Bengbu Aipu Compressor Manufacturing Co.,Ltd
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Risk Control and Mitigation Measures of Natural Gas Compressor

Risk Control and Mitigation Measures of Natural Gas Compressor

1. The design and installation meeting the requirements

(a) Natural gas compressors should be arranged in the open air or in shed;

(b) Ventilation measures should be taken on the top of the natural gas compressor shed or enclosed workshop;

(c) The floor slab of the natural gas compressor workshop should be partially made of grates;

(d) A combustible gas alarm device should be installed in the compressor workshop;

(e) The compressor equipment foundation and base should be solid and complete;

(f) The anchor bolts and the connecting bolts of each part should be fully buckled, neat and fastened;

(g) The grounding resistance of the equipment should be less than 10 Ω.


2. Complete accessories and auxiliary systems

(a) The transmission facilities between the compressor and the power machine should use V-belts or protective couplings;

(b) Cooling and gas-liquid separation equipment should be installed between each stage of the multistage compressor;

(c) Secondary instrument transmitters such as pressure, flow, temperature and liquid level should be calibrated once a year;

(d) All levels of separator liquid level control, high and low liquid level alarms and emptying facilities should be in good condition;

(e) Relevant safety valves and pressure gaugesshould be complete, reliable and regularly checked.


3. Reliable measures to prevent and eliminate sparks

(a) When driven by an internal combustion engine, the exhaust pipe of the internal combustion engine should have a thermal insulation layer and a fire cover should be installed at the exit;

(b) When a gas engine or gas turbine is used for driving, the exhaust pipe outlet of the prime mover should be led to an outdoor safe area;

(c) Explosion-proof electrical appliances should be used for electrical facilities in the compressor explosion hazardous area;

(d) The installation of junction boxes, conduits and instrumentation equipment should meet the explosion-proof requirements.


4. Complete measures to prevent leakage and evacuation

(a) There should be measures to prevent negative pressure for the compressor intake pipe;

(b) Shaft seal packing should be regular replaced to ensure no leakage;

(c) The start and stop safety interlock system (the pressure and temperature of natural gas of the compressor's inlet and outlet, the pressure and temperature of the lubricating oil, the pressure and temperature of the coolant, compressor vibration, separator liquid level, etc.) should be sensitive and reliable;

(d) Before the newly installed or overhauled compressor is put into operation, the unit, pipeline, container, and installation system shall be replaced with nitrogen gas, and the test should be qualified.


5. Thoughtful safety protection measures

(a) The compressor natural gas pipeline should be laid on the ground, with inspection points for regular thickness inspection;

(b) Compressor couplings, air coolers and other operating parts should be equipped with protective covers;

(c) The lubricating oil system, oil sealing system, cooling system, gas seal, balance pipe, etc. should be smooth and easy to use without leakage. The selection of lubricating oil and coolant should meet the requirements;

(d) Compressor operating parameters (temperature, pressure, speed, etc.) and the temperature of each bearing and cross-head should be normal;

(e) The compressor should run smoothly without noise, and the amplitude of the body and pipe system should be within the allowable range;

(f) The compressor shed should adopt noise reduction treatment, and staff on the post should wear soundproof earmuffs when entering and leaving the compressor room.


6. Maintenance meeting the regulations

(a) The equipment manual, parts catalog, equipment structure diagram and vulnerable parts diagram should be complete;

(b) Equipment files such as regular lubricant analysis records, regular condition monitoring records, and maintenance records should be complete;

(c) The daily maintenance of the compressor should be implemented in accordance with the equipment manual provided by the manufacturer.


7. Various sound management systems and thoughtful measures

(a) The natural gas compressor body and various accompanying equipment materials should be complete, and various maintenance and overhaul records should be filled carefully and standardizedly;

(b) Post personnel should be trained and have a certificate (pressure vessel operation certificate) and can work in accordance with the job standards program to start (stop) the compressor, competent for on-site monitoring of natural gas compressor repair and maintenance;

(c) The compressor should establish regular leak detection, tightening of anchor bolts, lightning protection grounding detection, combustible gas alarm calibration, compressor with pressure vessel periodic detection, vibration detection, compressor chain alarm shutdown, periodic verification of safety accessories, oil product testing, video surveillance. And maintenance systems and measures should be in place;

(d) The maintenance office should have complete qualifications and procedures. Signed safety contracts and maintenance agreements to ensure that the maintenance contracts should be performed thoroughly;

(e) Formulate a specific maintenance personnel management system, and all the post personnel should pass the safety training and business skills examination;

(f) When the new compressor is put into operation, nitrogen replacement should be carried out. After the oxygen concentration is detected to be lower than 2%, the air intake can be adjusted;

(g) According to the needs of employees at different levels, formulate annual compressor training plans should be carried out as planned;

(h) Establish a management system for outsiders and maintenance personnel, and all personnel entering the booster station should have complete labor insurance and wear soundproof earmuffs;

(i) Emergency fire-fighting equipment should be in place and checked regularly. Fire-fighting passages of the treatment plant should be unblocked, emergency doors should be intact, emergency warehouse materials should be adequately stocked, and the fire brigade of the nearest treatment plant should be on standby at any time;

(j) Ventilation facilities such as axial fans and windows should be intact, video surveillance cameras can cover every compressor in the booster station, and the DCS operating platform in the central control room can realize remote shutdown of the compressor;

(k) Carry out the risk identification of booster stations, formulate detailed emergency plans for fire and explosion of natural gas compressor room, and conduct regular drills.

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