Safety2 Safety Instruction STD

Nuovo Pignone
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SAFETY INSTRUCTION STD
Electronically approved draw. GE NuovoPignone Internal DT-'N'
COMM. – JOB
0805133
1 Updated Par 1.10.4 on Residual Electrical Risk Tavazzi Baldini B. Copponi M. 22/09/11 N. SOM6607109/4
0 EMESSO - ISSUED Pileggi 18/05/06 LINGUA-LANG. PAGINA-SHEET
REV. DESCRIZIONE - DESCRIPTION PREP'D CONT-CHK'D APP-APPR'D DATA-DATE A 1/2
Il presente documento è di proprietà NUOVO PIGNONE. A termine di legge ogni diritto è riservato. SOSTITUISCE IL – REPLACES
This document is the property of NUOVO PIGNONE. All rights are reserved according to law. SOSTITUITO DA - REPLACED BY
This document list Safety information under Product Safety ownership. Whatever revision must be approved by the owner.
Nuovo Pignone
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Index
1. Gas Turbine (TU/GA) Safety Instructions……..pag.3
2. Turbocompressor (TU/GA + CO/CE) Safety Instructions…….pag.102
3. Turbogenerator (TU/GA + EL. Generator) Safety Instructions…….pag.210
4. Centrifugal Compressor (CO/CE) Safety Instructions…….pag.309
5. Motocompressor (Electric Motor + CO/CE) Safety Instructions……pag.415
6. Steam Turbine (TU/VA) Safety Instructions……..pag.520
7. Turbocompressor (TU/VA + CO/CE) Safety Instructions…….pag.618
8. Turbogenerator (TU/VA + EL. Generator) Safety Instructions…….pag.726
9. Turbogenerator (TU/VA + EL.Generator) Safety Instructions…….pag.824
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LINGUA-LANG. PAGINA-SHEET
REV DESCRIZIONE - DESCRIPTION A 2/3

Il presente documento è di proprietà NUOVO PIGNONE. A termine di legge ogni diritto è riservato. SOSTITUISCE IL - REPLACES
This document list Safety information under Product Safety ownership. Whatever revision must be approved by the owner.
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INDEX
1. SAFETY INSTRUCTIONS .................................................................................. 103

1.1 INTRODUCTION ........................................................................................ 103
1.2 SYMBOLS USED IN THE MANUAL........................................................... 105
1.3 DEFINITIONS............................................................................................. 106
1.4 INTENDED USE OF A MACHINE .............................................................. 109
1.5 IDENTIFICATION OF HAZARDOUS ZONES ............................................ 112
1.6 ACOUSTIC ENCLOSURE ACCESS PRACTICE INFORMATION ............. 114
1.7 PUTTING THE MACHINE IS SAFE CONDITIONS PRIOR TO
MAINTENANCE.................................................................................................. 119
1.8 LOCK-OUT AND TAG-OUT PRACTICE INFORMATION .......................... 121
1.9 SAFEGUARDING (SAFETY DEVICES AND GUARDS) AND STOP
DEVICES ............................................................................................................ 125
1.10 RESIDUAL RISKS...................................................................................... 128
1.10.1 Generic residual risk ..................................................................... 128
1.10.2 Residual mechanical risk .............................................................. 133
1.10.3 Risks during hoisting and handling operations.............................. 135
1.10.4 Residual electrical risks................................................................. 137
1.10.5 Residual thermal risks................................................................... 140
1.10.6 Residual risks generated by noise ................................................ 141
1.10.7 Residual risks from materials and substances .............................. 142
1.10.8 Description of symbols used for signaling residual risk, prohibition
and obligation. ............................................................................................ 144
1.11 INFORMATION ON HAZARDS IN CASE OF FAILURE............................. 147
1.12 GENERAL INFORMATION OF WARNING ................................................ 148
1.13 EUROPEAN ATEX DIRECTIVE INFORMATION ....................................... 152
APPENDIX .................................................................................................................. 158
A.1 PERSONAL PROTECTION EQUIPMENT (PPE)....................................... 158
B.1 CLASSIFICATION, SYMBOLOGY AND LABELING OF THE PRODUCTS
ACCORDING TO THEIR FEATURES ................................................................ 178
C.1 INSTRUCTIONS ON PROCESS GAS CONTAINING H2S (PROCESS GAS
10PPM) (HYDROGEN SULFIDE OR SULFURETED HYDROGEN)................................... 192
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This document list Safety information under Product Safety ownership. Whatever revision must be approved by the
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1. SAFETY INSTRUCTIONS
These safety instructions are intended for all turbocompressor (TU/GA + CO/CE)
supplied by Nuovo Pignone.
References to CE marking directives including ATEX are applicable to installations
where CE marking is required by law and if it is contractually required by
Customers, also outside the European community.
1.1 INTRODUCTION
It is important that all the instructions, directions, warnings and rules relative
to accident prevention must be fully respected.
This document is intended for operators and skilled personnel and provides
instructions about procedures and operations aimed at ensuring correct and
functional use of the plant concerned.
For the purpose of favoring immediate consultation of this document, it is

recommended that it be made easily accessible, as well as known, to all of
the users involved.
In compliance with the provisions of the directives applicable to the supplied

product, indicated in the Declaration of Conformity issued by Nuovo Pignone,
this documentation contains important information, whose knowledge we
consider to be fundamental both for operators and for maintenance
technicians, in order to be able to work in safety conditions.
Every operation described herein must be performed by the operator
considered most suitable for the tasks to be carried out.
Personnel operating on the plant must have sufficient knowledge of the

functioning of the plant itself and must have read this document carefully, and
must then apply the provisions given in it and follow the instructions received
from the manufacturer. Moreover, the operator and for the authorized to the
maintenance must have acquired sufficient training for the activity he is to
carry out.
For this reason the operator must have received proper training, also through
an initial training period, provided by the GE Oil & Gas Nuovo Pignone
Training Center.
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! DANGER
FOR ALL SITUATIONS NOT DESCRIBED IN THIS DOCUMENT AND IN ANY CASE
WHERE SPECIFICALLY INDICATED, IT WILL BE NECESSARY TO CONTACT THE
NUOVO PIGNONE ASSISTANCE SERVICE. UPDATED LISTS OF CONTACTS CAN
BE FOUND ALSO AT THE SITE WWW.GEPOWER.COM.
Before beginning any activity the operator must also take note of the
particular safety prescriptions issued by the manufacturers of the individual
devices. These prescriptions are found in the Manuals for the auxiliary
equipment and the instrumentation. The safety prescriptions contained in this
document are to be utilized in the operating procedures for running the plant.
The machinery and its auxiliaries have been designed and constructed in
such a way as to reduce to a minimum any risk to the operator. The residual
risks and relevant precautions are reported both in this section (for those of
general nature) and in the various sections pertinent to the relevant activities
and the ensuing possible damage to things or persons.
! DANGER
FAILURE TO OBSERVE SAFETY REGULATIONS AND/OR THE REMOVAL OR

