Occupational safety in the industry for welding specialties. General safety rules for the operation of portable acetylene generators

General safety rules for the operation of portable acetylene generators

Modern acetylene generators are simple in design, with proper preparation for operation and maintenance, they are safe to operate. Violation or failure to comply with safety instructions or technical operation may cause explosion and accidents.

1. It is forbidden to use self-made acetylene generators and those whose designs are not approved by VNIIAavtogen.

2. Each portable acetylene generator must have a passport and instructions for operation and safety precautions and an inventory number, according to which the generator must be registered in the register and technical inspections.

3. The generator must be located at a distance of at least 10 m from the place of gas-flame work, as well as from any other source of fire and sparks.

4. It is not allowed to install the generator in an inclined position; during operation, it should be protected from bumps, bumps and falls.

5. It is not allowed to work from a portable generator installed on the same cart with an oxygen cylinder. Joint transportation of an uncharged generator with an oxygen cylinder is allowed.

6. The portable generator must not be left unattended during operation.

7. It is forbidden to load calcium carbide of lesser granulation into the generator than indicated in the generator passport.

8. It is prohibited to use one portable generator to supply acetylene to more than one flame treatment post.

It is allowed to supply up to four posts with acetylene from a GVR-3 type generator. In this case, in addition to the safety lock on the generator, a water lock must be installed at each post.

9. When operating portable generators in the open air or in unheated rooms at temperatures below 0 0 С, you should:

1. close the generator with a frost protection cover;
2. during long breaks and after the end of work, remove the loading device, completely drain the water from the generator and remove carbide sludge;
3. cover the hose and the valve body on the water seal with heat-insulating material (for example, string asbestos);
4. fill water locks with non-freezing liquid;
5. when water freezes in the generator, water seal or hoses, they should be warmed up in a warm room at a distance of at least 10 m from a source of fire, sparks, etc. It is allowed to heat the generator with hot water or steam. It is forbidden to use an open flame, hot metal, electric heaters, etc. for heating;
6. in the case of using the generator to power the post located in the room, it is allowed to remove the water seal from the generator and install it in the room, connecting it to the generator with a rubber hose.

10. At the end of the work, the calcium carbide in the generator should be completely finished, drained of sludge, the body and retorts washed with water, and the generator and unused calcium carbide in a closed container should be installed in a safe place.

11. The room in which the operating portable generator was installed must be thoroughly ventilated upon completion of work.

12. Lime sludge removed when recharging a portable generator must be unloaded into a container adapted for this purpose and drained into a sludge pit or a special bunker (box).

13. Near the silt pits and places of storage of silt, inscriptions should be posted on the prohibition of smoking, making fire and bringing incandescent or smoldering objects at a distance of less than 10 m;

14. Silt pits must be cleaned in a timely manner, their overflow with silt is prohibited.

15. It is forbidden to install acetylene generators in aisles, driveways, in crowded places in unlit places, in rooms where it is possible to release substances that form self-explosive mixtures with acetylene, or release flammable substances, as well as in operating boiler rooms and near places where air is taken by compressors and fans.

16. Periodically inspection of portable generators should be carried out by the technical administration of the enterprise (organization). The results of the inspection must be made an appropriate entry in the passport and the log of technical inspections. If during the inspection faults are found, then its further operation should be suspended.

Safe working practices with calcium carbide

The most common way to obtain technical acetylene is the decomposition of calcium carbide with water in acetylene generators.

Calcium carbide is a compound of calcium with carbon. It is obtained by fusing in an electric furnace at a temperature of 2000º C quicklime with coal or coke. The content of pure calcium carbide in technical carbide is usually 65 - 70%. At a break, such a carbide has a light gray color; at a higher content, its color becomes purple. The main impurity of technical calcium carbide is quicklime.

The process of formation of acetylene from calcium carbide proceeds very rapidly with the release of a large amount of heat. So, for example, during the decomposition of 1 kg of calcium carbide with water, about 400 kcal of heat is released. Therefore, during the decomposition of 1 kg of calcium carbide, practically 5 to 15 liters of water are taken. The lack of water for the decomposition of calcium carbide can lead to severe overheating of acetylene and its explosive decomposition.

From 1 kg of calcium carbide, 200 - 350 liters of acetylene are usually obtained. In practice, taking into account various losses, to obtain 1000 liters of acetylene, from 3.7 to 5 kg of calcium carbide and the size of its pieces (granules) are consumed. The larger the pieces of calcium carbide, the higher the yield of acetylene.

The process of decomposition of calcium carbide with water also proceeds extremely unevenly, the intensity of the reaction continuously weakens. Initially, while the pieces of calcium carbide are not yet covered with a lime crust, and the surface of the pieces is relatively large, acetylene is released violently, the decomposition reaction rate is maximum. As the surface of the pieces decreases in size and a lime crust forms on it, the contact of undecomposed calcium carbide with water becomes more difficult, the intensity of the reaction decreases, which leads to a decrease in the release of acetylene.

The main impurity in calcium carbide is slaked lime (silt) and the more it is, the lower the decomposition rate. In addition to lime, calcium carbide can contain ferrosilicon, which also reduces the rate of decomposition.

In addition to the listed impurities, calcium carbide contains a certain amount of calcium phosphite and phosphorous carbon, which, when interacting with water, form hydrogen phosphide. If calcium carbide contains an increased amount of phosphorous compounds, then the acetylene formed from it can ignite spontaneously in contact with air at elevated temperatures.

Ignition can occur at the time of starting the generators of the "water to carbide" system with a content of hydrogen phosphide in acetylene of more than 0.15%. Aluminum sulfide and calcium sulfide are the main sources of sulfur compounds in acetylene, and their content in acetylene is affected by the conditions of decomposition of calcium carbide by water.

In the generators of the “carbide to water” system, that is, under conditions of a large excess of water, the resulting hydrogen sulfide is completely dissolved in it. An admixture of ammonia in acetylene is formed during the decomposition of nitrogenous magnesium and nitrogenous aluminum. The ammonia content in acetylene is even more dependent on the same conditions as the hydrogen sulfide content. With an excess of water and good cooling of acetylene, almost all ammonia remains dissolved in water.

S.V. SOBURY

FIRE SAFETY OF THE ENTERPRISE

3. Fire prevention measures duringhot work

In accordance with PPB 01-03, the following fire safety measures must be observed during hot work:

3.1. General requirements

To carry out all types of hot work at temporary sites (except for construction sites and private households), the head of the facility must issue a work permit (637).

Places of hot work should be provided with primary fire extinguishing equipment (fire extinguisher, box with sand and a shovel, a bucket of water) (638).

It is not allowed to place permanent places for hot work in fire and explosion hazardous rooms (639).

Technological equipment, which provides for the conduct of hot work, must be brought into an explosion-proof state by (640):

exemption from explosive and flammable substances;

disconnection from existing communications (with the exception of communications used to prepare for hot work);

preliminary cleaning, washing, steaming, ventilation, sorption, phlegmatization, etc.

When steaming inside process equipment, the temperature of the supplied water vapor should not exceed a value equal to 80% of the autoignition temperature of combustible vapor (gas) (641).

Process equipment should be flushed when the concentration of vapors (gases) in it is outside the limits of their ignition or in an electrostatically safe mode (642).

Methods for cleaning rooms, as well as equipment and communications in which hot work is carried out, should not lead to the formation of explosive vapor and dust-air mixtures and the appearance of sources of ignition (643).

In order to prevent hot metal particles from entering adjacent rooms, adjacent floors, etc. all inspection, technological and other hatches (holes), ventilation, mounting and other openings (openings) in the ceilings, walls and partitions of the premises where fire work is carried out must be closed with non-combustible materials.

The hot work site must be cleared of combustible substances and materials within the radius indicated in the table (644):

Height of the welding point above the floor level or the adjacent territory, m

Minimum cleaning zone radius, m

Building structures, flooring, finishing and cladding, as well as insulation and parts of equipment made of combustible materials located within the specified radii, must be protected from sparks by metal screens, asbestos sheets or other non-combustible materials and need watered (645).

In rooms where hot work is carried out, all doors connecting these rooms with other rooms, including the doors of vestibule locks, must be tightly closed. Windows, depending on the time of year, room temperature, duration, volume and degree of danger of hot work, should be, if possible, open (646).

Premises where accumulation of vapors of flammable liquids, gaseous liquids and gaseous gases is possible, must be ventilated before carrying out hot work (647).

The place for welding and cutting works in buildings and premises, in the constructions of which combustible materials are used, must be fenced with a solid partition made of non-combustible material. In this case, the height of the partition must be at least 1.8 m, and the gap between the partition and the floor - no more than 5 cm. 0x1.0 mm (648).

Before starting and during hot work, control over the state of the vapor-gas-air environment in the technological equipment on which the specified work is carried out and in the danger zone should be carried out.

In the event of an increase in the content of combustible substances or a decrease in the concentration of a phlegmatizer in a hazardous area or process equipment to the values ​​\u200b\u200bof the maximum permissible explosion-proof concentrations of vapors (gases), hot work must be immediately stopped (649).

Opening hatches and covers of technological equipment, unloading, reloading and draining products, loading them through open hatches, as well as other operations that can lead to fires and explosions due to gas contamination and dustiness of places where fire work is carried out, not allowed (650).

During breaks in work, as well as at the end of the work shift, the welding equipment must be turned off, including from the mains, the hoses must be disconnected and freed from flammable liquids and gases, and the pressure in blowtorches must be completely released. apparatus and equipment must be removed to specially designated premises (places) (651).

When organizing permanent places for conducting hot work at more than 10 posts (welding, cutting workshops), centralized electricity and gas supply (652) should be provided.

In a welding workshop, if there are no more than 10 welding posts, it is allowed to have one spare cylinder with oxygen and combustible gas for each post. Spare cylinders must be protected by shields made of non-combustible materials or stored in special annexes to the workshop (653).

When carrying out hot work, it is prohibited (654):

start working with faulty equipment;

carry out hot work on structures and products freshly painted with combustible paints (varnishes);

use clothes and gloves with traces of oils, fats, gasoline, kerosene and other flammable liquids;

store clothes, flammable liquids, combustible liquids and other combustible materials in welding booths;

allow students to work independently, as well as employees who do not have a qualification certificate and a coupon for fire safety equipment;

allow contact electrical wires with cylinders with compressed, liquefied and dissolved gases;

carry out work on devices and communications filled with combustible and toxic substances, as well as under electrical voltage;

carrying out hot work simultaneously with the installation of waterproofing and vapor barrier on the roof, installation of panels with combustible and slow-burning heaters, sticking floor coverings and finishing rooms using combustible varnishes, adhesives, mastics and other combustible materials.

Carrying out hot work on elements of buildings made of light metal structures with combustible and slow-burning heaters, not allowed (655).

3.2. Gas welding works

Portable acetylene generators should be installed in open areas. Their temporary work is allowed in well-ventilated rooms.

Acetylene generators must be fenced off and placed no closer than 10 m from hot work sites, as well as from air intakes by compressors and fans.

At the installation sites acetylene generator notices (placards) should be hung out: "No entry to outsiders - flammable", "No smoking", "Do not pass with fire" (656).

After the work of calcium carbide in portable generator must be worked out. Lime sludge removed from the generator must be unloaded into containers adapted for this purpose and drained into a sludge pit or a special bunker.

Open silt pits should be fenced with railings, and closed pits should have non-combustible ceilings and be equipped with exhaust ventilation and hatches for removing sludge.

Smoking and the use of open fire within a radius of less than 10 m from the places of storage of sludge is not allowed, which must be posted with appropriate prohibition signs (657).

The fastening of gas supply hoses to the connecting nipples of equipment, burners, cutters and gearboxes must be secure and carried out using clamps or at least in two places along the length of the nipple with soft annealed (knitting) wire.

The hoses on the water seal nipples must be snug but not fastened (658).

Calcium carbide must be stored in dry, ventilated areas.

It is not allowed to place warehouses for the storage of calcium carbide in basements and low flooded places (659).

In mechanized warehouses, it is allowed to store drums with calcium carbide in three tiers in a vertical position, and in the absence of mechanization - no more than three tiers in a horizontal position and no more than two tiers in a vertical position. Boards with a thickness of 40-50 mm should be laid between the tiers of drums.

The width of the passages between stacked drums with calcium carbide should be at least 1.5 m (660).

In the premises of acetylene plants, where there is no intermediate storage of calcium carbide, it is allowed to store at the same time no more than 200 kg of calcium carbide, and of this amount no more than one drum can be open (661).

Opened calcium carbide drums should be protected with watertight covers (662).

In places where calcium carbide drums are stored and opened, smoking, the use of open flames and the use of sparking tools (663) are prohibited.

Storage and transportation of gas cylinders should be carried out only with safety caps screwed onto their necks. When transporting cylinders, shocks and shocks should not be allowed. Cylinders must be delivered to the place of welding work on special carts, stretchers, sledges (664).

Cylinders with gas during their storage, transportation and operation must be protected from the action of sunlight and other heat sources.

Cylinders installed indoors must be located at least 1 m from heating appliances and stoves, and at least 5 m from heat sources with open fire.

The distance from the burners (horizontally) to bypass ramp (group) installations must be at least 10 m, and to individual oxygen or gas cylinders - at least 5 m.

Oxygen cylinders and gas cylinders, as well as calcium carbide, paints, oils and fats, should not be stored in the same room (665).

When handling empty oxygen or gas cylinders, the same precautions should be observed as for filled cylinders (666).

