Instructions on labor protection during the operation of stationary compressor stations for gas lift and gas injection into the reservoir

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Instructions on labor protection during the operation of stationary compressor stations for gas lift and gas injection into the reservoir. Full Document

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General provisions

1.1. This Instruction contains safety requirements for the design of the main and auxiliary equipment and the technology for operating compressor stations for gas lift and injection of hydrocarbon gases into the reservoir with a pressure of up to 50 MPa. On issues not covered by this Instruction, one should be guided by the "Safety Rules in the Oil and Gas Industry", "Electrical Installation Rules", "Rules for the Technical Operation of Consumer Electrical Installations", "Safety Rules for the Operation of Consumer Electrical Installations" and other relevant regulatory, technical and guidance documents approved in the prescribed manner.

The use of imported complete compressor units must be agreed with the Gosgortekhnadzor of Russia, and their operation must be carried out in accordance with the technical documentation of the supplier.

1.2. The enterprise operating installations, the design and location of which do not allow them to be brought to the requirements of this Instruction, develop additional measures to improve the safety of operation. Additional measures are approved by the chief engineer of the enterprise and agreed with the organization - the author of the compressor unit project, the industry design institute, local bodies of the State Mining and Technical Supervision and the relevant trade union bodies.

1.3. The operation of compressor units must be carried out according to the instructions of manufacturers and technological regulations for this production.

1.4. Instructions for the operation of compressor units must be posted at the workplace, and also issued against receipt to the maintenance personnel.

1.5. Periodic testing of the knowledge of personnel servicing compressor units should be carried out at least every 12 months. The results of the check must be documented.

1.6. For independent work on maintenance of compressor units operating on explosive and toxic gases, persons are allowed at least 18 years old, recognized as fit for health reasons, trained according to the appropriate program and having a certificate from the qualification commission for the right to service compressor units.

1.7. The choice of the type of execution and placement of electric motors, starting equipment, artificial lighting fixtures, automation equipment, power and lighting networks must be carried out depending on the class of the room, category and group of explosive atmosphere and comply with the requirements of the current regulations.

1.8. For work in wells where accumulation of gases is possible, it is necessary to use hose gas masks. In this case, the duration of continuous operation should not exceed 15 minutes. followed by rest in the air for 15 minutes. Before issuing a gas mask, personnel must be trained by the work manager in their correct use.

1.9. The work manager (foreman, foreman) is obliged to ensure that:

personal protective equipment (PPE) and a gas mask were issued in a timely manner and had the appropriate protective properties, type and size;
PPE, gas mask and safety devices were tested in a timely manner;
workers used PPE and devices only for their intended purpose.

1.10. Work on faulty equipment and mechanisms, with guards removed or faulty, as well as the use of faulty PPE is prohibited.

1.11. It is forbidden to allow to work persons who are intoxicated with alcohol and drugs, tired and sick.

1.12. The enterprise, on the basis of this Instruction, taking into account the peculiarities of local conditions, must develop and approve production instructions for personnel in the prescribed manner.

1.13. Entry of personnel on duty and departure from duty must be carried out in compliance with the requirements of the internal regulations. When taking on duty, the personnel are obliged to familiarize themselves with the entries in the shift log and check the serviceability of the serviced installations and related equipment, as well as the serviceability of emergency lighting and signaling to call the administration. If a malfunction is found, take corrective action.

1.14. Acceptance and handover of duty must be documented by the shift supervisor (shift supervisor) with an entry in the log, confirmed by the signature of the shift supervisor, indicating the results of checking the installations and equipment related to them. Workplaces should have safety posters and warning signs appropriate for the work being done.

1.15. Each compressor unit must have the following documentation:

design description and maintenance manual;
general view drawings and main equipment components;
passports of vessels subject to registration with the bodies of the State Gortekhnadzor;
passports and magazines for the operation and repair of ventilation units;
audit logs of instrumentation, automation and blocking tools;
a log of inspection, checking the condition and repair of pipelines;
schemes of communication lines of pipelines and placement of fittings;
schemes of gas lines in the piping of installations;
diagrams of devices and systems for manual and automatic control, control, alarm, blocking and emergency stop;
instructions of the enterprise on labor safety;
emergency response plan (PLA);
schedules of scheduled preventive inspections and repairs of equipment.
A metal plate with the following data must be affixed to the front of each unit:
name of the manufacturer;
plant serial number;
year of issue;
operating pressure and temperature of the working agent;
trial hydraulic pressure;
heating surface.