MODIFICATION OF SAFEGUARDS WILL NULLIFY THE MANUFACTURER’S
GUARANTEE AND MAKE THE USER FULLY LIABLE.
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1.2 SYMBOLS USED IN THE MANUAL
General
These warnings have been subdivided into three categories depending on

the type of information given and the problem evidenced, and in particular:
DEFINITIONS
! DANGER
THIS SYMBOL EVIDENCES A PROCEDURE, A PRECAUTION OR A CONDITION

WHICH, IF NOT OBSERVED, CAN CAUSE SEVERE, EVEN FATAL PERSONAL
INJURY TO THE OPERATOR. THE TERM OPERATOR INDICATES A PERSON OR
PERSONS ASSIGNED TO THE INSTALLATION, OPERATION, ADJUSTMENT,
MAINTENANCE, CLEANING, OR REPAIR OF THE MACHINES AND THEIR
AUXILIARY EQUIPMENT.
! WARNING
THIS SYMBOL EVIDENCES A PROCEDURE, PRECAUTION OR CONDITION

WHICH, IF NOT OBSERVED, CAN CAUSE DAMAGE, EVEN SEVERE, TO THE
EQUIPMENT.
 NOTE
THIS SYMBOL EVIDENCES ONE OR MORE DATA NECESSARY TO PERSONNEL

TO CARRY OUT AN OPERATING OR MAINTENANCE PROCEDURE CORRECTLY.
This symbology has been used throughout the manual. The following
subparagraphs present a list of general information concerning DANGER and
WARNINGS which the operator must always keep in mind before running the
plant and before operating on the equipment.
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1.3 DEFINITIONS
The information outlined below provides indications necessary to identify the

different professional roles.
A - OPERATORS
Staff without specific skills, able to perform simple tasks only, namely
machine operation by using the controls placed on the control panel, loading
and unloading of the materials used during production and service
adjustments on the machine with safety devices installed and active
B – MECHANICAL REPAIRMEN
Staff with specific mechanical skills, able to perform the operator’s tasks and
to carry out maintenance and/or repair operations on machines in normal
working condition with safety devices disconnected.
Not qualified for electrical work.
C – ELECTRICAL/ELECTRONIC SERVICEMEN
Staff with specific electric skills, able to perform the operator’s tasks and to
carry out maintenance and/or repair operations on machines in normal
working condition with safety devices disconnected.
Not qualified for work on mechanical parts.
D – MECHANICAL REPAIRMEN
Qualified staff with specific mechanical skills, able to perform the tasks
mentioned at point B and also to carry out competently all possible
adjustments and/or replacements of mechanical parts during installation and
maintenance operation.
Not qualified for electrical work.
E – ELECTRIC/ELECTRONIC REPAIRMEN
Qualified staff with specific electric/electronic skills, able to perform the tasks
mentioned at point C, to run the machine in normal working conditions with
disconnected protections and to carry out competently all possible
adjustments and/or replacements of electric/electronic parts during
installation and maintenance operation. Not qualified for work on mechanical
parts.
F – MANUFACTURER TECHNICIAN
Skilled technician put to customer’s disposal by the manufacturer in order to
perform complex operations in special situations or any tasks as may be
agreed upon with the user.
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EXPOSED PERSON
Anyone who is entirely or partly exposed to danger in any zone.
HAZARDOUS ZONE
Any zone inside of or in proximity to a machine in which a person is exposed
to the risk of injury or damage to health.
 NOTE
THE HAZARD WHICH CAUSES THE RISK CONSIDERED IN THIS DEFINITION:

IS EITHER PRESENT PERMANENTLY DURING THE INTENDED USE OF THE
MACHINE (MOVEMENT OF HAZARDOUS MOBILE ELEMENTS, ELECTRIC ARC
DURING WELDING, ETC.), OR CAN OCCUR UNEXPECTEDLY
(SUDDEN/UNEXPECTED STARTING, ETC.).
HAZARD
Source of possible injury or damage to the health.
 NOTE
THE TERM “HAZARD” IS GENERALLY USED ALONG WITH OTHER WORDS WHICH
DEFINE ITS ORIGIN OR THE NATURE OF THE INJURY OR DAMAGE TO HEALTH
INVOLVED: ELECTROCUTION HAZARD, CRUSHING HAZARD, SHEARING
HAZARD, INTOXICATION HAZARD, ETC.
RISK
Combination of probability and severity of possible injuries or damage to the
health in a dangerous situation.
RESIDUAL RISK
Risk which subsists after having adopted safety measures.
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SAFEGUARDING
Safety measures consisting of utilizing the specific technical means known as

safeguarding (guards, safety devices) to protect persons from hazards that
cannot reasonably be eliminated or sufficiently limited by planning.
SAFETY DEVICES
Device (other than a guard), which eliminates or reduces risk, either alone or
associated with a guard.
GUARD
Element of a machine used in a specific manner to provide protection

through a physical barrier. Depending on its construction, a guard may be
called hood, cover, screen, door, fence, etc.
 NOTE
A GUARD CAN BE FIXED OR INTERLOCKED.

THE FIXED GUARD IS EFFECTIVE WHEN LOCKED AND CORRECTLY
ASSEMBLED, WHEREAS A GUARD PROVIDED WITH A GUARD DEVICE
GUARANTEES SAFETY IN ANY POSITION.
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1.4 INTENDED USE OF A MACHINE
Use to which the machine is destined in accordance with the indications

furnished by the manufacturer, or that which is considered usual in relation to
its design, construction and function.
Intended use also implies respect for the technical instructions found in the
manual of instructions and taking into consideration the incorrect use which
can be reasonably expected.
 NOTE
AS CONCERNS INCORRECT USE, THE FOLLOWING BEHAVIOR IN PARTICULAR

