complete and informative. These components are:
(1) plant compliance history, (2) current compliance status, and (3) planned
future activities that can affect compliance.
3-15
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AJPPENDIX A
STAGE CHARGING PROCEDURES AND
COKE OVS1I JOB FUNCTIONS
AND WRITTEN MAINTENANCE PROCEDURES
FOR CHARGING AND TOPSIDE
A-l
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APPENDIX A
A.I JOB DESCRIPTIONS
The job descriptions in this section are intended only as
examples of the duties of key battery personnel with regard to
control of charging and topside emissions. Actual job descrip-
tions will obviously vary from plant to plant. These descrip-
tions are for operators of a four-hopper charging car with a
jumper pipe.
Larry Car Operator:
Inspection
1) At the start of each turn, check to be sure the re-
quired tools are on the larry car and that all its
components are functioning properly.
2) Report to supervision the following conditions:
a) Inadequate steam pressure
b) "Blowers" indicating that the oven must be re-
leveled or the gooseneck is plugged
c) Leaking liquor or steam hoses or piping
d) Boots, slides, flow control valves, measuring
chutes, jumper pipe, mechanical gooseneck cleaner,
or travel control not operating
e) Severely plugged standpipes or goosenecks
f) Liquor spraying into the standpipe and onto the
oven walls
g) Liquor spray flushing pattern inadequate or
plugged, and steam nozzle plugged
h) Defective standpipe caps
i) Opinion of general charging conditions during the
turn with regard to coal flow and leveling
A-2
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Cleaning
1) The gooseneck must be cleaned before each charge with
the mechanized gooseneck cleaner and/or a cutting bar.
The gooseneck is then measured with a gauge to insure
maximum opening.
2) The standpipe cap and its seat on the gooseneck are
cleaned with a cutting bar.
3) The area surrounding the steam nozzle on the inside of
the gooseneck is to be cleaned if the steam is found to
be misdirected.
4) The standpipe itself must be inspected and cleaned if
found to be restricted.
5) The larry car and floor beneath the coal bins are to be
kept clean and orderly at all times.
6) Supervision is to be notified immediately if gooseneck
or standpipe are very dirty. Supervision is to take
corrective action as soon as possible.
Duties
1) The following rules are adhered to before the charge is
dropped:
a) The larryman and lidsman are equally responsible
for charging the correct oven.
b) They must ascertain that both doors are on the
oven (and luted if applicable) before charging.
c) Out-of-series charging is not permitted unless
directed by supervision.
d) The larryman and lidsman must be alert and work
together at all times to ensure an emission-free
charge.
c) The charging holes must be inspected for excess
tar buildup or blockage.
2) The stage-charging process (incorporating a jumper
pipe).
a) The larryman. fills the hoppers of the larry car
from overhead coal bunkers to the capacity deter-
mined by the height of the adjustable measuring
rings. The height of the measuring rings is
controlled by supervision.
A-3
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b) The larryman proceeds to the oven to be charged
and spots the car in order to clean the gooseneck
with the mechanical gooseneck cleaner. The liquor
sprays are checked and the steam is tested before
the gooseneck is cleaned. The standpipe cap and
cap seat are then cleaned by hand and the cap is
closed and sealed with a mud slurry. Any problems
are reported to supervision and corrected before
charging the oven.
c) The larryman spots the car over the oven to be
charged and lowers the four boots (plus the jumper
pipe) simultaneously.
d) Only one hopper can be emptied at one time and the
sequence of unloading is as follows:
The operator presses a button in the cab and
the No. 1 hopper slide gate opens, initiating
coal flow. The coal depresses a paddle
switch located below the slide, which actuates
the rotation of the flow control valve to the
vertical position. The process is repeated
in the same manner for the other three hoppers,
A timer enables the operator to start the
same process on Hopper 4 while Hopper 1 is
discharging. Supervision determines at what
point to set the timer.
When Hopper 1 is empty, the paddle switch
returns to the horizontal position automati-
cally, actuating the closing of the slide
gate, which provides an adequate seal for the
aspiration system, and the flow control valve
returns to the horizontal position. The
process is repeated in the same manner for
the other three hoppers.
When Hopper 4 is empty, the slide gate is
closed. The operator presses a button and
opens the slide gate on Hopper 3. When
Hopper 3 is empty, the slide gate closes and
the operator presses a button, raising the
Hopper 3 boot. The lid is then replaced on
the Hopper 3 charging hole.
The operator then opens the slide gate on
Hopper 2, initiating coal flow. A timer on
this hopper, adjusted by supervision, signals
the operator after a predetermined period.
The operator then signals the pusherman to
begin the leveling process.
A-4
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After Hopper 2 is empty and the slide gate is
closed, the larryman again signals the push-
erman, thereby terminating the leveling
process. The jackman closes the chuck door,
enabling the larryman to raise the Hopper 2
boot and the lid is replaced.
The larryman then raises the Hopper 1 boot
and the lid is replaced. The Hopper 4 boot
is then raised along with the jumper pipe and
those lids are replaced. All the lids are
sealed with a clay slurry and the steam
closed.
The car is taken back to the coal bunkers to
be loaded.
Lidsman:
Inspection
1) Be sure the lids are not on the charging hole casting
when the drop sleeves are in the "down" position.
2) Report to supervision the following conditions:
a) Excess carbon buildup in the charging hole area
b) Low steam pressure or inoperable steam jet. This
is to be taken care of before charging the oven
c) Difficulty in moving damper arms
d) Defective damper evidenced by emissions from the
gooseneck after the oven is dampered
e) Cracked or warped charging hole lids or castings
Cleaning
1) No coal is to be swept into an empty oven.
2) The entire width of the battery including the area
between the standpipes is to be swept.
3) Charging holes, charging hole castings, and lids are to
be cleaned of carbon.
4) No coal is to be left on top of the battery.
Duties
1) The lidsman and le.rryman are equally responsible for
charging the correct oven.
A-5
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2) The lidsman is to damper off two to three ovens ahead
of the push for oven roof decarbonization.
3) While the larryman is cleaning the gooseneck, the lids-
man will inspect and clean, if necessary, the fixed and
movable jumper pipes, by using the cleaning bars provid-
ed or notify supervision if an unusually large amount
of material is built up in the pipes.
4) When the larry car is spotted over the oven to be
charged, the steam valve must be open on both the oven
being charged and the adjacent oven.
5) If, for any reason, the charge is delayed, the oven
must be taken off the main and the charging steam shut
off.
6) The lidsman will replace and seal each lid after the
oven is charged.
7) Steam in both goosenecks is then shut off.
8) These aspirations must be done quickly so that minimal
air is pulled into the gas system; therefore, it is
imperative that the oven be closed up and the steam
jets shut off as soon as possible. Steam must never be
left on for the entire coking cycle.
Pusherman:
Only those duties associated with the charging operation are
described here.
Inspection
1) The pusherman will inspect the standpipe base for
excess carbon buildup.
2) He/she must look into the oven to inspect for heavy
roof carbon accumulations and their location. If roof
carbon accumulations appear frequently, supervision is
notified and the carbon cutter is inspected for exces-
sive wear. In addition to the carbon cutter, decar-
bonizing air must be used with each push.
3) The pusher must be in position at the oven before the
larryman charges the first hopper. It is imperative
that leveling commence as soon as the larryman gives
the signal.
A-6
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4) If a more than the usual amount of coal is brought back
with the level bar, supervision must be notified because
this indicates abnormalities with the charging procedure,
5) The pusherman will pay strict attention to how the
level bar air seals are operating, or if they do not
stay in place against the housing while leveling the
oven.
Duties
1) The pusherman positions the pusher at the oven to be
charged before the larryman charges the oven.
2) The jackman manually pulls down the coal chute on the
pusher and waits for the signal from the larryman
before opening the chuck door.
3) After the larryman signals, the chuck door is opened
and the pusherman begins leveling.
4) Leveling is done in short strokes to ensure even coal
distribution within the oven.
5) When the larryman again signals, the level bar is
removed from the oven, the chuck door is closed, and
the coal chute is raised.
Spray Cleaner:
Inspection
1) Check damper shafts for ease of movement and possible
tar accumulations under the damper.
2) Check liquor pressure and regulate accordingly.
3) Periodically check tar buildup in the gas mains, espe-
cially in the area of the butterfly. Sprays on top of
the butterfly valve must be operational at all times.
4) Replace any damageid or plugged spray swirls on the
collecting main or gooseneck.
5) Report any abnormalities to supervision in regard to
the above.
Cleaning
1) Spray cleaner will inspect all liquor sprays on the
goosenecks weekly, fill out an inspection report, and
clean as needed.
A-7
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2) Collecting mains and crossovers will be cleaned weekly
or more often if needed.
Heater and Heater Helper:
(Note: Heater and heater helpers have other duties related
to battery heating controls, temperature measure-
ment and related matters. Only the duties related
to charging controls are given here.)
Inspection
1) Inspect each crossover control at least four times per
shift and make necessary changes on back pressure
control as directed to maintain the required pressure.
2) Inspect recording chart for proper operation.
3) If an inspection of the back pressure system shows a
deflection on the chart, this may indicate that steam
jet nozzles are still in the "on" position. Notify
supervision immediately.
4) Check to see that the butterfly valve is moving freely
and that the liquor spray over the butterfly is flowing
properly.
5) Communicate with the byproduct plant engineer and make
changes, if necessary, to the suction on the exhauster.
Cleaning
1) Clean steam jets, if necessary.
2) Clean any plugged gooseneck liquor sprays.
A.2 MAINTENANCE AND REPAIR CONTROLS
1) Maintenance personnel will inspect and clean the goose-
neck steam jet on a weekly basis. Steam jets will be
cleaned on individual ovens if a plugged condition
exists.
2) Gooseneck liquor sprays are checked by the larrymen and
spray cleaner and if necessary, maintenance (pipefitter)
will be done on all items pertaining to the spray
system.
A-8
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3) Gooseneck replacement is done in the following manner:
a) Oven is pushed but not charged.
b) Heat is reduced in the flues.
c) Back pressure is reduced to + 1 mm and old goose-
neck removed.
d) Blank is inserted in collecting main and back
pressure raised to normal.
e) Standpipe is changed at this time if necessary.
f) Brickwork under standpipe is cleaned and replaced
if necessary.
g) Standpipe is reset or replaced.
h) Gooseneck is replaced after lowering collecting
main pressure and removing blank.
i) Gooseneck is aligned with standpipe and collecting
main.
j) Area between gooseneck and collecting main is
sealed with asbestos rope, sand, and refractory
slurry. Area between standpipe base and battery
top is also sealed.
k) Liquor is put on sprays and damper seal is checked,
1) Oven is charged and put back in series as soon as
possible.
m) Collecting main pressure is raised to normal.
4) Standpipes and caps
a) Change standpipe as necessary as shown above.
Standpipe caps also are to be replaced as neces-
sary.
b) Seal standpipe bases every six months and more
often if necessary. Materials are troweled or
slurried, depending on condition.
5) Charging hole castings and lids.
a) Operations personnel check castings monthly for
cracks, warpage, and misalignment. Maintenance
replaces or reset the castings.
b) Procedure for changing charging hole castings:
1) Oven is pushed and not charged.
2) Temperatures are reduced in the flues.
3) Old casting is removed from the charging
hole.
4) Brickwork under and around the casting is
cleaned of old refractory cement and carbon.
5) A new or the same casting is reset in the
charging hole, aligned to proper position,
and leveled. Casting is grouted in place.
6) Larry car is spotted over the oven to check
alignment with drop sleeve.
A-9
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7) Oven is charged and returned to series as
soon as possible.
c) Charging hole lids will be inspected monthly by
operations personnel and replaced immediately if
defective.
6) Sealing of battery top pavement
a) The top of the battery is inspected and cracks
filled with refractory slurry every six months.
7) Damper system
a) Inspection and cleaning of liquor sprays above the
butterfly valve is done weekly by the spray clean-
er; however, pipe maintenance repairs defective
sprays and piping.
b) Inspection of damper shafts is to be performed by
maintenance for improper sealing, workability,
counterweight location, and lubrication every
month. Defective grease fittings will be changed
by the oven pipe personnel.
8) Collecting main pressure instrumentation is to be
checked weekly as follows:
a) Zero all crossover charts and adjust.
b) Steam out all impulse lines to pressure controller
and recording charts.
c) Check for full movement of controller and main
butterfly. •
d) Lubricate and clean controller as needed.
e) Report any abnormalities to supervision.
9) Aspiration system
a) Inspection of aspiration piping is to be done
weekly, i.e., steam piping, liquor piping, and
spray swirls.
10) Collecting main
a) All spray piping is to be inspected weekly and re-
placed as needed.
b) Refractory jamb between collecting main and goose-
neck is to be inspected quarterly and replaced as
needed.
A-10
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11) Battery equipment
a) Larry car maintenance and repair schedule
1) Inspection will include the following:
a) All hydraulically operated parts, for
example:
i) Flow control valve
ii) Slides
iii) Drop sleeves
iv) Gooseneck cleaner
b) Piping, pumps, hydraulic oil, and link-
ages associated with the hydraulic
system
c) Alignment of the boots with the charging
hole castings
d) Mechanically operated parts such as the
adjustable volumetric measuring rings,
bolts, bearings, and shafts
e) Electrical system including lights,
lines, and intercommunication equipment
f) The car will be lubricated on a daily
basis.
2) In the event major repairs are required, the
larry ca.r will be taken to the repair area
and work begun as soon as possible.
3) When a larry car drop sleeve becomes mis-
aligned with the charging hole castings, the
following procedure will be followed:
a) Larry car is removed from service and
inspected for the cause of misalignment.
b) Maintenance repairs any defective equip-
ment .
c) Blueprints are referred to as necessary.
d) After repairs are made, the car is lined
up on an oven and the drop sleeve align-
ment is checked with the charging hole
casting.
A-ll
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b) Pusher maintenance and repair schedule
1) Each pusher will be checked every other week
(meaning one pusher will be inspected every
week) by maintenance in addition to the daily
general inspection performed by operations
personnel.
