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Instructions on labor protection for the operator of the electrolysis plant. Full document

Occupational Safety and Health / Standard instructions for labor protection

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1. General provisions

1.1. The instruction on labor protection for the operator of the electrolysis plant is a document that establishes the requirements for workers to safely perform work.

1.2. Knowledge of the Instructions on labor protection is mandatory for all employees.

1.3. The head of the structural unit is obliged to create conditions at the workplace that meet the requirements of labor protection, provide employees with protective equipment and organize their study of this Instruction.

Each enterprise must develop and communicate to all personnel safe routes through the territory of the enterprise to the place of work and evacuation plans in case of fire and emergency.

1.4. Each employee must:

• comply with the requirements of this Instruction;
• immediately report to your immediate supervisor, and in his absence, to a higher manager about the accident that has occurred and about all violations of the Instructions he has noticed, as well as about malfunctions of structures, equipment and protective devices;
• keep the workplace and equipment clean and tidy;
• ensure the safety of protective equipment, tools, devices, fire extinguishing equipment and documentation on labor protection at their workplace.

1.5. For violation of the requirements of the Instruction, the employee is liable in accordance with applicable law.

2. General safety requirements

2.1. Persons at least 18 years of age who have undergone a preliminary medical examination and have no contraindications to perform this work are allowed to work in this profession.

2.2. An employee undergoes an introductory briefing upon hiring. Before admission to independent work, he must pass:

• training in professional training programs;
• initial briefing at the workplace;
• test of knowledge of instructions:
• on labor protection;
• to provide first aid to victims of accidents at work;
• on the use of protective equipment necessary for the safe performance of work;
• on fire safety.

For employees who have the right to prepare a workplace, admission, the right to be a work supervisor, an observer and a team member, it is necessary to check the knowledge of the Intersectoral labor protection rules (safety rules) for the operation of electrical installations (hereinafter referred to as the Rules) to the extent corresponding to the duties of responsible persons for labor protection .

2.3. Admission to independent work is issued by an appropriate order for the structural unit of the enterprise.

2.4. A newly hired employee is issued a qualification certificate, in which an appropriate entry must be made about checking knowledge of the instructions and rules specified in clause 2.2, and about the right to perform special work.

The qualification certificate for on-duty personnel during the performance of official duties may be kept by the shop shift supervisor or with him in accordance with local conditions.

2.5. Employees who have not passed the knowledge test within the established time limits are not allowed to work independently.

2.6. The employee in the process of work must pass:

• repeated briefings - at least once a quarter;
• verification of knowledge of the instructions for labor protection and the current instructions for providing first aid to victims of accidents at work - once a year;
• medical examination - once every two years;
• checking the knowledge of the Rules for employees who have the right to prepare a workplace, admission, the right to be a foreman, supervisor or team member - once a year.

2.7. Employees who have received an unsatisfactory mark during a qualification test are not allowed to work independently and must undergo a second test no later than one month.

In case of violation of labor protection rules, depending on the nature of the violation, an unscheduled briefing or an extraordinary knowledge test is carried out.

2.8. The victim or eyewitness must immediately notify his/her immediate supervisor of each accident or accident.

2.9. Each employee must know the location of the first aid kit and be able to use it.

2.10. If faulty devices, tools and protective equipment are found, the employee must inform his/her immediate supervisor about this.

It is not allowed to work with faulty devices, tools and protective equipment.

To avoid electric shock, do not touch or step on broken overhanging wires.

2.11. In electrical installations, people, mechanisms and hoisting machines are not allowed to approach energized, unprotected live parts at distances less than those indicated in Table 1.

Table 1. Permissible distances to live parts under voltage

* - direct current.

2.12. It is not allowed to clutter up approaches to shields with fire-fighting equipment and to fire hydrants, as well as to use fire-fighting equipment for other purposes.

2.13. The following hazardous and harmful production factors may occur at the workplace of the operator of the electrolysis plant (EU): increased voltage in the electrical circuit; flammability and explosion hazard due to the presence of hydrogen; harmful substances that can cause poisoning and chemical burns.

2.14. To protect against exposure to hazardous and harmful factors, it is necessary to use appropriate protective equipment.

To protect against electric shock, it is necessary to use electrical protective equipment: dielectric gloves, galoshes, rugs, voltage indicators, metalwork and assembly tools with insulating handles.

When preparing the electrolyte, a cotton suit, a rubberized apron, rubber gloves, acid-alkali-resistant boots, and protective sealed goggles should be used.

When staying in rooms with technological equipment (except for control panels), it is necessary to wear a protective helmet.

2.15. The operator must work in overalls and use protective equipment issued in accordance with current industry standards.