SHOULD BE TAKEN INTO CONSIDERATION IN ESTIMATING RISK:
 THE PREDICTABLE INCORRECT BEHAVIOR THAT RESULTS FROM
NORMAL NEGLIGENCE;
 THE INSTINCTIVE REACTION OF A PERSON DURING USE, IN CASE OF
MALFUNCTION, ACCIDENTS, FAILURE, ETC.;
 BEHAVIOR DERIVING FROM TAKING THE “LINE OF LEAST RESISTANCE”
IN CARRYING OUT A TASK.
The conditions of use intended for the machine and its auxiliaries are given in
the relevant data sheet annexed to service manual.
Use in conditions of fuel pressure and temperature, speed, exhaust
temperature, or load conditions other than those of design can create
conditions of damage to the machine and/or danger to the operators.
The functioning of the machine in such conditions is to be considered
incorrect use of the machine, as is its operation after having cut out or
removed any safeguarding device.
The properties of the gas and of the liquid fuel, if used, must have the
specified composition.
The presence of impurities (liquid or solid) in the fuel gas or in the filtered air
can damage the machine and cause erosion of its inner parts.
The properties of the treated gas must have the composition specified in the
above-mentioned data sheet.
The presence of liquids in the treated gas can generate conditions of damage
to the machine and erosion of its inner parts.
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Hazardous situations can also derive from operating the machine in proximity
to its critical speeds which have not been previously approved by the
technical department of GE Oil & Gas NP (reported in the document
"torsional analysis" or "Campbell diagram" annexed to instruction manual)
and/or in conditions of surge (reported in the document "antisurge control
diagram" annexed to instruction manual) since the high stresses on the
mechanical elements could lead to breakage with the projection of parts.
Modifications made in the machine and its control system, without the prior
authorization of GE Oil & Gas Nuovo Pignone, can determine hazardous
situations for personnel and/or the machine.
GE Oil & Gas Nuovo Pignone cannot be held liable for any consequences
deriving from incorrect or non-intended use of the machine and its auxiliaries.
! DANGER
ALWAYS VERIFY BOTH THE OPERATING CHARACTERISTICS AND THE SAFETY

DEVICES BEFORE STARTING THE TURBINE.
ANY DAMAGE TO PERSONS OR THINGS THAT MIGHT RESULT FROM NON-
SPECIFIED OR IN ANY CASE NON-REASONABLY FORESEEABLE OPERATING
CONDITIONS, OR FROM PROCEDURES, INADEQUATE MAINTENANCE OR THE
EFFECTS OF CORROSION, EROSION, ENCRUSTATION OR GRADUAL
DETERIORATION, WILL BE UNDER THE CUSTOMER’S RESPONSIBILITY AND AT
HIS EXPENSE.
! DANGER
IT IS PROHIBITED TO USE THE COMPRESSOR FOR COMPRESSING DIFFERENT

TYPES OF GAS OR FOR OPERATING IN AN ATMOSPHERE OTHER THAN THAT
OF DESIGN.
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! DANGER
NUOVO PIGNONE RECOMMEND AT THE CUSTOMER TO BE EXTREMELY

CAREFUL IN MANAGING LOGICS AND PARAMETERS RELATIVE TO THE
BALANCE OF PLANT (BOP) (IF, AND ONLY IF, COMPLETELY DESIGNED BY THE
CUSTOMER) DUE TO THE INTERACTION BETWEEN MACHINE AND PLANT
SYSTEMS, WHILE ANY MODIFICATION OF THE LOGICS RELATIVE TO
AUXILIARY SYSTEMS (AUX), CORE ENGINE, SEQUENCING (IF SUCH SYSTEMS
ARE DESIGNED BY NP) IS FORBIDDEN.
DUE OF THE HIGH SAFETY IMPACT, ONLY NUOVO PIGNONE OR NUOVO

PIGNONE AUTHORIZED PERSONNEL CAN MODIFY THE FOLLOWING LOGICS
AND PARAMETERS:
 PURGE SYSTEM:
 SEQUENCING LOGICS
 WASH TIME
 CRANK SPEED
 FUEL AT STARTUP:
 FUEL PRESSURE/FLOW RATE
 FUEL UPSTREAM CONTROL VALVE
 VALVE OPENING AT FIRING
 FIRING TIME
 FUEL VERIFICATIONS AT STARTUP
 FLAME DETECTION AND PROTECTION LOGICS
 BACKFLOW:
 PURGE LOGICS TO PREVENT BACKFLOW
 OVERSPEED PROTECTION LOGIC
 GAS DETECTION SYSTEM LOGICS AND LEVELS
 ANTIFIRE SYSTEM LOGICS AND LEVELS
 LIQUID FUEL DRAINAGE LOGICS
THE UNAUTHORIZED MODIFICATION OF SUCH PARAMETERS/LOGICS

CRITICAL FOR SAFETY MAY RESULT IN INJURIES TO PERSONNEL AS WELL AS
IN PENAL CHARGES.
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1.5 IDENTIFICATION OF HAZARDOUS ZONES
During the stages of installation and maintenance on the Turbocompressor

and its auxiliaries, hazards relevant to the specific activity carried out are
present. The safety warnings concerning such hazards are reported in the
respective sections of this manual.
During normal operation of the Turbocompressor and its auxiliaries, hazards
of various kinds are present, due to:
 presence of inflammable gas at high pressure in the turbine feed systems;

 presence of inflammable fluids (gas-oil, etc.) at high pressure in the turbine
feed systems (when applicable);
 presence of inflammable fluids (oils) at high pressure in the regulation,
lubrication and control systems;
 presence of fluids at high temperature (oils, water) in the lubrication and
cooling systems;
 presence of surfaces at high temperature (hot or cold) on the turbine,
auxiliary system and exhaust ducts;
 presence of liquids at high temperature in the turbine and auxiliary
systems;
 presence of exhaust at high temperature;
 utilization of medium and high voltages in the auxiliary and control systems
(medium voltage);
 utilization of high voltages in the auxiliary and transformer systems;
 presence of loud noise ;
 presence of slippery surfaces around the machine and the auxiliary
systems.
 presence of crushing and impact hazards when opening the acoustic
enclosure doors, in the case in which the internal pressurization /
depressurization system is on.
 presence of hazards due to the ejection of metal parts near the rotation
plane of the load coupling.
 presence of asphyxia hazards inside the acoustic enclosure, if the fire-
fighting system is on
 presence of gas at high and very high pressures in the process systems;
 presence of dangerous gas (inflammable, explosive or toxic). These
hazards can give rise to risks even at a notable distance;
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Acoustic Enclosure over the turbine and its auxiliaries
When an acoustic enclosure is provided, within it are present both the

hazards indicated in the preceding paragraph and those deriving from the
presence of a fire-fighting system (insufficient oxygen, etc.). In addition there
exists danger of projection of rotor parts subsequent to breakage of same.
The area inside the acoustic enclosure is thus always to be considered a
high-risk zone and, as such, access to it must be authorized.
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1.6 ACOUSTIC ENCLOSURE ACCESS PRACTICE INFORMATION
Access to a gas turbine enclosure with the machine running presents high
residual risks and is usually forbidden. The only cases in which it is permitted
are identified below.
The plant manager must be responsible for implementing an access
procedure based on Permit To Work approach.
! DANGER
DURING MACHINE OPERATING NOBODY MUST BE PRESENT INSIDE OR

ACCESS IN TURBINE ENCLOSURE, GEAR BOX ENCLOSURE AND IN THE
FILTERS HOUSE. THE RELATIVE DOORS MUST BE KEY LOCKED.
THE ONLY CASES IN WHICH IT IS PERMITTED ARE IDENTIFIED BELOW.
The restricted access also applies to a stopped machine until cool-down is

completed.
Based on Manufacturer experience the enclosure access is necessary for

these reasons:
At first start up or after an overhaul for:

 Checking abnormal noises during the run test
 Visual inspection for liquid fuel gas leakage (during warm up)
 Any DLN valve tuning at first start
 Settings (i.e. Pumps, pressure panel)
 Check manometer board at first start
Access for any other reason is forbidden.