2) The pushers will be taken to a repair area
and inspected for the following:
a) Level bar seal
b) Cables, rollers, and lubrication points
c) Electrical controller and motor
d) Decarbonizing air
e) Carbon cutter
A-12
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APPENDIX B
EFFECT OF STAGE CHARGING
ON TAR QUALITY
B-l
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TABLE B-l. EFFECT OF STAGE CHARGING ON TAR QUALITY'
Respondee
No.
6
7
15
19
27
32
33
41
43
Before stage charging.
Q.I., %
9-10
10
6
Not aval"
6-7
Moisture, %
1-3
5.8
6
able
2-3
Carbon disulfide
insolubles: 10-15
3.23
5/16-in. «
nozzlt
3.3
9-14
2.9
steam
;s
2.4
3.5-7.0
After stage charging
Q.I., %
12-15
Moisture, %
3.5-5
Increased for several weeks, then decreased.
In comparing stage charging battery with
conventional, the stage charging unit shows
an average Q.I. increase of 2%, and the
moisture content increased by a greater per-
centage . Stage charging practices must be
adhered to at all times to get uniform tar
moistures and Q.I.'s. Improper practices
quickly increase Q.I.'s and moistures.
Some. Steam pressure
pulverization are big
coal carryover.
and coal moisture and
factors in increasing
Q.I. increased, but because no separation
of tar occurred from different charging
modes, quantitative information is not
available.
13-15
5-6
After installing new charging steam orifices
(but without stage charging): 15-20.
5.77
9/16-in. stear
5.33
3/8-in. steam
4.20
8-13
2.8
n nozzles:
3.40
nozzles:
2.61
4-9
Reference 5.
Q.I. = Quinoline Insolubles, a measure of coal carryover.
B-2
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APPENDIX C
PRESSURE REGULATING SYSTEMS
C-l
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APPENDIX C
PRESSURE REGULATING SYSTEMS
Askania control--Jet pipe principle. The Askania Jet Pipe relay is the
nucleus around which all Askania Regulators are built. It converts a signal
(or impulse) from the source of measurement into a proportional movement of a
hydraulic cylinder that operates the final control element (butterfly valve).
The Jet Pipe is actually a stainless steel tube and nozzle from which oil
discharges toward two adjacent orifices located in a distributor block and
connected to either side of a power cylinder (Figure C-l). The impulse or
signal moves the Jet Pipe to change the position of the cylinder proportion-
ately to the change of signal.
The fundamental principle involved is the conversion of kinetic energy
(velocity pressure) into potential energy (static pressure). Oil leaving the
nozzle impinges upon the receiving orifices. If oil is entering the jet pipe
at 100 psi and the jet pipe is fully deflected toward one of the orifices,
pressure developed at the cylinder will be at least 90 psi, since recovery
through impingement is 90 percent or more.
A high degree of responsiveness (movement by extremely small signal
changes) is possible because of the Jet Pipe's almost frictionless movement.
The Jet Pipe swings between two bearings. At one end it is pivoted on a
miniature ball bearing and a highly finished pivot. At the other end it is
supported by a sleeve bearing, literally floating in oil.
The force that causes the Jet Pipe movement is obtained from the signal
change impressed on an impulse system such as a diaphragm, bellows, or elec-
trical coil.
Figure C-2 illustrates the regulator in a control system. The operation
can be described as follows:
1. A pressure signal from the main reaches the impulse system (in this
case a diaphragm).
C-2
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CYLINDER
COUNTERACTING
OIL FORCE
IMPULSE
JET PIPE
JET PIPE BEARING
DISTRIBUTOR
Figure C-l,, Jet pipe assembly.
C-3
-------
: IMPULSE LINES
MAIN
PUMP
TANK
BASE
Figure C-2. Diagram of the hydraulic control circuit.
C-4
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2. The pressure signal, multiplied by the diaphragm area creates a
force to act on the Jet Pipe. (This force is counterbalanced on the
other side of the Jet Pipe by a spring, in the case of pressure
control, or by another impulse system, in the case of ratio or pro-
portioning control. Here, we assume the counterforce to be a
spring.)
3. Assume that the force from the diaphragm becomes greater than that
of the opposing spring. The Jet Pipe is moved to the left--away
from the diaphragm; the pressure in the left receiving orifice is
increased and the pressure on the right orifice is decreased; this
impresses a differential pressure on the cylinder and causes the
cylinder to move.
4. The cylinder moves to close the butterfly valve, which decreases the
pressure and pressure signal until the diaphragm force balances the
spring counterforce. The Jet Pipe is then restored to mid-position.
The pressure in the two orifices are now equal, and the cylinder is
held stationary.
Hagan control--The Hagan control system is operated pneumatically instead
of hydraulically.
The impulse line is taken off the collecting main and the signal, either
high pressure or low pressure, causes a cylinder to move in a certain direc-
tion via a pneumatic control block valve. The cylinder is connected to the
butterfly valve in the gas main and either opens or closes the valve, depend-
ing on the impulse signal. When the pressure is relieved in the main (or is
built up), the air-operated cylinder is returned to mid-point, which keeps the
butterfly valve normal (about 45 degrees from the horizontal).
C-5
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APPENDIX D
COKE OVEN JOE FUNCTIONS FOR DOORS
D-l
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APPENDIX D
D.I JOB FUNCTIONS
Coking Process
Bricklayer and Bricklayer Helper:
Inspection, Cleaning, and Duties
1) The following procedure will be followed for door
repairs:
a) Remove the old brick from the door with the jack
hammer.
b) After removing brick, apply a one-inch coating of
insulating cement to the steel face of the door.
c) Install a new toe plate at the base of the door as
a foundation for the new brick.
d) Install new brick shapes and grout with Super 3000
refractory cement.
e) Cover the door with plastic or burlap bags to
allow cement to dry slowly under ambient condi-
tions.
f) Only portions of brick are removed to replace
chuck door or door latch castings.
2) Assist Patchers in repairing leaking gas guns.
3) Annually inspect regenerator faces and air box seals.
a) Assist Patchers in applying air setting cement to
the regenerator faces to prevent air filtering
into regenerators.
b) Assist Patchers in regrouting seals between air
boxes and regenerators and between air boxes and
waste'heat tunnel.
4) Assist Patchers in replacing door sill castings and
oven floor brick. This is normally done every 10
years.
D-2
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Luterman:
Coking Process
Inspection, Cleaning, and Duties
Inspection, cleaning, and duties of Luterman on both
sides of the battery are essentially the same.
Jamb Cleaning
Inspection
1) At the start of your shift be sure the required clean-
ing tools are on the pusher or door machine.
2) Report the following to your foreman:
a) Broken or missing door latches.
b) Bent keepers.
c) Very dirty doors.
d) Doors that do not fit properly after being cut.
e) Cracked chuck doors, pusher side.
Cleaning
1) Clean the jamb after the door is removed.
2) Clean up the dirt removed from the jamb and put in the
dirt buggy for reuse to make fresh mud.
3) Keep benches clean.
Duties
1) Work together with the Pusherman, Jackman, and Door
Machine Man.
2) After the door is removed from the oven, with the
cutting bar, remove all the tar and carbon deposits
from the jamb casting, lentil block and sill plate.
3) Clean up the area where the jamb was cut and put the
old dirt in the dirt buggy.
4) Report any problems concerning jamb cleaning to your
foreman.
D-3
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Luting
Inspection
1) At the start of your shift be sure the required tools
are on the mud trucks.
2) Inspect the quality of the luting mud.
3) Check to see that the benches were left clean by the
preceding shift.
4) Pay strict attention to door fires and put them out
immediately. If the door continues to burn, tell your
foreman so the problem can be corrected.
5) Inspect doors that smoke.
6) Relute and tamp any door that leaks smoke.
7) Report any door problems to your foreman.
Cleaning
1) Clean out the mud truck bin before loading with fresh
mud.
2) Clean the area around the door you just luted.
3) Clean the luting trowels when you finish your shift so
your relief has clean tools to work with.
Duties
1) At the start of your shift refill the mud truck with
fresh mud.
2) After the oven has been pushed and the door replaced,
fill the space between the door and the jamb with mud.
Do this around the whole outside of the door. Press
the mud deep into the void space around the door with
the finished trowel. Pay close attention to the top
and bottom of the door and behind the latches to get a
good tight seal.
3) After luting, clean up the bench area around the door.
4) Tamp and relute leaking doors.
D-4
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Jackman:
Coking Process
Inspection
1) At the start of your shift be sure the required tools
are on the pusher.,
2) Operate door jack to determine it is working properly.
3) Report the following to supervision:
a) Broken or missing door latches.
b) Bent keepers..
c) Doors that do not fit properly after being cut.
d) Missing door brick.
e) Cracked chuck doors or broken chuck door latches.
f) Mechanical problems with door jack.
g) Leaking air or water lines or valves that will not
shut off completely.
Cleaning
1) Clean up dirt removed from the cutting of a door or
jamb, and put the old dirt in the buggy for reuse in
making mud.
2) Help clean doors and/or jambs as directed.
3) Keep benches clean.
4) Clean coal off pusher and bench that may spill during
leveling.
Duties
1) Work together with the Pusherman and Luterman.
2) Operate the manually controlled jack on the pusher to
remove the door to be cleaned.
3) Aid the Pusherman in cleaning the door and/or Luterman
in cleaning the jamb.
4) Operate the manually controlled jack on the pusher to
replace the door on the oven after it is pushed.
5) Clean up all dirt accumulated during the cleaning
process and put in the buggy.
6) Report any problems concerning cleaning door and jamb
to your Foreman.
D-5
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Door Machine Man:
Coking Process
Inspection
1) At the start of your shift inspect mechanical and
electrical components of your machine, such as door
jack, travel controller, bearings, and lights.
2) Report the following to your Foreman:
a) Missing door brick.
b) Broken or missing latches.
c) Bent keepers.
d) Doors that cannot be replaced.
e) Doors that do not fit properly after being cut.
f) Very dirty doors.
g) Malfunctioning chipping gun, hoses, air valves,
etc.
3) Be sure proper tools are on your machine.
• 4) Inspect your machine at the start of your shift to see
that the preceding shift left it reasonably clean.
Cleaning
1) Clean the doors that you have been instructed to with a
cutting bar or the air-powered chipping gun.
2) Maintain your machine in a neat and workable condition.
Duties
1) Check the list you will receive from your Foreman of
the oven doors to be cleaned during the shift.
2) Remove the door of the oven to be cleaned and take it
to either the reverse room area, either at the north
end of No. 3 battery or the south end of No. 4 battery,
for cleaning.
3) With the chipping gun or cutting bar, remove all tar
and carbon deposits from the door brick retainer plate,
door shoulder, and the top and bottom of the door.
4) Remove old mud deposits from the luting surface of the
door in the same manner.
5) Keep the areas around where you cut doors clean by
putting the old mud, tar, and carbon in the dirt buggy
for reuse.
D-6
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6) After the oven has been pushed, be sure that;
a) The door fits correctly in the oven.
b) Both keepers are functional.
c) Both latches are secured in the keepers.
D-7
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APPENDIX E
OCCUPATIONAL HEALTH AND SAFETY
STANDARDS
Subpart Z - Toxic and
Hazardous Substances
(29 CFR 1910.1029, July 1, 1982)
Coke Oven Emissions
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§1910.1029 Coke oven emiMion*.
(a) Scope and application. This sec-
tion applies to the control of employee
exposure to coke oven emissions, except
that this section shall not apply to work-
Ing conditions with regard to which
other Federal agencies exercise statu-
tory authority to prescribe or enforce
standards affecting occupational safety
and health.
(b) Definitions. For the purpose of this
section: "Authorized person" means any
person specifically authorized by the
employer whose duties require the per-
son to enter a regulated area, or any
person entering such an area as a desig-
nated representative of employees for
the purpose of exercising the opportu-
nity to observe monitoring and measur-
ing procedures under paragraph (n) of
this section.
"Beehive oven" means a coke oven in
which the products of carbonization
other than coke are not recovered, but
are released into the ambient air.
"Coke oven" means a retort In which
coke is produced by the destructive dis-
tillation or carbonization of coal.
"Coke oven battery" means a structure
containing a number of slot-type coke
ovens.
"Coke oven emissions" means the ben-
zene-soluble fraction of total particulate
matter present during the destructive
distillation or carbonization of coal for
the production of coke.
"Director" means the Director. Na-
tional Institute for Occupational Safety
and Health, U.S. Department of Health.
Education, and Welfare, or his or her
designee.
"Emergency" means any occurrence
such as, but not limited to, equipment
failure which is likely to, or does, result
in any massive release of coke oven emis-
sions.
• "Existing coke oven battery" means a
battery in operation or under construc-
tion on January 20. 1977, and which is
not a rehabilitated coke oven battery.
"Rehabilitated coke oven battery"
means a battery which Is rebuilt, over-
hauled, renovated, or restored such as
from the pad up, after January 20. 1977.
"Secretary" means the Secretary of
Labor, U.S. Department of Labor, or hi*
or her designee.
"Stage charging" means a procedure
oy which a predetermined volume of coal
in each larry car hopper la Introduced
Into an oven such that no more than
two hoppers are discharging simultane-
ously.
"Sequential charging" means a proce-
dure, usually automatically timed, by
which a predetermined volume of coal In
each larry car hopper is introduced into
an oven such that Jio more than two
hoppers commence or finish discharging
simultaneously although, at some point.
all hoppers are discharging simultane-
ously.
"Pipeline charging" means any ap-
paratus used to introduce coal Into an
oven which uses a pipe or duct perma-
nently mounted onto an oven and
through which coal is charged.
"Green push" means coke which when
removed from the oven results In emis-
sions due to the presence of unvolatlHzed
coal.
(c) Permissible exposure limit. The
employer shall assure that no employee in the
regulated area is exposed to coke oven emis-
sions at concentrations greater than 150
micrograms per cubic meter of air (ISO
ug/m M. averaged over any 8-hour period.
(d) Regulated areas. (1) The employer
shall establish regulated areas and shall
iimit access to them to authorized per-
sons.
