INTRODUCTION
Solving the problem of life safety is to ensure normal (comfort) operating
conditions of people, their lives, to protect the human and the environment against
harmful interference in excess of the regulatory allowable levels. Maintaining
optimal conditions of human activity and rest creates prerequisites for higher
working capacity and productivity. Provision of labor safety and recreation
contributes to the preservation of life and health of people by reducing the injuries
and illnesses.
If we consider the number of accidents, industrial injuries of the Republic of
Kazakhstan, while the majority percent takes just enterprises that serving to all
industries with technical means, equipments, etc.
Linkages with this question on safety and labor protection is very actually.
Therefore, in the diploma project we are considering actual problems of labor
protection in LLP “Techno Trading LTD”. LLP "Techno Trading LTD"
established on the basis Mangyshlak Promgeophysic in 1999 in Almaty, the main
production of company located in the Mangistau region. The enterprise is appear
service enterprise in the petroleum industry. The main activity of company
geophysical, shooting-blasting operations in oil and gas wells and production
repair of oilfield equipment. In LLP “Techno Trading LTD” used equipment such
as the installation of pre-clean the inside of pump and compressor pipes,
installation of wastewater treatment and water recycling, machinecouplingscrewdriver, hydraulic test rig, lathe, electrical overhead traveling cranes,
etc. Found numerous dangerous and harmful physical factors: moving machinery;
various lifting and transport devices and move loads; unprotected movable
elements of production equipment (drive and transmission mechanisms, cutting
tools, and moving the rotating tool eth.); flying objects, worked material and tools,
electric current, high temperature surfaces of equipment and process materials and
harmful factors of anthropogenic origin (noise, vibration, electromagnetic fields,
ionizing radiation and others.), associated with production.
The considered enterprise does not have a separate department of labor
protection. Introduction to the production plan office of labor potection certainly,
will play a positive role in the preservation of life and health of employees in the
workplace, including legal, socio-economic, sanitary and other measures.
The purpose of this diploma project is to research the safety and labor
protection in the LLP “Techno Trading LTD”, the development of measures to
improve safety and working conditions in the enterprise.
1.1
Main responsibilities and functions of “Techno Trading LTD”
LLP "Techno Trading LTD" formed on the basis Mangyshlakskaya
Industrial Geophysics in 1999 in Almaty, the main production company located in
the Mangistau region. The enterprise is appear a service enterprise in the oil and
gas industry. The main activity of geophysical, shooting-blasting operations in oil
and gas production wells and repair of oilfield equipment. During the period of
formation and development, the company's management did not go on the way up
similar operations in the region, and on the way of development of new
technologies, the use of modern high-tech equipment often has no analogue in the
region and in the Republic of Kazakhstan.
The main customers are: JSC "Mangistaumunaigas" LLP "OSC", LLP
"OCC", LLC "OTK" and other oil and gas sector Mangistau. Today LLP "Techno
Trading LTD" - is a diversified, stable working and competitive company that has
in its arsenal: the management of Geophysics; shop for repair of oilfield
equipment; repair shop tubing and rods; shop for repair of electrical equipment;
land drilling and blasting. The result of 12 years of development are integrated
manufacturing base with unique equipment, modern organization and production
planning, professionalism and high intellectual potential of the team. Number of
employees in this time - 280 person.
1.2 General information of facility
Fasility Zhetybai located in the western part of the peninsula
Mangishlak and administrative subordination is included in part Karakiya
district of Mangistau region of the Republic of Kazakhstan. The nearest
fasility settlement are Zhetybai village (1km), Kuryk district centre (60 km), the
city of New Uzen (70 km), 80 km the city from Aktau.
In regard to spelling district is vast plateau, plateau immersed in the southwest direction. Marks relief vary from 145 to 170 meters. The climate is
continental. Precipitation falls to 140mm. The absolute maximum temperature plus
47℃, absolutely minimum minus 35℃. The average annual air temperature is
10℃, the area characterized by strong winds and dust storms. Winds prevail northeast direction. The depth of the frost line reaches 1 meter.