When carrying out gas welding or gas cutting work, it is prohibited (667):

thaw frozen acetylene generators, pipelines, valves, gearboxes and other parts of welding installations with open fire or hot objects;

allow contact of oxygen cylinders, reducers and other welding equipment with various oils, as well as oiled clothing and rags;

work from one water lock to two welders;

load calcium carbide with oversized granulation or push it into the funnel of the apparatus using iron rods and wire, as well as work with carbide dust;

load calcium carbide into wet loading baskets or in the presence of water in the gas collector, as well as load baskets with carbide more than half of their volume when the "water to carbide" generators are operating;

purge the hose for the GG with oxygen and the oxygen hose of the GG, as well as interchange the hoses during operation;

use hoses whose length exceeds 30 m, and during installation work - 40 m;

twist, twist or pinch gas supply hoses;

move the generator if there is acetylene in the gas collector;

force the operation of acetylene generators by deliberately increasing the gas pressure in them or increasing the one-time load of calcium carbide;

use a copper tool for opening drums with calcium carbide, as well as copper as a solder for soldering acetylene equipment and in other places where contact with acetylene is possible.

3.3. Electric welding works

Floors in rooms where permanent places for welding are organized must be made of non-combustible materials. It is allowed to install wooden end floors on a non-combustible base in rooms where welding is performed without preheating parts (668).

It is not allowed to use wires without insulation or with damaged insulation, as well as to use non-standard protection devices (669).

Welding wires should be connected by crimping, welding, soldering or special clamps. Connection of electrical wires to the electrode holder, the workpiece to be welded and the welding machine must be carried out using copper cable lugs fastened with bolts and washers (670).

Wires connected to welding machines, switchboards and other equipment, as well as to places of welding, must be reliably insulated and in necessary places protected from high temperatures, mechanical damage or chemical attack (671).

Cables (wires) of electric welding machines must be located at a distance of at least 0.5 m from oxygen pipelines, and at least 1 m from pipelines of acetylene and other gas generators (672).

Steel or aluminum tires of any profile, welding plates, racks and the welded structure itself can serve as a return conductor connecting the workpiece to be welded with the welding current source, provided that their cross section ensures safe flow under heating conditions current.

The connection between the individual elements used as a return conductor must be carried out using bolts, clamps or clamps (673).

The use of internal railway tracks, grounding or grounding networks, as well as metal structures of buildings, communications and technological equipment as a return conductor is not allowed. In these cases, welding must be carried out using two wires (674).

When carrying out electric welding in explosive and fire hazardous rooms and structures, the return conductor from the workpiece to be welded to the power source is made only with an insulated wire, and in terms of insulation quality it should not be inferior to a straight conductor connected to the electrode holder (675).

The design of the electrode holder for manual welding should ensure reliable clamping and quick change of electrodes, as well as exclude the possibility of a short circuit of its body on the workpiece being welded during temporary interruptions in work or if it accidentally falls on metal objects. The handle of the electrode holder must be made of non-combustible dielectric and heat-insulating material (676).

The electrodes used in welding must be factory-made and correspond to the nominal value of the welding current.

When changing electrodes, their remains (ends) should be placed in a special metal box installed at the welding site (677).

The electric welding installation must be grounded during operation. In addition to grounding the main electric welding equipment in welding installations, it is necessary to directly ground that terminal of the secondary winding of the welding transformer, to which the conductor leading to the product (return conductor) (678) is connected.

Cleaning of the unit and starting equipment should be carried out daily after the end of work. Maintenance and preventive maintenance of welding equipment must be carried out in accordance with the schedule (679). The arc in atomic hydrogen welding installations must be supplied from a separate transformer. Direct supply of the arc from the distribution network through any type of current regulator is not allowed (680).

In atomic hydrogen welding, the burner should be provided with automatic power off and stop the supply of hydrogen in the event of a circuit break.

Burners must not be left unattended (681).

When carrying out electric welding work in fire and explosion hazardous areas (682):

it is recommended to use DC power supplies or special AC power supplies that are designed pulse generators, increasing the voltage between the electrode and the workpiece to be welded at the moment of re-excitation of the arc (power source of the "discharge" type);

in fire hazardous areas class P-P hard-to-reach places for cleaning from dust are recommended to be treated with a 2% foaming agent solution at the rate of 1 liter of solution per 1 m2;

welding in a vertical and overhead position must be performed with electrodes with a diameter of not more than 4 mm. In this case, the value of the welding current should be 20% lower than when welding in the lower horizontal position;

Before turning on the electric welding unit, make sure that there is no electrode in the electrode holder.

3.4. metal cutting

During gasoline and kerosene cutting works, the workplace should be organized in the same way as during electric welding. Particular attention should be paid to preventing spills and proper storage Flammable and combustible liquids, compliance with the cutting regime and maintenance of the fuel tank (683).

Storage of a fuel supply at the site of gasoline and kerosene cutting operations is allowed in an amount not exceeding a shift requirement. Fuel should be stored in a serviceable, unbreakable, tightly closed special container at a distance of at least 10 m from the place of hot work (684).

For gasoline and kerosene cutting operations, fuel without foreign impurities and water should be used. It is not allowed to fill the tank with fuel more than 3/4 of its volume (685).

The fuel tank must be in good condition and sealed. Tanks that have not passed hydraulic tests with a pressure of 1 MPa, that have a combustible mixture leak, a faulty pump or pressure gauge, are not allowed for operation (686).

Before starting work, it is necessary to check the serviceability of the fittings of the gasoline and kerosene cutter, the tightness of the hose connections on the nipples, the serviceability of the threads in the union nuts and heads (687).

It is not allowed to heat up the torch evaporator by igniting an flammable liquid or liquid liquid poured at the workplace (688).

The fuel tank must be located no closer than 5 m from oxygen cylinders and from a source of open fire and no closer than 3 m from the worker.

places. In this case, the tank must be positioned so that it is not exposed to flames and sparks during operation (689).

When carrying out gasoline and kerosene cutting works, it is prohibited (690):

have an air pressure in the fuel tank that exceeds the operating pressure of oxygen in the torch;

overheat the torch evaporator, as well as hang the torch vertically during operation, head up;

pinch, kink, or kink hoses supplying oxygen or fuel to the torch;

use oxygen hoses to supply gasoline or kerosene to the torch.

3.5. Soldering work

The workplace during soldering work must be cleared of combustible materials, and structures made of combustible materials located at a distance of less than 5 m must be protected by screens of non-combustible materials or watered with water (an aqueous solution of a foaming agent, etc.) (691).

Blowtorches must be kept in good working order and checked for strength and tightness at least once a month with the results and the date of the check recorded in a special journal. In addition, at least once a year, their control hydrotests (692) should be carried out.

Each blowtorch must have a passport indicating the results of factory hydrotesting and the permissible working pressure. The safety valves must be adjusted to the specified pressure, and the manometers on the lamps must be in good condition (693).

Blowtorches should be filled with fuel and kindled in places specially designated for this purpose (694).

To prevent flame ejection from blowtorch the fuel refilled into the lamp must be free of impurities and water (695).

To prevent blowtorch explosion, do not (696):

use as a fuel for lamps running on kerosene, gasoline or a mixture of gasoline and kerosene;

increase the pressure in the lamp reservoir when pumping air over the allowable working pressure specified in the passport;

fill the lamp with fuel more than 3/4 of the volume of its reservoir;

unscrew the air screw and filler plug when the lamp is on or has not yet cooled down;

repair the lamp, as well as drink from it or fill it with fuel near an open fire (including a burning match, cigarette, etc.).

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1.1. This manual has been drawn up taking into account the requirements technical specifications/passport/ generator, fire safety rules for welding and other hot work; rules for the design and safe operation of pressure vessels; safety rules in the gas industry.

1.2. All acetylene generators must have a passport of the established form, an inventory number, and must be supplied with operating instructions.

1.3. Portable acetylene generators should be installed outdoors or under a canopy. To perform temporary work, it is allowed to install acetylene generators in production and office premises with a volume of at least 300 m3 for each apparatus, provided that these premises are well ventilated. If the generator is installed in a cold room, and gas welding work is carried out in another, adjacent room, then the volume of the room in which the generator is installed must be at least 100 m3 for each device.

2. General safety requirements.

2.1. Persons at least 18 years of age who have undergone special training, passed an exam, and have an appropriate certificate are allowed to independently work on servicing portable acetylene generators and performing gas welding and gas cutting work.

2.2. If it is necessary to install portable acetylene generators in passageways or on stairwells, they must be fenced and be under continuous supervision.

2.3. At negative temperature air generators should be located in insulated booths.

2.4. Filling the gas generator with water must be carried out exactly up to the control valves or to the control levels.

2.5. The minimum distance from the place of welding to the warehouse of flammable materials and installations / including gas cylinders and gas generators / must be at least 10 m.

2.6. The use of open fire or incandescent objects for heating gas generators is prohibited. Frozen acetylene generators may only be heated with steam or hot water that does not contain traces of oil; it is allowed to heat portable generators indoors at a distance of at least 10 m from an open fire and in the presence of ventilation.

2.7. During operation and transport, the generator must be protected from shocks, impacts and falls.

2.8. It is not allowed to work from a portable generator located on the same cart with an oxygen cylinder.

3. Security measures in preparation for work.

3.1. Before starting work, the welder / cutter / serving the portable acetylene generator is obliged to tidy up the overalls.

3.2. Install portable generator as required of this manual.

3.3. Load the generator chamber with pre-crushed pieces of calcium carbide in a size appropriate for the generator system.

3.4. Sealed drums with carbide must be opened with a knife specially designed for this purpose.

4. Security measures during work.

4.1. Check the fastening of the gas-conducting hoses on the connecting panels of the equipment, burners, cutters, reducers, which must be reliable. For this purpose, special clamps must be used. On the nipples of water locks, the hoses must be tightly put on, but not fixed.

4.2. At least 3 times per shift, check the liquid level in the water lock with the valve off.

• work with a faulty water lock or without a lock;
• work with faulty and unadjusted safety valves or in their absence, as well as install plugs instead of safety valves;
• force gas formation in excess of the capacity established by the passport and artificially increase the pressure in the generator in excess of the established norm, jam or install any weights on the generator bell;
• turn off automatic controllers;
• open the cover of the loading device of the retort of the medium-pressure generators of all systems until the gas under pressure is released;
• work from one generator with several burners and cutters;
• purge the hose for combustible gases with oxygen and the oxygen hose with combustible gases, as well as interchange hoses during operation, use hoses whose length exceeds 30 m;
• twist or pinch gas hoses;
• move generators if there is acetylene in the gas collector, check the hoses after each blowback;
• work on carbide dust;
• load and unload calcium carbide into wet boxes or baskets and perform these operations without gloves;
• load calcium carbide into the apparatus in excess of the norm, established instruction operation of the acetylene generator;
• smoking in the place of storage and opening of drums with calcium carbide;
• use open flames and use tools that can generate sparks upon impact when opening drums with calcium carbide;
• insert and pull out the chamber with carbide sharply with jerks into the generator socket;
• push the carbide into the chamber with steel bars.

5. Security measures at the end of work.

5.2. Before cleaning acetylene installations, all openings must be open for ventilation / purge valves, hatches, etc. /. Safety valves should be flushed at least once a month.

5.3. Lime sludge removed from the generator must be unloaded into containers adapted for this purpose and drained into a sludge pit.

5.4. Workers unloading sludge from the generator must wear respirators, canvas gloves and goggles.

5.5. Within a radius of up to 10 m from the places of storage of sludge, safety signs prohibiting smoking and the use of open flame sources should be posted.

If the operating rules are violated, acetylene generators can explode.

To ensure safe operation of the acetylene generator, the following rules must be observed:

Before starting the generator and during operation, check the water level in the generator and hydraulic seal using control cocks. The water level in the hydraulic seal is checked at least twice per shift and after each reverse flame stroke;

Check the tightness of the joints and the tightness of the closing of the retort lids;

Protect hoses from mechanical damage and contact with molten metal;

When the burner is heated to a temperature of 400 ° C, stop working, close the acetylene and oxygen valves, and cool the burner;

Load baskets with carbide no more than half the volume; grain size of calcium carbide 15 - 25 mm;

Do not use carbide dust and fines to load baskets;

In the event of a backfire, close the valves of the acetylene and oxygen pipelines, and cool the burner.

Production of gas welding works at the facilities consumer services it is advisable to concentrate in welding workshops built of non-combustible materials of at least II degree of fire resistance and having at least three rooms for accommodating acetylene generators or cylinders, oxygen cylinders and welding stations. It is not allowed to install generators in basements.

Of the oxygen cylinders, cylinders with a capacity of 40 - 50 liters are most widely used. At a pressure of 15 MPa (150 kgf / cm2), a 40-liter cylinder holds 6 m3 of oxygen. The use of oxygen cylinders requires special care. When working with them, it is necessary to make sure that there are no visible traces of oil on the valve fitting and take measures against contamination of the cylinder with oils through hands, rags, tools in order to avoid overheating and emergency release of gas. From the place of welding, oxygen cylinders are installed at a distance of at least 10 m. If this is not possible, then between the cylinders and the workplace of the welder (carver) it is necessary to install a screen of fireproof materials with a height of at least 1.5 m. During welding, the cylinders are securely fixed in vertical position. Oxygen is taken from the cylinder using a reducer to a residual pressure of at least 0.05 MPa (0.5 kgf/cm2). Cylinders for oxygen are painted blue, and the inscription "Oxygen" is made on the cylinder in black paint. It is allowed to install up to 10 working oxygen cylinders and 10 spare ones in the welding workshop.

Ensuring the fire-fighting regime in the production of welding work is entrusted to the head of the consumer services enterprise. Before being allowed to work, the welder is instructed on fire safety measures. For the performance of welding work outside the permanent places in the welding workshops, the welder is issued a written permit, agreed with the fire department of the enterprise. Obtaining a permit for the production of welding work in welding workshops is not required.