(2) The employer shall establish the
following as regulated areas:
The coke oven battery including
topside and its machinery, pushside and
its machinery, coke side and ltd machin-
ery, and the battery ends; the wharf;
and the screening station;
(11) The beehive oven and its machin-
ery.
(e) Exposure monitoring and measure-
ment—(1) Monitoring program. (1) Each
employer who has a place of employ-
ment where coke oven emissions are pres-
ent shall monitor employee! employed
In the regulated area to measure their
exposure to coke oven emissions.
(11) The employer shall obtain meas-
urements which are representative of
each employee's exposure to coke oven
emissions over an eight-hour period. All
measurements shall determine exposure
without regard to the use of respiratory
protection.
(ill) The employer shall collect full-
shift (for at least seven continuous
hours) personal samples, including at
least one sample during each shift for
each battery and each job classification
within the regulated areas Including at
least the following job classifications:
(a) Lltiman;
(b) Tar chaser;
(c) Larry car operator.
(d) Luterman;
(e) Machine operator, coke side:
(/). Benchman, coke side;
(?) Benchman, pusher side;
(ft) Heater;
«> Quenching car operator;
(j) Pusher machine operator:
(fc) Screening station operator;
(/) Wharf man;
(m) Ovenpatcher;
(n) Oven repairman;
(o) Spellman; and
(p) Maintenance personnel.
(iv) The employer shall repeat the
monitoring and measurements required
by this paragraph (e) (1) at least every
three months.
(2) Redetermination. Whenever there
has been a production, process, or con-
trol change which may result in new or
additional exposure to coke oven emis-
sions, or whenever the employer has any
other reason to suspect an Increase in
employee exposure, the employer shall
repeat the monitoring and measurements
required by paragraph (e)(l) of this
section for those employees affected by
such change or. increase.
(3) Employee notification. (1) The em-
ployer shall notify each employee in
writing of the exposure measurements
which represent that employee's exoosure.
within five working days after the re-
ceipt of the results of measurements re-
quired by paragraphs (e) (1) and (e) (2)
of this section.
(11) Whenever such results indicate
that the representative employee ex-
posure exceeds the permissible exposure
limit, the employer shall, In such notifi-
cation. Inform each employee of that fact
and of the corrective action being taken
to reduce exposure to or below the per-
missible exposure limit.
(4) Accuracy of measurement. The em-
ployer shall use a method of monitoring
and measurement which has an accuracy
(with a confidence level of 95%) of not
less than-plus or minus 35% for con-
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centrations of coke oven emissions
greater than or equal to 150 pg/m*.
(f) Methods of compliance. The em-
ployer shall control employee exposure to
coke oven emissions by the use of engi-
neering controls, work practices and res-
piratory protection as follows:
(1) Priority of compliance methods—
(i) Existing coke oven batteries, (a) The
employer shall institute the engineering
and work practice controls listed in para-
graphs (f)(2). (f)(3) and (f)(4) of this
section in existing coke oven batteries at
the earliest possible time, but not later
than January 20, 1980, except to the ex-
tent that the employer can establish that
such controls are not feasible. In deter-
mining the earliest possible time for in-
stitution of engineering and work prac-
tice controls, the requirement, effective
August 27, 1971, to implement feasible
administrative or engineering controls to
reduce exposures to coal tar pitch vola-
tlles. shall be considered. Wherever the
engineering and work practice controls
which can be instituted are not sufficient
to reduce employee exposures to or below
the permissible exposure limit, the em-
ployer shall nonetheless use them to re-
duce exposures to the lowest level achiev-
able by these controls and shall supple-
ment them by the use of respiratory
protection which complies with the re-
quirements of paragraph (g) of this sec-
tion.
(b) The engineering and work prac-
tice controls required under paragraphs
(f) (2). (I) (3) and (f) (4) of this section
are minimum requirements generally
applicable to all existing coke oven bat-
teries. If, after implementing all con-
trols required by paragraphs (f)(2),
(f)(3) and (f)<4> of this section, or
after January 20. 1980, whichever is
sooner, employee exposures still exceed
the permissible exposure limit, employ-
ers shall research, develop and Imple-
ment any other engineering and work
practice controls necessary to reduce ex-
posure to or below the permissible ex-
posure limit except to the extent that the
employer can establish that such controls
are not feasible. Wherever the engineer-
ing and work practice controls which can
be instituted are not sufficient to reduce
employee exposures to or below the per-
missible exposure limit, the employer
shall nonetheless use them to reduce
exposures to the lowest level achievable
by these controls and shall supplement
them by the use of respiratory protec-
tion which complies with the, require-
ments of paragraph (g) of this section.
(11) Neva or rehabilitated coke oven
batteries (a) The employer shall institute
the best available engineering and work
practice control! on all new or rehabili-
tated coke oven batteries to reduce and
maintain employee exposurei at or below
the permissible exposure limit, except
to the extent that the employer can
establish that such control* are not
feasible. Wherever the engineering and
work practice controls which can be In-
stituted are not sufficient to reduce em-
ployee exposurei to or below the per-
missible exposure limit the employer
shall nonetheless use them to reduce
exposures to the lowest level achievable
by these controls and shall supplement
them by the use of respiratory protec-
tion which complies with the require-
ments of paragraph (g) of this section.
If after Implementing all the en-
gtneering ami work practice controls re-
quired by paragraph (fHlMil) (o> of
this section, employee exposures still ex-
ceed the permissible exposure limit, the
employer shall research, develop and im-
plement any other engineering aad work
practice controls necessary to reduce ex-
posure to or below the permissible ex-
posure limit except to the extent that
the employer can establish that such
controls are not feasible. Wherever the
engineering imd work practice controls
which can be instituted are not sufficient
to reduce employe exposures to or below
the permlssllile exposure limit, the em-
ployer shall nonetheless use them to re-
duce exposures to the lowest level
achievable by these controls and shall
supplement them by the use of respira-
tory protection which complies with the
requirements of paragraph (g) of this
section.
(iii) Beehive oven*, (a) The employer
shall institute engineering and work prac-
tice controls on all beehive ovens at the ear-
liest possible time to reduce and main-
tain employee exposures at or below the
permissible exposure Limit, except to the
extent that i:he employer can establish
that such controls are not feasible. In
determining ikhe earliest possible time for
institution of engineering and work prac-
tice controls, the requirement, effective
August 27, 1971. to implement feasible
administrative or engineering controls to
reduce exposures to coal tar pitch vola-
tiles, shall be considered. Wherever the
engineering and work practice controls
which can be instituted are not sufficient
to reduce employee exposures to or below
the permissible exposure limit, the em-
ployer shall nonetheless use them to re-
duce exposures to the lowest level achiev-
able by these controls and shall supple-
ment them by the use.of respiratory
protection witiicb complies with the re-
quirements of paragraph (g) of this sec-
tion.
(b) If, after implementing all engineer-
tag and wort practice controls required
by paragraph (f) (i) (ill) (a) of this sec-
tion, employoe exposures still exceed the
permissible'exposure limit, the employer
shall research, develop, and implement
any other .engineering and work practice
controls necessary to reduce exposures
to or below tltie permissible exposure lim-
it except to the extent that the employer
can establish that such controls are not
feasible. Wherever the engineering and
work practice controls which can be In-
stituted are not sufficient to reduce em-
ployee exposures to or below the permis-
fible exposure limit, the employer shall
nonetheless use them to reduce exposurei
to the lowetit level achievable by these
controls and! shall supplement them by
the use .of respiratory protection which
compiles with the requirements of para-
graph <*> of this section.
(2) Engineering control*, (i) Charg-
ing, The employer shall equip and oper-
ate existing coke oven batteries with all
of the following engineering controls to
control coke oven emissions during
charging operations:
(o) One of the following methods of
charging:
(l) Stage charging as described in par-
agraph (f) (3(1) (b) of this section; or,
(2) Sequential charging as described
in paragraph (f) (3) (i) (b) of this section
except that paragraph (f) (3) (i) (b) (3)
(to) of this section does not apply to se-
quential charging; or
(j) Pipeline charging or other forms
of enclosed charging in accordance with
paragraph (f) (2) (1) of this section, ex-
cept that paragraphs (f)(2) (i) (b). (d),
(e). (/) and of this section do not
apply;
(b) Drafting from two or more points
in the oven being charged, through the
use of double collector mains, or a fixed
or moveable jumper pipe system to an-
other oven, to effectively remove the gases
from the oven to the collector mains;
(c) Aspiration systems designed and
operated to provide sufficient negative
pressure and flow volume to effectively
move the gases evolved during charging
into the collector mains, including suf-
ficient steam pressure, and steam jets of
sufficient diameter;
(d) Mechanical volumetric controls on
each larry car hopper to provide the
proper amount of coal to be charged
through each charging hole so that the
tunnel head will be sufficient to permit the
gases to move from the oven into the collector
mains;
(e) Devices to facilitate the rapid and
continuous flow of coal into the oven be-
ing charged, such as stainless steel liners,
coal vibrators or pneumatic shells;
(/) Individually operated larry car
drop sleeves and slide gates designed and
maintained so that the gases are effec-
tively removea from the oven Into the
collector mains;
(0) Mechanized gooseneck and stand-
pipe cleaners;
(H) Air seals on the pusher machine
leveler bars to control air infiltration
during charging; and
(I) Roof carbon cutters or a compress-
ed air system or both on the pusher ma-
chine rams to remove roof carbon.
(ii) Coking. The employer shall equip
and operate existing coke oven batteries
with all of the following engineering con-
trols to control coke oven emissions dur-
ing coking operations:
(a) A pressure central system on each
battery to obtain uniform collector main
pressure;
(b) Ready access to door repair facili-
ties capable of prompt and efficient re-
pair of doors, door sealing' edges and all
door parts;
(c) An adequate number of spare doors
available for replacement purposes;
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(d) Chuck door gaskets to control
chuck door emissions until such door is
repaired, or replaced; and
(e) Heat shields on door machines.
(3) Work practice control!. (1)
Charging. The employer shall operate
existing coke oven batteries with all of
the following work practices to control
coke oven emissions during the charging
operation:
(a) Establishment andlmplementation
of *- detailed, written inspection and
cleaning procedure for each battery con-
sisting of at least the following elements:
(1) Prompt and effective repair or re-
placement of all engineering controls;
(2) Inspection and cleaning of goose-
necks and standpipes prior to each
charge to a specified minimum diameter
sufficient to effectively move the evolved
gases from the oven to the collector
mains;
(3) Inspection for roof carbon build-up
prior to each charge and removal of roof
carbon as necessary to provide an ade-
quate gas channel so that the gases are
effectively moved from the oven Into the
collector mains:
«) Inspection of the steam aspiration
system prior to each charge so that suffi-
cient pressure and volume is maintained
to effectively move the gases from the
oven to the collector mains;
(5) Inspection of steam nozzles and
liquor sprays prior to each charge and
«»lw>ng as necessary so that the steam
nozzles and liquor sprays are clean;
(6) Inspection of standpipe caps prior
to each charge and cleaning and luting
or both as necessary so that the gases are
effectively moved from the oven to the
collector mains; and
(7) Inspection of charging holes and
lids for cracks, warpage and other de-
fects prior to each charge and removal
of carbon to prevent emissions, and
application of luting material to stand-
pipe and charging hole lids where neces-
sary to obtain a proper seal.
(b) Establishment and implementa-
tion of a detailed written charging pro-
cedure, designed and operated to elim-
inate emissions during charging for each
battery, consisting of at least the follow-
ing elements:
U) Larry car hoppers filled with coal
to a predetermined level in accordance
with the mechanical volumetric controls
.required under paragraph (f)(2)(l)(d)
of this section so as to maintain a suffi-
cient gas passage In the oven to be
charged;
(2) The larry car aligned over the
oven to be charged, so that the drop
sleeves fit tightly over the charging holes;
and
(J) The oven charged in accordance
with the following sequence of require-
ments:
«) The aspiration system turned oa;
(«) Coal charged through the-outer-
most hoppers, either individually or to-
gether. depending on the capacity of the
aspiration system to collect the gases
involved;
(SI) The charging holes used under
paragraph (f)(3)(i)(b)(3)(«) of this
section relldded or otherwise sealed off
to prevent leakage of coke oven emis-
sions;
(to) If four hoppers are used, the third
hopper discharged and relldded or other-
wise sealed off to prevent leakage of coke
oven emissions;
(t» The final hopper discharged until
the gas channel at the top of the oven
Is blocked and then the chuck door
opened and the coal leveled:
(trf > When the coal from the final hop-
per is discharged and the leveling oper-
ation complete, the charging hole re-
lidded or otherwise sealed off to prevent
leakage of coke oven emissions; and
(trfi) The aspiration system turned off
only after the charging holes have been
cloaed.
CO Establishment and implementa-
tion of a detailed written charging pro-
cedure. designed and operated to elimi-
nate emissions during charging of each
pipeline or enclosed charged battery.
(U) 'Coking. The employer shall oper-
ate existing coke oven batteries pursuant
to a detailed written procedure estab-
lished and implemented for the control
of coke oven emissions during coking,
of at least the following
elements:
Checking oven back pressure con-
trols to maintain uniform pressure con-
ditions In the collecting main;
(b) Repair, replacement and adjust-
ment of oven doors and chuck doors and
replacement of door jambs so as to pro-
a continuous metal-to-metal fit:
Cleaning of oven doors, chuck
doors and door jambs each coking cycle
so as to provide an effective seal;
(d) An inspection system and correc-
tive action program to control door emis-
sions to the maximum extent possible:
and
(e) Luting of doors that are sealed by
luting each coking cycle and reluting.
replacing or adjusting as necessary to
control leakage.
