process description gcs-1

Gas Compressor Station no. 1

Gas Compressor Station no. 13.1 PROCESS IN BRIEF

• Associated gas after separation from crude oil at an Oil Collecting Station (OCS) 1

enters a Gas Compressor Station 1 at pressure 2.2 kg/cm2.

• The gaseous stream passes through a Knock-Out-Vessel, Mist Extractor for

separation of any entrained liquid & enters the Low Pressure Booster Compressors.

• In the Low Pressure Booster Compressors gas is compressed to 14 -19 kg/cm2

(maximum).

• A portion of this HP gas is further compressed in Gas Lift compressors to about 85

- 90 kg/cm2 after dehydration at Glycol Dehydration Plant for use in artificial lifting

of crude oil from depleted wells.

• The remaining gas enters the distribution system for onward transportation to LPG

Recovery Plant/ Consumers.


Your safety means the Safety of your family

Gas Compressor Station no. 13.2 MAKE & CAPACITY OF GAS COMPRESSORS

LOW PRESSURE BOOSTER COMPRESSOR ( 2KG/CM2 TO 14/19 KG/CM2), COMMONLY KNOWN AS LPB:

LPB 4

Make : Compressor – Ingersoll Rand (C)

Prime Mover : 750 HP Electric Motor, NGEF

Capacity : 5400 Standard Cubic Mtrs /hr.

LPB 5

Make : Compressor – Worthington

Prime Mover : Caterpillar G399

Capacity : 2700 Standard Cubic mtrs /hr

LPB 6

Make : Compressor – Atlas Copco

Prime Mover : Waukesha L7042


GAS LIFT COMPRESSOR ( 14/19 KG/CM2 TO 85/90 KG/CM2), COMMONLY KNOWN AS GL:

GL 3

Make : Compressor – BPCL

Prime Mover : Waukesha L3711G


GL 5

Make : Compressor – BPCL

Prime Mover : 450 HP Electric Motor, BHEL


GL 6

Gas Compressor Station no. 1Make : Compressor – BPCL

Prime Mover : Caterpillar G 3516 NA


GI 4

Make : Compressor – Atlas Copco

Prime Mover : Waukesha L5790


AIR COMPRESSOR:

Air Compressor 1

Make : Compressor – IR 15T2

Prime Mover : Electric Motor

Capacity : 1 Standard Cubic Mtrs /min

Air Compressor 2

Make : Compressor – IR 25T2


Capacity : 1.5 Standard Cubic Mtrs /min

Air Compressor 3

Make : Compressor – KIRLOSKAR PNEUMATIC Co. Ltd


Capacity : 3.01 Standard Cubic Mtrs /min

3.3 CHEMICALS USED:

1. Lube Oil – 20W40, S121 – for Gas Engine & Compressor, Air Compressor, Genset lubrication

2. Methanol – for prevention of hydrate formation in gas lift lines in place of GDU

3. Triethylene Glycol – Purity - 99.99%, 99% - for Glycol Dehydration Plant

4. Hydraulic Oil – Servo 685. High Speed Diesel – for Genset and Air Compressor

6. Teepol - for cleaning purpose

3.4 GLYCOL DEHYDRATION PLANT:

ABAX(Imported – Canada)


3.5 SAFETY EQUIPMENT & SAFETY MANAGEMENT SYSTEM

• Spring Loaded Safety Relief Valves (SRV) in all pressure vessels, Compressors.

• DGMS Approved Portable Gas Detector.

• Safety Torch.

• Safety Shutdown Systems on Each Compressor Package.

• Emergency Remote Shutdown Device.

• Stand-by fire fighting crew at Central Fire Station, Duliajan round the clock (10 KM away).

• Periodic Mines Vocational Training, first Aid Training, Fire Fighting Mock Drills and Refresher Courses for operating personnel.

• Periodic hydraulic testing of pressure vessels.

• Periodic testing of SRV.

• Fire Contingency Plan.

• Static Water Storage Tanks for fire fighting.

• Electrical earthing in all pressure vessels, Compressors.