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Chemist's Handbook 21

Chemistry and chemical technology

Maintenance of acetylene generators

MAINTENANCE OF ACETYLENE GENERATORS

To work on maintenance of acetylene generators, calcium carbide warehouses and cylinders, regardless of the number of drums and cylinders with compressed gases stored in it, persons not younger than 18 years old are allowed. They must undergo special technical training and pass the technical minimum, know the device and principles of operation of the generator and other equipment, study the operating instructions, and have practical maintenance skills.

MAINTENANCE OF STATIONARY ACETYLENE GENERATORS

Work on mobile acetylene generators can only be safe if the maintenance personnel strictly follow all the rules of the maintenance, inspection and repair instructions. The knowledge of operating personnel should be checked periodically.

Portable acetylene generators are simple in design and easy to maintain. However, ignorance of safety regulations and lack of skills in handling the generator and gas welding equipment often lead to a violation of the technological mode of operation of generators, and sometimes to accidents.

Acetylene generators. Even short-term maintenance of mobile generators cannot be entrusted to persons who are not allowed to work with generators.

Many industrialized countries have detailed regulations for the care, maintenance, and operation of acetylene generators, supplemented by recommended technology standards issued by the Acetylene Associations, insurance companies, etc.

The production of acetylene from calcium carbide is carried out in acetylene generators. There are four systems of generators: contact action devices, devices with water falling onto carbide, devices with throwing carbide into water and dry type devices. The first two systems do not matter for large industrial productions. They have low productivity and are inconvenient to maintain.

The paper describes a case of fatal poisoning with phos- See pages where the term is mentioned Maintenance of acetylene generators: Watch chapters in:

Acetylene generator

Acetylene generators used for welding and cutting metals according to GOST 5190-78, classified according to the following criteria:

• performance - 1.25; 3; 5; ten; 20; 40; 80; 160; 320; 640 m 3 / h;
• according to the method of application - mobile with a capacity of 1.25-3 m 3 / h, stationary with a capacity of 5-640 m 3 / h;
• according to the pressure of the produced acetylene - low pressure up to 0.02 MPa, medium pressure from 0.02 to 0.15 MPa;
• according to the method of interaction of calcium carbide with water - generators of the KB system (“carbide to water”), in which the decomposition of calcium carbide is carried out when a certain amount of calcium carbide is supplied to the water in the reaction space;
• generators of the VK system (“water to carbide”), in which the decomposition of calcium carbide occurs when a certain amount of water is supplied to the reaction space, where calcium carbide is located;
• generators of the explosive system (“water displacement”), in which the decomposition of calcium carbide is carried out when it comes into contact with water, depending on the change in the level of water located in the reaction space and displaced by the resulting gas.

All acetylene generators, regardless of their system, have the following main parts:

• blowing agent;
• gas collector;
• safety lock;
• automatic adjustment of the produced acetylene depending on its consumption.

A plate with the following data is attached to the generator case:

• brand
• serial number and year of manufacture of the generator;
• productivity (m 3 / h);
• working pressure (MPa);
• temperature limits at which the acetylene generator can operate.

Acetylene generators of the KB system have a high utilization rate of calcium carbide, provide best conditions its decomposition, good cooling and gas flushing. The disadvantages of the KB system generators are significant water consumption, which leads to increased dimensions of the generators and a large amount of waste. This system has found application for stationary generators of high productivity.

Acetylene generators of the VK system simpler in design, require a small amount of water, able to work on carbide with different granulation. This system is mainly used for mobile devices with an acetylene capacity of up to 3 m 3 /h. The disadvantages of the generators of this system are the possibility of overheating of acetylene in the reaction zone and incomplete decomposition of calcium carbide.

Acetylene generators of the explosive system reliable and easy to use. This system has found application in mobile low and medium pressure apparatuses with a capacity not exceeding 10 m 3 /h. The disadvantage of the generators of this system is the possibility of overheating when gas extraction is stopped.

Basic requirements for acetylene generators:

1. The ambient temperature at which operation of acetylene stationary generators is allowed is from +5 to -35°С, mobile - from -25 to +40°С.
2. The performance of the generator must correspond to the consumption of acetylene.
3. The decomposition of calcium carbide in the generator must be controlled automatically depending on the gas flow.
4. The generator should not contain parts and fittings made of alloys containing more than 70% copper, as well as devices that can cause sparks during operation.
5. The coefficient of use of calcium carbide (KPI) must be at least 0.85.
6. The generator must be designed to work with a specific calcium carbide granulation.
7. The generator must be hermetic and have a gas collector of sufficient capacity so that when gas is stopped, acetylene is not released into the room.
8. Generators must be provided with a purge of all volumes before filling them with acetylene to remove residual air.
9. The design of the generator must provide good cooling in the reaction zone, so that the temperature of water and slaked lime in the reaction zone does not exceed 80°C, and acetylene 115°C.
10. The dimensions and weight of mobile generators should be kept to a minimum.

Rules for the maintenance of acetylene generators.

When servicing acetylene generators, remember that acetylene is an explosive gas, that it forms explosive mixtures with oxygen and air. Therefore, the gas welder must study the safety instructions for working with calcium carbide and acetylene and the operating instructions for the acetylene generator on which he works.

Before preparing the generator for operation, the water lock is filled with water to the level of the control valve. Retorts and baskets should be rinsed with water and dried. Calcium carbide is loaded into baskets only of the granulation and in the amount indicated in the instruction manual. The first portions of acetylene, containing an admixture of air, are released into the atmosphere so that an explosive mixture of acetylene with air does not remain in the generator.

During breaks in work winter time water must not be allowed to freeze in the generators, for which the generators are insulated, and during long breaks in operation, the water is drained. During operation, silt should not be left near the generator, it should be taken to special silt pits.

It is impossible to approach the generator or the slaked lime unloaded from the generator with a fire or a lit burner, since acetylene is always released into the atmosphere near them. environment and the formation of an explosive acetylene-air mixture.

A running generator must not be left unattended. After completion of welding work, the generator must be freed from sludge residues and thoroughly rinsed.

Preventive inspections of generators are carried out every three months, while the water seal, gas inlet and outlet pipes are disassembled and checked. The generator may only be disassembled, cleaned and repaired outdoors. The annual inspection of the generators is carried out by the administration of the enterprise, about which an appropriate document is drawn up.

For each acetylene generator, a passport and operating instructions must be drawn up. The instruction is approved by the chief engineer of the enterprise.

Portable acetylene generators are mainly used outdoors. It is not allowed to install portable acetylene generators in an inclined position and on the same cart with an oxygen cylinder.

The room in which the operating portable generator has been installed must be thoroughly ventilated at the end of work.

Occupational Safety and Health

What is the operating procedure for acetylene generators?

What is the operating procedure for acetylene generators?

Clauses 2.1, 2.2, 2.6 of the Fire Safety Rules for hot work.

The operation of stationary acetylene generators is permitted only after they have been accepted by the technical inspector of the trade union council. Permission to operate portable acetylene generators is issued by the administration of the enterprise in charge of these generators.

Portable acetylene generators for operation should be installed in open areas. Temporary work is allowed in well-ventilated areas.

Acetylene generators must be fenced and placed no closer than 10 m from the places of welding, from open flames and very hot objects, from places where air is taken by compressors and fans.

When an acetylene generator is installed, notices “No entry”, “Flameproof”, “No smoking” are posted.

At the end of the work, the calcium carbide in the portable generator must be completely finished. Lime sludge removed from the generators must be unloaded into containers adapted for this purpose and drained into a sludge pit or a special bunker.

Open silt pits should be fenced with railings, and closed pits should have fireproof ceilings and be equipped with exhaust ventilation and hatches for removing sludge.

Smoking and the use of sources of open fire within a radius of less than 10 m from the places of storage of sludge is prohibited, about which appropriate announcements must be posted.

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Instructions for labor protection during the operation of an acetylene generator

1. General provisions.

1.1. Portable acetylene generator (for example, ASP-10) for producing technical gaseous acetylene from calcium carbide and water and is used to power acetylene equipment for flame metal processing (welding, cutting) at ambient temperature from minus 20C to plus 30C.

1.2. The operation of the acetylene generator is allowed for employees who have reached the age of 18, have passed a medical examination for the profession of a gas welder, have been trained and passed a knowledge test on labor protection, a fire-technical minimum and have a certificate of completion of a special vocational school or welding courses.

1.3. Gas welders who have studied this manual, know the device and the principle of operation and the rules for servicing the generator, and have passed the knowledge test on the safe performance of these works, are allowed to independently work on servicing the generator.

1.4. Each portable acetylene generator must have a passport and operating instructions, an inventory number, according to which it is registered in the register and technical inspection. By order of the gas facilities enterprise, a responsible person from among the engineers for the technical condition and operation of the acetylene generator should be appointed.

1.5. Maintenance of a portable acetylene generator should be carried out within the specified time and scope.

fig.1a fig.1b. Fig.1a 1-gasifier; 2 - displacer; 3 - gas collector (washer); 4 - overflow pipe; 5 - overflow tube; 14 - plug; 15 - pressure gauge; 16 - safety valve; 17 - protective device; 18 - valve; 19 - support; 24 - gasket; 23 - sealing ring

fig.1b 6 - cover; 7 - gasket; 8 - traverse; 9 - rod; 10 - basket; 11 - sealing ring; 12 - plug; 13 - latch; 20 - rocker; 21 - handle-button; 22 - handle; 23 - bushing; 26 - nut; 27 - washer

1.5.1. At least once every three months, carry out a general preventive inspection of the generator, while checking the condition of the welds, the degree of corrosion of the casing walls, the condition of the color, and eliminate the tightness of detachable joints.

1.5.2. Rinse and clean the tube at least twice a month 5 and pipe 4 non-sparking means, as well as control and drain fittings.

1.5.3.Regularly check the status of the basket. If the bars are bent, straighten them by hand in place, while maintaining the same distance between them.

1.5.4. Check the integrity and correct installation of sealing gaskets.

1.5.5. Once a month, clean and lubricate the threaded connections and work surface stock 9 lubricants TsIATIM-221 (GOST 9430-80), or GS-6; GS-7.

1.5.6. Before each use of the generator, check the tightness of detachable connections and eliminate leaks.

1.5.7. At least once a year, test the generator housing for strength hydraulic pressure 0.23 MPa (2.3 kgf \ cm2), for which it is necessary to carry out in this order:

remove the safety valve and plug the hole under it;

Pour water into the generator through the neck;

Lay the generator in a horizontal plane and through the plug fittings 14 add water until the generator is completely filled;

· screw plugs 14 and set the generator in a vertical position;

· Create a pressure of 0.23 MPa (2.3 kgf/cm2) in the generator by connecting it to a pressure source (for example, using a pump for pumping air into car tires).

The generator is considered to have passed the test if after 5 minutes of testing no leaks, visible residual stresses and signs of rupture are found.

After testing, drain the water from the generator and dry the generator.

Tightness tests are carried out with compressed air at a pressure of 0.15 MPa (1.5 kgf / cm2) without a safety valve in the following order:

Install the lid (without basket) and seal it;

· plug all holes, except for one, through which to create the necessary pressure.

The generator is considered to have passed the test if no air bubbles are found in the places of detachable and one-piece connections when applying a soap solution.

The test results must be entered in the generator passport, in table 1.

Table 1 Generator Periodic Tests

Troubleshooting Measures Taken

1.5.8. After five operations to delay the detonation combustion of the acetylene-oxygen mixture, replace the protective device with a new one.

1.5.9.After each operation protective device(valve jamming is considered as actuation 6 in the seat of the body 1 after the impact of the detonation wave) it is necessary:

Disconnect the safety device from the valve 18;

· through the nipple 8 to squeeze out the jammed valve with a non-sparking (for example, brass) rod with a diameter of up to 5 mm;

Make an appropriate entry in Table 2.

Safety device trip

Responsible person's signature

Protective device replaced with a new one

1.5.10. The safety valve must be subjected to periodic tests once a quarter. The valve must start releasing gas at a pressure of 0.15 + 0.03 MPa (1.5 + 0.03 kgf / cm2). If necessary, adjustment and adjustment of the valve is carried out in this order :

· The stop plate is extended and the entire lever is removed, the lever and washer are removed from the valve stem. By turning the adjusting nut, set the start of gas release at a pressure of 0.15 + 0.03 MPa (1.5 + 0.3 kgf / cm2);

· Slide the washer and lever onto the valve stem and insert the entire lever, fitting the stop plate to prevent the entire lever from falling off the holes of the lever lugs and valve stem.

On the adjustment made, make an entry in the table of the generator passport. (see tab. 3)

Date of regulation or test

1.5.11. Cleaning of silt accumulations on the generator housing should be carried out with a brass or aluminum scraper.

1.5.12. If it is necessary to repair the generator associated with cutting, soldering and welding it, these works are carried out according to a specially developed plan with the issuance of a work permit for the performance of gas hazardous work approved by the chief engineer of the gas facilities operation department under the guidance and supervision of the person responsible for the technical condition and operation of the acetylene generator.

1.5.13. In case of need for long-term storage in a warehouse, rinse and dry the generator. Paint damaged areas of the anti-corrosion coating. Remove protective devices, valve, safety valve and pressure gauge from the generator, wrap in a plastic bag and put in the generator housing. All threaded connections and stem face 9 cover with grease. Plug holes.