(ill) Pushing. The employer shall op-
erate existing coke oven batteries with
the following work practices to control
coke oven emissions during pushing oper-
ations:
(a) Coke and coal spil'age quenched
at soon as practicable and not shoveled
into a heated oven; and
(b) A detailed written procedure for
each battery established and imple-
mented for the control of emissions dur-
ing pushing consisting of the following
elements:
Regular Inspection of the damper
system, aspiration system and collector
main for cracks or leakage, and prompt
implementation of the necessary repairs:
(d) Regular inspection of the heating
system and prompt implementation of
the necessary repairs;
(e) Prevention of miscellaneous fugi-
tive topside emissions;
(/) Regular inspection and patching of
oven brickwork;
(0> Maintenance of battery equipment
and controls in good working order;
(ft) Maintenance and repair of coke
oven doors, chuck doors, door jambs and
seals; and
<»> Repairs instituted ana completed
as soon as possible, including temporary
repair measures Instituted and completed
where necessary, including but not limit-
ed to:
(J) Prevention of miscellaneous fugi-
tive topside emissions; and
(2) Qhuck door gaskets, which shall
be installed prior to the start of the next
coking cycle.
(4) Filtered air. (i) The employer
shall provide positive-pressure, tempera-
ture controlled filtered air for larry car.
pusher machine, door machine, and
quench car cabs.
(11) The employer shall provide stand-
by pulpite on the battery topside, at the
wharf, and at the screening station,
equipped with positive-pressure, tem-
perature controlled filtered air.
(5) Emergencies. Whenever an emer-
gency occurs, the next coking cycle may
not begin until the cause of the emer-
gency is determined and corrected, un-
less the employer can establish that it
is necessary to initiate the next coking
cycle in order to determine the cause
of the emergency.
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(6) Compliance program. (i) Bach
employer shall establish and Implement
a written program to reduce exposures
solely by means of the engineering and
work practice controls required in paragraph
(f) of this section.
(11) Hie written program shall m-
clude.at least the following:
(a) A description of each coke oven
operation by battery, Including work
force and operating crew, coking time,
operating procedures, and maintenance
practices;
(b) Engineering plans and other
studies used to determine the controls
for the coke battery;
(o A report'of the technology con-
sidered In meeting the permissible expo-
sure limit;
«t) Monitoring data obtained in ac-
cordance with paragraph (e) of this
section;
(e) A detailed schedule for the Imple-
mentation of the engineering and work
practice controls required in paragraph (f)
of this section: and.
(/) Other relevant information.
(Ill) If, after implementing all con-
trols required by paragraphs (t) <2>-"y for
each employee who uses a non-powered.
particulate filter respirator.
(11) The employer shall allow each em-
ployee who uses a filter respirator to
change the filter elements whenever an
increase in breathing resistance is de-
tected and shall maintain an adequate
supply of filter elements for this purpose.
(Ill) The employer shall allow em-
ployees who wear respirators to wash
their face and respirator facepiece to pre-
vent skin irritation associated with res-
pirator use.
(h) Protective clothing and equip-
ment—(I) Provision and use. The em-
ployer shall provide and assure the use
of appropriate protective clothing and
equipment, such as but not limited to:
(i) Flame resistant Jacket and pants;
(11) Flame resistant gloves;
(ill) Face shields or vented goggles
which comply with i 1910.133(a) (2) of
this part;
(iv) Insulation from hot surfaces for foot-
wear;
,(v) Safety shoes which comply with
f 1910.136 of this part; and
(vi> Protective helmets which comply
with | mo. 135 of this part.
(2) Cleaning and replacement, (i)
The employer shall provide the protec-
tive clothing required by paragraphs (h)
(1) (i) and (11) of this section In a clean
and dry condition at least weekly.
(11) The employer shall clean, launder,
or dispose of protective clothing required
by paragraphs (h) (1) (1) and (11) of this
section.
(ill) The employer shall repair or re-
place the protective clothing and equip-
ment as needed to maintain their effec-
tiveness.
(Iv) The employer Shan assure that
all protective clothing is removed at the
completion of a work shift only in change
rooms prescribed in paragraph (1) (1) of
this section.
(v> The employer shall assure that
contaminated protective clothing which
U to be cleaned, laundered, or disposed
of. is placed in a double container in the
change room.
(vl) The employer shall inform any
person who cleans or launders protec-
tive clothing required by this section, of
the potentially harmful effects of ex-
posure to coke oven •m
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tectlve clothing and equipment when-
ever employees an required to wear pro-
tective cinth of this section.
(11) Drinking water may be consumed
to the regulated area.
(j) Medical ivneOIanee. (1) Genera
requirements. (1) Each employer shall
Institute a medical surveillance program
for all employees who are employed to
a regulated area at least 30 days per year.
(U) This program £iall provide each
employee covered under paragraph (j)
(1) (1) of this section with an opportu-
nity for medical examinations to accord-
ance with this paragraph .
(ill) The employer shall inform any
employee who refuses any required medl-
oj yrMninaM«»« of %hf possible health
consequences of such refusal and shall
obtain a signed statement from the em-
ployee indicating that the employee un-
derstands the risk involved to the refus-
al to be examined.
(iv> The employer shall assure that
all nwtif*i examinations and procedures
are performed by or under the supervi-
sion of a licensed physician, and are pro-
vided without cost to the employee.
(2) initial examination*. At the time
of initial rttlgiurr""* to a regulated area
or upon the institution of the medical
surveillance program, the employer shall
provide i medical examination for employees
covered under paragraph (j)(l Hi) of this lec-
tion, including at least the following elements:
(i) A work history and medical history
which shall include smoking history and
the presence and degree of respiratory
symptoms, such as breathlessness, cough.
sputum production, and wheezing;
of this section at least
seml-annually for employees 45 years of
age or older or with five («) or more years
employment to the regulated area.
(Ill) Whenever an employee who is 45
yean of age or older or with five (5) or
more years employment to the regulated
area transfers or is transferred from em-
ployment to a regulated area, the em-
ployer shall continue to provide the ex-
aminations specified to paragraphs (J)
(2)(i)-(vlll) of this section seml-an-
nually, as long as that employee is em-
ployed by the same employer or a suc-
cessor employer.
(iv) Whenever an employee has not
taken the examinations specified In par-
agraphs (j)(3)(l)-(lil) of this section
within the six (6) months preceding the
termination of employment, the employ-
er shall provide such examinations to the
employee upon termination of employ-
ment
(4) Information provided to the pftyti-
cion. The employer shall provide the fol-
lowing Information to the f^amtntng
physician:
(1) A copy of this regulation and its
Appendixes;
(11) A description of the affected em-
ployee's duties as they relate to the em-
ployee's exposure;
(ill) The employee's exposure level or
estimated exposure level;
(iv) A description of any personal pro-
tective equipment used or to be used: and
(v) Information from previous medi-
cal examinations of the affected employee
which is not readily available to the ex-
amining physician.
(5) Physician's written opinion. (1) The
employer shall obtain a written opinion
from the examining physician which
shall Include:
(a) The results of the medical exami-
nations;
(b) The physician's opinion as to
whether the employee has any detected
medical conditions which would place
the employee at increased risk of mate-
rial Impairment of the employee's health
from exposure to coke oven emissions;
(c) Any recommended limitations upon
the employee's exposure to coke oven
emissions or upon the use of protective
clothing or equipment such as respira-
tors: and
(d) A statement that the employee has
been informed by the physician of the
results of the medical examination and
any medical conditions which require
further explanation or treatment.
(11) The employer shall Instruct the
physician not to reveal to the written
opinion specific findings or diagnoses un-
related to occupational exposure.
(ill) The employer shall provide a copy
of the written opinion to the affected em-
ployee.
(k) Employee information and train-
ing—(1) Training program, (i) The em-
ployer shall institute a training program
for employees who are employed to the
regulated area and shall assure their par-
ticipation.
(11) The training program shall be pro-
vided as of January 27, 1977 for employ-
ees who are employed to the regulated
area at that time or at the time of in-
itial assignment to a regulated area.
(ill) The training program shall be
provided at least annually for all em-
ployees who are employed to the regu-
lated area, except that training regard-
Ing the occupational safety and health
hazards associated with exposure to coke
oven emissions and the purpose, proper
use, and limitations of respiratory pro-
tective devices shall be provided at least
quarterly until January 20,1978.
(Iv) The training program shall In-
clude informing each employee of:
(a) The information contained to the
substance information sheet for coke
oven emissions (Appendix A);
(b) The purpose, proper use, and lim-
itations of respiratory protective devices
required to accordance with paragraph
(g) of 'this section;
(c) The purpose for and a description
of the medical surveillance program re-
quired by paragraph (J) of this section
including Information on the occupation-
al safety and health hazards associated
with exposure to coke oven emissions;
(d) A review of all written procedures
and schedules required under paragraph
(f) of this section; and
A review of this standard.
(2) Access to training materials. (1)
The employer shall make a copy of this
standard and its appendixes readily
available to all employees who are em-
ployed to the regulated area.
(ii) The employer shall provide upon re-
quest all materials relating to the employee
information and training program to the
Secretary and the Director.
(I) Precautionary signs and labels —
(1) General. (1) The employer may use
labels or signs required by other statutes,
regulations or ordinances to addition to.
or to combination with, signs and labels
required by this paragraph.
(ii) The employer shall assure that no
statement appears on or near any sign
required by this paragraph which con-
E-6
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tradlcts or detract! from the effecU of
the required sign.
(Ill) The employer shall assure that
signs required by this paragraph are il-
luminated and cleaned as necessary so
that the legend is readily visible.
(2) Siffru. (1) The employer shall post
signs in the regulated area bearing the
legends:
DANGER
CANCER H**ABT>
AUTHORIZED PERSONNEL ONLY
NO SMOKING OB BATING
(11) In addition, not later than Janu-
ary 20. 1978. the employer shall post
signs in the areas where the permissible
exposure limit is exceeded bearing th*
legend:
DANGER
RESPIRATOR REQUIRED
(3) Labels. The employer shall apply
precautionary labels to all containers of
protective clothing contaminated with
coke oven emissions bearing the legend:
CAUTION
CLOTRTNO CONTAMINATED WITH COKZ
EMISSIONS
DO NOT REMOVE DUST BT BLOWING OB
SHAKING
(m) Recordkeeping.—(1) Exposure
measurement!. The employer shall estab-
lish and maintain an accurate record
of all measurements taken to monitor
employee exposure to coke oven emis-
sions required in paragraph (e) of this
section.
(i) This record shall include:
(a) Name, social security number, and
job classification of the employees moni-
tored;
(b) The date(s), number, duration and
results of each of the samples taken, in-
cluding a description of the sampling
procedure used to determine representa-
tive employee exposure where applicable;
(c) The type of respiratory protective
devices worn, if any;
(d) A description of the sampling and
analytical methods used and evidence of
their accuracy; and
(e) The environmental variables that
could affect the measurement of em-
ployee exposure.
(11) The employer shall maintain this
record for at least 40 years or for the
duration of employment plus 20 years,
whichever Is longer.
(2) Medical surveillance. The em-
ployer shall establish and maintain tn
accurate record for each employee sub-
ject to medical surveillance as required
by paragraph (j) of this section.
(1) The record shall include:
(a) The name, social security number.
and description of duties of the em-
ployee;
(b) A copy of the physician's written
opinion:
(c) The signed statement of any re-
fusal to take a medical examination un-
der paragraph (j) (1) (11) of this section;
and
(d) Any employee medical complaints
related to exposure to coke oven emis-
sions.
(11) The employer shall keep, or assure
that the examining physician keeps, the
following medical records:
(a) A cojiy of the medical examina-
tion results including medical and work
history required under paragraph (j) (2)
of this section;
(b) A description of the laboratory
procedures used and a copy of any stand-
ards or guidelines used to Interpret the
test results;
(c) The initial x-ray;
(d) The x-rays for the most recent 5
years;
(e) Any x-ray with a demonstrated
abnormality and all subsequent x-rays;
(/) The Initial cytologic examination
slide and written description;
(a) The cytologic examination slide
and written description for the most re-
cent 10 years; and
(ft) Any cytologic examination slides
with demonstrated atypla, if such atypla
persists for 3 years, and all subsequent
slides and written descriptions.
(Ill) The employer shall maintain
medical records required under para-
graph (m) (2) of this section for at least
40 years, or for the duration of employ-
ment plus 20 years, whichever is longer.
(3) Availability, (l) The employer
shall make available upon request all
records required to be maintained by
paragraph (m) of this section to the
Secretary snd the Director for exami-
nation and copying.
(ii) Employee exposure measurement
records and employee medical records re-
quired by this paragraph shall be provided
upon request to employees, designated
representatives, and the Assistant Secre-
tary in accordance with 29 CFR 1910.
2
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•Oil wear It U you are near visible emissions.
Sine* bow well your respirator flu your face
is very Important, your employer U required
to conduct fit tests to make lure the respira-
tor seals properly when you wear it. Then
tests are simple and rapid and will be ex-
plained to you during your training sessions.
B. Protective clothing: Tour employer is
required to provide, and you must wear,
appropriate, clean, protective clothing and
equipment to protect your body from re-
peated skin contact with coke oven emissions
and from the beat generated during the
coking process. This clothing should include
such items as Jacket and panta and flame
resistant gloves. Protective equipment should
include (ace shield or vented goggles, protec-
tive helmets and safety shoes. Insulated from
hot surfaces where appropriate.
ZV. KYGIXNK FACILJTTZa AND PRACTICXS
You must not eat, drink, smoke, chew gum
or tobacco, or apply cosmetics in the regu-
lated area, except that drinking water is
permitted. Tour employer is required to
provide lunchrooms and other areas for these
purposes.
Tour employer Is required to provide show-
ers, washing facilities, and change rooms.
II you work in a regulated area, you must
wash your face, and hands before eating.
Tou must shower at the end of the work
shift. Do not take used protective clothing
out of the change rooms without your em-
ployer's permission. Tour employer Is re-
quired to provide for laundering or cleaning
of your protective clothing.
V. SIGNS ANV LAXXLS
Tour employer is required to post warning
signs and labels for your protection. Signs
must be posted in regulated areas. The signs
must warn that a cancer hazard is present,
that only authorized employees may enter
the area, and that no smoking or eating is
allowed. In regulated areas where coke oven
emissions are above the permissible exposure
limit, the signs should also warn that res-
pirators must be worn.
TIB.
