Instructions on labor protection when servicing pressure vessels

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OCCUPATIONAL SAFETY AND HEALTH
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Instructions on labor protection when servicing pressure vessels

Occupational Safety and Health

Occupational Safety and Health / Standard instructions for labor protection

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Safe Operation

1. General safety requirements

1.1. Persons at least 18 years of age who have passed a medical examination are allowed to service pressure vessels, as well as:

introductory and primary briefings;
fire safety briefing;
electrical safety briefing;
training and testing knowledge on safety;
training and testing knowledge on the rules for the design and safe operation of pressure vessels through a training course complex.

1.2. Training and certification, periodic testing of personnel knowledge should be carried out in accordance with the requirements of the "Rules for the Design and Safe Operation of Pressure Vessels" of the Gosgortekhnadzor of the Russian Federation.

1.3. Maintenance of the unit should be carried out once every 3 months.

1.4. An external inspection of the semi-trailer should be carried out daily in preparation for leaving the line and caring for it upon returning to the car company.

1.5. Safety valves are subject to revision according to the schedule of the owner of the vessel, but at least once every 6 months.

1.6. Once every 6 months, the control pressure gauges should be checked for correct readings.

1.7. Once a year, pressure gauges must be tested in the Gosstandart laboratory.

1.8. Rubber-fabric sleeves assembled with clamps should be inspected daily in order to detect cracks, surface incisions.

1.9. Once every 3 months, the sleeves must be subjected to GI for strength at a pressure of 1,25 working pressure, a tag must be attached to the sleeves indicating the next test period.

1.10. After the first 2 fillings of the vessel with gas, clean and flush the filter screen with gasoline.

1.11. In the future, the filter should be washed monthly.

1.12. Grounding checks should be carried out at least once a year, and also after each repair of the equipment.

1.13. The operator servicing the vessels must:

undergo repeated and unscheduled briefings;
perform only the work that is included in the duties;
comply with the requirements of prohibiting, prescriptive posters.

1.14. The operator servicing the vessels must know:

actions on a person of dangerous and harmful factors;
rules for the design and safe operation of pressure vessels;
industrial hygiene requirements;
device equipment;
inner order rules;
appointment of PPE.

1.15. The operator servicing the vessels must use the following PPE: cotton suit (gown), combined gloves, rubber boots.

1.16. During operation, the following hazardous production factors may affect the operator servicing the vessels:

objects falling from a height;
insufficient illumination;
high humidity;
increased levels of noise and vibration;
high blood pressure.

1.17. The operator serving the vessels is allowed to work independently by order of the enterprise.

1.18. Periodic testing of knowledge of the personnel servicing the vessels takes place in the commission of the enterprise once every 12 months.

1.19. The operator is responsible for the implementation of the production instructions

1.20. Extraordinary examination of knowledge is carried out:

when new Rules and instructions come into force;
after an accident and an accident on the equipment;
when establishing the facts of unsatisfactory knowledge of the instructions and safety rules by the apparatchik.

1.21. Vessel service personnel are required to maintain the cleanliness of the equipment and workplace.

2. Safety requirements before starting work

2.1. Put on the required overalls and take the shift.

2.2. Before filling the vessel of a semi-trailer in operation, it is necessary:

make a thorough inspection of the outer surface of the vessels and fittings;
check the tightness of threaded and flanged connections (tighten if necessary);
inspect the shut-off valves, all valves must be closed.
check the presence of residual pressure (0,5 kg per cm2.);
check the serviceability of the semi-trailer devices;
check the serviceability of the control 85% filling is checked by briefly opening the valve on the instrument hatch. When the valve is open, gas should come out of the tube;
the serviceability of the pressure gauge is checked by briefly turning it off and on using a three-way valve located in front of the pressure gauge. When the pressure gauge is turned off, its arrow should go to zero;
the serviceability of the safety valves is checked by the corresponding entry in the passports of the semi-trailer vessel and by the presence of seals on the valves.

2.3. Visually check all fastening elements of the vessel to the undercarriage of the semi-trailer.

3. Safety requirements during work

3.1. When filling a semi-trailer vessel at a gas filling station, it is necessary:

install the semi-trailer on a horizontal platform;
turn off the engine;
hand over the engine ignition key to the filling operator;
place wheel chocks under the wheels;
to ground the semi-trailer;
remove the plugs from the nozzles of the liquid and vapor phases;
connect the pipes of the liquid and vapor phases of the semi-trailer vessel with the corresponding pipes of the filling columns with rubber-fabric sleeves;
smoothly open the valves VN15, VN21, VN19 on the semi-trailer;
slowly open the vapor phase valve on the filling column;
after equalizing the pressure of the vapor phase, slowly open the valve of the liquid phase on the filling column;
observe the filling of the vessel using the U1 level indicator and the BH1 maximum filling control valve;
when the gas level reaches 85%, close the valves on the filling column;
close the valves on the semi-trailer;
disconnect the rubber-fabric sleeves from the semi-trailer and columns, having previously bled the gas from the sleeves onto a candle, or into a special container;
install plugs on the pipes of the semi-trailer and lay the rubber-fabric sleeves in the casings;
remove the grounding and remove wheel chocks from under the wheels.