1.5.14. Store the generator in a locked room with natural ventilation.

1.5.15. The generator is transported by any transport in a vertical position, securely fastened with clamps.

1.5.16. Once every three months it is necessary to test oxygen hoses at a pressure of 2.0 MPa (20 kgf / cm2), and acetylene - 0.5 MPa (5 kgf / cm2)

2. Safety requirements before starting work (preparation for starting the generator).

2.1.During the depreservation of a new generator or after a long-term storage of the generator, it is necessary:

Install a valve, safety device, safety valve, pressure gauge or pressure indicator on the generator;

· check the reliability of fastening of the rocker arm to the movable stem of the cover;

pull up the plug 12 (see figure 1), while the rod should move relative to the cover with little effort;

Lubricate the stem and all threaded connections with TsIATIM-221 (GOST 9430-80) or GS-6, GS-7 grease;

2.2. During the preparation of the acetylene generator for operation, it is especially necessary for the gas welder to check the serviceability of the generator housing, pressure gauge, protective device, safety valve, ease of movement of the rod with a basket for calcium carbide;

2.3. The generator must be installed in a vertical position in such a place that it cannot fall from shocks or shocks. It is forbidden to install the generator in places of passage and crowding of people, in the passage of vehicles, in the entrances and stairwells of residential buildings, in closed, unlit, unventilated rooms, in places where air is sucked in by fans and compressors, in rooms where the release of substances (for example, chlorine) is possible , forming self-explosive mixtures with acetylene, or flammable substances (sulfur, phosphorus).

2.4. It is not allowed to perform even short-term one-time maintenance work on the generator (filling in water, transferring sludge, etc.) to persons who are not allowed to operate it.

2.5. Water is poured into the generator in the following sequence:

remove the stopper 14 washer;

Seal with cork 14 and rings 25 washer fitting;

Pour water into the neck to the level of the control-drain fitting in the washer;

Seal with cork 14 and rings 25 washer fitting.

2.6. Calcium carbide should be loaded into a dry, clean basket with a size of pieces from 25 to 80 mm in even layers without tamping and shaking. The amount of calcium carbide must correspond to the consumption of acetylene and the planned duration of work.

To prevent silting and local overheating of calcium carbide, the duration of the generator operation at the minimum allowable gas extraction (0.3 m3/h) should not exceed 60 minutes.

2.7. To ensure a reliable start of the generator when acetylene is withdrawn within the range of 1.1-1.5 m3 / h, it is necessary that the first layer of calcium carbide loaded into the basket consists of pieces no larger than 50 mm in size. If pieces of calcium carbide large sizes, then the contact area of ​​calcium carbide with water decreases, its decomposition reaction slows down and the required amount of acetylene for work is not produced.

3. Safety requirements during operation (operation) of the generator.

3.1. Hang the basket loaded with calcium carbide on the rocker, while the rod must be in the lowest position (position of the lock B).

3.2. Move the stem to the uppermost position (position of the latch O).

3.3. Lower the basket into the neck and turn the handle 22 seal the lid 6

(see fig 1). Not allowed to apply additional funds for more leverage.

3.4. Pull the safety valve lever away from the diaphragm by turning the lever to prevent the diaphragm from sticking to the valve seat, and then release it.

3.5. Lower the stem with the basket. Select the fixer position in accordance with the acetylene quantity selection mode. When taking acetylene within 0.3-1.0 m3/h, it is recommended to fix the handle-button in the grooves M and With, and when sampling within 1.1-1.5 m3 / h, fixing is carried out in grooves With and B.

3.6.After pressure stabilization, open the valve 18 .

3.7. Blow the hose and welding tool with acetylene for 0.5-1.0 min.

3.8. During the ignition of the burner or cutter, it is first necessary to slightly open the oxygen valve, then open the acetylene valve, directing the gas stream away from you, and only after short-term blowing of the hoses, ignite the mixture of gases with an open fire.

3.9. During the operation of the generator, monitor the pressure in the generator using the readings of a manometer or an indicator of the average pressure of acetylene, as well as whether there is a gas leak from the valve, plugs and connections. Places of possible gas leakage should be determined by washing with soapy water.

3.10. If the pressure in the generator has risen and is approaching the maximum allowable working 0.15 MPa (1.5 kgf / cm2), it is necessary to reduce the wetting of calcium carbide.

3.11. During breaks in the selection of acetylene:

Set the stem to its highest position (lock position O) and after 15-30 seconds close the valve 18 .

3.12.After a break, open the valve 18 , light the torch and lower the carbide soaking basket. Select the fixer position depending on the acetylene withdrawal mode (see item 3.5).

3.13. During the operation of the generator, do not allow discharge in it, which can lead to air being sucked through detachable connections and the formation of an explosive acetylene-air mixture. Vacuum can occur not only at the end of work, when the entire loaded amount of carbide has worked out, but also if calcium carbide is present in the generator (during its freezing or silting), as well as during the extraction of acetylene in an amount exceeding the maximum productivity of the generator. For the same reason, it is not allowed to work from one generator for two or more welders (cutters).

3.14. When the pressure in the generator drops below 0.01 MPa (0.1 kgf/cm2), it is necessary to increase the soaking of calcium carbide.

3.15. It is not allowed to accelerate the reaction of acetylene formation by shaking or rocking the generator that is running.

3.16. It is not allowed to leave a loaded generator and (during operation or during breaks in gas extraction) unattended.

3.17. Unloading the generator should be carried out after the complete decomposition of calcium carbide, which is determined by the pressure readings on the pressure gauge.

3.18. The generator is recharged in the following sequence:

Set the stem to the highest position (position of the latch O);

close the valve 18 ;

release the rest of acetylene through the safety valve into the atmosphere;

Remove the lid, disconnect the basket, rinse and dry it without the use of open flame;

drain sludge and water from the generator;

prepare the generator and start it up in accordance with paragraphs 2.5-2.7; 3.3-3.8 of this manual.

3.19. Unloaded generators are not allowed to be in the place of storage of unloaded generators; it is not allowed to kindle a fire, the presence of hot objects and the occurrence of sparks within a radius of 10 m.

3.20. It is not allowed to reuse water after processing a full load of calcium carbide. Reuse water causes silting or overheating of the generator, which may cause an accident.

3.21. If it is necessary to operate the generator under conditions sub-zero temperatures ambient air it is necessary to preheat the valve, safety device, safety valve and pressure gauge to positive temperature without the use of open fire. Insulate the protective device with any improvised means, warm the hose and blow it out of condensate. During the operation of the generator, interruptions in the selection of acetylene are not allowed. Also, before each recharge of the generator and after completion of work, the valve and protective device should be removed from the generator and blown through the inlet fittings to remove condensate. The condensate must also be removed from the hose.

4. Safety requirements at the end of work.

4.1. If the burner (torch) goes out, first close the acetylene valve, and then the oxygen valve.

4.2 Close the valves on the oxygen tank and generator.

4.3. After completion of welding and cutting operations, the calcium carbide in the generator must be completely worked out (decomposed), and the gas is released through the safety valve.

4.4. After reducing the pressure to zero, remove the cover, disconnect the basket, rinse and dry it without using open flame.

4.5. Drain sludge and water from the generator and flush all three compartments of the generator (gas generator, displacer, washer) from sludge, and drain condensate from the hose.

4.6. Lime sludge removed from the acetylene generator during its recharging and upon completion of work must be unloaded into a container specially adapted for this purpose and drained into a sludge pit or a special bunker. Open silt pits must be fenced along the perimeter with a fence at least 1 m high and signs must be posted within a radius of 10 m that prohibit smoking, making fire and bringing hot pieces of metal.

4.7. The room in which a working generator was installed should be thoroughly ventilated after completion of work.

4.8. The generator must be stored locked in a ventilated room with a depressurized neck and a control-drain hole.

5. Safety requirements in emergency situations.

5.1. During the occurrence of a reverse shock of the detonation combustion of the acetylene-oxygen mixture, immediately close the valves on the burner (torch) and on the generator near the protective device. Determine the cause of the kickback and eliminate it. Remove the rod with the basket from the soaking position to the uppermost position. Restore the safety device 17 in accordance with paragraph 1.5.9. this manual.

5.2. If the pressure in the generator rises above the maximum allowable operating pressure by more than 20%, even after the calcium carbide soaking is reduced, and the safety valve does not work, the gas should be released through the burner into the atmosphere for 5-30 seconds until the pressure drops below the maximum allowable operating pressure. . Take measures to quickly complete this charge of the generator under constant monitoring of the pressure in the generator. After the loaded calcium carbide is exhausted, unload the generator, remove the safety valve and repair and adjust it in accordance with paragraph 1.5.10 of this instruction.

5.3. In case of detection of leaks in the connection between the cover and the neck, in the places where valves, plugs, pressure gauges and other connections are installed on the generator that has been put into operation, it is necessary:

remove the calcium carbide basket from the soaking position (lock position 0 );

release acetylene from the generator through the safety valve to atmospheric pressure;

· perform additional tightening of the connection without using additional devices, to the keys and handles of the cover, in order to increase the tightening force of the connections;

If even after these measures the passage of gas does not stop, acetylene should be released through the safety valve until the calcium carbide is completely decomposed, without performing any welding, cutting and other hot work. Unload the generator in accordance with the requirements of paragraphs 3.17 and 3.18 of this manual.

5.4. In case of freezing or silting of calcium carbide, it is possible to remove the basket from the generator with unused calcium carbide only after the generator has cooled down for at least an hour and the pressure in the generator has decreased to atmospheric pressure.

5.5. In the event of a hose fire during welding work, it is necessary to bend it near the fire site on the generator side and close the valves on the generator and oxygen cylinder.

5.6. In case of water freezing in the generator or condensate in the protective device, pressure gauge, hose, they must be heated in a warm room at a distance of at least 10 m from sources of open fire, sparks, hot metal, electric heaters, it is also allowed to warm them with warm water or steam.

5.7. It is not allowed to use open fire, hot metal, electric heaters to warm the generator. It is also not allowed to chip off ice from the generator and bring dishes to it that were heated on an open fire.

5.8. All cases of emergency situations, violations of technological processes that can lead to dangerous consequences, cases of injury or illness, must be reported to the immediate supervisor of the work.

I compiled an instruction on labor protection during the operation of an acetylene generator.

1.1. This instruction has been developed in accordance with the Federal Law of July 22, 2008 No. 123-FZ " Technical regulation on fire safety requirements”, Chapter XVIII of the Rules of the fire regime of the Russian Federation, “Fire safety rules for enterprises and organizations of the gas industry” VPPB 01 04 98*, “Standard instructions for organizing the safe conduct of hot work at explosive objects” RD-09-364- 00, "Safety Rules for the Operation of Main Gas Pipelines" 1985, "Rules for the Operation of Main Gas Pipelines" STO Gazprom 2-3.5-454-2010, "Typical Instructions for the Safe Conduct of Hot Works at Gas Facilities of OAO Gazprom" "STO Gazprom 14- 2005. and other regulatory documents on fire safety and is mandatory for all workers and employees of the enterprise and establishes the basic requirements for safe organization hot work at LPUMG facilities.

1.2. Responsibility for the development and implementation of measures to ensure safety during hot work is assigned to the management of the department, as well as to persons appointed by order responsible for ensuring fire safety at the facilities.

1.3. Persons (electric and gas welder, gas cutter, gas cutter, solderer, etc.) who have passed special training and having a qualification certificate and a fire safety certificate.

Welding is allowed for persons who have been trained, instructed and tested for knowledge of safety requirements, who have an electrical safety qualification group of at least II and who have the appropriate certificates.

Welding work at height is allowed for workers who have passed a special medical examination, have at least one year of experience in steeplejack work and have a welder rank of at least III.

Women are not allowed to weld inside closed and hard-to-reach spaces and welding during steeplejack work.

1.4. Hot work includes production operations associated with the use of open fire, sparking and heating of structures, equipment, tools and materials to a temperature, ignition of a gas, steam, dust-air mixture and other combustible substances, the appearance of which in dangerous concentrations is possible in the zone these works (electric welding, gas welding, gasoline-kerosene cutting, soldering, mechanical processing of metal with the formation of sparks, etc.). (PBMG)

1.5. To carry out all types of hot work in temporary places (except for construction sites and private households), the head of the facility is obliged to issue a work permit.

1.6. Places of hot work should be provided with primary fire extinguishing equipment (fire extinguisher, a box with sand and a shovel, a bucket of water).

1.7. It is not allowed to place permanent places for carrying out hot work in fire and explosion hazardous premises.

1.8. Technological equipment, which provides for the conduct of hot work, must be brought into a fire and explosion safe state by:

exemption from explosive and flammable substances;

disconnection from existing communications (with the exception of communications used to prepare for hot work);

preliminary cleaning, washing, steaming, ventilation, sorption, phlegmatization, etc.

1.9. When steaming inside the process equipment, the temperature of the supplied water vapor should not exceed a value equal to 80% of the autoignition temperature of the combustible vapor (gas).

1.10. Flushing process equipment should be carried out at a concentration of steam (gases) in it outside the limits of their ignition or in an electrostatically safe mode.

The hot work site must be cleared of combustible substances and materials within the radius indicated in the table.

1.13. Located within the specified radii building construction, flooring, trim and cladding, as well as insulation and parts of equipment made of combustible materials, must be protected from sparks by metal screens, asbestos sheets or other non-combustible materials and, if necessary, sprinkled with water.

1.14. In the premises where hot work is carried out, all doors connecting these premises with other premises, including the doors of the vestibule locks, must be tightly closed. Windows, depending on the season, room temperature, duration, volume and degree of danger of hot work, should be opened as far as possible.

1.15. Premises where vapors of flammable liquids, gypsum and gypsum can accumulate must be ventilated before hot work.

1.16. The place for welding and cutting works in buildings and premises, in the constructions of which combustible materials are used, must be fenced with a solid partition made of non-combustible material. In this case, the height of the partition must be at least 1.8 m, and the gap between the partition and the floor - no more than 5 cm. To prevent the spread of hot particles, the specified gap must be fenced with a mesh of non-combustible material with a mesh size of not more than 1 x 1 mm.

