Instruction on labor protection for the driver of the ZIF-55 compressor

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OCCUPATIONAL SAFETY AND HEALTH
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Instruction on labor protection for the driver of the ZIF-55 compressor

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General requirements for labor protection

1.1. To work independently as a ZIF-55 compressor driver, a worker at least 18 years old, who has professional training and has passed: a preliminary medical examination; and:

introductory and primary briefings;
training in safe labor methods and techniques and testing knowledge of labor safety in the qualification commission;
re-instruction;
targeted and unscheduled briefings;
fire safety briefing;
internship.

1.2. The driver of the ZIF-55 compressor must use overalls and personal protective equipment in accordance with established standards: cotton overalls, leather boots, combined gloves.

For outdoor work in winter, in addition: a cotton jacket with an insulating lining, cotton trousers with an insulating lining; felt boots.

1.3. The ZIF-55 compressor driver undergoes a periodic knowledge test every 12 months, and the results of the test are documented in special protocols.

1.4. For trouble-free operation of the compressor, the driver must know:

ZIF-55 compressor device, purpose and principle of operation of all mechanisms;
rules of technical operation and care instructions;
inspection rules, causes of malfunctions, methods for their detection, prevention and elimination.

1.5. It is forbidden for the driver to transfer control of the compressor to anyone.

1.6. During operation, mobile compressors should be placed on horizontal platforms, while the wheels should be wedged (fixed), it is prohibited to install compressor stations near sources of combustible gases.

1.7. During the operation of ZIF-55 compressors, the greatest danger is an explosion in the cylinders of air compressors, air collectors or air ducts.

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

improper operation of the lubrication system and poor quality of lubricating oil;
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;
incorrect installation and operation.

1.8. All repair and installation work on the current-carrying parts of the compressor with electric drive motors, as well as work on connecting to the network and disconnecting the stations from the networks, must be performed with the voltage removed.

1.9. Mobile compressors with a capacity of up to 15 m3/min and an air pressure of not more than 10 kg/cm must have pressure gauges at each compression stage and on the air collector. On the scales of pressure gauges, marks of the highest allowable pressure should be marked with red paint, in case of exceeding which work is prohibited.

1.10. Pressure gauges must be checked and sealed. Retests are carried out at least once a year.

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

1.12. The serviceability of the safety valves must be checked every shift by lifting them with the help of special levers.

1.13. Air compressors must have air filters on the suction pipes of the first stage and water-oil separators on the subsequent compression stage.

1.14. Excessive oil supply to the lubricated surfaces may result in the release of lubricating oil vapors or products of its decomposition into the discharge line, which, under certain conditions, can lead to an explosion.

2. Labor protection requirements before starting work

2.1. Before starting work, the driver must:

inspect all the mechanisms of the station from the outside;
check the presence and serviceability of seals on control and measuring instruments;
make a trial run of the station (if the station has not worked before);
eliminate the noticed malfunctions and then take the station on the move (if the station did not work before).

2.2. It is prohibited to start the compressor with the air collector valves closed.

Before each start-up of the compressor, the distributing and purge cocks on the air collector and the intercooler should be opened to allow free air to escape. After the compressor develops a normal number of revolutions, the valves must be closed and the compressor transferred to the working stroke.

2.3. Before starting the compressor, you must:

open the valves of the air collector, intermediate cooler and water-oil separator;
check the presence of lubricating oil in the compressor and engine; check the presence of fuel in the engine and prepare for start-up. The engine must be started with the compressor off. If the compressor was previously under repair or did not work for a long time, you must first turn the crankshaft manually.

2.4. When starting a frozen starting motor of a mobile compressor, it is forbidden to heat the crankcase and engine block with an open flame of a blowtorch or a torch. To heat a cold engine, it is necessary to use hot water poured into the cooling system and heated oil poured into the crankcase.

3. Labor protection requirements during work

3.1. It is necessary to constantly monitor the normal operation of all compressor units, observe the readings of pressure gauges, thermometers and other instruments and devices that control and regulate temperature, pressure and compressed air consumption, and prevent overloading of the compressor and engine.