Any other access request must be authorized by the Manufacturer.
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It is anyhow strictly forbidden to enter the acoustic enclosure in the

following cases:
 During an expected and remarkable load variation

 In case of gas detection alarm, fire or high temperature in the acoustic
enclosure
 In case of gas leak
 During fuel type change (if expected)
During the operation of the turbine startup system, further residual risks are
present, determined by possible breaks and subsequent projection of parts of
the starting system; therefore, keep clear from the machine.
In the event of gas loss, oil leakage and other similar anomalies, do not try
any repair, but stay far from the machine and trip it. Any repair intervention is
forbidden with the machine running.
! DANGER
IT IS PROHIBITED ANY REPAIRING WHEN THE MACHINE IS RUNNING

FILTER MAINTENANCE MUST NOT BE CARRIED OUT DURING MACHINERY
OPERATION.
! DANGER
IT IS IN ANY CASE PROHIBITED THE PRESENCE OF PERSONNEL INSIDE THE

ACOUSTIC ENCLOSURE WHEN ALL THE DOORS ARE CLOSED.
Residual risks relative to access to the enclosure with machine running
The opening of the door to the acoustic enclosure normally produces a

disturbance of the acoustic enclosure design ventilation flows, which causes
the gas detection system to be unreliable; the use of personal detectors,
cannot guarantee an effective detection of leaks.
The disturbance of the ventilation flows may also cause malfunctions related
to the cooling of the turbine casing with probable mechanical damages and
hazards for personnel, especially in case of aeronautics derived turbines
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Other residual hazards:
 Impact risks due to unexpected door movement by enclosure

pressurization / depressurization
 Hot surfaces, even turbine external ones, exhaust duct, etc.
 Possible hot gas or vapour jets
 Metallic parts ejection in case of breakage of working system too
 Gas explosion
 Oil or fuel fire
 High environmental temperature (heat stroke risk)
 Possible presence of dangerous gases (i.e. H2S in the fuel)
 Dangerous extinguish gas (i.e.CO2 anti-fire)
 Insufficient oxygen
 High noise
 Mechanical parts in motion
 Slipping
In case of fuel gas with a H2S content higher than 10 ppm, a special
procedure must be arranged by the plant manager (refer to
Appendix C of this section).
Minimum requisites of the procedure for entering the enclosure
SUCH PROCEDURE SHALL BE IMPLEMENTED BY THE EMPLOYER / PLANT

MANAGER, ALSO BASED ON THESE INFORMATION, AND SHALL BE RECALLED
BY THE WORK PERMIT SYSTEM.
PERSONNEL SHALL BE ADEQUATELY TRAINED AND INFORMED ON HAZARDS
AND PRECAUTIONS TO BE TAKEN WHEN ACCESSING THE TURBINE
ENCLOSURE.
AUTHORIZED (BY WORK PERMISSION) PERSONNEL TO ENTER THE ACOUSTIC

ENCLOSURE, WHEN THE MACHINE IS IN COOL-DOWN CONDITION, MUST MAKE
USE OF PROPER PERSONAL PROTECTION EQUIPMENT SUITABLE FOR THE
HAZARDS IN THE AREAS ABOVE.
THE IDENTIFICATION OF THE SPECIAL PERSONAL PROTECTION EQUIPMENT

MUST BE PLANT MANAGER’S TASK, AS DEFINED IN THIS MANUAL.
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In the access to the acoustic enclosure procedure some environmental

parameters and the minimum requirements listed below must be verified and
met:
 The machine must be placed on idle or minimal speed condition.

 Oxygen content, LEL level, and, if necessary CO or H2S level,
 In case there is an extinguishing device, the system must be
mechanically disabled closing and locking the block valves (as
described in the plant manager’s Lock-out procedure)
 The procedure must also guarantee that, after access, the fire
protection system is reactivated.
 Suitable extinguishers must be easily accessible.
 The fire & gas detection system must be kept on (in the event of
detection it is necessary to leave the acoustic enclosure immediately
even if the fire has been put out).
 Arrange for another operator, who must remain in visual contact both
with the one who enters the acoustic enclosure and with the one in the
control room, to be present. The second operator must also make sure
that the access door inside the acoustic enclosure is open.
 The operator who remains outside must be equipped with a portable
fire-extinguisher.
 Before entering the enclosure, verify that the turbine is running
regularly and that no abnormal operation is expected.
 Access to any area, which is hardly accessible or devoid of escapes is
prohibited.
 Avoid contact with hot parts and wear special gloves provided with
thermal isolation.
 Avoid contact with mechanical parts in motion, which may accidentally
move. (IGV).
 In high and medium voltage electrical devices, it is necessary to
disconnect the power supplies to the device and to lock out them in
disconnected (off) position. Locate the electrical switches to be
disconnected using the wiring diagrams enclosed to the instruction
manual.
 Lock all the control devices and switches whenever possible.
Otherwise, affix “Out of order” warning notices on the switches in order
to avoid accidental activation.
 Affix a “Do not start” tag on controls to avoid the accidental start of the
unit from stop condition.
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! DANGER
THE ACOUSTIC ENCLOSURE IS PRESSURIZED, THE ACCESS DOORS CAN

PRESENT A CRUSHING HAZARD. VENTILATION, IN FACT, EXERTS PRESSURE
ON THE DOOR, DETERMINING ITS UNTIMELY MOVEMENT IF OPENED.
! DANGER
IN THE PRESENCE OF A DEPRESSURIZED ACOUSTIC HOOD OR ENCLOSURE,

THE ACCESS DOORS CAN PRESENT A CRUSHING HAZARD, IN THE CASE OF
UNTIMELY MOVEMENT OF THE DOORS FROM OPEN POSITION.
LOCK THE DOOR IN OPEN POSITION.
! DANGER
DO NOT ENTER IN THE ACOUSTIC ENCLOSURE, OR OPEN THE DOOR AFTER