1.16. In the premises of compressor units it is forbidden to place equipment and equipment that are technologically and structurally not related to compressors.

1.17. The room in which the compressor equipment is located must comply with the requirements of the current SNiP and the Sanitary Standards for the Design of Industrial Enterprises.

1.18. When using hoisting and transport vehicles and mechanisms, it is necessary to observe measures to ensure their safe operation in explosive and fire hazardous rooms.

1.19. Electrical devices installed in explosive rooms and outdoor installations must be designed in accordance with the categories and groups of the media used in accordance with the rules.

2. Basic requirements for equipment

2.1. Compressor units

2.1.1. The transmission of motion from the engine to compressors operating on explosive gases can be carried out through a coupling, a gearbox and, as an exception, through a V-belt device. The use of flat belt drives is not allowed. Direct landing of the rotor of the electric motor on the compressor shaft is allowed, while the level of protection of the electric motor must comply with the standards.

2.1.2. If the gas to be compressed is both toxic and explosive, then the compressor installation must meet the requirements for compressor installations operating on both toxic and explosive gases.

2.1.3. It is not allowed to use a compressor unit for compressing gas that differs from that provided for by the project, without agreement with the manufacturer and the organization - the executor of the technical design of the unit.

2.1.4. Compressor units must have devices to prevent lubricating oils from spilling onto the floor.

2.1.5. The location of the equipment of compressor units, control panels and instruments should ensure the safety and convenience of their maintenance, operation and repair in production conditions.

2.1.6. In compressor units operating on explosive gases, when using levers, sprockets, cams and swivel joints to drive valves, measures must be taken to ensure reliable protection against sparks in rubbing parts and during impacts.

2.1.7. In compressor units, gas must be drained from stuffing boxes, lanterns, a tank of the stuffing box flushing system, a stilling tank at the drain of condensate (water) and oil from blowdowns, an oil sump in accordance with the requirements set out in clause 2.2.1.13 of this Instruction. These nodes must be sealed.

2.1.8. Parts of the compressor unit where condensate and oil can accumulate must be purged into the purge tank to separate condensate and oil from the gas.

The purge tank must be connected to the suction line of the XNUMXst stage and the atmosphere in accordance with the requirements of this Instruction and have a device that prevents the tank from being connected to the gas communication and the atmosphere at the same time.

2.1.9. Compressor installations must have a double shut-off valve with an air vent on the suction line of the XNUMXst stage.

Compressor units must have double shut-off valves with an air vent on the gas outlet line after the last stage, from which gas extraction is provided.

2.1.10. The high-pressure purge tank, which is permanently connected to the suction line of the XNUMXst stage, must be equipped with a safety valve, calculated in accordance with the requirements of this Instruction, with gas discharge into the atmosphere.

2.1.11. The purge pipeline of the devices must be calculated up to the shut-off device inclusively for the operating pressure of the stage; downstream of the shut-off valve to the purge tank - by gas-dynamic calculation, and subject to the passage of gas through all fully open purge shut-off valves and behind the purge tank - to the pressure of the safety valve installed on the purge tank.

2.1.12. In compressor units, emergency release of pressure (gas) into the atmosphere or flare system through shut-off valves and a silencer (or without it) from the discharge line of the last stage should be provided. Compressor units operating with gas extraction after any intermediate stage with a break in the intra-compressor communication must have an emergency discharge from the discharge line of this stage. Shut-off valves must be installed upstream of the muffler.

2.1.13. In all cases, the discharge of gas from the purge tanks, safety valves installed on the purge tanks, and other components of the compressor unit, as well as the discharge of gases discharged from the stuffing boxes, must be carried out in a specially closed system with a pressure of not more than 500 mm of water. Art., allowing the return of products back to production or to the torch.