3.6 IN-HOUSE FIRE FIGHTING EQUIPMENT

STATIC GEARS Static Water Tank Monitor & Hydrant Point Electric Fire Siren Sand Bins

PORTABLE GEARS Equipment Type Capacity

Make Safety a Habit to remember, from January to December

Gas Flow Rate – 10 & 15 MMSCFDInlet Water Content - 260 lbs/MMSCFD at 250 PSIG and 110oF flowing conditionFlow temp - 110 oF design (122 maxM.)Gas Specific Gravity - 0.63-0.7Flowing Pressure - 250 psig design, 200 min; 275 maxTEG Circulation Rate - 4.0 / 5.0 USGPMOutlet Water Content - 6 lbs/MMSCFDDew point - -5OF to 5oF dew point at 250 psiDew point depression - 105oFSpecific Gravity - 0.717

Gas Compressor Station no. 1 Dry Chemical Powder extinguishers BC 10 kgs. Dry Chemical Powder extinguishers BC 75 kgs. CO2 extinguishers C 2 kgs.

3.7 MEDICAL FACILITIES

Stretcher First Aid Box Stand-by doctor at OIL Hospital, Duliajan, round the clock (10 KM away) Ambulance available at OIL Hospital, Duliajan. Emergency Vehicle available at Control Room (GCS-5) & nearby/adjacent OCS.

Don’t be safety blinded, be safety minded

Gas Compressor Station no. 13.8 REGISTERS AND RECORDS MAINTAINED

EMPLOYEES BIODATA (FORM B).

NOTICE OF COMMENCEMENT AND END OF WORK (FORM A).

EMPLOYEES LEAVE POSITION (FORM G).

EMPLOYEES ATTENDANCE RECORDS.

DGMS APPROVAL LETTER.

JUNIOR ENGINEERS REPORT BOOK.

PROCESS FLOW DIAGRAM.

ACCIDENT RECORDS.

MINES VOCATIONAL TRAINING RECORDS.

FIRST AID AND FIRE FIGHTING TRAINING RECORDS.

FIRE CONTINGENCY PLAN AND FIRE ORDER.

COLD / HOT WORK PERMITS.

RECORDS OF HYDRAULIC TESTING OF PRESSURE VESSELS.

SAFETY VALVES TEST RECORDS.

EARTH RESISTANCE TEST RECORDS.

RECORD OF NEAR MISSES.

COMPRESSOR MAINTENANCE RECORDS.

3.9 REGULAR DUTIES OF SHIFT INCHARGE FOR SAFE OPERATION PRACTICE

To conduct TOOL BOX MEETING regularly in each shift for safe operation / maintenance of the installation and record it.

To check drain system of all pressure vessels in each shift and if the auto drain system is not working it should be drained manually and inform SCADA and Installation Manager for corrective action.

To monitor and record all the process parameters of compressors /units and compare it with tripping set points. If the operating parameters are outside the tripping range the same should be stopped immediately and inform SCADA and Installation Manager.

To check all the system and to conduct Gas Testing daily. If gas leakage is detected beyond 20 % LEL the same should be informed to SCADA and Installation Manager for corrective action.

To ensure use of proper PPE by all personnel inside the installation.

To check work permits if any job has to be carried out by service personnel.

Courtesy & Common sense promote safety

Gas Compressor Station no. 13.10 WHAT TO DO IN CASE OF FIRE

SHOUT FIRE, FIRE. BLOW SIREN.

FIGHT FIRE WITH AVAILLABLE FIRE EXTINGUISHER

INFORM FIRE SERVICE TELEPHONE NO 7333 MENTIONING THE EXACT LOCATION OF FIRE AND YOUR TELEPHONE NUMBER 5232 AND YOUR REGN. NO.

OPERATE BOTH THE EMERGENCY SHUTDOWN SWITCH (SERVO) AND ELECTRICAL S/D SWITCH NEAR THE MAIN GATE.

SHUTDOWN AN UNIT WHICH IS STILL IN OPERATION, IF ANY.

CLOSE THE ISOLATION VALVE OF THE FOLLOWING:

o 250 PSIG DISTRIBUTION ISOLATION VALVE(V1)

o 30 PSIG LOW PRESSURE GAS ISOLATION VLAVE (V2)

o 1500 PSIG GAS LIFTER MAIN DELIVERY VLAVE (V3)

o FUEL GAS ISOLATION VALVE

INFORM TO INSTALLATION MANAGER AND MAKE CALL ACCORDING TO THE LIST DISPLAYED IN THE NOTICE BOARD (FIRE CALL LIST).

