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Instruction on labor protection for the driver of a mobile compressor (station). Full document

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

General labor protection requirements

1. To manage and maintain mobile compressors (stations) with an electric motor or an internal combustion engine, men are allowed at least 18 years of age who have passed a medical examination to determine whether their condition meets the requirements for the work performed, trained in the appropriate program and having a certificate for the right to work as a driver mobile compressor with a certain type of motor. Persons who, in addition, have a certificate for the right to drive a car, are allowed to work on self-propelled automobile compressors (stations).

2. A newly hired compressor driver is allowed to work independently only after he has passed an introductory briefing on labor safety, environmental requirements and an initial briefing at the workplace, about which appropriate entries must be made in the registration logs of the introductory briefing and at the workplace with a mandatory signature instructed and instructed.

3. Primary briefing at the workplace is carried out with each compressor driver individually with a practical demonstration of safe working practices and methods. All compressor drivers after the initial briefing at the workplace and testing of knowledge for 3-5 shifts (depending on length of service, experience and nature of work) perform work under the supervision of a mechanic or foreman, after which their admission to independent work is issued. Admission to independent work is fixed by the date and signature of the instructing person in the instruction log at the workplace.

4. The knowledge of the compressor driver on labor safety must be checked by the permanent examination commission of the enterprise or organization at least once every 12 months. The results of the check are drawn up in the minutes of the commission, and a corresponding mark is made in the certificate and personal card. If the driver of a mobile compressor receives an unsatisfactory grade when checking knowledge of safety requirements until a re-check after one month, the driver is not allowed to work independently.

5. When changing the technological process, replacing or upgrading equipment, fixtures, tools, when new or revised rules, instructions, labor protection standards, changes and additions to them are put into effect, if the driver violates labor safety requirements that may lead or have led to injury, accident, fire, explosion or poisoning, during breaks in work for more than 30 calendar days, as well as at the request of supervisory authorities, an unscheduled briefing is carried out.

6. When performing work in dangerous and especially dangerous conditions, as well as other unusual work not related to the direct duties of the driver, a targeted briefing is carried out and a work permit is issued (GOST 12.0.004-90).

7. About the repeated and unscheduled briefing, a corresponding entry is made in the briefing registration log at the workplace with the obligatory signature of the instructed and instructing. When registering an unscheduled briefing, the reason that caused it to be held is indicated. Target briefing is recorded in the work permit, allowing the performance of work.

8. A compressor driver who has been instructed and has shown unsatisfactory knowledge is not allowed to work. He must re-instruct. The knowledge gained during the briefing is checked by the employee (foreman, engineer of the labor protection service, foreman, mechanic) who conducted the briefing. It is allowed to operate a mobile compressor only if there is an instruction and a manufacturer's passport, as well as an operator's labor protection instruction developed on the basis of this standard instruction. These documents must contain all technical data, instructions for operation, repair, installation and safe working practices and methods.

9. Each mobile compressor is assigned by order of the head of the enterprise or organization to a specific driver responsible for its operation and labor safety.

10. When operating the compressor, the driver must monitor compliance with safety requirements by workers performing work with the applied manual pneumatic machines.

11. The compressor driver must have the II qualification group for safety. The qualification group must be confirmed annually in the prescribed manner with an entry in the safety requirements knowledge check log.

12. The compressor driver must know:

  • manufacturer's instructions for the compressor device;
  • rules and instructions for its operation, maintenance and preventive maintenance;
  • work production technology;
  • ways to detect and eliminate malfunctions in the operation of the compressor;
  • instructions on labor protection, developed on the basis of a standard one, taking into account local conditions;
  • internal regulations for the organization of labor and requirements for the implementation of work and rest regimes.

Before leaving for the work site, the mobile compressor must be in good condition, checked by a mechanic and documented.

13. The compressor driver must be aware and remember that the operation of the compressor is associated with increased danger.

14. The greatest danger in the operation of mobile compressors is an explosion in the cylinders of air compressors, air collectors or air ducts.

15. An explosion can occur as a result of a number of reasons, the main ones being:

  • improper installation and operation of the compressor;
  • overheating of the walls of the compressor cylinders due to a significant increase in the temperature of the compressed air;
  • excess pressure of compressed air above the allowable;
  • improper operation of the lubrication system;
  • use for lubrication of oils not provided for by GOST and the manufacturer's instructions;
  • failure of safety valves;
  • violation of the requirements of the manufacturer's instructions for the operation of the compressor.