FIRE SHUTDOWN UNTIL A MINIMUM OF 3 HOURS HAS ELAPSED. THIS WILL
ALLOW MAXIMUM CONCENTRATION LEVELS OF EXTINGUISHANT TO BE
MAINTAINED AND SURFACE TO COOL. OXYGEN WILL BE PREVENTED FROM
ENTERING THE ACOUSTIC ENCLOSURE, REDUCING THE RISK OF RE-IGNITION
AND POSSIBLE INJURY.
Minimum personal protection equipment to be used:
 Fire-proofing clothes, i.e. Nomex (acetate, nylon, polyester, rayon

clothes are prohibited)
 Hearing protection equipment
 Helmet
 Safety glasses
 Heat-proofing gloves
 Safety shoes
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1.7 PUTTING THE MACHINE IS SAFE CONDITIONS PRIOR TO

MAINTENANCE
Before starting with maintenance activities, the machine must be put in “safe
conditions”, as described in the following paragraphs.
Access to the zones surrounding the machine is allowed only to authorized
maintenance personnel.
Access into the enclosure is allowed only when the machine is not running
and after the cool-down period has elapsed.
Maintenance on the Turbocompressor and its auxiliaries is to be carried out
only after the Cool-down period has elapsed.
Maintenance operations are those which are statistically most
dangerous.
! DANGER
PERSONNEL AUTHORISED TO CARRIED OUT MAINTENANCE ACTIVITIES MUST

MAKE USE OF PERSONAL PROTECTION EQUIPMENT SUITABLE FOR THE
HAZARDS IN THE AREA ABOVE.
THE IDENTIFICATION OF THE SPECIAL PERSONAL PROTECTION EQUIPMENT IS
THE PLANT MANAGER’S TASK, AS DEFINED IN THIS DOCUMENT.
The following prescriptions shall be incorporated in Lock-out Tag-out

procedures prepared by the plant manager.
Prior to operating on the Turbocompressor or its auxiliaries, it is

indispensable to put them in safe conditions.
To do this it is necessary to:
 For maintenance operations inside the acoustic enclosure, proceed to
cutting off the discharge piping of the fire-fighting system (by locking
the valves) so as to eliminate the risk of accidental discharge. In
addition, adequate fire extinguishers must be easily accessible.
 During maintenance it is necessary to mark off with signaling tape or
similar the area of operation, limiting it by access signs and affixing a
warning notice, reporting the following text:
Warning! – Personnel at work
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 In the following page a special matrix for the making of the warning
notice above may be found, recommended colors are: black for
drawings and inscriptions on yellow background.
 Isolate it from any source of external power:
 Electric power (In high and medium voltage electrical devices, it is
necessary to disconnect the power supplies to the device and to
lock out them in disconnected (off) position. Locate the electrical
switches to be disconnected using the wiring diagrams enclosed to
the instruction manual).
 Fuel gas power (Lock-out the isolating valve)
 Pneumatic power (Lock-out the isolating valve)
Mechanically disassembly the plants so that they cannot be accidentally reactivated
during the period (Lock-out)
 Indicate with cards placed on the switches, on the control panel, on
the cut off elements, that the source of power must not be reactivated
(Tag-out)
 Discharge any sources of internal power (such as springs, pressure
vessels, capacitors , electric and pneumatic accumulators, etc.)
 Upon completing maintenance, prior to reactivating the power
supplies, check (twice) that any guards that have been removed have
been put back in place, and that the components of the fuel, hydraulic
and pneumatic lines have been correctly tightened (according to the
seal check procedure).
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1.8 LOCK-OUT AND TAG-OUT PRACTICE INFORMATION
Lock out/Tag out (LOTO) is a process of isolating or controlling or

safeguarding any machinery or source of hazardous energy that any
operator/employee/ user may encounter while manufacturing, operating,
maintaining, scrapping the machinery or source.
It is the responsibility of the site management to develop appropriate LOTO

procedures and train all employee/personnel to follow them. Refer EU
directive 89/391/EEC.
Locks
The central component of our safety system is the lock. One method is the
one lock, one key philosophy.
This means that when a lock is issued to be placed on a piece of equipment,
only one key will be issued for that lock.
A spare key may be placed on a master key ring. The master key ring will be
under control of the startup manager only. Only the startup manager can
authorize the cutting of a lock with bolt cutters. Lock size and quality will vary,
as long as they provide a sufficient barrier to unauthorized operation of the
system.
Tags
Caution or danger tags may be utilized to designate the specific boundaries

of a system. During commissioning there may be times when there is only a
tag on a system, though a lock is to be placed on any system or piece of
equipment that is not to be operated.
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ATTENZIONE!!
WARNING!!
NON TOCCARE
DO NOT TOUCH
PERSONALE DI ASSISTENZA IN SERVIZIO
SULLA MACCHINA
SERVICE PERSONNEL AT WORK ON THE
MACHINE
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Key box
This is a box containing all active keys; these are the keys to locks that are
installed on the equipment.
Lock Box
This is a box containing inactive locks, or locks that are designated for
locking out equipment but not installed on any equipment.
Logbook
A logbook is utilized to track what lock is where and who has a system locked
out and why. If a lock is to be cut off a piece of gear, the reason should be
written in this logbook. Responsibility for maintaining the lockout program
falls on anyone who must operate, or work on, any plant equipment. The
Startup Manager should ensure everyone is aware of the procedure and that
it is in use throughout the job site.
Lock-out Sheet
This form will include the work to be done, specific boundaries of the system
or subsystem to be worked on, who is doing the work and for how long.
There should be two copies of this sheet, one in the logbook and the other on
or visibly about the equipment.
Work permission
We recommend the establishment of formal procedures for releasing “work

permissions” and for recording the data relative to them.
To obtain the authorization to effect functioning tests or maintenance on the
plant, it is necessary to consult the safety manager and the maintenance
manager, who will have to release a work permission.
The “Work Permissions” files must be elaborated according to “Plant Parts”
and must include:
 The description of the operation to be carried out.
 The amount of operators who must effect the operation, this never has
to be less than two.
 The description of the last operation effected and the data relative to
the one who has carried it out.
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 Date and time for the operation to be started and the maximum time
by which the operation must be performed.
 The fields for records (operator’s name, date, notes and signature).
The countersigned records of the maintenance performed must be verified by

the Maintenance Manager and successively entered in the Maintenance
computer records.
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1.9 SAFEGUARDING (SAFETY DEVICES AND GUARDS) AND STOP

DEVICES
Safety devices of mechanical and electronic type are installed on the

Turbocompressor and its auxiliary systems.
! DANGER
THESE DEVICES SHOULD NOT BE REMOVED OR ELUDED DURING ANY STAGE