2.1.14. When purging the compressor unit with an inert gas, the gas mixture must be discharged into the atmosphere in accordance with the requirements set forth in paragraph 2.2.1.13 of this Instruction.

2.2. Fittings and pipelines

2.2.1. Underground and channel laying of gas pipelines in the compressor plant room is not allowed.

2.2.2. Shut-off valves must be installed on pipelines supplying and discharging gas from the compressor unit. Locking devices must be equipped with manual and remote-controlled drives that allow you to quickly stop the supply of gas mixtures.

The first on the compressor side should be a remote-controlled valve, the second one with manual control.

The valves on the emergency pressure relief lines must have, in addition to manual, remote control. In this case, of the two valves in series, the remote control must have a second (in the direction of the gas) valve.

2.3. Vessels and devices of compressor stations operating under pressure

2.3.1. Vessels and apparatus of compressor stations operating under pressure (tanks, coolers, purge tanks, etc.) must be manufactured in accordance with the Rules for the Design and Safe Operation of Pressure Vessels.

2.3.2. Vessels and devices of compressor installations must have fittings that allow you to connect lines of water, steam or inert gas for flushing and purging.

2.3.3. There must be no shut-off device between the vessel and the safety valve.

2.3.4. Vessels and apparatus of compressor units after manufacture and repair must be tested in accordance with the requirements of the Rules for the Design and Safe Operation of Pressure Vessels. Testing of compressor cylinders after manufacture and repair must be carried out in accordance with the requirements of the manufacturer or departmental regulations.

2.3.5. Vessels and devices of compressor units before starting after installation and overhaul, after a hydraulic test, must be tested for tightness. The tightness test is carried out with an inert gas or air under pressure on the assembled sections of communications and equipment. In this case, the tightness of all detachable connections is carried out using a soap solution or other reliable methods. If leaks are found, the pressure must be relieved and the faults repaired.

2.3.6. It is allowed to combine the tightness test with the test of the compressor unit under load with inert gas or air, provided that all communication elements have reached full working pressure.

2.3.7. When the operating pressure in the test vessel and apparatus is reached, the supply of inert gas or compressed air is stopped, the pressure drop is monitored for at least 4 hours during periodic checks and at least 24 hours for newly installed equipment.

The results of the tightness test are considered satisfactory if the pressure drop in 1 hour does not exceed 0,2% for newly installed vessels and apparatuses and 0,5% for vessels and apparatuses subjected to repeated testing.

2.4. Safety devices

2.4.1. Each compressor stage must be provided with a safety valve.

2.4.2. The safety valve must be installed in places with the least fluctuation of gas pressure, taking into account the thermal effect during throttling. If the gas is cooled to low (minus) temperatures during throttling, it must be diverted to the safety valve before cooling in the refrigerator.

2.4.3. Safety valves and compressor units must be designed and calibrated for the maximum allowable excess of the operating pressure in the overpressure stage up to 3 kgf/sq. cm inclusive no more than 0,5 kgf / sq. cm; with pressure from 3 to 60 kgf/sq. see no more than 15%; with pressure over 60 kgf/sq. cm no more than 10%.

The capacity of the safety valve at this pressure should not be less than the capacity of the compressor.

2.4.4. Compressor units must be equipped with check valves installed on the discharge line of the last stage up to the shut-off valves.

2.5. Control and measuring devices

2.5.1. Compressor units and other components of compressor stations must be equipped with the necessary control and measuring instruments (pressure gauges, thermometers, flow meters, etc.) to ensure their trouble-free operation.

2.5.2. Instrument scales must be clear and clearly visible. The lighting of the instruments and the convenience of observing them should be provided.

2.5.3. Pressure gauges should be selected according to GOST 2405-88.

On the dial of the manometer, a red line must be applied through the division of the scale corresponding to the permitted working pressure.

2.5.4. Each stage of compressors with gas pressure above 100 kgf/sq. cm must be equipped with two pressure gauges installed before and after the refrigerator. For shell-and-tube coolers with gas flow between the tubes, the pressure gauge must be installed upstream of the cooler.