HELP AND GUIDE THE FIRE TENDER PERSONNALS.

3.11 WHAT TO DO IN CASE OF EARTHQUAKE

DO NOT PANIC

BREAK THE GLASS AND PRESS THE ELECTRICAL SHUTDOWN SWITCH AND OPEN THE EMERGENCY SHUTDOWN VALVE (SERVO) LOCATED NEAR THE MAIN GATE.

SHUTDOWN ANY UNIT WHICH ARE / IS STILL IN OPERATION.

CLOSE THE ISOLATION VALVE OF THE FOLLOWING:

o 250 PSIG DISTRIBUTION ISOLATION VALVE (V 1)

o 30 PSIG LOW PRESSURE GAS ISOLATION VLAVE (V2)

o 1500 PSIG GAS LIFTER MAIN DELIVERY VLAVE (V3)

o FUEL GAS ISOLATION VALVE (V5)

INFORM TO INSTALLATION MANAGER AND SCADA CONTROL ROOM 6418 & 8438.

STAY OUTSIDE IN AN OPEN AIR WITH NO STRUCTURE NEARBY.

Safety is as simple as ABC – Always Be Careful

Gas Compressor Station no. 13.12 HOW TO SHUTDOWN THE GCS

NOTE DOWN ALL THE PARAMETERS OF ALL THE UNITS (GAS COMPRESSORS AND GLYCOL PLANT) WHICH ARE IN OPERATION.

INFORM TO OCS 1 (5233), SCADA CONTROL ROOM (6418) AND INSTALLATION MANAGER, Mr. P.K. DUTTA (6414).

UNLOAD THE GLYCOL CONTACTOR TOWER OR STOP METHANOL PUMP.

SHUTDOWN ALL THE GAS COMPRESSOR ONE BY ONE, AND CLOSE EACH FUEL VALVE FOR LPB AND GL. AND SWITCH OFF THE ELECTRICAL PANEL FOR METHANOL PUMP (IF RUNNING), AND THE AIR COMPRESSORS.

CLOSE EACH OF THE SUCTION AND DELIVERY VALVE OF ALL THE GAS COMPRESSORS INCLUDING AIR COMPRESSOR.

SHUTDOWN THE GLYCOL PUMPS AND CLOSE DOWN THE MAIN FUEL LINE TO PILOT AND MAIN BURNER.

CLOSE THE FOLOWING VALVES IN ORDER OF THE SERIAL NO:-

o MAIN FUEL ISOLATION VALVE (V5)

o Low pressure, 2kg/cm2(30 PSIG) ISOLATION VALVE (V2)

o High pressure, 17kg/cm2(250 PSIG) ISOLATION VALVE (V1)

o High pressure, 95kg/cm2 (1500 PSIG) ISOLATION VALVE (V3)

NOTE: PUT AN IDENTIFICATION MARK IN EACH AND EVERY VALVE YOU HAVE CLOSED.

3.13 HOW TO RESTART THE GCS

INFORM OCS 1.

RUN THE AIR COMPRESSOR AFTER OPENING THE ENTIRE CLOSED VALVE.

OPEN THE FOLLOWING VALVES SLOWLY IN ORDER OF THE SERIAL NO:-

o 30 PSIG ISOLATION VALVE (V2)

o 250 PSIG ISOLATION VALVE (V1)

o MAIN FUEL ISOLATION VALVE (V5)

o 1500 PSIG ISOLATION VALVE (V3).

DRAIN ALL THE LIQUIDS FROM ALL THE VESSELS.

OPEN ALL THE VALVES WHICH WERE CLOSED WHILE SHUTTING DOWN THE GCS (MARKED DURING SHUTDOWN OF THE GCS.)

START THE GDU AS PER STANDARD PROCEDURE.

DO NOT PUT ANY LIFTER ON LOAD BEFORE REBOILER TEMPERATURE REACHED 350 DEG F IN CIRCULATION DURING WINTER.

START THE COMPRESSORS AS PER STARTING PROCEDURE OF EACH UNIT.

LOAD THE CONTACTOR TOWER.

TAKE READINGS OF ALL THE PARAMETERS OF EACH UNIT.