TO
lUBfBUAIICl
vi. mnirAi. KXHUNATTOMS
If you work in a regulated area at least
SO days per year, your employer Is required
to provide you with a medical examination
every year. The medical examination must
Include a medical history, a cheat x-ray:
pulmonary function test; weight compari-
son; skin examination; a urlnalysis and a
urine and sputum cytology exam for the early
detection of urinary or lung cancer. The
cytology exams are only Included in the
initial exam until you are either 45 years or
older or have 5 or more years employment
in the regulated areas when the medical
exams including these tests are to be given
every 6 months. The examining physician
will provide a written opinion to your em-
ployer containing the results of the medical
exams. Tou should also receive a copy of this
opinion.
viz. csMBVAtioit OF Momrostnto
Tour employer Is required to monitor your
expocure to coke oven emissions and you are
entitled to observe the monitoring procedure.
Tou are entitled to receive an explanation of
the measurement procedure, observe the
steps taken in the measurement procedure,
and to record the results obtained. When the
monitoring procedure Is taking place In an
area where respirators or personal protective
clothing and equipment are required to be
worn, you must also be provided with and
must wear the protective clothing and
equipment.
Tou or your representative are entitled to
records of your exposure to coke oven emis-
sions upon request to your employer. Tour
medical examination records can be fur-
nished to your physician upon request to
your employer.
IX. T»AIJ«IJ«0 AND DOTATION
Additional Information on all of these
items plus training as to hazards of coke
oven emissions and the engineering and work
practice controls associated with your Job
will also be provided by your employer.
AWXNDIX B INDUSTXIAL HYGIXNI AND MEDICAL
SUIVKIUANCX OurnxuNxs
I. WDCSTXIAL HTGIXNI OOTDILIHIS
A. Sampling (Benzene-Soluble Fraction
Total Paniculate Matter).
Samples collected should be full shift (at
least 7-hour > samples. Sampling should be done
using a personal sampling pump with pulsation
damper at a flow rate of 9 liters per minute.
Samples should be collected on 0.8 microme-
ter pore six* silver membrane filters (37 mm
diameter) preceded by Oelman glass flber
type A-E filters encased in three-piece plastic
(polystyrene) field monitor cassettes. The
cassette face cap should be on and the plug
removed. The rotameter should be checked
every hour to ensure that proper flow rates
are maintained.
A minimum of three full -shift samples
should be collected for each job classification
on each battery, at least one from each shift.
If disparate results are obtained for particu-
lar job classification, sampling should
be repeated. It U advisable to sample each
ahfft on more than one day to account for
environmental variables* (wind, precipita-
tion, etc.) which may affect sampling. Differ-
ences in exposures among different work
shifts may indicate a need to Improve work
practices on a particular shift. Sampling re-
sults from different shifts for each Job classi-
fication should not be averaged. Multiple
samples from . the same shift on each battery
may be used to calculate an average exposure
for a particular job classification.
A. General.
The minimum requirements for the medi-
cal examination for coke oven workers are
given in paragraph (J) of toe standard.
The initial examination is to be provided to all
coke oven workers who work at least SO days in the
regulated area. The examination includes at 14" x 17"
The examination Includes at 14" Z 17"
posterior-anterior chest x-ray and a ILO/trc
rating to assure some standardization of
x-ray reading, pulmonary function tests
(PTC and TIT 1.0). weight, urlnalysis. skin
examination and a sputum »"^ urinary
eytologlc examination. These tests are to
serve as the baseline for comparing the em-
ployee's future test results. Periodic exams
Include all the elements of the Initial exams
except that the cytologic tests need be
performed only on those employees who an
46 years of age or older or who have worked
for 6 or more years In the regulated are:;
periodic exams are to be performed seml-
annually for this group Instead of annually.
The examination contents are minimum re-
quirements, additional testa such as lateral
and oblique x-rays or additional pulmonary
function tests may be performed If deemed
1. All extraction glassware Is cleaned with
dichromic acid cleaning solution, rinsed with
tap water, then dlonleed. water, acetone, and
allowed to dry completely- The glassware is
rinsed with nanograde benzene before use.
The Teflon cups are cleaned with bansane
then with acetone.
I. Pre-weigh the 2 ml Telfon cups to one bun-
dredUi ot a milligram (0.01 mg> on an auto-
balance AD 2 Tare weight of the cups is about
SO mg
3. Place the silver membrane filter and
glass flber filter Into a 16 ml test tube.
4. Extract with S ml of benzene for five
minutes In an ultrasonic cleaner.
6. Filter the extract in 15 ml medium glaes
fritted funnels.
6. Rinse test tube and filters with two 1.6
ml allquots of benzene and filter through the
fritted glass funnel.
7. Collect the extract and two rinses In a
10 ml Kontes graduated evaporative concen-
trator.
B. Evaporate down to 1 ml while rinsing the
sides with benzene.
9. Plpet 0.6 ml into the Teflon cup and
evaporate to dryness in a vacuum oven at
40 * C for 3 hours.
10. Weigh the Teflon eup and the weight
gain Is due to the bencene soluble residue in
half the Sample.
B. fvlmonarf function tetti.
Pulmonary function tests should be per-
formed In a manner which minimizes sub-
ject and operator bias. There has been shown
to be learning effects with regard to the re-
sults obtained from certain tests, such as FBV
1.0. Best results can be obtained by multiple
trials for each subject. The best of three
trials or the average of the last three of five
trials may be used in obtaining reliable re-
sults. The type of equipment used (manu-
facturer, model, etc.) should JM recorded with
•he results as reliability and accuracy varies
and such information may be important in
the evaluation of test results. Care should be
exercised to obtain the best possible test-
ing equipment.
C. Sputum cytoiopy.
Sputum can be collected by aerosol inhala-
tion during the medical exam or by spon-
taneous early morning cough at home. Spu-
tum Is induced by transoral inhalation of an
aerosolized solution of eight per cent (8%)
sodium chloride in water. After inhaling as
few as three to five breaths the subject usu-
ally yields an adequate sputum specimen. A
minimum of three samples should be col-
lected by the subject at home. All sputum
should be collected directly into sixty percent
(M%) alcohol.
Scientific evidence suggests that chest x-
rays and sputum cytology should be used
together as screening tests for lung cancer in
high .risk populations, such as coke oven
workers. The tests are to be performed every
six months on workers who are 46 years of
age or older or have worked In the) regulated
area for 6 or more years. Bines the Mats seem
to be complementary. It may be advantageous
to alternate the test procedures. For Instance.
chest x-rays could be obtained in June and
December and-sputum cytology* could be
obtained in March and September. Facilities
for providing necessary diagnostic Investiga-
tion should be readily available as well as
chest physicians, surgeons, radiologists,
pathotoglsts and Immunotheraplsts to pro-;
•
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APPENDIX F
METHOD 109
DETERMINATION OF VISIBLE EMISSIONS
FROM COKS OVEN BATTERIES
F-l
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METHOD 109. DETERMINATION OF VISIBLE EMISSIONS
FROM.COKE OVEN BATTERIES
Introduction
This method involves the determination of visible emissions
emitted from charging systems, topside leaks (leaking offtake
systems, stationary jumper pipes, oven lids, and collection mains),
and coke oven doors. No specific training or certification is
required of an observer before applying this method, but the observer
must be educated on the general procedures for determining the level
of visible emissions. As a minimum, the observer should be aware of
the effects of background contrast, ambient lighting, relative
observer position, and the presence of uncombined water (condensing
water vapor) on the visibility of emissions. Furthermore, prior to
conducting a performance test using this method, an inexperienced
observer should become familiar with the coke oven battery and with
the charging system being employed. Such familiarization can be
accomplished in a period of 4 to 8 hours by observing the operation of
the coke oven battery and the charging system in the company of someone
familiar with the operation of the battery and/or the application of
this method.
Part A of this method establishes the procedures for determining
visible emissions during the oven charging period for larry car
systems charging wet coal. Part A of this method does not apply to
preheated-coal charging systems. Visible emissions from the
charging operation are emitted from the area around each topside port
F-2
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and from the top of the larry car hoppers. This method involves
recording the total time that emissions are visible during the
charging period. The emissions can be steady, but are usually
intermittent or pulsating during well-controlled charges. These
intermittent emissions result from momentary pressure buildups,
which occur as coal is charged to and leveled in the coke oven.
Except for these pressure surges, the oven is under a slight vacuum
during the charging period.
Part B of this method establishes the procedures for determining
emissions from offtake systems, stationary jumper pipes, topside
ports, and collection mains. These points provide the potential
for numerous leaks on the battery topside; furthermore, because of the
varying pressures within the battery, the leaks can be intermittent.
The large number and variability of potential leaks make it nearly
impossible to identify the occurrence or duration of all emissions
occurring at any time, and thiis method is not intended to do so.
Instead, this method involves a quick inspection of all the ovens on
a single battery.
Furthermore, leaks from these sources can be of any magnitude;
the leaks can be large or can be as small as a wisp from a smoking
cigarette. This method.does riot differentiate between small and large
"teaks; all visible emissions (other than vapor from steam) are recorded
as leaks.
The number of leaks in the collection main(s) are counted and
recorded. The leaking topside ports are counted and recorded.
The leaking offtake systems and stationary jumper pipes are counted
F-3
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and recorded. To inspect the offtake systems or topside ports, the
•
observer walks the center!ine of the battery and counts leaking
offtake systems or topside ports. To count leaks 1n the collection
main(s), the observer walks down the topside at the edge closest to
the main, or the observer walks down the catwalk(s) above the collection
main(s). During each inspection the observer walks at a normal and
steady pace, pausing only to record data. A typical traverse (run) of
a 70-oven battery should take approximately 4 minutes. An average rate
of 6 seconds per oven for each traverse (run) is the maximum amount
of time permitted. During the run, the observer does not stray from
the center!ine of the battery in order to get a "closer look" at the
topside ports, stationary jumper pipes, or offtake systems. In many
cases, fugitive emissions from other sources (I.e., door leaks, hot
coke car) will partially obscure the vision of the observer. In such
cases, the observer must make an effort to distinguish among the sources
of the emissions, but the observer should not allow fugitive emissions
to significantly delay the inspection of the battery. If there is any
doubt as to whether the source being inspected is actually leaking,
the observer shall not record a leak.
Part C of this method establishes the procedures for determining
emissions from coke oven doors. During the coking cycle, leaks can
occur in the sea! between the oven door and oven frame (door jamb)
and 1n the seal between the chuck door and chuck door frame. Because
the pressures within the coke oven vary, a leak from an oven door
can start or stop at any time during the full coking cycle.
F-4
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Each oven door and each chuck door on the battery 1s a potential
emission source. The large number and variability of potential
leaks make it nearly Impossible to identify the occurrence and
duration of all door leaks on a battery at any given time and this
method is not intended to do so. Instead, this method involves a
successive inspection of all the oven doors and chuck doors on a
single battery. To perform the inspection, the observer first inspects
either the push side or coke side of the battery. The observer takes
a position on the ground at one end of the chosen side of the battery.
The observer looks at each oven and chuck door and counts the doors
that have visible emissions whiile walking along the ground to the
other end of the battery. The inspection is completed by observing
the doors on the other (coke or push) side of the battery. During
the inspection the number of the ovens with leaking doors is recorded;
the percent doors leaking is calculated based on the number of
potential sources and is recorded as the emission rate.
Parts A, B, and C of this method establish procedures for
determining emissions from charging operations, topside leaks, and
door leaks. Different regulations apply to all these emission sources;
therefore, the procedures of this method may be selectively applied
to determine emissions from only the particular source(s) of interest
at the time.
The high temperatures and the large amount of mobile heavy
machinery used in the coking process make a coke oven battery
environment potentially very hazardous. Consequently, special
F-5
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consideration must be given to safety when applying this test
method. Safety must be considered when choosing observation
locations and traverse routes as well as when implementing any
of the provisions of this method. Furthermore, special safety
precautions are required since coke oven emissions are suspected
carcinogens. The precautions required can be found in the
Occupational Safety and Health Administration (OSHA) regulations
pertaining to exposure of coke oven workers (Federal Register.
Vol. 41, No. 206, part III, Friday, October 22, 1976). In general,
the regulation requires that special fire-retardant clothing and
respirators be worn in certain restricted areas of the coke battery.
Furthermore, certain activites such as chewing gum, smoking, and
eating are restricted. Prior to using this test method, the observer
should obtain a copy of the OSHA regulation and become familiar with
its contents.
F-6
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PART A-DETERMINATION OF VISIBLE EMISSIONS
DURING THE OVEN CHARGING PERIOD
•
1. Applicability and Principle
1.1 Applicability. Part A of this method applies to the
determination of charging emissions from coke oven batteries
charging wet coal (as defined in the applicable subpart).
Observation of the appropriate number of oven charges as specified
by the applicable subpart is required.
1.2 Principle. The visible emissions emitted from charging
systems and topside ports are visually determined by an observer
familiar with coke oven battery operations.
2. Definitions
2.1 Charging Period. The period of time commencing when coal
starts flowing into the oven and ending when the last oven lid is
put in place. The charging period does not include the period of time
during which the topside port lids are reopened in order to sweep
spilled coal into the oven.
2.2 Charging System. An apparatus used to add coal to an oven
(e.g., a larry car).
2.3 Coke Oven Battery. A facility for the production of coke
containing one or more ovens with an integral heating system.
2.4 Oyen. A chamber used for the destructive distillation of
coal to produce coke.
2.5 Topside Port. Any opening in the topside of an oven except
for offtake systems and heating flue inspection ports.
F-7
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3. Equipment
An accumulative-type stopwatch with a sweep second hand and
unit divisions of at least 0.5 second is required.
4. Procedure
4.1 Position. Stand on the coke oven battery topside in a
position that affords a good view of the charging system and of
all the topside ports of the oven being charged. A position in
the center of the battery and 10 to 15 ovens from the oven being
charged is recommended.
4.2 Observations. During the charging period, watch for all
of the potential emission sources from the entire charging system
including the topside ports and larry car hoppers. Upon observing
any visible emission, start the accumulative stopwatch. Stop the
watch when the visible emission ceases, and restart the watch when
the visible emission reappears. Continue this procedure for the
entire charging period (defined in section 2.5). Visible emissions
may occur simultaneously from several points during a charge, e.g.,
from around all drop sleeves at the same time. In this case, time the
visible emissions collectively, not independently. Also, visible
emissions may start from one source immediately after emissions from
another source stop. Time this asi one continuous visible emission.