2.5.5. Control and measuring electrical appliances of normal design must be installed in rooms isolated from explosive environments. It is allowed to install such devices in explosive rooms and outdoor installations inside sealed shields purged with air or inert gas under excess pressure with its release into the atmosphere, or when the contacts of electrical contact devices and equipment are connected to intrinsically safe circuits.

2.5.6. Fully automated compressor installations operating on explosive and toxic gases must have devices that signal the appearance of mechanical faults and shutdown devices.

2.6. Inert gas purge requirements

2.6.1. Compressor units must be provided with a purge inert gas.

2.6.2. The amount of inert gas for each purge, determined by the number of machines subject to simultaneous purge, their capacity and the duration of the purge, must be sufficient to reduce the concentration of compressed gas in the installation to sanitary standards.

2.6.3. The oxygen content in the inert gas and the degree of its drying must comply with the requirements established by industry standards or regulations for a given production.

2.6.4. The duration of purging the equipment of the compressor unit with an inert gas must be specified in the manufacturer's instructions and ensure the purging of stagnant sections of pipelines and tanks at dead ends.

2.6.5. The pressure of the purge inert gas must be higher than atmospheric pressure, but not more than the pressure specified in the technological regulations for fittings, apparatus, cylinders and pipelines on the suction line of the XNUMXst stage of the compressor unit.

2.6.6. If the pressure of the purge inert gas exceeds the pressure in the suction line of the XNUMXst stage of the compressor plant, the following devices must be installed in the purge gas supply line (in sequence, counting along the purge gas flow): manual shut-off valve, manually operated pressure reducing valve, safety valve, non-return valve , a removable section of the gas pipeline and a manual shut-off valve.

If the pressure of the purge inert gas is equal to the pressure in the suction line of stage I of the compressor unit or less, the following must be installed in the purge gas supply line (in sequence, counting along the purge gas flow): a manual shut-off valve, a check valve, a removable section of the gas pipeline and a manual shut-off valve.

After purging, the removable section of the pipeline must be removed, and plugs must be installed on the fittings.

2.6.7. Purging of the compressor unit with inert gas can be carried out from the main engine or from the turning device in accordance with the instruction manual for the compressor unit.

2.7. Automation system

2.7.1. Automated compressor units must also be equipped with devices for manual control.

2.7.2. Automation systems for compressor units must have "Stop" buttons that allow the compressor to be stopped both from the local compressor panel and from the central control point.

2.7.3. Automatic devices (interlocks) must not allow the compressor motor to start:

a) when the pressure in the suction line of the compressor operating on explosive gas is lower than the specified one;

b) when the pressure in the cooling water line is below the permissible one with an open drain and at a water flow rate below the permissible one with closed systems;

c) when the oil pressure is lower than the permissible value in the circulating lubrication system (in compressor units that compress toxic gases, also when the oil pressure is reduced in the oil seal flushing system);

d) when the turning mechanism engages with the compressor shaft;

e) without pre-purging the compressor motor casing with air in accordance with the operating instructions;

f) without preliminary start-up of electric motors of drives of lubricators of the lubrication system of cylinders and stuffing boxes;

g) when the air pressure in the system of ventilation blowing devices is lower than the permissible one.

2.7.4. Automatic devices (interlocks) must stop the compressor motor:

a) when the pressure in the suction line of the compressor drops below a predetermined minimum;

b) when the compression pressure at the outlet of the compressor rises above the permissible value;

c) when the pressure in the cooling water line drops below the permissible level with an open drain and a decrease in flow for closed cooling systems;

d) when the oil pressure drops below the permissible value in the circulating lubrication system (in compressor units that compress toxic gases, also when the oil pressure drops in the oil seal flushing system);

e) when the temperature of the main bearings for compressors with a piston force of more than 10 tf rises above the value set by the passport;

f) when the air pressure in the system of ventilation blowing devices drops below the permissible value;

g) when the electric motor of the lubricators of the lubrication system of cylinders and seals is turned off.