1.17. During breaks in work, as well as at the end of the work shift, the welding equipment must be turned off, including from the mains, the hoses must be disconnected and freed from flammable liquids and gases, and the pressure in blowtorches must be completely bled.

Upon completion of work, all apparatus and equipment must be removed to specially designated premises (places).

1.18. During hot work prohibited :

start working with faulty equipment;

carry out hot work on freshly painted structures and products;

use clothes and gloves with traces of oils, fats, gasoline, kerosene and other flammable liquids;

store clothes, flammable liquids, combustible liquids and other combustible materials in welding booths;

allow students to work independently, as well as employees who do not have a qualification certificate and a fire safety coupon;

allow contact of electrical wires with cylinders with compressed, liquefied and dissolved gases;

carry out work on devices and communications filled with combustible and toxic substances, as well as under electrical voltage;

simultaneous hot work during the installation of waterproofing and vapor barrier on the roof, installation of panels with combustible and hardly combustible heaters, sticking floor coverings and finishing rooms using combustible varnishes, adhesives, mastics and other combustible materials. Carrying out hot work on building elements made of light metal structures with combustible and hardly combustible heaters are not allowed.

II. Fire safety measures during gas welding operations.

2.1. Portable acetylene generators should be installed outdoors. Temporary work is allowed in well-ventilated areas.

Acetylene generators must be fenced off and placed no closer than 10 m from hot work sites, as well as from air intakes by compressors and fans.

At the installation sites of the acetylene generator, notices (placards) should be hung out: “Entrance to strangers is prohibited - it is flammable”, “Do not smoke”, “Do not pass with fire”.

2.2. At the end of the work, the calcium carbide in the portable generator must be exhausted. Lime sludge removed from the generator must be unloaded into containers adapted for this purpose and drained into a sludge pit or a special bunker.

Open silt pits should be fenced with railings, and closed pits should have non-combustible ceilings and be equipped with exhaust ventilation and hatches for removing sludge.

Smoking and the use of open flames within a radius of less than 10 m from the places of storage of sludge is not allowed. About what the appropriate prohibition signs should be posted in accordance with GOST 12.4.026-76 (Appendix No. 2 of the general facility instruction).

2.3. The fastening of gas supply hoses to the connecting nipples of equipment, burners, cutters and reducers must be reliable and performed using clamps.

Instead of clamps, it is allowed to fix hoses in at least two places along the length of the nipple with soft annealed (knitting) wire.

On the nipples of water locks, the hoses must be tightly put on, but not fixed.

2.4. Opened calcium carbide drums should be protected with watertight lids.

2.5. In places where calcium carbide drums are stored and opened, smoking, the use of open flames and the use of sparking tools are prohibited.

2.6. Storage and transportation of gas cylinders should be carried out only with safety caps screwed onto their necks. When transporting cylinders, shocks and shocks should not be allowed. Cylinders must be delivered to the place of welding work on special carts, stretchers, sledges. Carrying cylinders on the shoulders and arms is not allowed.

2.7. Gas cylinders during their storage, transportation and operation must be protected from sunlight and other heat sources.

Cylinders installed indoors must be at least 1 m away from heating appliances and stoves, and at least 5 m away from heat sources with open fire.

Storage in the same room of oxygen cylinders and cylinders with GG, as well as calcium carbide, paints, oils and fats is not allowed.

2.8. When handling empty cylinders of oxygen or gas, the same safety precautions must be observed as with filled cylinders.

2.9. When carrying out gas welding and gas cutting works prohibited:

• thaw frozen acetylene generators, pipelines, valves, gearboxes and other parts of welding installations with open fire or hot objects;

• allow contact of oxygen cylinders, reducers and other welding equipment with various oils, as well as oiled clothing and rags;

• work from one water lock to two welders;

• load calcium carbide with oversized granulation or push it into the funnel of the apparatus using iron rods and wire, as well as work with carbide dust;

• load calcium carbide into wet loading baskets or in the presence of water in the gas collector, as well as load baskets with carbide more than half of their volume when the “water to carbide” generators are operating;

• purge the hose for the GG with oxygen and the oxygen hose of the GG, as well as interchange the hoses during operation;

• residual pressure of gases in cylinders should not be less than 0.5 kgf/cm

• use hoses whose length exceeds 30 m, and during installation work - 40 m;

• twist, twist or pinch gas supply hoses;

• move the generator if there is acetylene in the gas collector;

• force the operation of acetylene generators by deliberately increasing the gas pressure in them or increasing the one-time load of calcium carbide;

• use a copper tool for opening drums with calcium carbide, as well as copper as a solder for soldering acetylene equipment and in other places where contact with acetylene is possible.

2.10. Fire safety requirements for gas welding and metal cutting equipment are set out in the relevant instructions.

III. Fire safety measures during electric welding.

3.1. Floors in rooms where permanent places for welding are organized must be made of non-combustible metals. It is allowed to install wooden end floors on a non-combustible base in rooms where welding is carried out without preliminary heating of parts.

3.2. It is not allowed to use without insulation or with damaged wire insulation, as well as to use non-standard electrical fuses.

3.3. Welding wires should be connected by crimping, welding, soldering or special clamps. The connection of electrical wires to the electrode holder, the workpiece to be welded and the welding machine must be carried out using copper cable lugs fastened with bolts and washers.

3.4. Wires connected to welding machines, switchboards and other equipment, as well as to places of welding work, must be reliably insulated and, where necessary, protected from high temperatures, mechanical damage or chemical influences.

3.5. Cables (wires) of electric welding machines must be located at a distance of at least 0.5 m from oxygen pipelines, and at least 1 m from pipelines of acetylene and other gas generators.

3.6. Steel or aluminum busbars of any profile, welding plates, racks and the welded structure itself can serve as a return conductor connecting the workpiece to be welded with the welding current source, provided that their cross section ensures the current flow that is safe under heating conditions.

The interconnection of individual elements used as a return conductor must be carried out using bolts, clamps and clamps.

3.7. The use of internal railway tracks, grounding or grounding networks, as well as metal structures of buildings, communications and technological equipment as a return conductor is not allowed. In these cases, welding must be carried out using two wires.

The design of the electric holder for manual welding should ensure reliable clamping and quick change of electrodes, as well as exclude the possibility of a short circuit of its body on the workpiece to be welded during temporary interruptions in work or if it accidentally falls on metal objects. The handle of the electric holder must be made of non-combustible dielectric and heat-insulating material.

3.8. The electrodes used in welding must be factory-made and correspond to the nominal value of the welding current.

When changing electrodes, their remains (ends) should be placed in a special metal box installed at the welding site.

Before welding, the electrodes must be dried at the temperature specified in the passports for a specific type of electrode coating. The coating of the electrodes must be uniform, dense, without swelling, sagging and cracks.

3.9. Electric welding installation must be grounded during operation. In addition to grounding the main electric welding equipment in welding installations, the terminal of the secondary winding of the welding transformer, to which the conductor leading to the product (return conductor) is connected, should be directly grounded.

3.10. Sheds made of non-combustible materials should be built over portable and mobile electric welding installations used in the open air to protect them from atmospheric precipitation.

3.11. Cleaning of the unit and starting equipment should be carried out daily after the end of work. Maintenance and scheduled preventive maintenance of welding equipment must be carried out in accordance with the schedule.

3.12. The heating temperature of individual parts of the welding installation (transformers, bearings, brushes, contacts of the secondary circuit, etc.) should not exceed 75 ° C.

3.13. Fire safety requirements for electric welding installations and welding stations are set out in the instructions "Fire safety of electric welding installations LPUMG"

IV. Fire safety measures during soldering.

4.1. The workplace during soldering work must be cleared of combustible materials, and structures made of combustible materials located at a distance of less than 5 m must be protected by screens of non-combustible materials or watered with water (an aqueous solution of a foaming agent, etc.).

4.2. Blowtorches must be kept in good working order and checked for strength and tightness at least once a month with the results and the date of the check recorded in a special journal. In addition, at least once a year, their control hydraulic tests should be carried out.

4.3. Each blowtorch must have a passport indicating the results of factory hydrotesting and the allowable working pressure. Safety valves must be adjusted to the specified pressure, and the manometers on the lamps must be in good condition.

4.4. Blowtorches should be filled with fuel and kindled in places specially designated for this purpose.

4.5. To prevent the emission of a flame from a blowtorch, the fuel refilled into the lamp must be free of impurities and water.

4.6.To avoid blowtorch explosion prohibited :

• use as fuel for lamps running on kerosene, gasoline or a mixture of gasoline and kerosene;

• increase the pressure in the lamp reservoir when pumping air over the allowable working pressure specified in the passport;

• fill the lamp with fuel to more than ¾ of the volume of its tank;

• unscrew the air screw and filler plug when the lamp is on or has not yet cooled down;

• repair the lamp, as well as pour fuel out of it or fill it with fuel near an open flame (including a burning match, cigarette, etc.).

  V. Organization of the safe conduct of hot work at explosive and explosive objects.

5.1. General requirements.

5.1.1. This instruction contains the basic requirements for the organization and safe conduct of preparatory. actual hot and final work in the total amount of repair work at existing and commissioned control facilities.

5.1.2. The instruction is a mandatory document for all enterprises \regardless of departmental affiliation\ that directly carry out repairs and construction work at existing LPUMG facilities.

5.1.3. Hot work at operating explosive and fire-explosive facilities is allowed in exceptional cases when these works cannot be carried out in permanent places specially designated for this purpose.

5.1.4. Hot work at explosive and explosive objects should be carried out only in the daytime \ except in emergency cases \.

5.1.5. Hot work is divided into scheduled, performed according to the work permit\permit\\Appendix No. 1\ and the work organization plan, emergency, performed to eliminate the consequences or prevent an accident in accordance with the accident elimination plan drawn up by the on-site work manager.

5.1.6. Scheduled hot work at control facilities is carried out according to the list (with an indication of the officials admitted to supervise these works). \Appendix No. 2\.

At the facilities (in services), a list of hot work should be developed with an indication of the officials allowed to manage these works \ Appendix No. 2 \.

The list of hot work should be reviewed every three years, as well as after the reconstruction of facilities, changes in technology or equipment upgrades, as prescribed by state oversight bodies and higher organizations.

If there is a need to perform work that is not included in the list, it should be included in this list before the start of work.

5.1.7. The list of LPUMG facilities where hot work is carried out according to the work permit and the plan for organizing their safe conduct is set out in Appendix No. 3.

5.1.8. The following plans for organizing the safe conduct of hot work are approved and coordinated with OAO Gazprom's gas supervision authorities:

• carried out as part of a general set of works with the shutdown of one or both gas transmission systems at the outage;

• related to the connection of completed construction, reconstruction and repair of gas pipeline facilities;

• associated with a complete shutdown and bleeding of gas from technological communications of the compressor station;

• CS or MG conducted on communications at the same time in several places by two or more organizations \teams\;

• conducted by third parties.

5.1.9. Hot work at the facility is carried out, as a rule, by LPUMG employees.

Brigades, individual specialists from third-party organizations, technical equipment with service personnel who have undergone special training, passed exams and received certificates in their enterprises can be involved in the performance of individual stages of work and operations.

In this case, a bilateral order for the LPUMG is issued indicating the names and qualifications of the persons allocated by the involved organization to carry out the work, a representative of the LPUMG is appointed as the head of the work.

5.1.10. Hot work can be carried out only with a work permit.

In emergency cases, a work permit for conducting hot work may be issued by the head of the facility or a person replacing him where hot work is to be performed.

In this case, hot work is carried out under the direct supervision of the person who issued the work permit with the obligatory notification of the head \ chief engineer \ department \ association \.

5.2. Permission to carry out hot work.

5.2.1. To carry out hot work, including in emergency cases, a work permit must be issued in writing, according to the attached form.

5.2.2. The head of the facility where hot work is carried out, or a person replacing him, appoints the person responsible for the preparation and conduct of hot work, and also determines the scope and content of work, organizational and technical safety measures in the preparation and conduct of hot work, the procedure for controlling the air environment and means protection, which is confirmed by his signature in clause 8 of the work permit.

Organizational activities include:

• drawing up, coordination and approval of the work plan;

• verification of the sufficiency of the proposed technical measures to ensure safety during these works;

• issuance of an order to carry out the above works, requiring coordination of the actions of several units, brigades, when they are carried out on technologically related communications;

• providing workers with overalls, protective equipment and the right tool

• instructing the personnel involved in the work with written registration;

• issuance of a work permit;

• admission of the brigade to work;

• control over the safe production of works;

• completion of work completion.

Technical activities include:

• shutdown of a section of a gas pipeline or apparatus on which work will be carried out;

• bleeding gas from a gas pipeline, communication or apparatus;

• checking the residual gas pressure or its absence in the disconnected section;

• taking measures against erroneous or spontaneous rearrangement of valves;

• checking the absence of condensate \pyrophoric compounds\ in the pipeline or apparatus, taking measures to remove it \them\;

• hanging prohibiting and warning posters on fittings and fencing the work area;

• installation of rubber locking balls or clay plugs;

• check of gas contamination at the place of work;

• providing the place of work with means of communication and fire extinguishing;

• Ensuring sufficient lighting in the place of work.

  • The work permit is drawn up in two copies and handed over to the persons responsible for the preparation and conduct of hot work to carry out the activities specified in it.