3.2. When filling the vessel with a pump installed on a semi-trailer, the actions of the personnel are practically the same, only after attaching rubber-fabric sleeves to the nozzles of the liquid and vapor phases, it is necessary:

smoothly open valves VN15, VN21, VN17, VN18 on the semi-trailer;
slowly open the vapor phase valve on the filling tank, then the liquid phase valve;
after filling the pump with the pumped liquid, turn on the pump;
observe the filling of the semi-trailer vessel by the indicator U1 and the control valve BH1 of maximum filling;
when the level reaches 85%, turn off the pump;
close the valves on the filling tank;
close the valves on the semi-trailer;
release the remaining gas from the rubber-fabric sleeves onto the candle;
disconnect the rubber-fabric sleeves from the semi-trailer;
install plugs on the pipes of the semi-trailer.

The procedure for filling cylinders with liquefied gas of gas-balloon vehicles

3.3. Upon arrival at the filling site for LPG vehicles, the driver must:

turn off the engine of the towing vehicle and remove the key from the ignition lock;
ground the semi-trailer and the control post;
make sure there is no open fire;
place wheel chocks under the wheels of the semi-trailer.

3.4. Preparing the semi-trailer for filling cylinders:

the semi-trailer must be installed so that gas-balloon cars drive up from the side of the meter installation;
the power cable for powering electrical equipment must be extended to its full length so that gas-cylinder vehicles cannot run over it;
by external inspection, check the serviceability of all electrical equipment when the central switch is turned off;
turn on the central switch;
briefly turn on the pump, check the direction of rotation of the electric motor;
start the pump according to the sequence specified in the passport for the pump;
open valves VN17, VN19 supplying gas to the pump, valve VN18 to the bypass and the valve on the discharge pipeline;
turn on the electric motor and check the operation of the pump on the bypass according to the pump passport;
open the VN13 valve to the CHIZHGE-20 meter;
open the valve installed on the vapor phase pipeline BH15 and the valve for removing the vapor phase from the car cylinder (BH10).

3.5. The procedure for filling automobile cylinders.

before filling the car cylinder, check the cylinder check stamp in the driver's waybill and the signature of the person responsible for checking them; in cars, check the inspection mark on the cylinder plate;
connect the filling clamp CT1 to the filling valve of the automobile cylinder;
open the valve on the car cylinder;
open valve BH14;
turn on the remote control "Spring-CHP" in accordance with the operation manual 118.00.OORE on the remote control "Spring-CHP";
dial on the remote control "Spring-CHP" the amount of the sold product;
press the "Start" button on the CHIZHGA-20 device;
turn on the electric pump;
open clamp CT1 (filling process should start).

After filling the car cylinder, you must:

close clamp CT1;
turn off pump H1;
disconnect the CT1 clamp from the cylinder;
make a note on the itinerary.

3.6. Upon completion of the filling of automobile cylinders, it is necessary:

close all valves on the semi-trailer communications;
turn off all electrical equipment, disconnect the plug connectors, assemble the cable.

3.7. Draining of gas from the semi-trailer vessel must be carried out according to the instructions of the enterprise where it is carried out.

3.8. When draining gas from a semi-trailer vessel at the consumer (underground group installation), the following should be done:

install the semi-trailer at the group installation;
turn off the engine;
call a representative of the house management;
ground the semi-trailer and place stops under the wheels;
remove the plugs and connect the drain and vapor phase pipes of the semi-trailer vessel with the corresponding pipes at the group unit;
open the vapor phase valve VH15 on the semi-trailer and on the group unit and follow the pressure gauges for equalizing the pressures in the vessel of the semi-trailer and the group unit;
open the valve for the liquid phase of gas VN18, VN20 on the semi-trailer and drain the gas into the group unit;
after draining the gas, turn off the valve, disconnect the sleeves, install the plugs, remove the grounding and stops.

3.9. It is forbidden to fill with liquefied gas cylinders in which;

examination period has expired;
hull damaged;
there are no established brands and inscriptions;
tightness is broken;
color is broken;
there is no residual pressure of 0,5 kg per cm2 .;
check valve defective.

4. Safety requirements in emergency situations

4.1. The vessel must be stopped in an emergency in the following cases:

the term of the appointed examination of the vessel and the term of revision of the safety valves have expired;
the body or bottom of the vessel is damaged (dents, cracks, severe corrosion);
there is no passport for the vessel;
the thread on the fittings and rubber-fabric sleeves is faulty;
if the pressure in the vessel has risen above the permitted one (16 kg per cm2) and does not decrease, despite the measures taken by the personnel;
when a malfunction is detected in the operation of one of the safety valves;
in case of failure of all water-indicating levels;
in case of malfunction of safety interlocks;
in case of a fire that directly threatens the operation of the vessel.

4.2. Causes of an emergency stop are recorded in the shift log

5. Security measures at the end of work.

5.1. After the filling of gas-balloon vehicles with liquefied gas, it is necessary to turn off the electricity supplying the electrical equipment of the semi-trailer.

Tidy up the workplace, make the necessary entries in the shift journal.

5.2. Put the tool and the remaining unused materials in their places.

5.3. Record equipment problems

5.4. Take a shower.

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