2.8. Noise and vibration requirements

2.8.1. Vibration at workplaces should not exceed the maximum permissible values.

2.8.2. Permissible maximum vibration amplitudes of the main pipelines and interstage devices are 0,20 mm at a frequency of up to 40 Hz.

The vibration amplitudes of the compressor itself must be limited to the same limits as the vibration amplitudes of the foundation specified in paragraph 2.2.8.1 of this Instruction.

The parameters of vibrations excited by operating compressors at permanent workplaces in the premises of compressor installations should not exceed the values allowed by the "Sanitary Design Standards for Industrial Enterprises".

2.8.3. The sound level at workplaces during long-term continuous operation of compressors should not exceed 85 dB.

3. Operation and repair

3.1. Before starting the compressor from the local control panel, the driver must give a warning signal to the shift supervisor or operator to start the compressor, and only after receiving a response signal confirming the readiness of the process line and allowing the compressor to start, its main engine can be turned on.

Immediately before starting the compressor, a warning signal for the operating personnel must be activated.

3.2. The emergency stop must be carried out immediately without unloading the compressor.

The idle compressor unit must be disconnected from the shop gas manifolds and pressure removed from it. After an emergency shutdown of the compressor, it is necessary to immediately close the valves on the lines connecting it to the workshop manifolds and relieve pressure in the entire gas system of the installation.

3.3. During long shutdowns of the compressor and shutdowns for repairs, the disconnection of its pipelines from the shop manifolds is performed using two shut-off valves with the opening of air vents between them. If a water seal is provided on the suction line, the disconnection from the collector is carried out by a water seal.

3.4. The compressor must be stopped immediately if:

a) failure of the compressor protection means (blocking) listed in paragraph 2.2.7.3 of this Instruction;

b) seal failures and gas leaks;

c) the appearance of extraneous knocks and shocks in the compressor and in the engine or the detection of their malfunction, which can lead to an accident;

d) overload of the main motor (high temperature of the motor windings);

e) failure of control and measuring devices of the compressor unit, in cases where it is impossible to replace them on a running unit;

e) lack of lighting;

g) fire.

3.5. Stopping the compressor unit for repairs or for a long time should be carried out after purging its equipment with an inert gas, then air.

3.6. Compressor units operating on explosive gas must be purged with an inert gas before start-up:

a) after repair;

b) after opening for inspection or repair of at least one unit operating in an explosive gas environment;

c) after a long stop.

3.7. All control and measuring devices must be systematically checked according to special instructions and a schedule approved by the chief engineer of the enterprise.

3.8. Checking and maintenance of pressure gauges must comply with the requirements of the instructions and rules of the State Committee for Standards. Checking pressure gauges with their sealing or branding must be performed at least once every 12 months, in addition, at least once every 6 months, the enterprise must conduct an additional check of working pressure gauges using a control pressure gauge with recording the results in the log of control checks.

In the absence of a control pressure gauge, an additional check is allowed to be carried out with a verified working pressure gauge. Pressure gauges are not allowed to be used in cases where:

a) there is no seal or brand;

b) the term for checking the pressure gauge is overdue;

c) the pointer of the pressure gauge, when it is turned off, does not return to the zero reading of the scale by an amount exceeding half of the permissible error for this pressure gauge;

d) the glass is broken or there are other damages to the pressure gauge that may affect the correctness of its readings.

3.9. It is forbidden to instruct the drivers during their duty to perform work not related to the maintenance of the compressor unit. It is allowed during a short-term absence of the driver to entrust the maintenance of the compressor unit to another person who has the appropriate rights.

3.10. Unauthorized persons are prohibited from entering the compressor room. Outside, at the entrance door to the compressor room, a warning sign "No entry is allowed" should be posted.

3.11. The compressor room must be provided with reliable communication and signaling with technologically related workshops and departments, and, if necessary, with a code signaling device.

3.12. For compressor installations operating on explosive gases, plans for the elimination of possible accidents should be developed. Maintenance personnel must be trained in the correct actions to prevent and eliminate an emergency.

3.13. At the workplace, it is necessary to post instructions for the operation of the compressor unit, safety precautions and fire prevention.

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