OF OPERATION OF THE MACHINE AND ITS AUXILIARIES. IN ORDER TO
GUARANTEE THE OPERATORS’ SAFETY AND THE CORRECT OPERATION OF
THE MACHINE, THE SAFETY DEVICES MUST BE MAINTAINED AND CHECKED
PERIODICALLY (EACH TIME THAT THE MACHINE STOPS AND BEFORE
STARTING IT) TO ENSURE THEIR EFFICIENCY.
What to inspect
Equipment Inspection frequencies Turbine status
for
Guard Check for damage When the machine stops or before Shout down
& for correct starting it
assembling
Limit switch Functional check When the machine stops or before Shout down
installed on starting it
the door
Horn Functional check When the machine stops or before Shout down
starting it
Lamp Functional check When the machine stops or before Shout down
starting it
Push button Functional check When the machine stops or before Shout down
starting it
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Mechanical safety devices
The mechanical safety devices installed on the Turbocompressor and its

auxiliaries consist of the following:
 guards, coupling guards and shields aimed at preventing access to

danger zones (mechanical parts in movement, hot surfaces, live electric
parts)
 anti-implosion door, placed on the inlet duct
 pressure release valves
 non-return valves
 overspeed trip device on the rotor of some Turbine models, which
determines its trip.
The location of the valves is indicated on the P&ID annexed to the instruction
manual.
Electronic safety devices
The safety devices of electronic type, controlled by the machine or plant

control system, are divided according to the functions of alarm and trip.
Alarm systems
In general, an alarm indicates malfunction in the machine and its auxiliaries,

but not such as to produce immediate danger. Such malfunction must
however be eliminated as rapidly as possible.
The alarm devices present on the acoustic enclosure are:

 System for detecting open acoustic enclosure access door.
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Trip systems
The electronic trip systems determine the arrest of the Turbocompressor to

provide protection against damage to the machinery, which could cause
situations of danger for the operator.
The trip devices present on the Turbocompressor and its accessories consist
mainly of:
 system for detecting speed of rotation, vibrations and axial displacement
of the rotor;
 system for detecting exhaust gas temperature;
 system for detecting pressure, temperature and flow rate of fuel gas and
of liquid fuel when used;
 system for detecting pressure and temperature of lube oil, hydraulic oil
and control oil;
 system for detecting gas and fire;
 system for detecting temperature inside the acoustic enclosure;
 system for detecting pressure inside the acoustic enclosure;
 comparison between multiple measurements of critical operating
parameters (intervalve gas pressure, axial compressor discharge
pressure, exhaust gas temperature, position of gas valves, position of
bleed valves, position of IGV actuators, etc.).
 system for detecting temperature and pressure of process gas;
 system for detecting pressure at the seal vents;
Other safety systems prevent starting in conditions of danger.
The main ones are:
 verification of the open doors for access to the acoustic enclosure;
 verification of the oil and gas systems prior to starting;
 verification of starting systems;
 verification of ventilation system;
 established starting sequence.
The complete list of these devices is given in the "Instrument List" or “Device
Summary” annexed to instruction manual.
All of the electronic safety devices with the function of trip determine the
arrest of the Turbine and the driven machines in safe conditions and in the
shortest time possible.
Lastly, emergency stop systems with manual actuation are provided,
consisting of push buttons, which send a stop command to the control
system.
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1.10 RESIDUAL RISKS
Introduction
The purpose of this section is that of indicating the residual risks of general
nature and furnishing the warnings necessary to minimize such risks.
Other warnings on residual risks of specific types are indicated in the relevant
sections of the instruction manual.
Failure to respect warnings can cause accidents to operators, which may

even be fatal.
1.10.1 Generic residual risk
The zone surrounding the plant and the external zone are considered
dangerous. Limit presences in this zone.
Provide adequate supervision to prevent access of non-authorized
persons.
! DANGER
THE ZONE SURROUNDING THE ACOUSTIC ENCLOSURE IS A HIGH RISK ZONE

AS INDICATED IN PARAGRAPH 1.5 (TO WHICH REFERENCE SHOULD BE MADE)
AND AS SUCH, ACCESS TO IT MUST BE PROHIBITED WITH THE MACHINE
RUNNING AND DURING COOL-DOWN.
! DANGER
MAINTENANCE PERSONNEL ARE ABSOLUTELY FORBIDDEN TO REMAIN

INSIDE THE ACOUSTIC ENCLOSURE WITH THE ACCESS DOOR CLOSED.
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! DANGER
BEFORE STARTING THE TURBINE VERIFY THAT NOBODY IS IN THE VICINITY

OF THE PLANT IN A DANGEROUS ZONE.
! DANGER
IN GENERAL, OPERATORS MUST UTILIZE THE PERSONAL PROTECTION

DEVICES SUITABLE TO THE DANGERS PRESENT IN THE ZONES TO WHICH
THEY ACCEDE AND TO THE OPERATIONS TO BE CARRIED OUT.
IDENTIFICATION OF THE SPECIFIC PERSONAL PROTECTION DEVICES IS THE
RESPONSIBILTY OF THE PLANT MANAGER, ALSO ON THE BASIS OF THE
INFORMATION GIVEN IN THIS DOCUMENT.
THE OPERATOR’S CLOTHING MUST BE ADEQUATE TO THE HAZARDS
PRESENT, AND IN PARTICULAR MUST BE SUCH AS TO AVOID ANY DANGER OF
BEING CAUGHT IN THE MACHINERY.
! DANGER
ONLY OPERATORS AUTHORIZED BY THE PLANT MANAGER CAN CARRY OUT

COMMAND AND ADJUSTMENT OPERATIONS, EXTERNAL TO ACOUSTIC
ENCLOSURE ON THE TURBOCOMPRESSOR AND ITS AUXILIARIES WITH THE
MACHINE STOPPED. THIS IS PROHIBITED DURING NORMAL OPERATION.
ANY ADJUSTMENT AND CONTROL OPERATIONS FOR WHICH IT IS
INDISPENSABLE TO HAVE THE TURBOCOMPRESSOR AND ITS AUXILIARIES
RUNNING MUST BE REDUCED TO A MINIMUM AND PREVIOUSLY AUTHORIZED
BY THE PLANT MANAGER.
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! DANGER
GIVEN THE TYPE OF OPERATION OF THE MACHINE AND THE TYPE OF

ENVIRONMENT IN WHICH IT OPERATES (PRESENCE OF GAS, HIGH
PRESSURES, ETC.) IT IS EXTREMELY RISKY FOR PERSONNEL TO CARRY OUT
OPERATIONS NOT SPECIFIED IN THIS DOCUMENT (EVEN WITH THE MACHINE
SWITCHED OFF). FOR SUCH OPERATIONS IT IS ALWAYS NECESSARY TO
CONSULT THE ASSISTANCE SERVICE OF GE OIL & GAS NUOVO PIGNONE.
 During operation, all parts of the equipment must be in perfect

condition;
 The equipment must not be put in service if any defects or anomalies
have been observed;
 It is prohibited to make changes in the operating parameters of the
equipment or the settings of the instruments and fixtures: this could lead to
highly dangerous situations;
 It is prohibited to change the set values of the alarm or trip devices or
other parameters entered on the control panel;
 All control and safety devices must be checked, calibrated and tested
at regular intervals;
 Do not cut out nor remove the safety devices and guards installed on
the equipment;
 In case of long periods of idleness of the machines, adequate
protection and preservation of same must be provided according to the
instructions given in the relevant section of the instruction manual;
 Replacing parts with non-original spare parts not only nullifies the
warranty, but can also create dangerous situations.
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! DANGER
THE INSTALLATION AND FIRST STARTUP OF THE EQUIPMENT MUST BE