16. Mobile compressors must have pressure gauges at each compression stage and at the air receiver. On the scales of pressure gauges, marks of the optimally permissible working pressure should be marked with red paint, above which work is prohibited. It is forbidden to put a red mark on the glass of the manometer.

17. Pressure gauges must be verified and sealed. Re-tests of pressure gauges are carried out at least once every 12 months, in addition, at least once every 6 months, the enterprise must carry out additional verification of working pressure gauges with a control pressure gauge, recording the results in the control verification log.

18. It is forbidden to use a pressure gauge in cases where:

  • there is no seal or brand;
  • overdue calibration period;
  • the arrow of the pressure gauge does not return to the zero mark of the scale when it is turned off;
  • the glass is broken, there is no mark for the optimally permissible working pressure, there are other damages that may affect the correct readings of the pressure gauge.

19. Pressure gauges must be selected with such a scale that the working pressure measurement limit is in the second third of the scale.

20. Pressure gauges must be installed so that their readings are clearly visible to the driver, while its scale must be in a vertical plane or tilted forward up to 30 °. The pressure gauge must be protected from radiant heat and from cold.

21. At each stage of air compression and on the air collector, independent automatic safety valves must be installed, each of which is adjusted to the maximum pressure and sealed.

22. The installation of lever weight valves on a mobile compressor is prohibited.

23. Serviceability of safety valves must be checked every shift by lifting them with the help of special levers.

24. Mobile air compressors must have serviceable air filters (air cleaners) on the suction pipes of the first stage and water and oil separators at the next compression stage. The filter device must not be deformed or vibrate during air intake.

25. Compressor lubrication and oils used must comply with the manufacturer's instructions and the requirements established by GOST.

26. The flash point of the compressor oils used must be at least +240°C, ash content - 0,03%, mechanical impurities should not exceed - 0,007%.

27. Each batch of compressor or industrial oil must have a factory passport-certificate indicating the physical and chemical properties of the oil.

28. Transportation and storage of compressor and industrial oil must comply with the requirements of GOST 1510-84 and be carried out in closed containers special for this purpose, having a distinctive color and the inscription "Clean compressor (industrial) oil of the brand.". Vessels must be kept clean, protected from moisture and heat. The use of contaminated vessels for compressor or industrial oil is prohibited.

29. Filling oil into lubricating devices should be done by the driver only through funnels with a filter. Oil filters in the forced lubrication system must be systematically cleaned at the time specified in the manufacturer's instructions, but at least once a month.

30. The suitability of an unknown brand of oil for lubricating compressors can only be determined on the basis of laboratory analysis.

31. The movement of trailer compressors (stations) towed by a truck is only allowed with the help of a rigid tug. It is forbidden to attach the drawbar to the vehicle hitch using wire, chains, etc.

32. For operation, the mobile compressor should be installed on a flat area with the wheels secured with wheel chocks (shoes), in a dry and shaded place, taking into account the direction of prevailing winds and dust from working pneumatic tools. The air in the places where the compressor is installed must have the least amount of dust.

33. In winter, the site for the installation of the compressor must be cleared of snow and ice, and in case of sleet, sprinkled with sand or slag.

34. When working for a long time, the compressor is installed on the pads.

35. The compressor must not be installed:

  • near (at a distance of less than 30 meters) from containers with combustible gas;
  • directly under the wires of existing power lines (TL) of any voltage. Regardless of the brand of the machine and the type of engine, the installation is carried out outside the security zone of the power transmission line at a distance, depending on the voltage, in accordance with Appendix 5 of GOST 12.1.013-78;
  • in enclosed spaces that do not have a special outlet for the exhaust gases of the drive engine;
  • closer than 3 m from ledges of ditches, quarries and in other places where soil sliding is possible.

36. The operation of the compressor in the security zone of the operating power transmission line is allowed only in exceptional cases, in agreement with the organization operating the power line and according to the permit signed by the chief engineer or chief power engineer of the enterprise in the presence of a representative of the energy supervision or the power plant of the enterprise.

37. All vessels (air collectors) operating under the pressure of non-caustic, non-toxic and non-explosive media at a temperature not exceeding 200 ° C, in which the product of capacity in liters and pressure in kgf / cm exceeds 10, is subject to # registration with the Gosgortekhnadzor of Russia. If such a vessel (air collector) is not registered, the driver does not have the right to work with it.