3.14 WHAT TO DO IN CASE OF SUDDEN RISE OF PRESSURE IN GAS LINES:Safety isn’t expensive, it is priceless


IN GAS LIFT DELIVERY LINE

In normal operating condition, there should NOT be sudden rise of Pressure in Gas Lift Delivery Lines (1500 PSI) since there is an OVERPRESSURE CONTROLLER system available at GCS 1. The Overpressure Controller Valve is set to open at 92 Kg/Sq.cm and deliver the gas to Lifter Suction Line (250 PSI). However, in case of malfunction of the Overpressure Controller, the following steps have to be taken.

UNLOAD ALL THE LIFTERS.

CHECK WHETHER GAS LIFT OVER PRESSURE BY-PASS CONTROLLER IS WORKING PROPERLY OR NOT, IF NOT, INFORM SCADA (6414).

CLOSE THE 1500 PSIG ISOLATION VALVE.

INFORM SCADA CONTROL ROOM, OCS 1 AND INSTALLATION MANAGER.

YOU WILL BE ADVISED WHETHER TO SHUTDOWN THE LIFTER OR NOT.

IN DISTRIBUTION LINE

UNLOAD ALL THE LOW PRESSURE BOOSTERS.

CHECK WHETHER OVER PRESSURE BY-PASS CONTROLLER IS WORKING PROPERLY OR NOT, IF NOT, INFORM TO SCADA.

CLOSE THE 250 PSIG ISOLATION VALVE.


YOU WILL BE ADVISED WHETHER TO SHUTDOWN THE LOW PRESSURE BOOSTER (LPB) OR NOT.

3.15 WHAT TO DO IN CASE OF SUDDEN DECREASE OF PRESSURE IN GAS LINES:

IN GAS LIFT LINE

UNLOAD ALL THE LIFTERS.

CHECK WHETHER HIGH PRESSURE BY-PASS CONTROLLER IS WORKING PROPERLY OR NOT. IF NOT, CLOSE THE UPSTREAM MANUAL VALVE OF CONTROLLER AND INFORM SCADA. IF YES, INFORM THE GAS FIELD SECTION TO CHECK ARTERY LINE, OCS OPERATOR TO CHECK THEIR GAS LIFT WELL.


YOU WILL BE ADVISED WHETHER TO SHUTDOWN THE LIFTER OR NOT.

IN DISTRIBUTION LINE

INFORM SCADA CONTROL ROOM, CONCEREND OCS AND INSTALLATION MANAGER TO KNOW WHETHR THERE IS ANY LEAKAGE IN DISTRIBUTION SYSTEM.

YOU WILL BE ADVISED WHETHER TO START ADDITIONAL BOOSTERS OR SHUTDOWN THE RUNNING LOW PRESSURE BOOSTER(S).

3.16 BRIEF STARTING PROCEDURE OF GAS COMPRESSORS . Working safely each day will keep the Doctor away

Gas Compressor Station no. 1For UNIT no. LPB 5, LPB 6 and GL 3

WALK AROUND THE COMPRESSOR TO CHECK VISUALLY FOR ANY OBVIOUS DAMAGE.

LEAVE VENT (BLOWDOWN) VALVE CLOSED.

SET MANUAL SPEED CONTROLLER AT ZERO.

RESET THE PANEL UNTIL ALL THE FLAGS TURN GREEN.

OPEN THE FUEL VALVE FULLY.

PUSH START BUTTON TO CRANK ENGINE.

CHECK PANEL IMMEDIATELY FOR ENGINE & COMPRESSOR OIL PRESSURE AND LEVEL.

RUN ENGINE UNDER NO LOAD UNTIL ENGINE OIL TEMPERATURE RISES TO 140OF -150OF

SLOWLY INCREASE MANUAL SPEED CONTROLLER TO OPERATING RANGE.

OPEN THE SUCTION BLOCK VALVE.

OPEN THE DISCHARGE VALVE.

CLOSE SLOWLY THE BYPASS VALVE.

CHECK SUCTION PRESSURE; DISCHARGE PRESSURE AND

TEMPERATURE; PISTON ROD PACKING; ENGINE OIL PRESSURE, TEMPERATURE AND LEVEL; COMPRESSOR OIL PRESSURE, TEMPERATURE AND LEVEL; ENGINE WATER TEMPERATURE.