2.16. The following personal protective equipment must be issued to the operator free of charge in accordance with industry standards:

• cotton suit - for 1 year;
• rubber overshoes - for 9 months;
• protective helmet - for 2 years;
• rubber gloves - on duty;
• apron made of rubberized fabric - on duty;
• dielectric boots - on duty.

When issuing a double replaceable set of overalls, the wear period is doubled.

Depending on the nature of the work and the conditions of their production, the apparatchik is temporarily given additional overalls and protective equipment for these conditions free of charge.

2.17. It is not allowed to smoke in the EU room, enter with fire, use tools that can give a spark, store flammable explosives.

In the room of the power plant, portable explosion-proof lamps with a voltage of not more than 12 V should be used.

3. Safety requirements before starting work

3.1. Before accepting a shift, the electrolysis operator:

• tidies up the uniform. Sleeves and floors of overalls should be fastened with all buttons, hair should be removed under a helmet. Clothing must be tucked in so that there are no hanging ends or fluttering parts. Shoes should be closed and low heels. It is not allowed to roll up the sleeves of overalls;
• bypasses the serviced equipment along a certain route, checks the safe condition of the equipment;
• checks at the workplace for the presence and serviceability of a tool, an electric lamp, fire extinguishing equipment, posters or safety signs;
• familiarizes with the entries in the operational journal;
• checks for the presence of neutralizing solutions;
• makes sure that there are dielectric mats on the floor near each device.

3.2. Before starting repair work on a power plant that is disconnected and freed from hydrogen, it is necessary:

• turn on the supply and exhaust ventilation;
• close the valves through which hydrogen, oxygen or electrolyte can flow to the place of work, hang posters on them "Do not open. People are working!";
• reduce the pressure in the repaired section of the circuit to atmospheric;
• check for visible breaks or plugs in the pipeline and carry out the necessary purge;
• outlet valves in the purge system must remain open;
• put up a "Work Here" poster at the place of work.

4. Safety requirements during work

4.1. When working with electrolyte, it is necessary to use protective clothing and goggles. The electrolyte sample for density change should only be taken with the pressure removed.

4.2. During the operation of the power plant, an explosive mixture of hydrogen with oxygen or air must not be allowed. The purity of hydrogen must be at least 98%, oxygen - at least 5%.

4.3. Devices and pipelines of the power plant (except for receivers) must be purged with nitrogen before start-up. It is not allowed to purge these devices with carbon dioxide. EI receivers can be purged with nitrogen or carbon dioxide.

4.4. If it is necessary to inspect the receiver internally, it should be purged with carbon dioxide or nitrogen to remove hydrogen, disconnected from other groups of receivers with shutoff valves and metal plugs with shanks protruding beyond the flanges, and then purged with compressed air.

Purging of receivers with inert gas, air and hydrogen should be carried out until the concentration of components in them is reached in accordance with the standards.

4.5. When carrying out welding or repair work requiring the opening of the power plant equipment, as well as when the power plant is turned off for a period of more than 4 hours, it is necessary to purge its apparatus and pipelines with nitrogen until the complete absence of hydrogen.

4.6. Frozen pipelines and valves can only be thawed with steam or hot water. Leakage of gas from connections should be determined with special leak detectors or with the help of a soapy solution.

4.7. The inclusion of the electrolyzer in operation can be carried out only after checking the condition of the insulation, inspecting the equipment and in the absence of foreign objects on it.

4.8. During the operation of the power plant, it is not allowed to tighten the bolts and nuts of devices and fittings under pressure. Hoses and fittings must be properly grounded.

4.9. The operation of electrolyzers in the absence of visible liquid levels in the sight glasses of pressure regulators is not allowed.

4.10. In the event of a power plant shutdown for up to 1 hour, it is allowed to leave the equipment at nominal gas pressure. In this case, the signaling of an increase in the pressure difference in the hydrogen and oxygen pressure regulators should not be turned off.

4.11. When transporting and preparing alkaline electrolyte, the following requirements must be observed:

• do not mix the electrolyte by blowing air into it through a rubber hose;
• use only cold water when preparing the electrolyte for the solution;
• crushing the crystalline alkali in the barrel should be done with light blows of a sledgehammer, covering the barrel with burlap;
• transport crushed alkali in polyethylene buckets on carts;
• prepare an alkaline solution in a clean cast-iron or iron dish.

4.12. In case of contact with alkali on the skin or in the eyes, wash it off with plenty of flowing water and rinse with a 3% solution of boric acid.

If acid gets on the skin or eyes, immediately wash it off with a plentiful stream of water, then rinse with a 1% solution of baking soda, and then report the incident to the shift supervisor.

4.13. Carrying bottles with aggressive substances over short distances within the workplace should be carried out in baskets with two handles by at least two employees after a preliminary check of the strength of the handles and the bottom of the basket.