1.1.2 Management on repair of pump and compressor pipes (MRPCP)
Management on repair of pumping and compressor (MRPCP) founded in
2006 and put into operation in 2007. Equipped with automated complex of modern
equipment, allowing the full cycle of repair of pump and compressor pipes and
rods deep pumps (PR).
Management is located directly on the Zhetybai Mangistau region. It
consists of 5 buildings and a separate pre-wash area, has an autonomous heat
supply,
gas,
electricity.
The management RPCP includes:
 Area receiving, sorting and culling pumping and compressor pipes (after
a hot wash)-shed #5 and #6;
 Area cleaning the pumping and compressor pipes from the salt deposits
shop #2;
 Area sorted handling pumping and compressor pipes and flow to the area
of cleaning and repair shed #4;
 Area cleaning and repair of the pumping and compressor pipes- shop #1;
 Area sorting and packaging of finished products-shed #3;
 Area cleaning and repair of sucker rods (SR)-shop #1.
Supplied to repair equipment (pumping and compressor pipes, rods) after
pre-sorting come to the site pre-treatment, where the preliminary (visual) rejection
of the pipes and rods. Conventionally acceptable pipes and rods are fed to a hot
wash. After washing by transport systems come to the site grading, where, after a
separation of control pumping and compressor pipes into 2 streams:
1 Salt deposits pipe coming to the site clean from solid deposits, where the
removal of deposits from the internal surfaces of the pumping and compressor
pipes - shop #2.
2 Pumping and compressor pipes without salt deposits on the transport
system of the vehicle are supplied to the primary site of repair, where they undergo
a full cycle of repair. Pipes after cleaning hard deposits, also on the vehicle comes
to the site repair shop #1.
Pumping rods after prewash TS served on the site of repair, where the full
cycle of repair - shop #1. After the repair of pumping and compressor pipes and
rods arrive at the warehouse of finished products. Performance (input) is (planned):
 PCP ∅ 73×5.5-up to 1000 pipes/night
 Rods – up to 800 units/day
1.1.3 Section on repair pumping and compressor pipes (PCP) - shop #1
Performance, pipes / day - up to 1000; nominal diameter tubing in
accordaning with GOST 633-80, mm – 73, 89; length of PCP, m. – 5.5 ÷ 10.5.
Table 1- Name of the basic operations, characteristics of the equipment
Nomination
Characteristics of the
process
Washing and cleaning of the Working fluid - water,
inner and outer surfaces of the Operating pressure of
pumping and compressor pipes water - up to 23.0; 40.0
Name of equipment
Automated line
washing, water
recycling system and
from oil and paraffin.
MPa
water treatment.
Table 1 continues
Nomination
Gauging
Flaw detection, automatic
application of technological
marking.
Loosening joints
Characteristics of the
process
Control template
according with GOST63380
Control parameters: the
continuity of the pipe
material, thickness
measurement;
boundaries of defective
sections of pipe.
Till 6000
Automatic segment of
defective sections of pipe
Machining
Bimetal segment saw
2,465 x 27 x 0.9 (mm)
Threading according to
GOST 633-80
Screwing the new couplings
With electronic torque
control
Pressure 30,0MPa
Hydrotest
Hot-air drying
The temperature of
70˚...80˚ C
Measure the length of the pipe Measured pipe length, the
total length of the
package, the number of
pipes
Marking
Application of the mark
indentation, up to 20
characters at the end of the
coupling
Setting transport plugs on the
thread
Formation of a predetermined
number of packets pipe length
or sorted by groups of strength
Keeping records of
Identification number
manufacture and certification pipes, maintenance of
of PCP
computer certificates.
Name of equipment
Installing templating
with automatic length
defective areas.
Automated inspection
line, equipped with the
instrument system
"Uran-2000M". Auto
Markers with industrial
inkjet printer.
Machine couplings
screwdriver
Machine belt cutting.
Pipe Threading Lathe
specialized type RT 772.
