Instructions for labor protection when working with compressor units.

1. General provisions.

1.1. This instruction defines the basic provisions and requirements of labor protection, which are aimed at preserving the life and health of employees.
1.2. The instruction was developed on the basis of the “Regulations on the development of instructions for labor protection”

DNAOP 0.00-4.15-98, “Standard regulations on training on occupational safety” DNAOP 0.00-4.12-99, “Rules for the construction and safe operation of pressure vessels” DNAOP 0.00 – 1.07 – 94, “Labor safety rules in DPO of the Ministry of Internal Affairs of Ukraine”, and other documents regulating labor protection issues
1.3. The instruction defines the procedure for performing safe techniques and work methods when working with compressor units (further – compressors) contained in the part, and is intended for training, briefings and testing knowledge on labor protection issues.
1.4. Employees authorized to work with compressors are instructed according to this manual
before starting work (initial training) and then every 3 months (retraining). The result of the briefing is entered in the “Log of registration of briefings on labor protection issues”.
1.5. The instruction is valid for 3 years from the date of approval.
1.6. Employees who are allowed to work with compressors are required to know and follow valid instructions, should perform only the work that is assigned by the management of the unit and for which he is instructed, and not to follow those instructions that contradict the rules of labor protection.
1.7. Training and certification of personnel servicing vessels must be carried out in educational institutions, educational and course combines (courses), as well as in courses specially created by enterprises that have the permission of the State Supervision and Protection of Labor of Ukraine.
Individual training of personnel is not allowed.
1.8. Certificates are issued to persons who have passed the exams indicating the name and parameters of the working environment of the vessels to which these persons are admitted.
1.9. Periodic checks of the knowledge of employees who maintain compressors are carried out at least once every 12 months.
1.10. The admission of employees to the independent maintenance of vessels is issued by an order by part.
1.11. To work with compressors, employees who have undergone appropriate training, passed a medical examination, introductory and initial briefing on labor protection at the workplace are allowed.

1.12. The head of the unit must establish a procedure so that the personnel allowed to work on the compressor conduct a thorough observation of the equipment assigned to him by inspecting it, checking the operation of fittings, control and measuring devices, safety and blocking devices and maintaining the vessels in good condition.
The results of inspection and inspection must be recorded in a variable log.

1.13. The employee must know:
•    structure of the compressor, operating parameters, principle of operation of the compressor, measuring devices and equipment, procedure and terms of their inspection, operational requirements for them;
•    “Rules for construction and safe operation of pressure vessels”;
•    instructions for the person responsible for the good condition and operation of the compressor;
•    compressor manufacturer’s instructions;
•    manufacturing instructions on the mode of operation of vessels and their safe maintenance for the masters of GDZS;
• scheme of compressed air (oxygen) pipelines, refrigerators, water-oil separators and other devices;
•    places of installation and scheme of control and measuring devices;
•    methods of finding and eliminating malfunctions in the operation of the compressor;
•    installation scheme;
•    instructions for testing the tightness of vessels working with
gases or liquids dangerous for people;
•    “Rules for the technical operation of electrical installations of consumers”, “Rules for the safe operation of electrical installations” in the part related to the electrical equipment of the compressor.
•    ways (to be able to) provide first aid in case of accidents;
rules for using primary fire extinguishing means.

1.14. Depending on the nature of the violations, employees who are allowed to work with compressors if they do not meet the safety requirements set forth in the labor protection manual are subject to disciplinary, material and criminal liability in accordance with current legislation.

1.16. Workplace when working on a compressor: compressor with a machine that grounds the circuit, electric wire, starting device, pressure gauge.

1.17. The main dangerous and harmful production factors that can affect an employee are:
• increased surface temperature of the equipment;
•    increased levels of noise, vibrations at the workplace;
• action of moving and rotating parts of equipment and mechanisms
•    possibility of electric shock
insufficient lighting of the working area;
•    increased gassing of the working area.

1.17. The technical condition of the compressor must meet the requirements of standards related to labor safety, environmental protection, as well as the rules of technical operation, instructions of manufacturers’ factories and other regulatory and technical documentation.
1.18. The responsibility for ensuring the serviceable condition and safe operation of the compressor is entrusted by the head of the unit to the members of the senior staff.
1.19. An employee who is allowed to work on a compressor must:
•    to comply with the rules of internal labor regulations;
•    remember personal responsibility for compliance with occupational health and safety rules
colleagues at work;
•    perform only the work for which he is instructed and assigned by the manager;
•    do not follow instructions that contradict the rules of labor protection;
•    use overalls and personal protective equipment;
• prevent outsiders from entering your workplace;
• be able to provide first aid to victims of accidents;
•    keep the workplace clean and tidy