38. With a smaller product, such vessels are not subject to registration in the Gosgortekhnadzor bodies.

39. Each mobile compressor must be provided with a collapsible inventory protective fence 1,2 m high (GOST 23407-78), and compressors driven by an electric motor additionally with an inventory grounding device.

40. A mobile compressor driven by an electric motor must be grounded before connecting to the mains.

41. The connection of the mobile compressor frame to the grounding device must be strong and reliable. The earth electrode located in the ground should not be painted.

42. It is forbidden to use pipelines with flammable and explosive liquids or gases as grounding conductors, as well as bare aluminum wires.

43. Air ducts supplying compressed air must have such a cross section that the air pressure drop at the place of consumption does not exceed 0,01 MPa.

44. At the point of connection of pneumatic manual machines, the pressure drop in the air duct during its operation should not exceed 0,15 MPa. The air ducts going from the main air duct to the pneumatic machines must have a U-shaped bend at the connection points so that condensed moisture does not enter the pneumatic motor of the pneumatic machine.

45. For road works related to the mobile nature of work, it is necessary to use collapsible air ducts made of steel pipes at an operating pressure of 1 MPa (GOST 3262-75, GOST 10704-76) or rubber-fabric pressure hoses (GOST 18698-73).

46. ​​The air duct should be laid with a slope in the direction of air movement, using special gaskets for this purpose or the natural slope of the microrelief.

47. The length of the hose, which is directly connected to the pneumatic machine, should not exceed 10 m. The maximum permissible length of the hose is the length at which the operating pressure at the inlet to the pneumatic machine with the engine running is not lower than 0,5 MPa.

48. The connection of two sleeves with each other must be made using a double-sided nipple.

49. The compressor driver is obliged to monitor the connection of the air ducts, preventing leakage of compressed air.

50. The compressor driver must work in the overalls established for him, not allowing them to be put on overhand, leaving hanging sleeves and fasteners.

51. Open the caps of barrels of fuels and lubricants with the help of keys. It is forbidden to open the plugs with blows from a hammer, crowbar, chisels and other metal objects.

52. When servicing compressors with an electric motor, the driver must use personal protective equipment: dielectric gloves, rugs. Monitor their serviceability and the timing of the next test.

53. For failure to comply with the requirements of the instructions for labor protection, developed on the basis of this model, the driver is liable in accordance with the internal labor regulations and the current legislation on labor protection.

Occupational safety requirements before starting work

54. Before starting work, the compressor driver must:

  • receive from the foreman at the place of work a specific task and instructions for its implementation using safe methods and methods of work;
  • to familiarize the workers employed at work with manual pneumatic machines with the mode of operation of the compressor;
  • put on overalls;
  • get acquainted with the place of work and determine the place of installation of the compressor;
  • install a compressor and deploy a network of air ducts;
  • ground the mobile compressor driven by an electric motor and in accordance with the requirements of the manufacturer's operating instructions;
  • prepare personal and fire protection equipment, the necessary tools and equipment;
  • clear the workplace of unnecessary items and free the work area from unauthorized persons.

55. The work area must be protected by a protective fence (GOST 23407-78) and marked with safety signs.

56. During continuous operation during the acceptance and delivery of shifts, as well as after installing the compressor at a new place of work, it is necessary to inspect all compressor mechanisms from the outside, check the serviceability and illumination of control and measuring instruments, the presence of seals on them, and in case of a malfunction, perform preventive repairs.

57. If malfunctions are found that cannot be eliminated on their own, it is necessary to report this to the foreman or mechanic and do not start the compressor until the malfunctions are eliminated and the foreman or mechanic gives permission.

58. Before starting the compressor, you must:

  • get acquainted with the entries in the shift log and eliminate the comments related to the operation of the compressor;
  • check the installation and all fastenings in the compressor and engine;
  • check the presence of lubricating oil at the lubrication points of parts and assemblies of the compressor, the presence of fuel in the tank and top up if necessary. To check the fuel level, you should use a measuring ruler, bring an open flame to the tank and do not smoke while refueling;
  • securely close containers with fuel and compressor oil and place them in a designated shaded place at a distance of at least 5 meters from the compressor;
  • check the presence of cooling water;
  • check the condition of the filters;
  • remove carbon deposits formed from the decomposition of lubricating oil near the covers of air distribution valves;
  • check the starting devices for turning on the electric motor. It is forbidden to turn on the electric motor with twisted ends of the wires. Starting devices should only be factory-made;
  • wipe the components and parts of the compressor from oil, dust and dirt. Only linen or cotton fabrics may be used as cleaning materials. When wiping, the use of wiping material made of woolen fabrics is not allowed;
  • lay an air duct and connect hoses, it is prohibited to connect hoses directly to the line and pneumatic machine without valves;
  • before each start of the compressor, open the distributing and purge cocks on the air collector, intermediate cooler and oil separator for free air outlet. It is forbidden to start rotary vane compressors PR-10 with open valves of the distributing air duct;
  • make a trial run of the compressor and blow out the hoses before connecting to the pneumatic machine, while it is forbidden to look inside the blown hose, as dust and sand that accidentally get into them can injure the eyes and face;
  • attach hoses to pneumatic machines. It is allowed to connect the hoses to the pneumatic machine and the air duct and disconnect them only when the shut-off valves installed on the air collector or outlets from the main air duct are closed.

