Gas Compressor Station no.

Gas Compressor Station no. 1

3.1

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.

Act safe, Feel Safe

Gas Compressor Station no. 1

Your safety means the Safety of your family

Gas Compressor Station no. 1

3.2 MAKE & CAPACITY OF GAS COMPRESSORS

LOW PRESSURE BOOSTER COMPRESSOR ( 2KG/CM2

COMMONLY KNOWN AS LPB:

LPB 4

Make

: Compressor Ingersoll Rand (C)

Prime Mover

: 750 HP Electric Motor, NGEF

Capacity

14/19 KG/CM2),

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

Capacity

5400 Standard Cubic Mtrs /hr.

GAS LIFT COMPRESSOR ( 14/19

AS GL:

GL 3

TO

KG/CM TO

Make

: Compressor BPCL

Prime Mover

: Waukesha L3711G

Capacity

85/90 KG/CM2), COMMONLY KNOWN

3167 Standard Cubic Mtrs /hr.

GL 5
Make

: Compressor BPCL

Prime Mover

: 450 HP Electric Motor, BHEL

Capacity

3167 Standard Cubic Mtrs /hr.

Gas Compressor Station no. 1

GL 6
Make

: Compressor BPCL

Prime Mover

: Caterpillar G 3516 NA

Capacity

3200 Standard Cubic Mtrs /hr.

GI 4
Make

: Compressor Atlas Copco

Prime Mover

: Waukesha L5790

Capacity

2197 Standard Cubic Mtrs /hr.

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

Prime Mover

: Electric Motor

Capacity

: 1.5 Standard Cubic Mtrs /min

Air Compressor 3
Make

: Compressor KIRLOSKAR PNEUMATIC Co. Ltd

Prime Mover

: Electric Motor

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.
3.
4.
5.
6.

Methanol for prevention of hydrate formation in gas lift lines in place of GDU
Triethylene Glycol Purity - 99.99%, 99% - for Glycol Dehydration Plant
Hydraulic Oil Servo 68
High Speed Diesel for Genset and Air Compressor
Teepol - for cleaning purpose

Gas Compressor Station no. 1

3.4 GLYCOL DEHYDRATION PLANT:
ABAX(Imported Canada)
Gas Flow Rate
Inlet Water Content
condition
Flow temp
Gas Specific Gravity
Flowing Pressure
TEG Circulation Rate
Outlet Water Content
Dew point
Dew point depression
Specific Gravity

10 & 15 MMSCFD
- 260 lbs/MMSCFD at 250 PSIG and 110oF flowing
-

110 oF design (122 maxM.)

0.63-0.7
250 psig design, 200 min; 275 max
4.0 / 5.0 USGPM
6 lbs/MMSCFD
-5OF to 5oF dew point at 250 psi
105oF
0.717

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

Gas Compressor Station no. 1

Sand Bins

Make Safety a Habit to remember, from January to December

PORTABLE GEARS

Equipment
Dry Chemical Powder extinguishers

Type
BC

Dry Chemical Powder extinguishers

BC

CO2 extinguishers

Capacity
10 kgs.
75 kgs.
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.

Dont be safety blinded, be safety minded

Gas Compressor Station no. 1

3.8 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. 1

3.10 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)

30 PSIG LOW PRESSURE GAS ISOLATION VLAVE (V2)

1500 PSIG GAS LIFTER MAIN DELIVERY VLAVE (V3)

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:

250 PSIG DISTRIBUTION ISOLATION VALVE (V 1)

30 PSIG LOW PRESSURE GAS ISOLATION VLAVE (V2)

1500 PSIG GAS LIFTER MAIN DELIVERY VLAVE (V3)

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. 1

3.12 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:-

MAIN FUEL ISOLATION VALVE (V5)

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

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

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:-

30 PSIG ISOLATION VALVE (V2)

250 PSIG ISOLATION VALVE (V1)

MAIN FUEL ISOLATION VALVE (V5)

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.

Gas Compressor Station no. 1

Safety isnt expensive, it is priceless
3.14 WHAT TO DO IN CASE OF SUDDEN RISE OF PRESSURE IN GAS
LINES:
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.

INFORM SCADA CONTROL ROOM, OCS 1 AND INSTALLATION MANAGER.

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.

INFORM SCADA CONTROL ROOM, OCS 1 AND INSTALLATION MANAGER.

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.

Gas Compressor Station no. 1

YOU WILL BE ADVISED WHETHER TO START ADDITIONAL BOOSTERS OR

SHUTDOWN THE RUNNING LOW PRESSURE BOOSTER(S).

Working safely each day will keep the Doctor away

3.16 BRIEF STARTING PROCEDURE OF GAS COMPRESSORS.
For 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

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,

IMMEDIATELY BY PUSHING THE STOP BUTTON.

OPERATING RANGE.

STOP

THE

ENGINE

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,

Safety is Everybodys Business

Gas Compressor Station no. 1

RUN THE MAIN MOTOR.

OPEN THE SUCTION VALVE AND THE DISCHARGE VALVE.

CLOSE SLOWLY THE BYPASS VALVE.

CHECK SUCTION PRESSURE; DISCHARGE PRESSURE AND

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. 1

Gas Compressor Station no. 1

Gas Compressor Station no. 1

3.17 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.

Safe actions bring lasting satisfaction

Gas Compressor Station no. 1

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.

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.

Open the Door to Safety; Awareness is the Key

The door to safety swings on the hinges of Common Sense

Gas Compressor Station no. 1

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.

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 tonnes
Span
: 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.

Gas Compressor Station no. 1

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 its care.

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.

Gas Compressor Station no. 1

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.

Safety You
will regret
if you
forget if it s capable of
A sling shall be visually inspected
before
use to
determine
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

3.22.2 MAINTENANCE OF CRANE

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

crane manufacturers standard practices. However, maintenance practices shall
be followed based upon utilization of the crane.

Periodic/ Preventive maintenance schedule shall be followed as per standard

manufacturers practices/ operators 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 General 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.

Gas Compressor Station no. 1

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 elses 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.

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.

Safety is a full time job; dont make it a part time practice

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.

Gas Compressor Station no. 1

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,
Safety is not a job; its a way of life
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.

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

Push handtrucks (rather than pull) whenever possible.

Powered Hand Trucks

a

Permit only properly trained employees to use powered hand trucks.

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

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 GCS
several 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.

Hazards
1. 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.

Only qualified employees authorized by their supervisors are permitted to

perform welding or burning.

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

Ensure fire detection systems have been shut down.

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.

Gas Compressor Station no. 1

6

Keep fire extinguishers as standby.

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

Thoroughly clean and purge containers

that
have
Better be safe
than
to beheld
sorrytoxic or flammable
materials before welding. Test the environment with the available gas tester if
you are unsure.

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 Protection
1

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

protection from harmful rays and flying objects.

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.

Woolen clothing provides better protection than cotton because it is less

flammable.

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.

Isolate welding areas with shields or screens to protect nearby employees.

Nearby employees may also need eye protection.

Ventilation
1 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.