Mufti-screwdriver
machine
Installing the hydraulic
test
drying chamber
Setting the
measurement of length
Setting the branding
program-controlled
Booth
Stillage system with
stored
ACS system PCP and
certification
1.1.4 The purification section of the solid salt deposits pumping and
compressor pipes (PCP)- shop #2
Productivity, pipes / day – till 200; Nominal diameter of the pipes in
accordance with GOST 633-80, mm - 73; 89; The length of tubing, m – 5.5 ÷ 10.5
Table 2 - Name of the basic operations characteristic of the equipment
Nomination
Washing with hot water to
remove the paraffin oil (if
necessary)
Table 2 continues
Nomination
Pre-clean the inner surface of
the pipe from the salt deposits
shock-rotational method.
Finishing washing pipes
Characteristics of
the process
-0.5 MPa pressure,
temperature - 95˚C
Characteristics of
the process
Working tool, drill
bit, the drummer
Name of equipment
Installing a hot wash
Name of equipment
-
Final cleaning of the Installing the washing
inner surface of the and finishing pipe
pipes by means of
cleaning.
nozzles. Waterpressure up to 80
MPa
1.1.5 Section on repair of rod pumping shop #1
Complex equipment designed to perform the following operations: cleaning
rod, received after the operation, unscrewing couplings, thread control, editing,
destructive testing (non-destructive testing), on the basis of grading of
"fit"-"marriage" screwingclutche sand, bagging.
Technical parameters: Performance, pcs/ day - 800; Rod size(GOST 1387796); Length, mm - 8600-9000; Diameter, mm - 19 ÷ 22. The installed capacity of
the units, kW - 250.
Table 3 - Characteristics of equipment
Nomination
Automated installation of
Operations
Cleaning the outer
Note
Purification by water
washing
surface of the rod from circulating without
the asphaltene
chemical additives under
resinparaffinig
high pressure.
contaminants AFS.
Couplingscrewdriver machine Unscrewing the
couplings with rods.
Installing straightening rod
Edit the end portions
end portions
of the rods
Machine for straightening
Edit the body bars and
body bars.
ensure straightness its
axis according to the
requirements of
GOST.
Automated system for
Detection of surface
inspection bodies and fillets
and structural defects
rod "Uranium 2000SHM"
unacceptable rod body
and surface defects
fillets according to the
requirements of
GOST.
Table 3 continues
Nomination
Couplings machine
Operations
Wrap joints on the bar.
Note
-
Automated control system for
the repair of sucker rods
Designed for software
linking of process
equipment, the
issuance of the
necessary information
for accounting issue
renovated and the
number of defective
rods, the formation of
reporting
documentation.
-
2
Basic legislative rules and regulations
In connection with the above present for all sections of RPCP, sucker rod
pumps are the most dangerous work, including work with the technical equipment.
Therefore, the organization must comply with all legal and regulatory issues, and
must provide their workers regulations (comfort) working conditions.
Thereby, first of all should work on the basis of the Constitution of the
Republic of Kazakhstan, as well as the Labor Code of the Republic of Kazakhstan
(May 15, 2007).
Except the above-indicated laws, the company must comply with all
requirements of the Law of Technical Regulation (November 9, 2004, with
additions 2012).
The main purpose of the Law "Technical Regulation" is:
In the field of compulsory regimentation: ensuring the safety of products,
processes for human life and health and the environment, including flora and
fauna; ensuring national safety; prevention of actions misleading consumers
regarding the safety and quality of products and services; elimination of technical
barriers to trade.
On the basis of this law in the Republic of Kazakhstan has the technical
regulations for each production site.
The organization shall comply the following requirements of technical
regulations:
1 Technical Regulations "Requirements for signal colors, markings and
safety signs at work sites" Resolution of the Government of the Republic of
Kazakhstan dated August 29, 2008 # 803.
Application field of technical regulation:
Signal colors, markings and safety signs should be used on objects to attract
people's attention to the danger, dangerous situation, warning the danger of a
possible outcome in the case of neglect, regulations or requirements of certain
actions, and to communicate relevant information. The choice of the type, size,
order of application, number, place of installation and location of signal markings
and safety signs must meet the requirements of this Technical Regulation, as well
as governmental, intergovernmental, international standards approved for use in
the territory of the Republic of Kazakhstan, construction and sanitaryepidemiological rules and norms, labor protection regulations and, fire safety, duly
approved.