IF EXCESSIVE NOISE, VIBRATION, OIL OR COOLANT LEAKS, OR

LOW OIL PRESSURE OCCURS DURING STARTUP, STOP THE ENGINE IMMEDIATELY BY PUSHING THE STOP BUTTON.

For UNIT no. LPB 4 and GL – 5

WALK AROUND THE COMPRESSOR TO CHECK VISUALLY FOR ANY OBVIOUS DAMAGE.

LEAVE VENT (BLOWDOWN) VALVE CLOSED.

ENSURE THAT SUCTION VALVE IS CLOSED AND LOADING/UNLOADING VALVE IS OPEN.

RESET THE PANEL UNTIL ALL THE FLAGS TURN GREEN.

WHEN THE PANEL IS READY, RUN THE LUBE OIL PUMP MOTOR

RUN ALL THE COOLER FAN MOTOR AND WATER PUMP MOTOR.

CHECK PANEL FOR COMPRESSOR OIL PRESSURE AND LEVEL, WHETHER WATER CIRCULATION IS OK OR NOT. IF ALL ARE OK,

RUN THE MAIN MOTOR.

OPEN THE SUCTION VALVE AND THE DISCHARGE VALVE.

CLOSE SLOWLY THE BYPASS VALVE.

CHECK SUCTION PRESSURE; DISCHARGE PRESSURE AND

Safety is Everybody’s Business

Gas Compressor Station no. 1 TEMPERATURE; COMPRESSOR OIL PRESSURE, TEMPERATURE AND LEVEL;

COMPRESSOR WATER TEMPERATURE.

IF EXCESSIVE NOISE, VIBRATION, OIL OR COOLANT LEAKS, OR

LOW OIL PRESSURE OCCURS DURING STARTUP, STOP THE MAIN MOTOR IMMEDIATELY BY PUSHING THE STOP BUTTON.

Basic Operation of Altronic Panel ( GL-6)

Gas Compressor Station no. 13.17 SHUTDOWN PROCEDURE OF GAS COMPRESSOR .

For UNIT no. LPB 5, LPB 6 and GL 3 OPEN THE BYPASS VALVE.

CLOSE THE DISCHARGE BLOCK VALVE.

CLOSE THE SUCTION BLOCK VALVE.

RUN ENGINE AT REDUCED SPEED AND UNDER NO LOAD FOR FIVE MINUTES.

REDUCE THE SPEED FURTHER AND RUN THE ENGINE AT LOW IDLE FOR 30 SECONDS.

STOP ENGINE BY PUSHING THE STOP BUTTON ON THE PANEL.

CRACK OPEN VENT (BLOWDOWN) VALVE TO RELEASE PRESSURE.

For UNIT no. LPB 4 and GL – 5

OPEN THE BYPASS VALVE SLOWLY.

RUN MAIN MOTOR UNDER NO LOAD FOR TWO MINUTES.

SWITCH OFF THE MAIN MOTOR.

CLOSE THE SUCTION BLOCK VALVE.

CLOSE THE DELIVERY VALVE.

STOP THE COOLER FAN MOTORS, WATER PUMP MOTOR AND LUBE OIL PUMP MOTOR BY PUSHING THE STOP BUTTON ON THE PANEL.

CRACK OPEN VENT (BLOWDOWN) VALVE TO RELEASE PRESSURE.

3.18 STARTING PROCEDURE OF AIR COMPRESSOR

Before starting a new compressor, always fill the crankcase up to the filler hole with a good grade of lubricating oil. Check the motor bearing for lubrication.

Open the water mains in case of water coiled unit and ensure that water flows freely in all the outlet pipes and there is no water leakage.

Open the intercooler, after cooler drain clocks, by-pass valve and air receiver outlet valve.

Turn compressor over a few revolutions by hand to see that everything is free and in working condition.

Remove tools, rags and any other objects from the vicinity of the compressor before throwing the switch.

Never put hands on the belts of an idle unit. It may be connected to start and stop automatically and should start, a hand can very easily be caught between the belt and the motor pulley or belt wheel. Start the motor and observe the direction of rotation of compressor. Note down the current drawn by the motor pulley or belt wheel.

Make sure that oil pressure (1.5 – 2 ksc) is being indicated on the lubricating oil pressure gauge. If the gauge fails to register any pressure, then stop the compressor and investigate.