5.2.4. After completing all the activities provided for in the work permit, the persons responsible for the preparation and conduct of hot work put their signatures in paragraph 11, respectively, after which the head of the facility where hot work is carried out, or the person replacing him, checks the completeness of the implementation of the measures , coordinates with the fire department of the department, labor protection engineer \ if necessary with other services \, which is recorded in the journal, \ Appendix No. 4 \ signs in the permit order (clause 12), and submits it for approval to the head of the medical facility or the chief engineer. When appointing the head of the medical facility responsible for carrying out hot work, the work permit is approved by the head

5.2.5. The composition of the team of hot work performers and a mark on the passage of the briefing are entered in clause 9 of the work permit.

5.2.6. The work permit is agreed with the fire brigade of the department in terms of ensuring fire safety measures and the availability of primary fire extinguishing equipment at the site of hot work.

5.2.7. One copy of the work permit remains with the person responsible for conducting hot work, the other is transferred to the main control room to the shift dispatcher / engineer / shop, at whose facilities the work is carried out and recorded in the journal. \Appendix No. 5\.

When carrying out work at facilities that are not under the control of a shift dispatcher / engineer / work permit is registered in a similar log, which must be maintained at each control facility responsible for its operation and fire safety.

5.2.8. The work permit is issued separately for each type of work and is valid for one day shift. If these works are not completed within the prescribed period, then the work permit may be extended by the head of the facility where the hot work is carried out, or by the person replacing him, but not more than for one shift (clause 14).

5.2.9. When conducting overhauls and work on the reconstruction of workshops with a complete stop of production, the work permit is issued for the period provided for by the schedule of major repairs and reconstruction work.

5.2.10. When hot work is performed by the repair shops of the enterprise or third-party organizations, a work permit for hot work must also be issued in accordance with the requirements of this instruction.

5.2.11. When issuing a work permit for conducting hot work inside tanks, apparatuses, wells, collectors, trenches, etc. all safety measures provided for by this instruction and the instruction for the organization and safe conduct of gas hazardous work must be taken into account.

5.2.12. The entries in both copies of the work permit must be identical and clear. It is forbidden to fill in the work permit with a pencil, corrections in the text and signatures of responsible persons under a carbon copy.

5.2.13. At the end of the work, the person responsible for carrying out hot work and the head of the facility \ shift dispatcher \ "close" the work permit by signing it (clause 15).

5.2.14. One copy of the work permit after its "closing" is transferred to the office for labor protection \ about which a note is made in the log \ the other is stored with the shift dispatcher \ head of the facility \ for at least three months.

5.2.15. The plan for the organization of repair work is drawn up by the relevant production department, service, at the facilities or within the boundaries of whose activities the work is performed, and determines the organizational and technical sequence of their implementation.

5.2.16. The work organization plan \accident liquidation plan\ is drawn up in any form, but must include:

• name of the object, place of work, dates, time of their beginning and end;

• brief technical and design requirements to the repaired\restored\ elements of the gas facility, as well as the performance of all types of special work with reference to SNiP, VSN, other regulatory document or drawing number;

• instructions on the material support of work;

• arrangement of equipment, mechanisms, means of communication, security posts, points of rest and eating, as well as the list of personnel involved in the work, indicating the names and positions of the persons responsible for the work;

• the order and sequence of switching / disconnections, switching on / sections of pipelines, process equipment, electrochemical protection equipment and others;

• a detailed diagram of the node \sections of gas pipelines to be repaired;

• operational schedule of repair work and testing of repaired units \ sections of gas pipelines \.

5.2.17. Issued work organization plans and work permits for conducting hot work are recorded in a special journal kept by the dispatcher\shift engineer\of the enterprise \Appendix No. 5\.

5.2.18. When performing a complex of repair work performed by several teams of performers, an order should be issued for their implementation and a plan for its implementation should be developed.

The issuance of an order for a complex of repair work is necessary in the following cases:

• simultaneous repair work at several technologically related facilities;

• the need for coordinated actions or the use of resources of several production units;

• simultaneous repair work in several dispersed places at one gas facility.

5.2.19. An order to carry out a complex of works should appoint its head and the units \services, workshops, teams \, responsible for carrying out individual repair work - participants in the work with specification of the personnel allocated by them, equipment, machines, mechanisms, instrumentation and control tools, communications, materials, PPE and means of collective protection, medical and fire-fighting support.

The order for the specified set of works is issued based on the scope of work of the health facility together with the involved organizations.

5.2.20. If the preparation and direct conduct of hot work is carried out by one team of performers, then it is advisable to appoint one person responsible for the preparation and conduct of work, provided that he has the necessary organizational skills and technical knowledge, knows safe working methods and techniques, and is relieved of other duties for the period of performance these works.

5.2.21. Works related to the reduction of production, transportation and supply of gas to the consumer must be coordinated with the production dispatch service of the production association (PDS), and, if necessary, with the Central Production Dispatch Office (CPDU).

5.2.22. When a medical facility is requested to carry out hot work, information is sent to the PDS indicating their objects, place, timing, responsible persons \ Appendix No. 6 \.

5.2.23. Registration of notifications and permits for conducting hot work is carried out in operational logs of dispatch services.

5.2.24. Requests and permits are processed in the following order:

• when performing work at the industrial sites of the CS, GDS, requests and notifications to the PDS are made out by entries in the journal of the medical facility manager;

• when performing work on the gas pipeline route, requests and notifications for the beginning, main and intermediate stages \ air displacement after the liquidation of the accident, etc. \ and completion of work are recorded in the log of the work on the route and the operational log of the dispatcher of the medical facility;

• requests for obtaining permits to carry out work are drawn up signed by the head of the health facility;

• notification of the completion of work is made by the person responsible for the production of work;

• requests for the beginning, completion of work can be transmitted via telephone channels indicating the number of the message\telephone message\, date and name of the signatory and acceptor of the message.

5.2.25. Registration of responses to requests and obtaining permits for conducting hot and gas hazardous work is carried out in the following order:

• PDS, on the basis of the registered approved plan of hot work and the received request for readiness, in agreement with the production departments and management by telephone, gives a response to the name of the head of the medical facility on the permission or prohibition of work;

• when carrying out hot work carried out according to plans developed on the ground, the PDS, on the basis of a request received from the medical facility, gives an answer prepared by the production department and signed by the deputy head for the direction of activity.

5.2.26. When issuing responses, the PDS identifies upcoming possible violations of the regime, reductions in gas transport, the possibility of reserving gas pipeline strings, the duration of work, etc. Takes measures to notify consumers of upcoming restrictions in gas supplies, determines the start and end time of work.

5.3 Preparatory work.

General requirements.

5.3.1. Preparatory work includes all types of work related to the preparation of equipment, communications, structures for hot work.

5.3.2. The preparation of a gas facility for hot work is carried out by the operating personnel of this facility \ subdivision of the workshop, production \ in accordance with the permit \ work permit \ and the work organization plan.

• Preparation of an object for carrying out hot work on it is carried out by the operational personnel of the workshop (service) under the guidance of a specially designated responsible person, including when work is performed at the object by a third-party organization.

• Responsible for the implementation of preparatory work can be assigned only to specialists of this facility.

• When preparing for hot work, the head of the facility where hot work is carried out, or the person replacing him, together with those responsible for the preparation and conduct of these works, determines the danger zone, the boundaries of which are clearly marked with warning signs and inscriptions.

• Prior to the start of work, documentation describing the technical condition and reliability of process equipment and gas pipelines should be studied in order to identify leaks of explosive substances, flammable liquids, which, by their intensity and location, pose a danger during the performance of the specified hot work.

• Platforms, metal structures, structural elements buildings that are located in the hot work area must be cleared of explosive, explosive products \ dust, tar, flammable liquids and materials, etc. \.

Drain funnels, outlets from trays and other devices associated with sewage, which may contain flammable gases and vapors, must be blocked. At the place of hot work, measures must be taken to prevent the spread of sparks.

5.3.8. Places for welding, cutting, heating, etc. marked with chalk, paint, a tag or other clearly visible identification marks.

5.3.9. Devices, machines, tanks, pipelines and other equipment on which hot work will be carried out must be stopped, freed from explosive, explosive, fire hazardous and toxic products, disconnected with plugs from operating devices and communications \ about which an entry should be made in the installation log and removal of plugs \ and prepared for hot work, in accordance with the requirements of this manual and instructions for preparing equipment for repair work. Starting equipment designed to turn on machines and mechanisms must be de-energized, and measures taken to prevent sudden start-up of machines and mechanisms.

5.3.10. If gas leaks are detected within the danger zone, faulty gas pipelines, depending on the intensity of gas outflow, must be completely released from it or the pressure in them must be reduced by at least 30% of the maximum working pressure recorded in the surveyed area during the last year of operation.

5.3.11. The hot work area must be prepared for its safe and convenient execution; free approaches and entrances to the place of work were organized, interfering objects, explosive and harmful substances were removed.

5.3.12. To prevent unauthorized persons, vehicles, and animals from entering the hot work zone, posts equipped with danger warning devices \light, sound\ and two-way telephone or radio communication with the head of the work should be set up.

5.3.13. the hot work site must be reliably disconnected \ isolated \ from sources of possible ingress of explosive and hazardous substances, including from adjacent technological systems, and the gas equipment or sections of gas pipelines to be repaired must be freed from the filling medium to a pressure that ensures safe work \ 100 - 500 Pa\.

5.3.14. Measures must be taken to prevent erroneous or spontaneous rearrangement of shut-off valves that turn off the work site.

To do this, it is necessary to establish the duty of trained personnel who control the position and, if necessary, control the shut-off valves.

If there is no need to control the valve, you should:

• on pneumatic-hydraulic valves - bleed the impulse gas, remove the hoses \ impulse pipes \ from the pneumatic hydraulic actuators and remove them, and plug the fittings, remove the checks \ pins \ of valves that serve to transfer them from automatic control to manual;

• remove handwheels from manually operated valves or lock the actuator with a chain;

• hang appropriate safety signs and posters: "Do not open", "Do not close" \where necessary\.

5.3.15. In places of the forthcoming separation of flanges or cutting of coils, electrical jumpers with a cross-sectional area of ​​at least 25 mm2 should be installed, and electrochemical protection means should be turned off immediately before the start of hot work.

5.3.16. The hot work site must be provided with the necessary primary fire extinguishing equipment \fire extinguisher, sandbox and shovel, etc.\.

5.3.17. After the completion of the preparatory work, the person responsible for its implementation, together with the head of the hot work, is obliged to check and confirm the completion of this stage of the repair work.

5.4. Preparation of gas equipment.

5.4.1. Gas equipment \pressure vessels, fittings and piping lines\, subject to repair, must be disconnected from all pipelines connecting it to the pressure source and freed from gas \flammable liquids\.

Vessels and containers must be disconnected with plugs in accordance with the requirements of the "Rules for the Design and Safe Operation of Pressure Vessels" of Rostekhnadzor of the Russian Federation and the requirements of industry safety rules and instructions for preparing equipment for repair work.

It is allowed to turn off gas equipment by two devices installed in series with drainage between them.

5.4.2. Residual gas condensate \LVZH\ after emptying the equipment, drain by gravity, pump out with a pump, squeeze out natural gas or nitrogen into the purge tank.

It is forbidden to extrude with compressed air, as well as drain to the ground / floor / and into the sewer.

5.4.3. After release, the vessels and pipelines should be thoroughly steamed and blown with compressed nitrogen and air.

If there are pyrophoric deposits in the vessels and pipelines, their cavities after steaming should be washed with water before purging. Filling the vessels with water for washing is carried out with the upper bed open. Wash water is discharged into industrial sewerage, and pyrophores are removed to a fireproof place under a layer of water.

5.4.4. After purging, the vessels must be ventilated naturally \with the upper and lower hatches open\ or forcibly during a time period that ensures a three-time exchange, but not less than 1 hour.

5.4.5. Vessels heated during operation or preparation for hot work must be cooled to a temperature not exceeding 303 K \ 30 C \ before admitting people into them.

If it is impossible to cool the vessel to the specified temperature, it is allowed to work at more than high temperature with the development of additional measures for safety and facilitation of work \ additional blowing with cool air, the use of heat-insulating PPE, frequent breaks in work, etc. \.

5.4.6. After preparing the vessel for hot work, it is necessary to analyze the air inside it for the content of harmful and explosive substances.

5.5. Underground gas pipeline preparation.

5.5.1. At the beginning of preparation for hot work, an inspection of the pipelines to be repaired and adjacent \\ laid in parallel, converging and crossing it \\ pipelines within the boundaries of hazardous areas should be carried out to determine the necessary safety measures.

5.5.2. The boundary of the danger zone is a conditional circle circumscribed around the place of hot work with a radius taken equal to the minimum distance given in Appendix No. 7.

5.5.3. When performing work, the integrity of adjacent pipelines must be ensured. If it cannot be ensured, then these pipelines must be taken out of service and freed from the product before the start of work.

5.5.4. It is allowed to open a gas pipeline with the help of mechanisms and manually release it from isolation without reducing the pressure in it in a section that does not have gas leaks, or other factors identified during operation, indicating a decrease in the strength characteristic of the pipeline.

When opening, the moving parts of the mechanisms must pass at a distance of at least 0.5 m from the generatrix of the gas pipeline.

5.5.5. Before opening a gas pipeline section with damaged insulation, the pressure in the gas pipeline must be reduced by at least 10% of the maximum working pressure recorded during the last year of operation.

In case of non-through and other damages (corrugations, mechanical damages), the through-flow working pressure is reduced by at least 30% of the maximum allowed pressure in this area.

5.5.6. The organization of earthworks for the opening of underground gas pipelines for the performance of hot work must comply with the requirements of the Rules of Protection main pipelines and production instructions construction works in protected areas of main pipelines.

5.5.7. The size of the pit \trench\ is determined by the conditions for the safe performance of hot work. The machines and mechanisms by which the work is carried out can be located, based on the convenience and safety of performing hot work, both on the edge of the trench and in the pit. The pit must have at least two exits in opposite directions - one on each side of the pipeline with a diameter of up to 800 mm, 4 exits - with a diameter of more than 800 mm.

