OCCUPATIONAL SAFETY AND HEALTH
Instruction on labor protection for the driver of a mobile compressor (station). Full document Occupational Safety and Health / Standard instructions for labor protection 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:
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:
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:
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:
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:
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:
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:
66. During the operation of a mobile compressor, the compressor driver must control:
67. During the operation of the compressor, the driver is prohibited from:
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:
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:
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:
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