If the machine is running alright, then fully close the drain –cocks, by pass valve and slowly close the air outlet valve to the extent that the 2nd stage

Safe actions bring lasting satisfaction

Gas Compressor Station no. 1gauge registers a pressure of 3 ksc. Observe the performance of machine, at this pressure for about 30 minutes.

Allow the compressor to run and observe for any leakage of oil, water or any abnormal sound for about 10 minutes. If the machine is running alright, then fully close the drain –cocks, by pass valve and slowly close the air outlet valve to the extent that the 2nd stage gauge registers a pressure of 3 ksc. Observe the performance of machine, at this pressure for about 30 minutes.

Next, raise the air pressure to 5 ksc by closing the air outlet valve and run the machine at this pressure for about 30 minutes.

Now close the air outlet valve till the air pressure reaches the specified working pressure.

Check that the loading and unloading of the compressor is taking place at a minimum differential of 1 ksc of the specified working pressure.

The compressor is now ready for use.

3.19 SHUTDOWN PROCEDURE OF AIR COMPRESSOR

To shut the machine down, close the service valves and run the machine for approximately 5 minutes and then turn the toggle switch to “OFF” position.

3.20 STARTING PROCEDURE OF GLYCOL DEHYDRATION PLANT

Fill the reboiler first until glycol appears in the surge tank and then fill the surge tank approximately full.

Check to see that all valves on the burner manifold are closed.

Close all valves gas supply to the reboiler.

Close all glycol and gas valves around the pumps.

Close glycol outlet valve from absorber.

Check pumps, motors etc. for lubrication etc.

Slowly turn static pressure into the absorber (Contactor tower) and check for leaks.

Open gas supply to reboiler and check for leaks.

Adjust regulators to maintain 20 psig supply pressure to controls and approximately 15 psig to burner manifold.

Light the pilot burner. If the burner is equipped with a pilot burner it will be necessary to reset the temperature control until the element is sufficiently heated.

Turn the temperature dials to open the fuel valve, thus lighting the main burner. Adjust the primary and secondary air to give a blue flame with yellow tip.

Glycol circulation can be started now. Open glycol suction and discharge lines. Open filter block valves, if applicable. Start pump and bleed air from lines.

Open the Door to Safety; Awareness is the Key

Gas Compressor Station no. 1 When starting a gas driven pump, the pump will run on gas until glycol has

been pumped into the absorber. It will then automatically control the glycol level at the high pressure glycol outlet.

Add glycol to the surge tank as the level is pumped down. Caution should be taken however, that the surge not to be filled too full. Glycol will expand as it comes up to the operating temperature.

Adjust the temperature controller to the proper temperature. When two controllers are used, the overriding shut down control should have full 20 psig output while the other control is throttling.

Gas can now be turned through the absorber. Apply the load very slowly.

Adjust the glycol pump rate. The rate required varies with the application and equipment. Generally, a glycol rate of 3-4 gallons per pound of water in the inlet stream is sufficient to provide adequate dehydration. Lower rates are usually adequate where additional trays are provided.

3.21 SHUTDOWN PROCEDURE OF GLYCOL DEHYDRATION PLANT.

Turn off gas to absorber.(Contactor Tower) Close valves on burner manifold. Stop pumps. Turn off gas to reboiler.

Bleed pressure off downstream of absorber, if unit is to be down for any extended period of time.

The absorber and reboiler should be water flushed and drained. The pumps should be cleaned, the packing removed on electric driven and gas driven pumps and plungers coated with rust preventive.

3.22 SAFE OPERATING PROCEDURE & MAINTENANCE OF OVERHEAD CRANE:

Crane specification:Capacity : 5 tonnesSpan : 20 mtrs.Supplier : Matting

Before starting the operation, operator shall verify the testing and validity certificate of load testing.

Operator shall verify that all pre-use inspections as per standard practices or manufacturing guidelines have been completed.

Crane to be load tested every time any major maintenance job is carried out in the crane even if the load testing certificate is valid.

The Operator shall be responsible and check work permit for any operation of the crane by working crew for operations under his direct control.

While lifting / placing of the load , no unauthorized person shall remain underneath the load.

For any safety reasons, the crane operator shall stop handling loads/operations and report the matter to the Installation Manager fro further instructions.

The operator shall be familiar with the use of equipment and it’s care.