CONDUCTED UNDER THE SUPERVISION OF NUOVO PIGNONE GE OIL & GAS
PERSONNEL.
! DANGER
BEFORE STARTING THE COMPRESSOR, LEAK TESTS MUST BE CARRIED OUT

TO VERIFY THAT INSTALLATION OF THE COMPRESSOR HAS BEEN EXECUTED
CORRECTLY ACCORDING TO THE API STANDARDS, TO GUARANTEE LEAK
TIGHTNESS AT A PRESSURE INCLUDED BETWEEN 1 AND 1.1 TIMES AS HIGH
AS THE MAXIMUM OPERATING PRESSURE, AS PRESCRIBED AT POINT 8.2 OF
THE EN 1012-1 STANDARD.
! DANGER
DO NOT PUT THE TURBOCOMPRESSOR AND ITS AUXILIARIES IN SERVICE FOR

THE FIRST TIME BEFORE ALL OPERATORS HAVE RECEIVED ADEQUATE
TRAINING IN SAFETY INSTRUCTIONS, DEVICES AND PROCEDURES.
! DANGER
IT IS ABSOLUTELY FORBIDDEN TO ELUDE THE PURGE SEQUENCE IN ANY

CASE INCLUDING MISFIRING (FALSE START) OF THE MACHINE.
! DANGER
RE-CALIBRATION OF THE VALVE GAS AFTER MAINTENANCE HAS AN IMPACT

ON THE SAFETY OF THE OPERATOR AND OF THE INSTALLATION. THIS
OPERATION MUST BE CARRIED OUT BY QUALIFIED PERSONNEL ONLY.
QUALIFIED PERSONNEL ARE INTENDED TO BE GE NUOVO PIGNONE
TECHNICAL ASSISTANTS ONLY. IN NO EVENT SHALL GE BE LIABLE FOR
ASSEMBLY-DISASSEMBLY OF VALVES IF PERFORMED BY PERSONNEL OTHER
THAN GE NUOVO PIGNONE PERSONNEL.
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! DANGER
IN CASE OF A FAULT ALARM, THE MACHINE WILL NO LONGER BE

COMPLETELY PROTECTED, THEREFORE THE OPERATOR HAS TO PROCEED
QUICKLY TO AN INSPECTION FOLLOWING THE RULES IN THE SAFETY PLAN
ESTABLISHED FOR THE PLANT. AT THE SAME TIME, A CHECK MUST BE MADE
FROM A DUE DISTANCE IN ORDER TO VERIFY THE EXISTENCE OF SIGNALS
INDICATING THE PRESENCE OF A FIRE INSIDE THE ACOUSTIC ENCLOSURE/S.
IN THE CASE OF A FIRE, THE OPERATOR HAS TO ACTIVATE A MANUAL
DISCHARGE OF THE FIRE FIGHTING SYSTEM. THE VERIFICATION WILL BE
CONSIDERED CONCLUDED AND THE MACHINE COMPLETELY PROTECTED
WHEN THE FIRE FIGHTING SYSTEM HAS BEEN COMPLETELY RESET.
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1.10.2 Residual mechanical risk
! DANGER
IT IS PROHIBITED TO START THE EQUIPMENT UNTIL ALL OF THE REQUIRED

GUARDS HAVE BEEN INSTALLED. FURTHERMORE, IT IS PROHIBITED TO
REMOVE THEM DURING OPERATION.
! DANGER
IT IS PROHIBITED TO REMAIN IN THE VICINITY OF THE ROTATING PARTS.
! DANGER
THE COUPLING GUARD IS NOT DESIGNED TO PREVENT PARTS FROM BEING

EJECTED BY THE HIGH SPEED OF ROTATION, NOR TO PROTECT FROM
INJURY. PERSONNEL MUST AVOID STANDING IN THE NEARBY ROTATING
PLANE DURING OPERATION. THE CUSTOMER SHOULD ENSURE THAT
APPROPRIATE WARNINGS ARE PLACED IN THE SURROUNDING AREA AND
DELIMITING YELLOW SAFETY STRIPED ON THE FLOOR.
! DANGER
IN THE TURBOCOMPRESSOR AND IN SOME AUXILIARY SYSTEMS (LUBE OIL,

HYDRAULIC OIL, CONTROL OIL, GAS OR LIQUID FUEL, COOLING WATER, SEAL
OIL, SEAL GAS) ARE FLUIDS WHICH ARE HOT AND/OR UNDER PRESSURE.
SPECIAL CAUTION MUST BE ADOPTED IN OPERATING BLEED AND VENT
VALVES ON THE SYSTEMS IN QUESTION .
PRIOR TO BEGINNING ANY MAINTENANCE PROCEDURE THAT INVOLVES
DISASSEMBLY, ENSURE THAT THE INTERNAL FLUID HAS BEEN PROPERLY
COOLED AND THAT IT IS NOT UNDER PRESSURE.
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! DANGER
TRIPPING, SLIPPING AND FALLING HAZARDS ARE PRESENT IN THE ENTIRE

PLANT AND INSIDE THE ACOUSTIC ENCLOSURE.
KEEP THE OPERATIONAL AREA CLEAR OF OBSTACLES AND IMMEDIATELY
CLEAN ANY OIL LEAKS RESOLVING THE CAUSE.
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1.10.3 Risks during hoisting and handling operations
! DANGER
HOISTING AND HANDLING OPERATIONS MUST BE EFFECTED BY SPECIALLY

TRAINED PERSONNEL PROVIDED WITH PROTECTIONS AGAINST INDUSTRIAL
ACCIDENTS, WHO CAN MAKE USE OF CRANES AND HOISTING DEVICES.
WHILE HANDLING THE MACHINE OR DEVICES IT IS NECESSARY TO MAKE USE