5.5.8. With the influx of ground / storm, flood / water in the pit / trench / a pit is made to collect and pump out water.

In swampy areas and in the presence of quicksand, the soil should be spread using sheet piles or other devices to limit the flow of water to the place of work and protect the walls of the pit / trench from collapsing.

5.5.9. If gas condensate and other flammable liquids get into the pit \ trench \, they should be removed together with the impregnated soil to a safe place, and the cleaned surface should be covered with \ sprinkle \ with dry sand \ soil \.

5.5.10. When opening extended sections, measures should be taken to prevent sagging of the gas pipeline and the occurrence of additional stresses in it.

5.5.11. Before starting hot work on a linear section of a gas pipeline, the following should be done:

- disconnect it from neighboring sections and branches;

• release from gas;

• check the absence of residual gas condensate, other flammable liquids in its cavity at the place of hot work, as well as the possibility of their getting to the place of work.

5.5.12. The shut-off fitting must provide a tight shutoff. Valves must be sealed with a sealing compound \paste\.

5.5.13. If the shut-off linear fitting on the gas pipeline after opening is not tight enough, then, together with the repaired section, it is necessary to disconnect and free the adjacent section located behind the faulty \leaky fittings\, ensuring its communication with the atmosphere for the entire duration of hot work.

5.5.14. The section of the gas pipeline should be released by releasing gas onto the candle. The performer of this work must be provided with appropriate PPE, including noise protection, and a helmet.

Personnel not directly involved in the release of gas, as well as technical means, should be removed from the candle at least 200 m to the windward side.

Gas from the gas pipeline must be released to a pressure that ensures the safe performance of work, 100 - 500 Pa \10 - 50 mm of water column - depending on the diameter of the gas pipeline, and maintain it until the end of hot work.

5.5.15. Checking the absence of gas condensate, flammable liquid is recommended to be carried out using a probe inserted through a hole drilled hand drill at the top of the pipe.

If \flammable gas condensate is found in the gas pipeline, it must be pumped into a mobile container or released into an earthen barn with subsequent incineration.

5.5.16. The location of the barn and its distance from the gas pipeline should be chosen taking into account the volume of the discharged flammable liquid and the direction of the wind \weather conditions\.

Before removing flammable liquids from the gas pipeline, fire extinguishing equipment, PPE and collective protective equipment should be ready.

5.6. General requirements for hot work.

5.6.1. To carry out hot work, a responsible person should be appointed from among the engineering and technical workers of the workshop who are not currently engaged in the conduct of the technological process and knowing the rules safe conduct of hot work at explosive and fire-explosive objects.

5.6.2. Hot work is allowed to start in the absence of explosive and explosive substances in the air or their presence is not higher than the maximum permissible concentration according to current sanitary standards.

5.6.3. During hot work, periodic monitoring of the state of the air environment in the apparatus, communications, on which the specified work is carried out and in the danger zone, should be carried out. The results of the analysis are recorded in the work permit (clause 10)

5.6.4. In the event of an increase in the content of explosive and flammable substances in the hazardous area, inside the apparatus or pipeline, hot work must be immediately stopped and resumed only after the causes of gas pollution have been identified and eliminated and the normal air environment has been restored.

5.6.5. During hot work, the technological personnel of the facility must take measures to exclude the possibility of release into the air of explosive, explosive and flammable substances.

It is forbidden to open hatches and covers of apparatuses, unload, reload and drain products, load through open hatches, as well as other operations that can lead to fires and explosions due to gas contamination and dustiness of places where hot work is carried out.

5.6.6. Before the start of hot work, the person responsible for carrying out hot work is instructed with the performers on the observance of safety measures when performing hot work at this facility. The briefing is recorded in the work permit by the signatures of the performers and the person responsible for conducting hot work.

5.6.7. The admission to the performance of hot work is carried out by the person responsible for carrying out hot work, after acceptance of the equipment on behalf of the person. responsible for preparing for hot work, and in a satisfactory condition of the air environment.

5.6.8. Hot work is allowed to begin after completion of the preparatory work in full.

5.6.9. Performers of hot work must start it at the direction of its leader, who gives an order on the beginning and procedure for carrying out hot work.

5.6.10. The number of participants in hot work in the danger zone should be minimal.

5.6.11. In exceptional cases, the person responsible for carrying out hot work may change the composition of the team and the scope of work with the implementation of the necessary organizational and technical measures in addition to the issued work permit and coordination through the available communication channels with the person who issued the work permit.

When changing the composition of the brigade, new people must be included additionally in the work permit.

5.6.12. Line pipeline operators, compressor station drivers, repairmen, electric welders, gas welders, etc., who have undergone special training in the prescribed manner, passed a knowledge test and received an appropriate certificate, having a permit, sufficient work experience and the necessary qualifications, are allowed to hot work.

Welders of the 6th category who have passed the established certification are allowed to weld guarantee joints.

5.6.13. Entering and entering the danger zone should be with the permission of the head of fire work.

Workers must wear appropriate PPE and RPE outside the hazardous area.

5.6.14. When the air pollution of the working area is above the MPC, as well as the lack of oxygen, hot work must be performed in appropriate gas masks.

5.6.15. Hot work can be carried out when the gas content in the air of the working area is not higher than the maximum permissible explosion-proof concentration, i.e. 20% of the VAT. With an increase in concentration of more than 20% of the NK PV, immediately stop hot work, and remove people from the danger zone.

Frequency of air control at least every 30 minutes.

5.6.16. Work during rain, snowfall, strong wind must be carried out with special shelter. Bleeding gas and finding people at line valves and near blowing candles during a thunderstorm is prohibited.

5.6.17. The head of hot work is obliged to immediately stop it in case of non-compliance\violation\of the measures of safe work, provided for by the work permit and production instructions, violation of the technology of work, as well as the creation of an explosive and fire hazardous situation in the working or hazardous area.

5.6.18. Hot work must be stopped in the event of an emergency at a facility located in a hazardous area; with a sudden sharp \negative\ change in organizational, technical, technological and weather conditions performing fire work.

5.6.19. When carrying out hot work, transport and fire fighting equipment, special equipment, mechanisms, radio communication equipment, materials must be located on the windward side. They should be installed taking into account their possible rapid movement and maneuver simultaneously and separately.

5.6.20. Personnel not directly involved in the operation being performed vehicles, equipment, materials and other valuables not used in it, as well as places of rest, heating, eating, a first-aid post, a command post \ mobile trailers, tents, etc. \ must be located outside the danger zones indicated in the table minimum distances radii of dangerous zones \Appendix 7\.

5.6.21. In the event of a fire and explosion hazardous situation, it is necessary to turn off the internal combustion engines of mechanisms, special equipment and vehicles, as well as turn off the power supply to welding machines and other current collectors located in the danger zone, and remove people from the danger zone.

Then measures should be taken to identify the causes of the emergency and eliminate it.

5.6.22. Hot work should be resumed by order of its head after the full restoration of safe working conditions in accordance with this Instruction.

5.6.23. A message about a violation, change, termination and resumption of hot work and the measures taken must be transferred to the control manager.

5.6.24. Carrying out hot work at the same time in several places on one section of the technological line, not separated by shutoff valves, is not allowed.

If it is necessary to carry out hot work simultaneously in several places on one section of the linear part of the main gas pipeline that is not separated by shutoff valves, the work organization project provides for special safety measures or the procedure for carrying out work / performing individual operations and stages associated with a violation of tightness, including gas pipeline cutting, excluding the mutual influence of hot work.

Hot work on welding of caverns, welding of cathode terminals, etc., carried out without violating the tightness of the pipeline, is allowed to be carried out simultaneously in several sections of the gas pipeline.

5.6.25. It is necessary to open and close shut-off valves during hot work in accordance with the work organization plan by order of its manager. In unforeseen cases, the work manager has the right to change the position of the valve provided for by the work organization plan, after agreement with the head of the unit \ shift supervisor \.

Before this operation, hot work should be stopped, and its participants should be removed from the danger zone.

5.6.26. Cylinders with acetylene, oxygen and liquefied hydrocarbon gases, as well as gas generators, must be located no closer than 10 m from the place of fire work on the leeward side.

5.6.27. The welding unit with an internal combustion engine and cylinders with combustible gas during hot work in the room must be installed outside it.

5.6.26. Special equipment with an internal combustion engine and electrical equipment, as well as vehicles must have a spark arrester and a working electrical system.

5.6.28. To ensure the safety of hot work, it is necessary to fill with nitrogen or exhaust gases (carburetor internal combustion engines) the repaired equipment or pipeline section.

5.7. Hot work at the LPUMG industrial site.

5.7.1. Hot work on the industrial site of a gas facility should be carried out, as a rule, after its decommissioning and preparatory work.

5.7.2. It is allowed to carry out hot work on a separate node \ vessel, fittings, pipeline \ without reducing the gas pressure in adjacent nodes and production lines, and if it is technically possible, then during the continued operation of the facility, in cases where the zone of this work does not touch / does not coincide \ with explosive zones of existing \ under pressure \ explosive installations and exhaustive measures have been taken to prevent an emergency situation at these installations.

5.7.3. If it is necessary to carry out hot work at a gas facility without stopping it, the following should be done:

• establish constant control over the explosive and fire hazardous state of the hot work zone in the process of its implementation, including possible leakage of gas, gas condensate \flammable liquids\ from equipment, fittings, pipelines that continue to work and technological gas emissions \flammable liquids through candles and equipment safety valves;

• prohibit blowing equipment, fittings and pipelines / release of gas, gas condensate, flammable liquids, as well as other work that can lead to complication and increase the danger of the work being carried out;

• organize continuous, effective and operational control of the gas contamination of the air of the working area at the MPC /maximum permissible explosive concentration of an explosive substance in the air/.

5.7.4. Hot work in the room should be carried out after turning off the necessary gas, gas condensate and flammable liquids \ communications entering \ and leaving \ into the room, using fittings installed outside it, relieving gas \ condensate pressure, flammable liquids \ and equipment, pipelines inside the room, as well as performing the following additional measures;

• provision of emergency \natural and forced\ ventilation of the premises at least 10 minutes before the start and during the hot work;

• air control in the room by express gas analyzers \ regardless of the presence of stationary gas analyzers \ signaling devices \ in the room.

5.7.5. The purpose of the appointment of on-duty observers for the state of the hot work zone is to give a signal about the immediate cessation of work in the event of a pre-emergency situation or additional danger, failure of equipment, equipment, ventilation systems, signaling of collective protection equipment, increase / decrease / pressure, temperature above \ below \ permissible values, sudden leakage of gas, gas condensate \flammable liquids, etc.

5.7.6. In exceptional cases, by permit, hot work is allowed in explosive premises of the compressor shop \ supercharger gallery, (supercharger compartment) \ with operating units when additional safety measures are taken:

• appointment of the head of the \chief engineer\ of health care facilities as the head of work;

• if there is a reserve in the workshop, provide for the loading of the gas compressor unit in such a way that the neighboring and repair units are stopped and the gas is vented from the technological communications;

• before starting hot work, check the operability of the design gas pollution control system, turn on emergency ventilation 1 hour before the start of hot work;

• seal the gaps in the places where the suction and exhaust pipes of the supercharger pass through the cartridges elev. 4.0, in the pit of the float chamber;

• provide for the installation of protective screens or screens so that sparks and welding flash during welding do not scatter to the sides of neighboring units;

• set up observation posts at the entrance to the supercharger gallery and on the "guitar";

• during the period of hot work in the supercharger gallery, it is prohibited to start up, stop the units in this workshop, and accept protections at the gas compressor unit. In the event of an emergency shutdown of the gas compressor unit, hot work must be immediately stopped, as well as when gas enters the working area;

• the system of supply and exhaust ventilation during the work must be constantly included in the work;

• after the hot work is completed, the welding equipment must be turned off and removed from the blower gallery.

5.7.7. Hot work is allowed in the engine room of the compressor shop, where they work gas turbines, the drive of blowers located behind the partition, during the operation of other units in normal mode, except for the one to be repaired, provided that the following requirements are met:

• disconnection of the repaired unit from the inlet and outlet communications, including fuel and starting gas with the installation of plugs;

• disconnection of the electric and pneumatic conduits to start the unit or individual valve assemblies, taking measures to prevent their accidental activation, and, if necessary, dismantling the electrical conduit\the electrical wiring supplying it must first be disconnected\;

• hermetic sealing of compressor drive shafts in places of their passage through the partition separating the machine room \gas-pumping unit drive room in the block-box\ and the gallery of superchargers \supercharger room in the block-box\;

• more careful selection of participants in hot work according to production discipline, qualifications and work experience;

• check of tightness and elimination of leaks of gas, gas condensate \LVM\ from the connections of the piping and fittings of the unit to be repaired in case of block design and other units in the turbine hall;

• preparation of fire extinguishing systems and means for immediate use.

5.8. Hot work in vessels and wells.

5.8.1. Before hot work, the vessel \apparatus, container\ must be prepared (clause 5.3. of this instruction).

5.8.2. To work inside the vessel or well, a team consisting of at least three people must be assigned: one working in the vessel and two understudies \observers\.

5.8.3. Before working in a vessel or well, the air environment should be analyzed for the relevant harmful substances. Measurements are carried out by an express gas analyzer at at least three points, starting from the entrance \at the hatch\.

5.8.4. Before each descent of an employee into a vessel or well, the work manager inquires about his well-being, checks the equipment, clarifies the conversational code, the duration of one working cycle of stay in the vessel, which should not exceed 30 minutes.