Do not time the following visible-emissions:
4.2.1 Visible emissions from smoking coal caught in the hopper
gate "coal box" present on some larry cars. Distinguish between
smoldering coal and oven emissions by noting the color and magnitude
F-8
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of the emissions, as well as the location of the emissions. Emissions
•
from smoldering coal are generally white or gray and are continuously
emitted from the hopper shrouds at or near the slide gates. These
emissions generally have a plumu of less than 1 meter 1n length.
Charging emissions are generally yellow/brown or black.
4.2.2 Visible emissions from burning or smoldering coal spilled
on top of the oven or topside port lid during charging.
4.2.3 Visible emissions emitted from the standpipe cap(s) during
the charging period.
4.2.4 Visible emissions emitted from the coke oven doors
(including chuck door) during the charging period.
4.2.5 Condensing water vapor.
4.2.6 Visible emissions that drift from the top of a larry car
hopper, but have already been timed as a visible emission from the
drop sleeve below the hopper. When the slide gate closes on a larry
car hopper after the coal has been added to the oven, the gate may not
provide an airtight seal. On occasion a puff of smoke observed at the
drop sleeve shrouds is forced past the slide gate up into the
larry car hopper. From there tlhe smoke may drift from the top of
the larry car hopper over a much longer period than it was visible at
the shroud; time these visible elnissions only at the shroud.
If the larry car hopper does not have a slide gate or the slide gate
1s left open or only partially closed, visible emissions may quickly
pass through the larry car hopper without being observed at the shroud.
In this case, the emission from the larry car hopper will appear as a
strong surge of smoke and 1s to be timed.
F-9
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4.3 Visual Interference. Occasionally, fugitive emissions
•
from other sources at the coke battery (e.g., condensing water
vapor from the coke oven wharf or door leaks) prevent a clear view
of the charging system during a charge. If the view of the potential
emission points is obscured to such a degree that the observer
questions the validity of the readings, the observer clearly notes
this fact on the data form.
4.4 Recording Data. Record all the information requested at
the top of the data form prior to starting the inspection. For each
charge observed, record the number of the oven charged and the
approximate time the charge is begun. For each charge, the
accumulated seconds recorded on the stopwatch is the total time that
visible emissions were observed during the charge period. Record
this time (seconds) in column 3 of the charging operation data sheet
(Figure 109-1) to the nearest 0.5 second. In the cases where
interference from fugitive emissions prevents a valid reading (see
paragraph 4.3), record the oven number and make the following
notation in column 3 of the data form: "No reading, visual
interference."
5. Calculations
See applicable subpart.
F-10
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PART B--DETERMINATION OF VISIBLE EMISSIONS
FROM COKE OVEN TOPSIDE LEAKS
1. Applicability and Principle
1.1 Applicability. Part B of this method applies to the
determination of the emissions from leaking offtake systems,
topside ports, and collection mains from by-product coke oven
batteries. Separate runs are required for determining compliance
with any one of the separate emission standards for topside ports,
offtake systems and stationary jumper pipes, and collection mains.
Compliance with any one or all of the topside leak emission standards
may be determined by conducting the appropriate number of runs as
specified in the applicable subpart.
1.2 Principle. The visible emissions emitted from leaking
offtake systems and stationary jumper pipes, topside ports, and
collection mains are visually .determined by an observer familiar with
coke oven battery operations.
2. Definitions
2.1 Battery Traverse. The act conducted by the observer
consisting of walking the length of the battery from one pinion wall
to the other pinion wall.
2.2 Coke Oven Battery. A facility for the production of coke
containing one or more ovens with an integral heating system.
2.3 Collection Main'. Any apparatus connected to one or more
offtake systems that provides a passage for conveying gases from
a coke oven battery.
F-ll
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2.4 Decarbonization Period. The period of time for combusting
oven carbon that commences when oven lids are removed from topside
*
ports or when standpipe caps are opened, or 30 minutes before the
oven is pushed if the latter occurs sooner, and ends with the
initiation of the next charging period for that oven.
2.5 Offtake System. An apparatus for each oven (e.g., stand-
pipe and gooseneck) that provides a passage for conveying gases from
an oven to a coke oven battery collection main. The offtake system
includes the standpipe and standpipe cap, gooseneck, stationary jumper
pipe and connecting flanges. An oven may have more than one offtake
system (i.e., double collection main batteries).
2.6 Oven. A chamber used for the destructive distillation of
coal to produce coke.
2.7 Oven lid. An apparatus used to cover a topside port.
2.8 Stationary Jumper Pipe. An apparatus permanently connecting
two ovens for the purpose of increasing oven aspiration during charging.
2.9 Topside Port. Any opening in the topside of an oven except
for offtake systems and heating flue inspection ports.
2.10 Operating Oven. Any oven which is not out of operation for
rebuild or maintenance work extensive enough to require the oven to be
skipped in the charging sequence.
3. Procedure
3.1 Position. Perform the observations from the battery topside.
Collection main inspections may also be made from the topside catwalk.
3.2 Observations.
3.2.1 General. "Inspect" the coke oven battery by conducting
a series of runs. During a run, conduct a "battery traverse" by
traveling the length of the battery at a steady pace, pausing only
F-12
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to make appropriate entries on the topside inspection sheet
(Figure 109-2). Travel at'a normal walking pace; 1t should take
approximately 4 minutes (70 oven battery) to complete a single
traverse. An average rate of 6 seconds per oven for each traverse
is the maximum amount of time permitted, excluding any time spent
waiting for the larry car or other piece of equipment to move from
the battery. If the larry car obstructs the view during the traverse,
either wait for the car to move before completing the traverse or
exclude from the inspection the ovens obscured from view and make an
appropriate notation on the delta form. (If the latter case is chosen,
the total number of sources on topside is still used to determine the
percent leaks.)
During any one run, record the number of topside ports that have
visible emissions, or record the number of offtake systems and
stationary jumper pipes that have visible emissions, or record the
number of leaks from the collection main(s). A run consists of either
one or two battery traverses depending upon the physical characteristics
of the battery as explained ini the following paragraphs.
3.2.2 Offtakes and Stationary Jumper Pipes. To perform a run,
walk down the center!ine of the battery topside looking far enough
ahead (two to four ovens) to easily see the stationary jumper pipes
and offtake systems. Use a traverse line as close to the batteVy
center!ine as possible. During the run, do not stray from the traverse
line in order to get a "closer look" at the stationary jumper pipes
or offtake systems. The object of the procedure is to stand far
enough from the offtakes to provide a clear view of the entire
F-13
-------
offtake system for each oven. If for some reason the center!1ne of
•
the battery cannot be used to provide a clear view, pick a viewing
location on the topside further from (rather than closer to) the
offtake systems. This situation may occur when the standpipes
are extremely tall (greater than 15 feet); in such a case, pick a
traverse location closer to the coke side edge in order to observe
the push side offtake system. If a double-collection main
battery has extremely tall offtakes, two traverses may be required
for each run, i.e., one traverse close to the coke side edge of
topside for observing the push side offtake system and one traverse
close to the push side edge of topside for observing the coke side
offtake system. In such a case, the two traverses constitute a
single run. Observation positions other than from topside (e.g.,
catwalk) must be approved by the Administrator.
Record the time the traverse begins. During the traverse,
offtake systems and stationary jumper pipes with visible emissions
are noted. Upon noting a leak from an offtake or stationary jumper,
pause and record the information (oven number, number of offtake
systems and jumper pipes with leaks) required on the topside inspection
data form; then resume the traverse. Record the time the traverse is
completed.
During the inspection, leaks at the flange between the gooseneck
and collection main ("saddle") are counted as offtake leaks and not
collection main leaks. Leaks from the junction point of the standpipe
and oven ("standpipe base") are also counted as standpipe leaks.
F-14
-------
All leaks emitted from other parts of the standpipe are also counted
•
as standpipe leaks. Do not record the following as emissions:
3.2.2.1 Visible emissions from standpipe caps open for a
decarbonization period or from standpipes of an oven being charged.
3.2.2.2 Visible emissions caused by maintenance work in progress
at an oven.
3.2.2.3 Condensing Water Vapor. This includes condensing water
vapor (steam) emitted from wet-sealing material.
3.2.3 Topside Ports. To perform a test run, walk down the centerline
of the battery topside looking far enough ahead (two to four ovens)
to observe all of the topside ports of a particular oven by
using a sweeping view from one side of the battery to the other side
of the battery. Use a traverse line as close to the battery centerline
as is possible. Only one traverse is required for each test run. Record
the time the traverse begins. During the traverse, topside ports with
visible emissions are noted. Upon noting a leak from a topside port,
pause and record the information (oven number and number of topside ports
leaking) required on the topsiide inspection data form; then resume the
traverse. Record the time the traverse is completed. Do not record
the following as emissions:
3.2.3.1 Visible emissions from topside ports open during a
decarbonization period or charging period.
3.2.3.2 Visible emissions caused by maintenance work in progress
at an oven.
3.2.3.3 Condensing Water Vapor. This includes condensing water
vapor (steam) emitted from wet-sealing material.
F-15
-------
3.2.3.4 Visible emissions emitted from between the brickwork
and the oven lid casing or*emissions emitted from cracks in the
oven brickwork.
3.2.4 Collection Main(s). To perform a test run, walk on
topside along the side closest to the collection main or walk on
the catwalk beside or above the collection main. On a double-main
battery, two traverses (one for each main) are required for a single
test run. Record the time the traverse begins. Upon noting a leak,
pause and record the information (number of the oven closest to the
leak location) required on the topside inspection data form; then
resume the traverse. Record the time the traverse is completed. If
the oven has dual mains, conduct a second traverse. As noted in
paragraph 3.2.2, leaks from the "saddle" are recorded as offtake leaks
and, therefore, are not recorded as collection main leaks.
3.3 Recording Data.
3.3.1 General. Record all the information requested at the
top of the data form prior to starting the inspection. Record the
time all traverses begin and end. If a traverse is delayed by
ooerations occurring on the battery, explicitly note this fact
and the actual time delay on the form.
3.3.2 Offtakes and Stationary Jumper Pipes. For each oven
with offtake or stationary jumper pioe emissions, list tbe oven number in
column 2 of the topside inspection data form (Figure 109-2). For each oven
listed in column 2, record the number of offtake systems and stationary
F-16
-------
jumper pipes with any visible emission in column 4 of the data form.
•
Regardless of the number of emission points from any offtake system
or stationary jumper pipe, a single entry is made for that offtake
or jumper pipe. Note: A stationary jumper pipe connecting two
ovens is counted as one unit, i.e., there are about one-half as many
jumper pipes as ovens; therefore, for any one jumper pipe the maximum
entry is "1" even though the pipe could be leaking at the junction to
two ovens. Consequently, the maximum entry in column 4 for any one
oven with a single offtake system and no stationary jumper pipes is
"1," for a single offtake system with stationary jumper pipes is "2,"
and for a double-main oven is "2.."
3.3.3 Topside Ports. For each oven with topside port emissions,
list the oven number in column 2 and the number of topside ports with
emissions in column 3 of the topside inspection data form (Figure 109-2),
Regardless of the number of emission points observed for any one
topside port, a single entry is made for that topside port. Therefore,
the maximum entry in column 3 of the data form for a three-hole oven
is "3," a four-hole oven is "4," and a five-hole oven is "5."
3.3.4 Collection Main(s). Record collection main leaks by
placing a check in column 5 of the topside inspection data form
(Figure 109-2) for each leak whi'le indicating in column 2 £he number
of the oven closest to the location of the leak. The number of
recorded leaks from a single collection main is not limited; record
all leaks observed.
F-17
-------
4. Hale til at Ions
•
4.1 Offtakes and Stationary Jumper Pipes. For each offtake
system test run, sum the total number of leaking offtake systems
(including jumper pipes) recorded in column 4. Divide this sum by
the total number of offtakes and stationary jumper pipes on
operating ovens in the battery and multiply by 100 to determine
the percent of offtake systems leaking. Round off this percentage
to the nearest tenth of one percent and record this percentage as
the emission rate for the run.
4.2 Topside Ports. For each topside port run, sum the total
number of leaking topside ports recorded in column 3. Divide this
sum by the total number of topside ports on ovens in operation on
the battery and multiply by 100 to determine the percent of topside
ports leaking. Round off this percentage to the nearest tenth of
one percent and record this percentage as the emission rate for the
run.
4.3 Collection Main(s). For each collection main run (if the
battery has a double collection main system, two traverses are
required for each run), sum the total number of collection main leaks
recorded in column 5. Record this sum.
F-18
-------
Page of.
Company:
Location:
pt>sprui»f
Daite:
Sky condit
Oven
number
i
ion: _
Clock
time
Visible
emissions,
seconds
Comments
Wet coal charging operation.
F-19
-------
Page of.
Company:.
Location: .
Observer:
Date:
Company representative(s):
Battery
number.
Total
number of: Ovens
Topside
ports
Offtake
systems
Indicate sun position, wind speed and direction, and location of traverse:
Sky condition: .
Run number: -
CS
PS
Time traverse
started/
completed
Oven
number
Visible emissions
Number of
topside
ports
•
Number of
offtake
systems
Collection
mains
-
Comments
Topside inspection.
. F-20
-------
Page of.
Company Observer:
Location: Date:
Battery numbe
Run number:
r'
Time traverse
started/
completed
Oven
number
Visible emissions
Number of
topside
ports
Number of
offtake
systems
Collection
mains
Comments
Topside inspection (continued).
F-21
-------
PART C--DETERMINATION OF VISIBLE
EMISSIONS FROM COKE OVEN DOOR AREAS
1. Applicability and Principle
1.1 Applicability. Part C of this method applies to the
determination of the emissions from leaking oven and chuck
door areas of by-product coke oven batteries. The appropriate number
of runs as specified in the applicable subpart is required.
1.2 Principle. The visible emissions emitted from coke oven
door areas are visually determined by an observer familiar with
coke oven battery operations.