2 Technical Regulations "General requirements for fire safety" Resolution
of the Government of the Republic of Kazakhstan dated January 16, 2009 # 14.
This Technical Regulation "General requirements for fire safety" adopted in
order to:
1) Implementation of the laws of the Republic of Kazakhstan: November
22, 1996 "About Fire safety", dated July 16, 2001 "About Architectural, urban
planning and construction activities in the Republic of Kazakhstan", dated
November 9, 2004 "Technical Regulation";
2) Protect the life and health of citizens, property of individuals and legal
entities, as well as state property from fires.
3 Technical Regulations "Requirements for Safety of low-voltage
equipment" Resolution of the Government of the Republic of Kazakhstan dated
January 23, 2009 # 42.
This Technical Regulations "Requirements for Safety of low-voltage
equipment" extends to produce for circulation in and commissioned low-voltage
equipment: new, not previously been in operation, regardless of the country of
origin; in service after modernization; were in operation imported into the Republic
of Kazakhstan.
In this technical regulation under the low-voltage electrical equipment
means an electrical equipment corresponding to the definition of Section 2 of this
Regulation and intended for use at nominal voltage up to 1000 V alternating
current and inclusive to 1500 V inclusive direct current.
4 Technical Regulations "Requirements for Safety equipment,
operating under pressure "Resolution of the Government of the Republic of
Kazakhstan of 21 December 2009 # 2157.
This technical regulation "Safety requirements for equipment operating
under pressure" establishes requirements for equipment operating under pressure,
and the processes of its life cycle.
5 Technical Regulations "Requirements for Safety ventilation systems"
Resolution of the Government of the Republic of Kazakhstan dated March 2, 2009
#234.
This Technical Regulation "Safety requirements for ventilation systems"
dilate ventilation systems and their components used in the manufacturing
facilities.
6 Technical Regulations "Requirements for Safety of hot water and steam
boilers" Resolution of the Government of the Republic of Kazakhstan dated 15
December 2009 # 2126.
This technical regulation " requirements for safety hot water and steam
boilers" (hereinafter - Technical Regulations) establishes requirements for the
safety of hot water and steam boilers operating at a pressure of more than 0.07
MPa, and hot water heating temperature above 115 ℃, as well as to the processes
their life cycle.
3 Special chapter
3.1 Actual problems of labor protection in the management of repair
pumping and compressor pipes (MRPCP)
3.1.1 Labor protection measures
Measures to the organization in order to ensure effective working conditions.
For safe operation, shall be responsible the operators of facilities. Chief mechanic
responsible for the proper and safe operation of electrical and inspection
instruments. Chief mechanic instruct, shall be responsible for compliance with
safety regulations and sanitary hygiene, proper use of special clothing and safety
products workers. And the head is involved in the investigation and elimination of
accidents, industrial poisoning.
All employees of pre-employment are attestation commission. The
composition of the attestation commission includes chief engineer, safety engineer,
chief mechanic, chief electrician, department of frames.
According to the character and time of holding instructing on labor safety
are divided into: introductory, primary, repeated, unscheduled and targeted.
Introductory instruction performs work safety specialist, or the person to
whom the order of the company (board decision) assigned these responsibilities to
the program developed by occupational health services, taking into account
peculiarities of production. In order to improve the qualification annually workers
are pass online learning.
According to the Labor Code of the Republic of Kazakhstan, Article 312,
the employer at its own expense shall arrange for periodic medical examinations
and surveys of employees engaged in heavy work or work under harmful
(particularly harmful) and (or) dangerous working conditions, in accordance with
the legislation of the Republic of Kazakhstan .
Workers employed in jobs associated with increased risk, machines and
mechanisms, must undergo a medical examination before their shifts. List of
occupations requiring pre-shift medical examination determined by the authorized
state body in the field of public health.
3.1.2 Industrial accident
By accident affects the following hazardous and harmful physical factors:
moving machines and mechanisms; various lifting and transport devices and
moving cargo; unprotected movable elements of production equipment (gearing
and transmission mechanisms, cutting tools, and moving the rotating tool eth.);
particles flying off the processed material and a tool, an electric current, increased
surface temperature of the equipment and processing materials, etc.