Basic Compressor Safety and Operation

Air and Gas MixturesAir+Gas+Pressure+Heat=Explosion

Relief ValvesThese valves are to relieve pressure should the system exceed the rated maximum working pressure.

The Units Safety Kill SystemSafety Kill Systems are put in place to prevent the unit from operating outside the safe operating parameters. They are set to protect you and the equipment.

Safety Tips While Working On Compressors

Working on the Unit

Working on the Unit (cont)

Working on the Unit (cont)

Starting the Unit

Running the Unit (cont)

Always Ask Yourself

Summary

Summary (cont.)Protection from these and other hazards are achieved by following proper procedures and eliminating risk-taking.Write and use JSAs.Follow LOTO procedures.Follow good housekeeping practices.Follow start up, purging, loading, and shut down proceduresBe familiar with the location, valves, and job task.

If you are unsure about anything!!! You have the authority and obligation to Stop the Job. Until you are completely sure it is safe to proceed.

What does a gas compressor do?Moves gas!Low pressure gas enters the compressor through the suction line.High pressure gas is discharged from the compressor to the discharge line.Discharge flow rates will vary depending on suction volumes, pressure and discharge pressure parameters.

Compressor SafetyMake sure you understand all the safety features of the compressor.Know proper starting and loading procedures before attempting to do so.If in doubt STOP THE JOB

The right mixture of air; natural gas; at the right temperature and pressure can explode! Never mix air with natural gas in any piping systems or pressure vessels.To eliminate the possibility of accidental combustible air-gas mixtures, never Tee air and gas sources together into the starter piping of an engine. Do not operate an air compressor if natural gas vapors are present. These vapors will be picked-up by the air compressor and could form a combustible airgas mixture in the volume tank.

Our compressors are equipped with pressure relief valves to protect employees and equipment.They can be found in the gas compressors process piping and vessels, fuel gas system, and engine starter piping system.Never remove or tamper with any relief valve.Make sure all relief valve vents are braced.

Never disable any safety device.Never operate the unit with the main ignition ground (kill wire) disconnected from the magneto or control panel. The safety kill system utilizes power generated from the magneto to perform the safety shutdown functions of the unit. Disconnecting the main ignition ground de-activates the safety kill system and exposes you and the compressor to serious hazards.

Always wear the proper PPE for the task and your environment.Always keep your eyes and mind on your task, keep your body parts out of the line-of-fire, and watch your balance, traction and grip.Always be on the look-out for natures best: insects, spiders, snakes, etc.Always use your gas detector to sniff the area for atmospheric hazards prior to approaching the unit.Always follow the proper sequence when shutting down a unit.

Never remove safety guards when the unit is operating, they are in place to protect you from becoming caught in rotating equipment (line-of-fire). If guards are removed, they must be replaced before starting the unit.Always blow-down the compressor cylinders and gas process piping before attempting to work on the compressor.Always verify that the vent line or the blow-down lines are braced / secured.Keep the compressor unit and the location clean. Many incidents are the result of clutter (balance and traction)Always adhere to our companys LOTO program. Do not rely on others to LOTO the equipment.At a minimum, the compressors suction line, discharge line, starter system piping, fuel piping and dumps must be LOTO closed and the vent line (blowdown) LOCKED OPEN.Never modify the compressor package without authorization. Improper modifications can destroy piping and vessel code ratings and pose potential hazards.

If you are attempting to bar the unit, you must disconnect the spark plug wires and make sure the manual fuel valve and starting valves are fully closed.Before starting the unit, visually inspect for loose components, tools, position of valves (opened or closed), missing equipment, guards, etc.Do not re-set or back the kill switches when starting the compressor, use the test timer.

Always monitor the panels gauges for any abnormalities during start-up and running.Do not adjust clearance or kill set points without Universal Compressions approval.Do not exceed rated maximum working pressure of any compressor package components.

Am I wearing the necessary PPE.Am I protected from hazards (nature-wasp, snakes, etc., slips and trips, moving equipment, or atmospheric-H2S, etc.).JSA-Job task steps; Hazards; EliminationWhy did the unit shut down? What really happened?Do I have the proper training, equipment, or man-power to correct the problem?Are all valves in the proper position?

Hazards exist in compressor operations and maintenance.Flammable gasesGases under pressureMoving and rotating equipmentChemicals-solvents, oils, coolants, etc.Sharp objectsTrip hazardsHeavy lifting H2S NatureOthers depending on site conditions