2. Definitions
2.1 Battery Traverse. The act conducted by the observer
consisting of walking the length of the battery from one pinion wall
to the other pinion wall.
2.2 Buckstay. The metal structure located around .and between
the ovens forming the support of the coke oven battery.
2.3 Buckstay Leak. A leak emitted from a crack between the
buckstay and the oven brickwork.
2.4 Chuck Door (leveler bar door). The small door on the push
side which is opened during the oven charging period in order to
permit the leveler bar to enter the oven and level the coal. The
chuck door is usually an integral part of the push side door; however,
in some cases, the chuck door is a separate door located above the
i
oyen door.
2.5 Chuck Door Leak. A leak emitted from the sealing area
between the chuck door and chuck door frame.
F-22
-------
2'.6 Coke Oven Battery. A facility for the production of coke
containing one or more ovens with an integral heating system.
•
2.7 Coke side. The side of a battery where the quench car for
receiving the coke during a push is located.
2.8 Door Area Leak. Any leak on the vertical face of a coke oven
emitted between the bench and the top of the battery and between two
adjacent buckstays.
2.9 Door Jamb. The metal casing built into the oven forming
the housing to which the oven door is fitted and attached. The door
jamb face forms the surface to which the door is sealed.
2.10 Jamb Leak. A leak emitted from a crack between the door
jamb and the brickwork.
2.11 Lintel Area. The area of the coke oven between the top
edge of the oven door and the top edge of the battery.
2.12 Oven. A chamber used for the destructive distillation of
coal to produce coke.
2.13 Oven Door. The removable structure utilized for sealing
the end (coke side and push side) of each oven on a slot type
by-product battery.
2.14 Oven Door Leak. A 'leak emitted from the sealing area between
the door jamb and the coke oven door.
2.19 Push side. The side of a battery from which the coke is
pushed when an oven is being emptied.
2.16 Operating Oven. Any oven which is not out of operation for
rebuild or maintenance work extensive enough to require the oven to
be skipped In the charging sequence.
3. Procedure
3.1 Position. Perform the observations from ground level on each
side of the coke oven battery.
F-2-3
-------
3.2 Observations.
3.2.1 General. "Inspect" the coke oven battery by conducting
•
a traverse along each side of the battery. A single test run
consists of two traverses, one for the coke side and one for the
push side of the battery. Conduct the battery traverse from a
location on the ground as close to the battery as safety and visibility
conditions permit. Generally, this location is outside of the pusher
machine and quench car tracks. First choose either the coke side or
the push side of the battery, and then begin a traverse by walking on
the ground at a steady pace from one end to the other end of the
battery. Walk along the side of the battery at a normal pace, pausing
only to make appropriate entries on the door inspection form
(Figure 109-4). A single traverse (one side) should take approximately
4 minutes to complete (70-oven battery). An average traverse rate on
each side of 6 seconds per oven is the maximum time permitted,
excluding any time spent waiting for the hot car, pusher machine, or
door machine to move from a position blocking the view of a series of
doors. Once the traverse is completed on the coke or the push side of
the battery, the remaining door areas on the other side of the battery
are inspected. A test run of a battery is to be completed within a
period of 45 minutes.
3.2.2 Procedure. Record the time and then start a traverse
along one side of the battery. During the traverse, look around the
entire perimeter of each oven door and chuck door in order to identify
all leaks. Upon noting an oven door area leak (including oven
door leaks, chuck door leaks, buckstay leaks, and jamb leaks)
F-24
-------
pause and record the Information (oven number) required on
the door inspection form (Figure 109-4). When a piece of
•
equipment prevents a view of a series of ovens during the traverse,
proceed according to one of the following three options:
1. Wait for the equipment to move before completing the
traverse.
2. Complete the traverse and then, once the equipment has
moved, return to inspect the ovens on that side of the battery either
immediately after completing the traverse on that side, or after
completing the traverses of both sides of the battery.
3. Simply exclude the ovens blocked from view by the coke oven
equipment from the inspection. (If this option is chosen, the total
number of sources on the battery is still used to determine the
percent leaks).
After completing the traverse of one battery side, record the
time. Then, either inspect the series of door areas previously blocked
from view by machinery (if applicable) or move to the other side
of the battery. Record the time the traverse on the second side
of the battery is started and then conduct the traverse. Record the
time the traverse of the second side is finished. To complete the
run, at this time conduct an inspection of any door areas previously
blocked from view by machinery,, if applicable.
Do not record the following as door area emissions:
3.2.2.1 Condensing water vapor (steam).
3.2.2.2 Emissions from ovens with the doors removed.
F-25
-------
3.2.2.3 Emissions from oven doors on which maintenance work
1s being conducted.
3.2.3 Visual Interference. Occasionally, fugitive emissions
from other sources at the coke battery (e.g., condensing water vapor
from the coke oven wharf) prevent a clear view of the door area. If
fugitive emissions delay a traverse, note this fact on the data form.
3.3 Recording Data.
3.3.1 General. Record all the information requested at the
top of the data form prior to starting the inspection. Record the
time all traverses begin and end 1n column 1 of the data form,
including the times for reinspection of any door areas previously
blocked from view by machinery. If the inspection 1s delayed because
of battery operations or fugitive emissions, explicitly note this on
the data form (i.e., the period of time delayed shall be recorded).
Prior to beginning a traverse on either side of the battery,
record which side (coke or push) is being inspected in column 2
of the data form.
3.3.2 Emissions. For each oven with door area emissions, record
the oven number in column 3 of the data form; also record the source(s)
of the leak by checking column 4 if the oven door 1s leaking
column 5 if the chuck door is leaking, or column 6 for other leaks.
Note that because the coke side and push side are inspected separately,
each oven number can appear twice on the data form for any given test
run.
F-26
-------
4. Calculations
To determine the total number of potential sources on the
coke oven battery, multiply the number of operating ovens 1n
the battery by 2. For each test run (one run includes both the
coke side and the push side), obtain the total number of emission
sources by summing the number of ovens with door area leaks as
listed in column 3. Note that multiple leaks from the same door
area (e.g., leaks from both the chuck door and the push side door
of a given oven) are counted as only one emission source, not as
two emissions sources. Divide this total by the total number of
potential sources on the battery and multiply by 100 to determine
the percent of door areas leaking. Round this percentage off to
the nearest tenth of one percent and record this percentage as
the coke oven door area emissfon rate for the run.
F-27
-------
Page of.
Company:.
Location: .
.Observer:
.Date:
Company representative!*):
Battery
number.
Total
. number of: Ovens
Oven
.doors.
Chuck
doors .
Indicate sun position, wind speed and direction, and location of traverse:
R"n number' pq
Time traverse
started/
completed
(PS/CS)
Oven
number
Visible emissions
Oven
door
Chuck
door
Other
Comments
Door area inspection.
F-28
-------
Page of.
Company:
1 oration- .
Battery number:
Run n(imhei" .,.,.
Time traverse
started/
completed
(PS/CS)
Oven
number
Observ
Date:
pr
Visible Emissions
Oven
door
Chuck
door
Other
Comments
Door area inspection (continued).
F-29
-------
APPENDIX G
EXAMPLE INSPECTION FORMS
6-1
-------
ALLEGHENY COUNTY HEALTH DEPARTMENT
BUREAU OF AIR POLLUTION CONTROL
Inspector
Date
Start hr.
Plant
min.
Plant Pi
Battery
End
hr.
min.
Distance to Source ft.
Stack Height ft.
Cloud Cover %
Wind: Speed MPH Direction
Ambient Temp.
Background : Sky Other
(Specify)
Smoke Color
Sun Visible Yes No Occ.
Stack No., Observation Position,
Distance to Stack, Wind Direction,
omments:
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
0
15
30
45
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
59
0
15
30
45
No. of Readings ^.20% Opacity
JDF/cg
4/18/80
No. of Readings
G-2
60% Opacity
-------
VISIBLE EMISSION REPORT
ENVIRONMENTAL PROTECTION AGENCY
REGION III
Date
Observer
Location..
Name
Address
Observation Point
Stack - Distance From Height
Wind - Speed Direction
Sky Condition
Background
Smoke Color
Type of Installation
Fuel
Observation Began Ended
Smoke Tabulation
Ramarka:
Draw Stack & Observation Position on
Back of Sheet
KPA-111-034-74-T
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
0*
Mi
0
15
30
45
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
5
54
55
5
5
5
59
0
15
30
45
raer
ftnager
Address
6-3
-------
NEW JERSEY STATE DEPARTMENT OF ENVIRONMENTAL PROTECTION
NAMF
LOCATION
TIME: FROM
A.M. T_
P.M TO
P.M: DATE
CHAPTER
SECTION
PLUME OBSERVATION
RECORD
HR.
RN.
-ii-
1}
1 i
H
1
s
j
0
%
40+
38
SO
25
20
IS
10
5
0
HR.
RN.
z*
i
i
i
i
'
0
%
40-
35
30
25
20
19
10
5
0
SEC. 4 8 12 16 20 24 28 32 36 40 44 46 52 56 60 TOTALS
WIN. o'l 02 03 04 05 06 07 08 09 10 ijl 12 13 14 15
TOT4LS
40
is
29
15
8
40
SO
20
10
0
SEC. 4 8 12 16 20 24 28 32 36 40 44 48 52 56 60 TOTALS
MIN.
16
17
ii ii. i i i i i i i i
18 19 20 21 22 23 24 25 26 27 28 29 30
HR.
RN.
J£_
>
1
i
j
0
%
40«
35
25
20
15
10
s
0
TOTALS!
40
«
25
IS
5
40
SO
20
10
0
' 1
SEC. 4 8 12 16 20 24 28 32 36 40 44 4& 52 56 60 TOTALS
MIN. 31
32
33 34 35 36 37 38 39 40 41 42 43 44 45
HR. •
RN.
-f1-
j
i
t
i
j
0
*
40-
40
35
30
25
20
15
10
g
0
TOTALS
40
25
15
5
40
SO
20
1?
0
SEC. 4 8 12 16 20 24 28 32 3*6 40 44 48 52 56 60 TOTALS
MIN.
46
47
48 '
9 5
0 51 5
2 53 !
4 55 5
6 57 58
9 *
TOTALS
0
40
25
15
5
40
so
20
10
0
RN
2*
2
1 }
»i
'J
i
J
i
i
0
T.
40*
40
39
SO
25
:c
15
10
S
0
QUARTER MINUTES/SEC.
•-
TOTAL
OM
TOTAL
MIN.
TOT*L
sec.
TOTALS
VIOLATION:
Min«./S.c.
6-4
-------
rage
PROCESS DATA
PERSONNEL ACTIVITIES
Larry car Inspector
Topside Inspector
Coke Side Inspector
Pusu Sid" ''
COMPANY
LOCATION
INSPECTOR.
DAT*
BATTERY
Indicate worker job title, number of persons working at this iob an^ brief
Job description, at the beginning of each day an'* when personnel change* are
made. Indicate spells provided by relief man.
TIME
Worker
Title
D°?<-riptior. c* Operations Performed
Personnel Activities Form
6-5
-------
TEAM LEADER
INSPECTOR,
DATE
Page
of
PLANT
PHOTOGRAPHY LOG
STILL
MOVIE
QUANTITY
WHEN
WHAT
Photography Log
6-6
-------
Investigator:
T ime of Inspect ion:
Company Contact:
Start:
Battery Number: •uwFom.iai
Number of Ovens:
Number of Charge Port Lids:
Pushing Controls in Operation ? Yes No
c
Company:
Address:
Sky Conditic
Temperature
r • -» i. jiup.
Ove
1
2
->
it
c
6
/
8
c
10
1 1
12
13
l*i
15
16
17
18
19
20
21
22
23
2*.
25
Door
pifl I i nn
Tok
Pu**
Chg.
pnr f
Oft
otal Number of
ven Doors:
umber Doors Leaking
1 "'
Qveri Emi
26
27
26
29
30
31
32
33
3^
35
36
37
38
39
*<0
<*)
kl
Chg. 0
Pqr{ J
) C
Total Number of
Offtake Piping:
Number Leak
X
ing:
ff- 1 Door
ke [^y pri Fni i c*; j nn*i
P
,51
52
53
5^
55
56
_5_2_
58
59
60
61
62
63
(>k
65
66
67
68
69
70
71
72
73
7<«
75
Coke
Total
;harge
umber
Push
Numbe
Port
Leak
Chg. off
P Q r l T a k
C
' Of
Lids:
DC
f» ve,r Em
P Co
76
77
78
75
80
81
82
83
Bk
85
86
87
88
89
90
91
H
93]
g't
95
96
97
98
99
100
>or I Chg. Q
^iflOS ^ Port T
Push
f
Number of Visible
Emission Points Alor
Main:
1 ) S i ng 1 e Me
2) Double Ma
in:
in:
ff-
f. Charqina
P Oven leconc
1
Total Nu
>g Seconds
Exemptec
liber ol
nber
ID
O
-------
PROCESS DATA
COKE OVEN CONDITION
Page _.
of
Coke Side Inspector
I'ush Side Inspector
i
00
COMPANY INSPECTOR
BATTERY
LOCATION DATE
UVEN
BROKEN. REFRACTORY AT
DOUR AREA
Check:
Yes(/)
No (x)
Indicate
Location: (X)
(End View)
DARK (COLD) SPOTS ON SIDE WALLS
Check:
Yes(^:
No (x)
Indicate Location: (X)
(Top View)
cs ps
cs ps
cs ps
OVEN ROOF CARBOM BUILDUP
lllustate:
End View
Side View (best estimate)
(Indicate standpipe and oven holes)
cs ps
cs Ps
cs ps
COMMENTS:
Coke Oven Condition
-------
TEAM LEADER
INSPECTOR,
DATE
PLANT
BATTERY
CHART LOG
Chart
Stack Flue Temperature CS
Stack Flue Temperature PS
Stack Draft Pressure CS
Stack Draft Pressure PS
Coke Oven Gas Pressure CS
Coke Oven Gas Pressure PS
Flue Gas Temperature
Pusher Machine: Turn
Turn
Turn
Requested
Acquired
/- Yes
X - No
Chart Log
G-9
-------
TEAM LEADER
Page.
of
INSPECTOR.