Gas Compressor Station no. 1 The operator will respond to signals given by unauthorized signal person.

Electrocution due to contact with power lines is the leading cause of crane related fatalities. Detailed regulations for proximity to high voltage sources must be strictly enforced. Any danger should be pointed out to the crane operator or a supervisor but never touch the crane at that time.

3.22.1 Before starting to lift, the following conditions should be verified:

Signals and will not respond unless signals are clearly understood.

The hook is brought over the load in such a manner as to minimize swinging.

The correct slings have been selected for the weight to be lifted.

Never attempt to lift a load that exceeds the crane lifting capacity.

During lifting, care should be taken that acceleration or deceleration of the moving load is accomplished in a smooth manner.

While the crane is in operation, no other work shall be performed on the crane.

Riding on loads and hooks is strictly prohibited.

No fewer that five (5) full wraps of rope will remain on the drum in any operation. Due consideration should be given to hoist manufacturers recommended practices especially fro ‘break away’ anchor type hoist.

The Operator should not leave the control until the load has been safely waded.

He must properly secure before going off duty when shutting down operations.

Appropriate non-electrical conducting tug or restraining lines should be used

where necessary to guide and control the load.

Sling, their fittings and fasteners, when not in use, should be inspected and

retired in accordance with the following guidelines:

Suitable protection to be provided between the sling and sharp surfaces of the

load to be lifted.

Proper storage should be provided for the slings when not in use.

Slings should never be choked in the splice.

Slings shall not be shortened with knots, bolts or other makeshift devices.

Slings shall not be loaded in excess of their rated capacities.

Hands or fingers shall not be placed between the sling and its load while the

sling is being tightened around the load.

Shock loading is prohibited.

A sling shall be visually inspected before use to determine if it s capable of

safely making the intended lift.

Slings between the crane operator and the designated signal person will be

discernible audibly or visually at all times. The crane operator will work with a

designated signal person who uses standard hand signals and radio

Safety – You will regret if you forget

Gas Compressor Station no. 13.22.2 MAINTENANCE OF CRANE

The maintenance of the crane shall be made on the recommendation of the

crane manufacturer’s standard practices. However, maintenance practices

shall be followed based upon utilization of the crane.

Periodic/ Preventive maintenance schedule shall be followed as per standard

manufacturer’s practices/ operator’s recommended practices.

The repairs and replacement of items shall be followed based upon the

recommendation of inspection agency. However, if any major item /part is

obsolete or not available, the same shall be replaced with compatible parts

which has to be approved by competent person/agency. No welding repair

should be made to critical components unless a repair procedure and

recommendations are approved.

3.22.3 Precautions during Major Repair & Maintenance

Any job will be started only after obtaining the hot / cold work permit at any site as per OISD Std. 105.

Care should be taken to ensure that arcing does not occur across the bearings.

Hooks should not be exposed to excessive beat.

Maintenance and inspection of wire ropes used in crane shall be done in accordance with OISD Std – 187.

3.23 G eneral Safety Guidelines

Report all unsafe practices or conditions to your supervisor immediately.

Report all injuries, no matter how minor, to your supervisor immediately.

Wear personal protective equipment (safety glasses, hard hats, gloves, etc.) as required for each job.

Wear appropriate clothing for the job.

Never keep or eat food in any area where hazardous materials are used or stored.

Wash your hands after handling hazardous materials especially before eating, drinking or smoking.

Follow all warning signs and tags; they are for the protection of you and your fellow workers.

Never remove locks, warning, danger, or lockout tags on any apparatus, valves or switches unless you placed them and the hazard no longer exists. Consult your supervisor if someone else’s lock or tag prevents work.

Be sure that operators can always see you when working around heavy equipment, cranes, or trucks.

Be alert to conditions and work processes in surrounding areas so that you can foresee and avoid dangers. Be aware of the presence of other employees and equipment.

Safety is a full time job; don’t make it a part time practice

Gas Compressor Station no. 1 Do not enter barricaded or “roped off areas” without appropriate authorization.

They are considered danger zones.

Do not throw or drop materials from one area or level to another unless under special controlled conditions and permitted by your supervisor.

3.23.1 Housekeeping Follow these procedures for cleaning up spilled materials or liquids:

If you know what the substance is, and you know that it is not hazardous, clean it up immediately.