59. If the compressor has not worked for a long time or is out of repair, it is necessary to check the engine crankshaft manually before starting. The engine must be started with the compressor off. When starting the engine, in order to avoid injury to the hand by reverse operation, it is not allowed to clasp the starting handle with your thumb.

60. When starting a frozen starting engine of a mobile compressor with an internal combustion engine, it is prohibited to heat the crankcase and engine block with an open fire. To heat the engine, it is necessary to use hot water poured into the cooling system or oil heated to a temperature of 70-80 ° C, poured into the crankcase.

61. When starting a compressor with an electric motor, the rotation of the compressor shaft must be checked to avoid dangerous disturbance of the oil circulation in the compressor. When viewed from the motor side, the coupling must rotate clockwise.

62. If ice appears on the delivery hoses, it must be carefully chipped off, while avoiding hitting hard and sharp objects or using cutting objects. Warm up pressure hoses in a warm and dry place. Heating frozen pressure hoses with open fire or steam is prohibited.

63. Open shut-off valves for compressed air supply to manual pneumatic machines.

64. Give a signal to start the compressor. Workers working with pneumatic tools should wear personal protective equipment and turn on pneumatic machines. 3-5 minutes after the start signal is given, start the engine. After the compressor is turned on and the normal speed is set, close the valves and transfer the work to the working stroke.

Occupational safety requirements during work

65. Safe operation of mobile compressors is ensured by:

  • compliance with the requirements of the manufacturer's instructions and the rules for the operation of compressors, labor protection instructions;
  • proper operation of safety devices, instrumentation and control mechanisms;
  • adjusted cooling and lubrication system;
  • quality and compliance of compressor oil;
  • proper cleaning of dust and moisture from the air sucked in by the compressor.

66. During the operation of a mobile compressor, the compressor driver must control:

  • pressure and temperature of compressed air after each compression stage;
  • compressed air temperature after cooling;
  • the mode of receipt of cooling water in compressors and refrigerators;
  • the temperature of the cooling water entering and exiting the cooling system by points;
  • stator current, and with a synchronous electric drive - rotor current;
  • oil pressure and temperature in the lubrication system;
  • - the correct operation of the lubricators and the oil level. The oil consumption for each lubrication point must not exceed that specified in the manufacturer's instructions.

67. During the operation of the compressor, the driver is prohibited from:

  • make any repairs;
  • leave the compressor unattended;
  • do any other work.

68. The driver may leave the running compressor only after replacing it with another driver or a person who has the right to do so (mechanic, assistant driver, foreman). If there is no replacement, the driver must stop the compressor and inform the foreman or workers about it.

69. During the operation of the compressor, the driver is obliged to accurately, clearly and systematically (at least every two hours) keep records in the compressor operation log book of the established form. The log must be checked daily and signed by the person responsible for the safe operation of the compressor.

70. During the operation of the compressor, the driver must monitor the implementation of safety requirements by the assistant driver, trainee (if these persons are assigned by order (instruction) of the head of the enterprise).

71. Operation of compressors during dust storms, thunderstorms, snowfall, rain, hail and strong winds is prohibited.

72. The compressor driver must systematically, after 2-3 hours of compressor operation, blow through the air collector and the intermediate cooler, removing the condensate accumulating in them. If the air humidity is high, purge after 30 minutes of operation.

73. In compressors with a pressure lubrication system and in drive internal combustion engines, it is necessary to monitor the readings of oil pressure gauges. Normal oil pressure in ZIL engines is not less than 1,2 kg/cm, in compressors DK-9 and KS-9 it must not be lower than 1,5 kg/cm, in engines KDM-46, KDM-60, KDM-100, D-54 - not less than 1,7 kg / cm.