Carrying bottles by hand is not allowed.

4.14. Concentrated acids and alkalis should be stored in glass bottles with ground stoppers. Corks are tied to the neck of the bottles. Bottles are stored in a separate room, they are placed on the floor in baskets or wooden crates. The necks of the bottles should have labels with the inscription.

4.15. Spilled electrolyte should be covered with sawdust, then the sawdust should be collected and removed from the EI room. The places where the electrolyte was spilled are neutralized with a solution of soda ash, washed with water and wiped dry with a rag.

4.16. When operating shut-off valves and valves, do not use great effort. When checking the correct operation of safety valves, pressure gauges and other fittings, one should stand away from the direction of gas emission when the valve is opened.

4.17. It is necessary to constantly monitor the reliability of the connection and the serviceability of the grounding device.

4.18. When servicing and repairing electrolyzers, current converters, instrumentation, it is necessary to use a tool with insulating handles, voltage indicators and dielectric gloves.

4.19. It is not allowed to work with open fire in the power plant room until the installation is turned off, air analysis is carried out and continuous ventilation of the room is ensured. The presence of hydrogen in the air in the event of an open fire leads to an explosion in the room and a fire at the power plant.

4.20. If it is necessary to carry out work with open fire on the devices of one power plant in the presence of a working second one, it is necessary to disconnect the pipelines of the operating installation from the one being repaired with the installation of plugs with tails. Protect the place of hot work with shields.

Repair work on devices containing hydrogen is not allowed.

4.21. Pots, especially end plates, should not be touched without protection. It is not allowed to get alkali on the insulating sleeves of the coupling bolts and on the insulators under the monopolar plates. If the insulation of these elements is broken, an arc may occur, which will lead to a fire and an accident.

4.22. To check the safety valves, the unit must be turned off and purged with nitrogen. Testing of valves during operation of the installation is not allowed.

5. Safety requirements in emergency situations

5.1. In the event of an emergency (accident, fire, natural disaster), you should immediately report the situation to your immediate supervisor.

5.2. In the event of a fire:

5.2.1. Notify all workers in the production area and take measures to extinguish the fire. Burning parts of electrical installations and electrical wiring under voltage should be extinguished with carbon dioxide fire extinguishers.

5.2.2. Take measures to call your immediate supervisor or other officials to the scene of the fire.

5.2.3. According to the operational situation, the local operational fire fighting plan should be acted upon.

5.3. In the event of an accident, it is necessary to immediately release the victim from the impact of the traumatic factor, provide him with first (pre-medical) medical care and inform the immediate supervisor about the accident.

When releasing the victim from the action of electric current, it is necessary to ensure that you yourself do not come into contact with the current-carrying part or under step voltage.

6. Safety requirements at the end of work

6.1. Tidy up your workspace. Remove tools and accessories and put them in the place provided for them.

Oiled rags and paper must be removed in a special container.

6.2. Notify the manager (foreman) about the end of the work.

6.3. Inform the manager (foreman), shift worker about all malfunctions and shortcomings noticed during work, and about the measures taken to eliminate them. In the absence of a leader or shift - write in a special journal.

6.4. Remove and store personal protective equipment.

6.5. Turn off all electrical appliances, turn off the water.

6.6. Lock the room of the power plant with a padlock, hand over the keys for storage in the prescribed manner.

6.7. Wash or take a shower.

7. List of accepted abbreviations

• AGP Field extinguishing machine
• ACS Automated control system
• PBX Automatic telephone exchange
• VL Overhead power line
• VLAN Overhead communication line
• HF communication High-frequency communication
• Main control panel Main control panel
• ZRU Enclosed switchgear
• IC Measuring (test) stand
• CL Cable power line
• KLS Cable communication line
• KRU (KRUN) Complete switchgear of internal
• (outdoor) installation
• KTP Complete transformer substation
• MTP Mast transformer substation
• NRP Unattended regeneration point
• NUP Unattended reinforcement point
• OVB Operational Field Brigade
• Outdoor switchgear
• OUP Serviced amplification point
• POR Work Management Design
• PPR Project for the production of works
• PRP HR Rules
• PUE Rules for the installation of electrical installations
• RZA Relay protection and automation
• RP Distribution point
• RU Switchgear
• SDTU Dispatch and process control facilities
• (cable and overhead lines of communication and telemechanics,
• high-frequency channels, communication and telemechanics devices)
• SMO Construction and installation organization
• SNiP Building codes and regulations
• TAI Devices for thermal automatics, thermal measurements and protection, means of remote control, signaling and technical means of automated control systems
• TP Transformer Substation
• EU Electrolysis Plant

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