3.2. The air sucked in by the compressor must be well cleaned of dust. Therefore, it is necessary to monitor the good condition of the air filters, which must be periodically cleaned, and the oil in them must be replaced with fresh oil every 40 hours of operation. Do not wash the filters with gasoline or kerosene.

3.3. It is necessary to constantly monitor the operation of the performance regulator, in the event of a malfunction of which it is prohibited to work on the compressor.

3.4. Systematically, every 2-3 hours of operation of the station, the air collector and the intermediate cooler should be purged, removing the water and oil condensate that accumulated in them.

3.5. It is forbidden to carry out any repair work with the air collector of the compressor station under compressed air pressure, including work to eliminate leaks in the air duct flanges.

3.6. Taps and valves on the air collector must not let air through.

3.7. The fastening of the hoses to the fittings must be done with the help of clamps. The use of wire for fastening is prohibited.

3.8. Hoses must not be broken, tangled, or crossed with a cable, electric cable and hose of gas welding machines. Frozen hoses should be thawed in a warm room. It is forbidden to heat the hoses with steam.

3.9. To connect the hoses to the tool and the air collector, or to connect the hoses to each other, use fittings and nipples with good threads. Hose connections must be airtight.

3.10. It is forbidden to turn off the air supply by breaking the hose or tying it in a knot.

3.11. Of particular danger is the accumulation of soot (coke, tarry residues) near the covers of air distribution valves, this can cause an explosion.

3.12. Lubricating oils of unknown composition must not be used to lubricate compressors.

3.13. The compressor crankcase should be replenished with oil every shift. It is possible to check the oil level in the crankcase and add oil to it only when the compressor is not running, when the oil drains from the crankcase walls.

3.14. To avoid an explosion, do not dilute crankcase oil with kerosene or diesel fuel.

3.14. Wash the internal surfaces of the compressors with kerosene or diesel fuel. It is possible to collect parts after cleaning them with kerosene no earlier than after 3 hours.

3.15. Safety valves may only be dismantled if they fail to function or are damaged. After repair, safety valves must be adjusted and sealed by a special person appointed by the administration. The compressor station operator is not allowed to independently calibrate the valves.

3.16. At least twice a year, it is necessary to clean the intermediate coolers, keeping in mind that the clogging of the inner and outer surfaces of the cooler tubes with dust and oil residues is the main reason for the increase in the temperature of the compressed air to above permissible limits.

3.17. The ZIF-55 compressor should be stopped immediately if:

increasing the air pressure in the air collector above the allowable;
an increase in the temperature of the air injected into the air collector by more than 140 ° C, as well as with continuously increasing heating of any components or parts of the compressor, if the driver cannot determine the cause and independently eliminate it;
the appearance of knocking in the mechanisms of the compressor or in the event of a breakdown;
drive motor overload.

3,18. Before stopping the compressor, open the air receiver and intercooler purge valves, and then stop the compressor by disengaging the clutch.

4. Labor protection requirements in emergency situations

4.1. The compressor must be stopped immediately if:

pressure gauges on the discharge line show pressure above the allowable one;
the pressure gauge of the lubrication system of the movement mechanism shows the pressure below the permissible lower limit;
the supply of cooling water or other emergency malfunction of the cooling system suddenly stopped;
knocks, shocks are heard in the compressor or engine, or their malfunctions are detected, which can lead to an accident;
the temperature of the compressed air is above the maximum permissible norm;
a fire broke out;
there is a smell of burning or smoke from the compressor or electric motor;
noticeable increase in vibration of the compressor or engine.

4.2. The driver must emergency stop the compressor (press the "stop" button) and only then report to the management.

4.3. After an emergency shutdown of the compressor, it can be started with the permission of the person responsible for the safe operation of the compressor unit.

4.4. In the event of a sudden power outage, the driver is obliged to immediately transfer the starting devices of the electric motors and control levers to the "stop" position.

5. Labor protection requirements at the end of work

5.1. Tidy up the workplace.

5.2. At low ambient temperatures (in the winter season), after the compressor has stopped, the oil from the crankcases and the engine and the compressor should be separately drained into a clean container so that it can be preheated at start-up, and drain the water from the cooling system.

5.3. Take off overalls.

5.4. Wash hands and face with warm soapy water or take a shower. Washing hands in oil, gasoline, kerosene is strictly prohibited.

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