5.8.5. In the course of work in 2-3 min. it is necessary to inquire \including with the help of the code\ about the well-being of the employee in the vessel. If there is no response and after a second request, the employee must be removed immediately.

5.8.6. Work inside the vessel without PPE may be permitted provided that the volume fraction of oxygen in the air is at least 20%. and the total content of harmful substances does not exceed the MPC.

5.8.7. Carrying out fire work in the well. including sewer, tunnel and similar structures must be agreed with the heads of services technologically related to these facilities.

5.8.8. It is allowed for a worker to descend into the vessel and climb out of it using a portable ladder, which must comply with safety conditions.

5.8.9. If the person working in the vessel felt unwell / gave a signal, does not respond to the signals. took off his helmet, mask, etc., then the understudies are obliged to remove it and provide first aid.

It is allowed to descend into the vessel of the understudy in RPE to save the victim if there are at least two people on the surface \ at the hatch \.

5.8.10. After the end of hot work, before closing the hatches, the work manager must personally make sure that there is no worker left in the vessel \ well \, mechanisms, tools, PPE, devices and materials are removed.

5.9. Hot work on underground gas pipelines.

5.9.1. Fire work on an underground gas pipeline. carried out in the traditional way, includes, as a rule, three main stages: cutting out technological holes for removing gas condensate \flammable liquids\ and \or\ installing temporary disconnecting devices. welding and installation work on the installation of a repair workpiece and sealing technological holes.

5.9.2. Technological holes are cut out at a pressure in the pipeline of 100 - 500 Pa \ 10-50 mm of water column \.

5.9.3. Before cutting holes in the gas pipeline, the pressure is measured with liquid manometers installed on the shut-off devices and at the place of hot work.

The pressure gauge should be connected to the gas pipeline with a tube and a special conical nipple pressed into a hole with a diameter of 6-8 mm drilled in the upper part of the gas pipeline.

Control holes are sealed by welding a standard nipple connection.

5.9.4. In the event of a gas pipeline rupture, when the section is completely free of gas, before cutting holes to displace an explosive mixture, the disconnected section is purged with gas with a pressure of not more than 0.1 MPa \ 1 kgf / cm2 \, supplied from both sides to the rupture site. The oxygen content in the gas after blowing through the gas pipeline should be no more than 2%.

5.9.5. The flame of the igniting gas during cutting should, if necessary, be extinguished with a felt mat or asbestos cloth, and the cut line should be covered with crumpled wet clay as the cutter moves.

At the end of the cutting, the flame of the burning gas must be extinguished completely.

5.9.6. When a gas \flammable liquid ignites inside a gas pipeline \flame flash\ or gas burns with a large flame that prevents hot work, it should be stopped immediately, people should be removed from the pit \trench\ at a safe distance, the ignited gas should be extinguished \using the minimum required number of workers\ using felt mats or other appropriate fire extinguishing media.

It is allowed to continue hot work after the identified malfunctions have been eliminated and the gas pressure in the gas pipeline has been restored to the required limits.

5.9.7. During hot work on pipelines, where pyrophoric iron can be deposited on the internal surfaces, when opening them, measures against its self-ignition \abundant wetting with water or other measures\ should be observed.

Deposits removed from pipelines containing pyrophoric iron must be immediately collected in a container under a layer of water and removed to a fireproof place.

5.9.8. The place where hot work is to be carried out on the installation of a repair workpiece must be disconnected from the gas pipeline. The most common way to turn off is with inflatable rubber balls. Before installing the rubber balls, their expiration date \storage\ and tightness are checked.

5.9.9. Rubber balls are installed in the gas pipeline at a distance of at least 8 - 10 m on both sides of the place of hot work between technological openings and the place of work. Before installation, make sure that there is no condensation, oils, etc.

5.9.10. Placed in a gas pipeline and neatly straightened, a rubber ball is inflated with air or nitrogen to a pressure of 2500 - 3000 Pa \ 250 - 300 mm. water.st. \ . The rubber ball must fit snugly against the inner surface of the pipe, ensuring hermetic disconnection of the gas pipeline cavity between the balls.

The condition of rubber balls and tubes must be constantly monitored \visually, by selecting rubber tubes or measuring the pressure inside the ball by a specially assigned worker\.

5.9.11. In order to hold the rubber ball in place \in the event of a draft in the gas pipeline or an increase in excess pressure\, the latter can be placed in a fixed mesh of thin and strong cords.

5.9.12. During hot work on gas pipelines with a diameter of up to 300 mm inclusive, it is allowed to turn off the place of work with temporary clay plugs.

5.10. Organization of communication during the preparation and conduct of hot work.

5.10.1. The organization of communication during the preparation and conduct of hot work should ensure clear and uninterrupted communication between the responsible work manager, security posts and posts at nodes with shutoff valves, with those responsible for hot work in individual areas. with the dispatchers of health facilities and the dispatcher of the PDS with minimal time spent on communication with the workers involved in the work.

5.10.2. Communication is established and tested well in advance of work.

5.10.3. When carrying out work at the sites of compressor stations and connection points, along with telephone communication, it is advisable to organize loud-speaking communication to notify all employees and call individuals to telephone communication.

5.10.4. At the main areas of hot work and units with shutoff valves, telephone sets should be installed at a distance of no more than 50 m from the place of work. In these places, round-the-clock duty of communications workers or involved persons is organized.

5.10.5. When using mobile radios, there is a person on duty with a mobile radio near the place of work outside the danger zone.

The duties of such an employee include:

• invitation on call to communicate with the responsible work manager or other employees participating in the work;

• information on behalf of the responsible head of the hot work of the dispatcher of the medical facility, PDS or other employees who get in touch with the place of hot work;

• periodically \once per hour\ interrogation of posts and communication center of health facilities to determine the readiness of communication facilities, to identify failures;

• inform the person responsible for the organization of communications and the responsible head of hot work about the identified violations of the means of communication.

5.10.6. When using mobile radio stations, a communication service employee may not be allocated at the discretion of the heads of medical facilities or the responsible head of hot work. At the same time, the responsibility for ensuring communication lies with the responsible persons at the crane units.

5.10.7. When performing work on the linear part of gas pipelines, an emergency communication vehicle is installed outside the security zone of gas pipelines. From the communication vehicle, a field telephone wire should be laid and a telephone set should be installed at the work site.

5.10.8. During the period of hot work or switching on gas pipelines. the use of communication means for negotiations of other employees, except for the responsible head of hot work, responsible for carrying out work at sections and posts, is allowed only after obtaining the permission of the responsible head of hot work.

5.11. Final work.

5.11.1. After the completion of fire \repair\ work and obtaining positive results of the inspection of welded joints, a set of final works is carried out, which include the displacement of the gas-air mixture, blowing, insulating, excavation, testing of gas pipelines.

When carrying out hot work on technological communications of the compressor station, it is necessary to think over such a scheme for displacing the gas-air mixture and blowing out the gas pipeline section so that rubber locking balls, if it is not possible to dismantle them, can be blown out through the candles of the connection unit. When performing hot work on the linear part of the main gas pipeline, locking balls, scale, etc. are removed from the cavity of the gas pipeline through the candle piping and the passage of magnetic and cleaning pistons.

5.11.2. Upon completion of work on pipelines of small diameters and complex configuration, it is necessary to perform work to remove clay plugs through fittings or flange connections.

Displacement of the gas-air mixture is carried out by gas with a pressure of not more than 1 kgf / cm 2 at the place of its supply.

The displacement is considered complete if the oxygen content in the outgoing gas-air mixture does not exceed 2% \by volume\. The control is carried out by a gas analyzer or by the absence of pops during the combustion of a gas sample taken into a rubber ball through a water seal in a safe place. When the air has been expelled, the purge plug closes.

5.11.3. Upon completion of the displacement of the gas-air mixture, the repaired section of the gas pipeline is tested by through pressure for two hours.

5.11.4. Before filling the communications with gas after repair, the personnel is removed from the danger zone. Upon reaching a pressure equal to 50% of the working pressure in the gas pipeline, the equipment and pipeline are inspected for tightness. In the absence of leaks, the pressure rises to the working one and after two hours a secondary inspection is performed.

5.11.5. To prevent a fire or explosion after the completion of hot work, a thorough check of the place of work should be ensured, and if necessary, leave the observer for a while.

VI. Duties and responsibilities of managers and performers of hot work.

6.1. To carry out scheduled hot work or a set of works performed according to the plans for organizing their safe conduct, depending on the complexity and volume of work, or its structural unit issues an order to carry out them.

Orders for carrying out hot work or a complex of work should appoint a responsible manager for their implementation, responsible for carrying out certain types or stages of work, determine the composition of employees involved in hot work, involved equipment, fire fighting equipment, etc.

6.2. The heads of the complex of works, depending on its complexity, as well as hot or gas hazardous work, can be appointed heads of "heads\their deputies\of production departments, heads of subdivisions", heads\their deputies\of shops, services, who have been trained and tested in their enterprises, who have sufficient experience in such work.

6.3. Responsible for carrying out complex \fire\works in the elimination of destruction, cracks and other defects in pipes, equipment, fittings that occurred during cleaning of the cavity and testing objects with gas for strength and tightness after completion of construction or overhaul, depending on the volume and complexity of work, may appointed engineering and technical personnel, heads of sections, heads and chief engineers of construction and installation enterprises and divisions who have been trained and tested in their enterprises and have sufficient experience in performing such work.

6.4. The replacement dispatcher must:

• register work permits in the register of hot and gas hazardous work;

• register the execution of each stage of work by an entry in the operational log \ upon receipt of information from the responsible work manager \;

• warn shift personnel about the work being carried out and make an appropriate entry in the shift acceptance and delivery log;

• ensure the maintenance of the technological process in accordance with the parameters established for the duration of the work;

• notify the person responsible for carrying out fire \ gas hazardous \ work about all possible shutdowns technological processes affecting the conduct of hot work.

• upon completion of hot work, check, together with the person responsible for carrying out hot work, the place where hot work was carried out in order to exclude the possibility of fire and ensure that the shift personnel observe the place of the most probable fire source for 3 hours.

6.5. The person responsible for preparing the facility for work is obliged to:

• start work only in agreement with the head of the shop \ service \ and the shift dispatcher, after receiving the work permit;

• ensure the consistency and completeness of the implementation of the activities provided for in the work permit;

• after completion of the preparatory activities, check the completeness and quality of their implementation.

• ensure timely analysis of the air environment at the site of hot work and in the danger zone.

6.6. Responsible for preparing the facility for work

is responsible for the correctness and reliability of shutting off the site of fire \ gas hazardous \ work with shutoff valves \ plugs \ and the implementation of safety measures provided for by the work permit.

6.7. Responsible for carrying out hot work is obliged to:

• organize the implementation of measures for the safe performance of hot work;

• instruct the performers on the rules for safe work and the procedure for providing first aid;

• check with the performers for the availability of certificates and coupons for fire safety, the availability of PPE, tools and devices in accordance with the nature of the work;

• provide the place of work with primary fire extinguishing means;

• be at the site of hot work, supervise the work of performers;

• allow work to be carried out only after obtaining a satisfactory analysis of the air environment in the work area, the invariability of pressure in the shut-off balls and other control parameters that ensure the safety of work;

• ensure control over the state of the air environment in the work area;

• take measures excluding the admission to the place of work of persons not engaged in its implementation;

• in the event of a dangerous situation, immediately stop work;

• stop work at the request of the head of the subdivision \ shop \, shift dispatcher, employees of the labor protection service, fire protection, Gosgortekhnadzor;

• when resuming hot, gas hazardous work after a break, check the condition of the work site and equipment;

• after the completion of hot work, check the workplace for the absence of possible sources of fire and “close” the work permit with your signature and the signature of the head of the workshop \ service \ (p. 15).

6.8. The person responsible for carrying out hot work is responsible for the correctness and completeness of the safety measures taken, for the completeness and quality of the instruction of the workers, for the quality and timing of the work, compliance with the technology and safety measures by the performers of the work.

6.9. Work performers are obliged to:

• carry a certificate of knowledge testing and a fire safety ticket;

• undergo a briefing on the safe conduct of work and sign the work permit \ journal - briefing \;

• get acquainted with the conditions, nature and scope of work at the place of their upcoming implementation;

• perform only the work specified in the work permit;

• start hot work only at the direction of the person responsible for carrying out this work;

• apply protective equipment, observe safety measures, work in overalls;

• know the signs of poisoning harmful substances and asphyxiation with gas;

• know the location of the first-aid kit, means of communication, the procedure for evacuating victims from the danger zone, be able to provide first aid medical care be able to use life-saving equipment;

• monitor the condition of workmates, provide them with assistance if necessary;

• in case of deterioration of one's own health or detection of signs of indisposition among comrades, stop work and immediately inform the person responsible for the work;

• after completion of work, tidy up the workplace, remove tools, eliminate violations that could lead to a fire, injuries and accidents;

• be able to use fire extinguishing equipment, be able to call the fire brigade if necessary;

• stop hot work in the event of a dangerous situation.

6.10. Performers of hot work are responsible for the implementation of all safety measures provided for in the work permit and in the instructions for the types of work.

6.11. Persons who have agreed on an admission order are liable in accordance with their duties stipulated by job descriptions and unified system management of labor protection in the gas industry.

6.12. The person who signed the work permit is responsible for the correctness and completeness of the developed measures for the safe performance of work specified in the work permit.

6.13. The person who approved the work permit is responsible for the sufficient qualifications of the person responsible for the production of work and the performers included in the brigade.

6.14. The person who approved the work permit for conducting hot work, the head of the service (workshop) where hot work is performed, or a person replacing him; a shift dispatcher (engineer), persons responsible for the preparation and conduct of hot work, performers are responsible for failure to fulfill their duties in accordance with applicable law.