If the substance is known to be hazardous, ask your supervisor for specialized instructions for clean up.

If you do not know what the substance is, try to identify it and contact the Safety Officer. Maintain a safe distance, and do not clean it up.

Collect rags, packing materials, sawdust and other combustible materials daily and place in appropriate containers.

Collect objects with sharp edges (scrap sheet metal, scrap glass, bottles, metal cans) and place in containers that will safely hold the material.

Return all tools and equipment to the appropriate storage area (toolbox, truck, storeroom).

Keep all work surfaces dry and clean to prevent slips and falls.

Keep walkways, aisles, roadways and other travel routes clear.

Protect floor openings by providing adequate barriers and covers.

3.23.2 Material Handling

Some Basic Principles Apply To All Material Moving Situations:

a. Use mechanical means of moving materials when possible.

b. Maintain all mechanical devices must be regularly.

c. Store or stack equipment and materials so as not to create falling or tripping hazards.

d. Permit only trained employees to perform material handling operations.

e. Designate, permanently mark, and keep aisle-ways and driveways clear to allow unhindered passage.

f. Permit only specially trained and qualified employees to handle asbestos, PCB, and certain other substances. Refer to the appropriate sections in this manual for safety guidelines.

Hand Trucks

Dollies, wheelbarrows and two-wheeled hand trucks are best suited for moving heavy or bulky materials over short distances.

a Load materials so that the weight is evenly balanced and the operators' view is not obstructed.

b Ensure cylinder cart is equipped with straps to secure the cylinder.

c Push handtrucks (rather than pull) whenever possible.

Safety is not a job; it’s a way of life

Gas Compressor Station no. 1Powered Hand Trucks

a Permit only properly trained employees to use powered hand trucks.

b Check to see if the load capacity of the truck is clearly marked. Do not exceed this capacity.

c Ensure the load is properly balanced before hand trucks are loaded, and know the weight, height, and stability of the load in advance.

3.24 Welding and Flame Cutting

Welding is a method of joining two metal surfaces by fusing the surfaces. At GCSseveral types of welding are performed such as oxygen/acetylene, arc, heli-arc, tig and wire feed welding. Flame cutting is typically performed using an oxygen/acetylene apparatus.

Hazards1. Damage to eyes and skin from glare and radiation.

2. Burns from contact with hot metal or sparks.

3. Health effects from breathing fumes and gases.

4. Electric shock.

5. Fire.

Safe Work Procedures

1 Follow Welding and Cutting Procedures, and complete a Welding/Cutting Permit. Permits may be obtained from the supervisor or the IM.

2 Only qualified employees authorized by their supervisors are permitted to perform welding or burning.

3 Inspect equipment before use. Be sure it is in good condition.

4 Ensure fire detection systems have been shut down.

5 Plan for emergency fire procedures when you weld in any areas where combustibles or flammables are present. Remove combustibles or carefully protect them from sparks.

6 Keep fire extinguishers as standby.

7 Weld on enclosed hollow containers, tanks, and piping systems only if they have a vent or opening to release pressure.

8 Thoroughly clean and purge containers that have held toxic or flammable materials before welding. Test the environment with the available gas tester if you are unsure.

9 Shut down equipment when not in use; bleed hose lines and turn off valves.

10 Remove and properly store regulators before transporting gas cylinders.

Personal Protection1 Wear welding masks, goggles, or other suitable eye protection to provide

protection from harmful rays and flying objects.

2 Cover all exposed skin, including face, wrists, and hands and use flameproof gauntlet, gloves and aprons. Protective clothing will protect against burns from metal sparks.

3 Woolen clothing provides better protection than cotton because it is less flammable.

Better be safe than to be sorry

Gas Compressor Station no. 14 Use flame resistant leather chaps, high topped work boots and metal screens in

front of legs when necessary. Depending on the type of welding you are performing and the environment in which you are working, additional types of protective clothing and equipment may be needed.

5 Isolate welding areas with shields or screens to protect nearby employees. Nearby employees may also need eye protection.

Ventilation1 Use a ventilating hood to control fumes at the welding bench.

2 Test the workspace for air quality and explosive gases when welding in confined spaces. Employees may have mechanical ventilation or need to wear respirators to ensure safety. See the Campus Confined Space Procedure in Section II for more guidelines.

process description gcs-1

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