1.20 Requirements for the premises of compressor units:

1.20.1 It is not allowed to place apparatus and equipment, technologically and constructively not
related to compressors;

1.20.2. The floor should be flat with a non-slippery, non-stable surface.
1.20.3. The room must be equipped with ventilation.
1.20.4. All moving and rotating parts of compressors, electric motors and other mechanisms
must be reliably fenced off.
1.20.5. Compressor housings must be grounded.
1.21. All compressor installations must be equipped with control and measuring devices
1.22. Manometers must have an accuracy class of not less than –1.5 at the working pressure of the vessel over 2.5 MP (25 kgf/cm2).
1.23. Manometers should have such a scale that at working pressure the arrow is in
middle third of the scale.
1.24. A red line should be drawn on the scale of the manometer, which would indicate the working pressure in the vessel. Instead of a red line, it is allowed to attach a metal plate, painted in red and tightly fitting to the glass of the manometer, to the body of the manometer.
1.25. A three-way valve or other similar device must be installed between the manometer and the vessel, which allows periodic checking of manometers using a control manometer
1.26. The manometer is not allowed to be used in cases when:
1.26.1 There is no seal, or stamp with a mark on the inspection.
1.26.2. The verification period has expired.
1.26.3. The needle of the manometer during its shutdown does not return to the zero mark of the scale by an amount that exceeds half of its error (error), which is allowed for this device.
1.26.4. The glass is broken or there is other damage that may affect the correctness of its readings.
1.27. Inspection of manometers with their sealing or branding should be carried out at least once every 12 months. In addition, at least once every 6 months, it is necessary to carry out an additional check of the working pressure gauges with a control pressure gauge, with the results entered in the log of control checks.
1.28. Each compressor must be equipped with safety devices against pressure increase above the permissible value.
1.29. Adjustment of safety valves should be carried out on special stands by persons who have the right to perform these works, with a record of the adjustment in the “Compressor Equipment Maintenance Log”.
1.30. The circuit of the vessels must be posted at the workplace.
1.31. To lubricate the compressor, it is necessary to use only those lubricants that are provided by the compressor manufacturer. Each batch of lubricants must have a factory certificate indicating the physical and chemical properties of lubricants.
1.32. Safety valves, oil-water separators, cylinders, valve boxes, etc. must be cleaned in a timely manner from condensate, contamination, oil deposits, soot, etc. in accordance with the compressor’s operating instructions.
1.33. The following should be painted on the compressor in a conspicuous place or on a special plate with a format of at least 200 x 150 mm:
– working environment (“Oxygen”, “Air”);
– permissible pressure.
1.34. After pumping the air, it is allowed to use the compressor as an oxygen compressor
only after washing and degreasing in special workshops and enterprises.

1.35. There should be technical documentation in the compressor room:
•    diagram of pipelines, indicating the places of installation of valves, control
measuring devices, automation, etc.;
Schedules of planned and preventive repairs of compressors (for 2004, 2005
•    magazine of maintenance of compressor equipment;
compressor logbook;
•    variable journal;
• passport-certificate of compressor oil;
•    instructions on labor protection when working on the compressor and the person responsible for its working condition and
safe operation of vessels;
•    logs of inspection of metrological equipment. Acts of laboratory tests of manometers;
Copies of passports for compressors;
•    copies of the order regarding the admission of workers to work on compressors and assignment
responsible for the serviceable condition and safe operation of compressors;
•    Copies of protocols for testing the knowledge of the masters of the GDZS working with the compressor.

1.36. To maintain the vessel in good condition, it is necessary to carry out its repairs in a timely manner (according to the schedule). The plan-schedule of planned and preventive repairs must be developed annually, according to the instructions of the manufacturer’s plant, other regulatory documents.
1.37. The results of the repair are recorded in the maintenance log of the compressor equipment.
1.38.Repairs using welding (soldering) of pressure vessels must be carried out according to the technology developed by the manufacturing enterprise, design or repair organization, before the start of work, and the results must be entered in the vessels’ passport.
1.39. Repair of vessels and their elements that are under pressure is not allowed.
1.40. Repair and cleaning of equipment and pipelines that are under pressure is prohibited.
1.41. During internal inspection, cleaning or repair of water-oil separators, air-gas collectors or other containers, they must be reliably disconnected from the corresponding network with plugs with shanks, completely freed from gas or air and blown with clean air for at least 10 minutes.
1.42. After cleaning and repairing compressor parts or assemblies, it is necessary to make sure that there are no foreign objects left in them.