74. During operation, it is forbidden to partially drain the oil from the sump, as this impairs lubrication and does not guarantee the safe operation of the compressor.

75. When changing the oil, care must be taken to prevent dirt, water, dust, etc. from getting into it.

76. During the operation of the compressor, it is forbidden to clean and wipe the rotating or moving parts, to carry out any repair work.

77. When using antifreeze in winter conditions, it is necessary to comply with the requirements for safe work with toxic and flammable substances.

78. When cleaning the air filter, do not use gasoline, kerosene and other liquids. Air filters should only be cleaned by blowing with air.

79. Repair work of the compressor is carried out only in stationary conditions of repair shops. These works are carried out by persons authorized to repair pressure vessels with the participation of a compressor driver.

80. In order to avoid an explosion, the air chambers of the block heads and nozzles should be inspected and cleaned of carbon and rust at least after 400 hours of operation. In case of minor damage to the surfaces of cavities filled with air, they must be painted with bakelite varnish with aluminum powder.

81. Intermediate coolers should be cleaned of dust and oil residues, which are the main cause of air overheating, at least after 400 hours of operation.

82. After repair, replacement of instrumentation and preventive maintenance, a test run of the compressor must be carried out under stationary conditions in the presence of a person responsible for the safety of the compressor operation and its driver.

Labor protection requirements in emergency situations

83. In all cases of emergency, the operation of the compressor must be stopped immediately. An emergency situation during the operation of a mobile compressor unit may occur in the following cases:

  • increasing the air pressure in the air collector by more than 7,5 kg/cm, and in the first stage by more than 2,2 kg/cm;
  • the occurrence of a sharp knock in the compressor;
  • the appearance of abnormal noise in the compressor;
  • supplying air with oil impurities to the receiver, knocking oil out of the breather;
  • malfunctions of air pressure gauges and compressor capacity regulator;
  • an increase in the temperature of the air injected into the air collector by more than +140 ° C, as well as with a continuous increase in the heating of any components and parts of the compressor;
  • drive motor overload;
  • sparks of the electric motor and starting electrical appliances of low-capacity compressors;
  • redundancy of oil supply to the lubricating surfaces of compressor assemblies and parts;
  • suction into the compressor of air with an admixture of combustible gases;
  • accumulation of soot (decomposition product of lubricating oil) at the covers of air distribution valves;
  • drop in compressor performance;
  • when there is a smell of burning or smoke from the compressor or electric motor;
  • with a noticeable increase in compressor vibration;
  • in the event of a sudden interruption in the supply of cooling water or other emergency malfunction of the cooling system.

84. After an emergency stop, the compressor driver is obliged to report this to the foreman or the person responsible for safe operation, the mechanic.

85. Repair of compressor components and assemblies at the work site is prohibited.

86. In the event of a fire, it is necessary to immediately stop the operation of the compressor, give a fire alarm, call the fire department, remove people from the danger zone and start extinguishing the fire with standard fire extinguishing equipment.

Occupational safety requirements at the end of work

87. Upon completion of work, the compressor driver must:

  • give a signal about the end of work;
  • 3-5 minutes after the signal is given, close the fuel supply valves to the engine (switch off the electric motor);
  • open the purge cocks of the air collector and the intercooler;
  • stop the compressor by disengaging the clutch;
  • close the dispensing valves;
  • turn off the pneumatic machines, disconnect the hoses from the main air pipeline;
  • control the preparation for the storage of pneumatic machines, tools and air hoses by the workers;
  • wipe and lubricate parts and components of the compressor, inspect the equipment;
  • make appropriate entries in the compressor log book;
  • put the workplace in order (fold the tool, check the safety and reliability of storage of fuels and lubricants, the presence of safety signs, etc.);
  • check the condition of overalls and safety shoes and, if necessary, put them in order or report to the master about their unsuitability;
  • change clothes, wash hands and face with warm water and soap;
  • report to the foreman or person responsible for the safe operation of the compressor about the completion of work and about all malfunctions, safety violations that occurred during the work.

88. During shift work, the compressor driver, who has completed the shift, transfers his workplace to the shifter in the presence of the foreman or the person responsible for the safe operation of the compressor and informs about:

  • operation of the compressor and equipment during shifts and maintenance;
  • malfunctions that have occurred and the measures taken to eliminate them;
  • possible situations that threaten labor safety;
  • entries in the logbook of the operation of the compressor;
  • the availability of fuels and lubricants and the place of their storage.

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