DATE
PLANT
COAL SAMPLE COLLECTION
TT
Battery
Sampling Point
No.
Time
Sample
No.
Time
Sample
No.
Time
Cool Sample Collection Form
6-10
-------
TEAM LEADER
INSPECTOR,
DATE
PLANT
Page of
COMPANY COAL ANALYSIS
Battery
Turn
Sample Location
% Moisture
% Volatile Matter
% Sulfur
? Ash
X
-------
COKE OVEN BATTERY
COAL CHARGING OBSERVATION
Engineer: Date:
Company Rep
«
Other Inspet
Charging Cor
Battery Numt
(s) Company
;tor(s) Location
itrol (s)
>er Number of ovens in this battery
Oven Clock
Number time
Visible
emissions ,
seconds
Comments
Opacity
TOTAL:
Seconds
Average time per oven charged:
Seconds
Certified Correct:
G-12
-------
Page of.
Company:
Location:
Date:
Sky condit
Oven
number
on: ..
Clock
time
Visible
emissions,
seconds
•
Comments
•
Wet coiil charging operation.
G-13
-------
ALLEGHENY COUNTY HEALTH DEPARTMENT
BUREAU OF AIR POLLUTION CONTROL
CHARGING INSPECTION
Inspector
Date
Plant Personnel
Battery
(Indicate sun position, observation position, and wind direction on
diagrams.)
START TIME
END TIME
VISIBLE
EMISSIONS
MAX. OPACITY
APPROX. DURATION
MAX. OPACITY
OVEN NUMBER
CS
COMMENTS:
PS
START TIME
END TIME
VISIBLE
EMISSIONS
MAX. OPACITY
APPROX. DURATION
MAX. OPACITY
OVEN NUMBER
CS
COMMENTS:
PS
START TIME
END TIME
VISIBLE
EMISSIONS
MAX. OPACITY
APPROX. DURATION
MAX. OPACITY
OVEN NUMBER
CS
COMMENTSi
PS
START TIME
END TIME
VISIBLE
EMISSIONS
MAX. OPACITY
APPROX. DURATION
MAX. OPACITY
OVEN NUMBER
CS
COMMENTSi
PS
START TIME
END TIME
VISIBLE
EMISSIONS
MAX. OPACITY
APPROX. DURATION
MAX. OPACITY
OVEN NUMBER
CS
COMMENTS:
PS
JDF/cg
4/11/80
G-14
-------
Company
Location
Company Rep.
Inspector
METHOD B
CHARGING OBSERVATIONS
Date
Sky Condition
Wind Speed _
Ambient Temp.
Background
[Indicate sun position,
on diagrams.]
observation oosition, and wind direction
BatL/Ovpp
Time Start
Time End
Comnent:
CS
PS
Total Emissions, Seoands
Charoe Period
'Seal Period
Total
Batt/Oyen.
Time Start
Time End
Corment:
PS
Total Emissions, Seconds
Charoe Period __
Seal Period
Total
Batt/Oven / cs
Time Start
Time End
Comment: **s
Batt/Oven / Cs
Tino Start
Time End
Coment:
S
Batt/Oven / CS
Tine Start
Tine End
Total Enissions,
Charoe Period
Seconds
Seal Period
Total
Total Emissions,
Cham* D*riO'I
Sec.onds
Ssal ^erio'l
Total-
Total Emissions,
Charoe Period
Seconds
Seal Period
rr^nnf ™ T°ta1 .
B
Method B.Charging Emissions Data Form
G-15
-------
Company
Location
Company Rep.
Inspector _
METHOD A
CHARGING OBSERVATIONS
Date
Sky Condition
Wind Speed _
Ambient Temp.
Background
Battery/Oven /_
Tine of Charge: Start
End
Tire 2 20S (seconds)
Cparlty
Charge period
Seal period
Total
ttoxlnum opacity
Comments
Indicate sun position, observation
position, and wind direction:
Mark dominant emission points:
i
A n
Battery/Oven
Time of Charge: Start_
End
Tin* 2 202 (seccnds)
Opacity
Charge period
Seal period
Total
Maximum opacity
Comments:
Indicate sun position, observation
position, and wind direction:
Mark dominant emission ooints:
LJ
Battery /Oven
Tine of Charge: Start_
Tire £205 (seconds)
Opacity
Charge period
Seal period
Total
Maximum opacity
Comments:
Indicate sun position, observation
position, and wind direction:
Mark dominant emission points:
nn
S il _J
A
0»0 140-«»0
Method A-Chorging Emissions Data For
m
A
6-16
-------
Page
of
CHARGING TIME STUDY
Larry car inspector
Topside Inspector
COMPANY
LOCATION
INSPECTOR
DATE
BATTERY
>.
T
V
0/EN CHARGED
-~~^^_^ Timino
Process Operation ^~~- — ~^___
Remove oven lids.
Fill tarry car at coai bunker.
Move car to oven.
Spot car on oven, drop sleeves.
Clean goosenecks, CS
standpipc caps and seats. PS
Close Standpipe, damper oven, CS
turn on aspirating steam. PS
Charge coai to oven:
.tfl ,
..((4;
_#3
02
Lute standpipe cap.
Replace oven lids.
Damper oven, turn off steam.
Return car to bunker.
Time
Start
p. 1 9 n c o (j
Min.
Sec.
Tine
Start
Elaos-d
Min.' Sec.
Comment
Number
COMMENTS:
Charging Time Study Form
G-17
-------
Page
of
PROCESS DATA
OVEN PORT CARBON
COMPANY
LOCATION
INSPECTOR
DATE
BATTERY
Indicate carbon buildup for each oven port prior to charging. If no carbon
is present indicate same with (OK).
Oven
Time
Carbon
CS
PS
Comment
Number
COMMENTS:
Oven Port Carbon Form
G-18
-------
TEAM LEADER
INSPECTOR.
DATE
PLANT
STEAM DATA
Battery
CVCT
Charged
Static
Steam Pressure (psig)
Dynamic Steam Pressure (psia)
1*
2**
3***
*Location_
"Location
***Location
Steam Data Form
G-19
-------
rage
of
PROCESS DATA
LARRY CAR INSPECTOR
COMPANY
LOCATION
INSPECTOR
DATE
BA1TERY
CD
i
ro
o
Oven
Charged
Coal Hopper
Volume Setting;
1231
Check Sheet - Indicate Yes (/) or No (fj)
Steam on
(Both
ends for
dual
mains)
04 and iM
hoppers
dropped
first
H and n
hoppers
dropped
Individually
Slide gates
closed
after
discharging
hoppers
1234
Goosenecks
cleaned*
PS ' CS
Gooseneck Carbon I Comnent
(Illustrate Carbon Buildup Number
after cle,-irin;j)
Pusher Side
Coke Side
COMMENTS:
*M - machine .
H - hand tool
Larry Car Inspector Form
-------
METHOD H
TOPSIDE OBSERVATIONS
Company
Location
Company Rep.
Inspector
re | ,
PS
Battery
number
Date
Sky Condition
Wind Speed
Ambient Temp.
Background
[Indicate sun position, observation
traverse, and wind direction.]
Total
number of: Ovens Lids
Oi :r cake
systems
Tin;e
Inspection
Started/
Completed
Oven
Number
Visible Emissions
Total Leaks
Collection
Mains
Number
of Lids
Number of
Offtake
Sy^tprr;
Signifi-
:ant Leaks
Number of
Offtake
^y^te"^*,
Comments
Indicate location of leak: Base = B, Cap = C, Saddle - S, Flanne = F, Other = 0
If decarbonizing indicate: Ignited = I, Ignited with Emissions = IE,
Emissions only = E
Check (/) oven number if excursion made.
Circle oven number if standpipe(s) and/or lids are open
Method H-Topside Leak Data Form
6-21
H
-------
Page.
.of.
Company:.
Location: .
Observer:
Date:
Company representative)*):
Battery
number.
Total
number of: Ovens
Topside
ports
Offtake
systems
Indicate sun position, wind speed and direction, and location of traverse:
Sky rnnrtitinn-
Run number:
CS
PS
Time traverse
started/
completed
Oven
number
Visible emissions
Number of
topside
ports
Number of
offtake
systems
Collection
mains
Comments
Topside inspection.
6-22
-------
Page of.
ComP*ny Observer:
Location: , Date:
Battery numbe
Run number:
'•
Time traverse
started/
completed
Oven
number
Visible emissions
Number of
topside
ports
Number of
offtake
systems
Collection
mains
•
Comments
»
Topside inspection (continued).
G-23
-------
TOP SIDE MUSKKVAT JON'S
COMPANY
LOCATION.
INSPECTOR
COMPANY REP.
BATTERY ID
DATE
OVEN NO.
LEAKING
TIME:
START
FTNT^H
•
PUSH SIDE
OPENINGS
PS
1
LIDS
?
3
CS
A
COKE SIDE
OPENINGS
COMMENTS
•
CODE: OPENING
C-CAP
F-fLANGE
B-BASE
0-OTHER
LIDS =
SNOW OR RAIN
SKY CONDITIONS
BACKGROUND
WIND DIRECTION
WIND
G-24
-------
ALLEGHENY COUNTY HEALTH DEPARTMENT
BUREAU OF AIR POLLUTION CONTROL
TOPSIDE INSPECTION
Inspector
Date
Plant Personnel
Start
hr.
Battery
min.
PS
CS
End
hr.
min.
Oven No. Push Side
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
? j
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
o
0
o
0
o
o
0
0
o
0
o
0
0
0
0
o
0
0
0
0
(Indicate sun position, observa-
tion traverse, and wind direction)
Oven Ho.
Coke Side
Oven No.
Lids
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
C
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
F
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
S
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
B
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
P
Q
0
O
0
O
0
O
0
0
o
0
0
o
0
Q
0
0
o
0
0
D
D
D
D .
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
1
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
2
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L L
L ( L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
4_
L
J
L
j
j
J
L
L
L
L
L
L
L
L
L
L
L
L
L JL
D - Decarbonizing
C - Cap
F - Flange
S - Slip Joint
B - Base
P - Piping
0 - Other
L - Lids
COMMENTS:
JDF/cg
5/15/80
G-25
-------
Page
of
PROCESS DATA
OVEN PORT SEALING
COMPANY
LOCATION
INSPECTOR
DATE
BATTERY
Indicate clock tine that any lid is either sealed or resealed. Indicate
lid(s) sealed (i.e., lid closest to push side is // 1 lid).
OVEN
TIME
TIME
TIME
TIME
TIME
TIME
TIME
TIME
Oven Port Sealing Form
6-26
-------
. PROCESS DATA
STANDPIPE SEALING
COMPANY
LOCATION
INSPECTOR
DATE
BATTERY
indicate clock time that any standpipe lid is either sealed or resealed.
Indicate cokeside (CS) or push side (PS),.
OVEN
TIME
TIME
TIME
TIME
TIME
TIME
TIME
TIME
Stand pipe Sealing Form
G-27
-------
Uoor
^s Lint
Observer.
Date
Plant
Battery.
o
o
o *.
as
in n
n> (u
•o ri LJ
rt rt
H- 3*
O
U<
2
. N>
f
p.
O> rt
n>
(-1
M
Door Machine Push Siuo
Door Machine Coke Side
a
rine of
Removal
Oven
No.
Sect.
©
©
©
0
©
©
©
©
©
©
©
(S)
©
©
©
©
©
O
Condit
or
*cfrac
torv
.ion o
i Pcmo>
to :e
F 'rif
E Door
/al
Gas
Chan
Enter:
1-Ko damage on door, knife edge (nq
dents, crocks, missing sect.)
2-Physical damage (cracks, deforma-
tions, r.issing soct.)
^-T^door is replaced with a fresh
door in this cycle
Knife
Clean
Edge
Depos
-------
ALLEGHENY COUNTY HEALTH DEPARTMENT
BUREAU OF AIR POLLUTION CONTROL
Door Inspection
Inspector
Date
Push Side: Start
End
Plant Personnel
Batter-/
hr. min.
hr . min .
Sun Visible No
Coke Side: Start
End
Yes
hr.
hr.
Occ
min.
min.
COMMENTS:
PUSH SIDE
OVEN «f
i
1
i
r
i
i
DOORS
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
£
C
C
C
C
C
C
C
C
r
C
C
C
C
C
M
M
M
M
M
M
M
M
M
M
M
M
M
M
M
OPACITY
TIME
COKE SIDE
OVEN #
DOORS
D
D
D
D
D
D
D
D
D
D
D
D
D
D
D
M
M
M.
J!
M
M
M
M
M
M
M
M
M
M
M
OPACITY
TIME
I
G-29
JDF/cy
&-'17/80
-------
METHOD C
DOOR OBSERVATIONS
Company
Location
Company Rep.
Inspector _
Battery
No. of Ovens
Date
Sky Condition
Wind Speed _
Ambient Temp.
Background _
CS
PS
[Indicate sun position, observation
traverse, and wind direction.]
OVEN NO
ID OF
LEAK*
PS or CS
OPACITY
%
TIME:
START
NTSH
COMMENTS
*D=door, C=chuck door, B=both door and chuck door
G-30
Op «40-iei
-------
TEAM LEADER
Page.
of
INSPECTOR,
DATE
PLANT
SPARE DOORS
Battery
Time
Number
PS
CS
COMMENTS
Spore Door Form
G-31
-------
Pa«e
of
COMPANY
LOCATION
PROCESS DATA
PUSHER MACHINE INSPECTOR
INSPECTOR
DATE
BATTERY
OVEN
APPEARANCE OF < OKE FACE
Check Yes (/) or No (X>
Partial (P) or Whole(W)
SMOKE
1LAME
TIME OF
PUSH
ELAfSED
PUSH
PERIOD
(sec)
CHUCK DOOR OPERATION
Check Yes (/) or No C*)
CLOSED
LATCHED
TIGHTENED
LEAKING
ELAPSED TIME
DOOR OPEN
BF.FORE LEVEL
B/.R STARTS
(sec)
COMMENT
NUMBER
co
ro
COMMENTS:
Pusher Machine Inspector Form
------- |