OF HOISTING DEVICES SUITABLE FOR THE LOAD APPLIED.
FOR NO REASON PERSONNEL ARE ALLOWED TO PASS UNDER OR IN THE

VICINITY OF THE LOAD.
THE SIGNALMAN WHO ATTENDS HANDLINGS, WILL HAVE TO FOLLOW THE

DIRECTIONS BELOW.
To guarantee the safety of the operators during hoisting and handling it is

necessary to operate as follows:
 Handling must be carried out slowly, with a suitable light and an empty
space in the hoisting area;
 Do not use hoisting devices to carry persons;
 Lift and lower the loads in vertical position with the aligned load, in
order to avoid improper side movements;
 Hoisting devices capacity must be suitable for the load to be handled;
 The total mass to be handled is obtained considering the load to be
lifted and the wait of the devices used;
 It is prohibited to use self-constructed equipment (supports, brackets,
fixtures, etc.), which has not been explicitly authorized by the pertinent
technical department of GE Oil and Gas Nuovo Pignone;
 Before hoisting any equipment, verify on the hoisting drawings the
hoisting position and points of hoisting;
 Do not utilize the hoisting points relevant to the machine alone to lift
the whole group of machine and baseplate;
 Verify the correct fixing and the correct positioning of the special tools;
 Do not make use the special tools for operations which differ from the
ones they have been made for;
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 In the presence of unbalanced loads (such as for example couplings

or other accessories) use additional cables to prevent overturning during
hoisting;
 Make use of bar spacers and padded slings to avoid damaging the
devices surfaces;
 Avoid damaging piping, accessories, flanges, paintings and protective
coverings;
 While carrying rotating machines, keep the rotating axis as horizontal
as possible;
 Do not let hanging load swing;
 Avoid excessive shocks to the equipments;
 Do not effect maintenance on the hoisting gear with an hanging load;
 Do not leave the load hanging;
 Do not leave the load suspended over long periods of time. The lifting
equipment must not be used also as a means for supporting the load.
After lifting and handling the load, it is necessary that the latter be always
mechanically secured;
 Authorized personnel are responsible for any incorrect slinging and
hoisting.
! DANGER
FAILURE TO OBSERVE THESE PRECAUTIONS CAN CAUSE SEVERE HARM TO

PERSONS.
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1.10.4 Residual electrical risks
! DANGER
MAINTENANCE OPERATONS ON ELECTRICAL EQUIPMENT MUST BE CARRIED

OUT BY EXPERT, AUTHORIZED PERSONNEL. NOTE THAT IN CIRCUITS WHERE
CAPACITORS ARE INSTALLED, THE VOLTAGE MAY REMAIN PRESENT FOR A
CERTAIN TIME EVEN AFTER THE POWER SUPPLY HAS BEEN CUT OFF.
! DANGER
INSIDE ELECTRIC PANELS AND IN THE VICINITY OF ELECTRICAL DEVICES

MOUNTED ON THE MACHINES (TURBINE AND GENERATOR WHEN PRESENT)
AND ITS AUXILIARIES, DANGEROUS VOLTAGES ARE PRESENT.
DO NOT REMOVE THE GUARDS BEFORE HAVING FIRST PUT THE EQUIPMENT
IN SAFE CONDITIONS. REMOUNT THE GUARDS PRIOR TO ENERGIZING THE
EQUIPMENT AGAIN.
! DANGER
NEVER WORK ALONE ON ANY ELECTRICAL EQUIPMENT. ENSURE THAT

PERSONNEL ASSIGNED TO THIS WORK ARE AWARE OF EMERGENCY FIRST
AID PROCEDURES IN CASE OF ELECTRIC SHOCK.
! DANGER
DO NOT CLIMB ON OR USE AS RESTS ELECTRIC DUCTS, JUNCTION BOXES OR

SIMILAR.
! DANGER
ALWAYS INSTALL GROUND LEADS FOR THE EQUIPMENT AS SPECIFIED BY

THE DESIGN.
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DO NOT REMOVE THESE CONNECTIONS FOR ANY REASON.
! DANGER
DO NOT USE WATER TO EXTINGUISH FIRES ON LIVE ELECTRICAL EQUIPMENT.

THE FIRE EXTINGUISHERS TO BE UTILIZED MUST BE APPROPRIATE TO THE
EQUIPMENT AND TO THE TYPE OF FIRE.
Safety recommendations for electric panel
 Power circuits inside the panel provide protections against short

circuits and overcurrents; the protecting equipments are selected on
the base of the electrical load connected to the circuits. Some devices
have additional internal protections realised by the producer.
 All the equipments inside the panel compliance with the low on safety
requirements as issued in the producer compliance declaration, their
installation strictly follows producer mounting recommendations.
 The panel was made to match the protecting level suitable for the
installation place as required in the commitment specifications.
 The panel structure was designed to avoid dangerous over-

temperature for the appliances installed.
 Some panels provide power supplies generating different waveforms

or voltage levels, in this case there is not a general switch capable of
turning off all the power supply at the same time. The access on active
electric parts, partially or totally not protected, give an additional risck
due to multiple power supplies. The final user is required to realize an
internal procedure to be followed by the operators.
 The emergency button, placed in the front of the panel, disables only
the controlling capabilities of the panel towards the outside but it will
not interrupt the general power supply.
 When the Unit Control Panel is connected to power, connect it via a

line-protection molded case circuit breaker or an earth-leakage circuit
breaker (Residual current operated protection device).
Otherwise, fire could occur.
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 Be sure to connect the ground wire(s).

Otherwise electric shock or fire could occur.
 Check before starting the wiring that the power is off (unless a PELV
system is used), otherwise electric shock could occur.
 Check before doing any Unit Control Panel maintenance activity that
the power is off (unless a PELV system is used), otherwise electric
shock could occur.
 The Unit Control Panel has to be grounded in accordance with the

national and local safety specification, otherwise electric shock could
occur.
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1.10.5 Residual thermal risks
! DANGER
DURING OPERATION SOME PARTS OF THE TURBOCOMPRESSOR, THE

EXHAUST SYSTEM AND THE AUXILIARY SYSTEMS REACH HIGH
TEMPERATURES. ACCIDENTAL CONTACT WITH HOT SURFACES CAN CAUSE
SEVERE BURNS.
BEFORE CARRYING OUT INSPECTION OR MAINTENANCE OPERATIONS
ENSURE THAT THE VARIOUS PARTS ARE SUFFICIENTLY COOL.
! DANGER
EXTERNAL TURBINE AND COMPRESSOR SURFACES ARE NOT ISOLATED, SO

THAT SPECIAL PRECAUTIONS MUST BE TAKEN TO AVOID PERSONNEL
ACCIDENTAL CONTACTS WITH HOT SURFACES.
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1.10.6 Residual risks generated by noise
! DANGER
TURBOCOMPRESSORIS A SOURCE OF LOUD NOISE
THEREFORE IT IS NECESSARY THAT PERSONNEL WORKING IN THE VICINITY OF THE SAME, WEAR
AN APPROPRIATE ACOUSTIC PROTECTION EQUIPMENT WHEN THE TURBINE IS RUNNING.
THE EMITTED NOISE LEVELS ARE INDICATED IN THE NOISE DATA SHEET OF
JOB.
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1.10.7 Residual risks from materials and substances
! DANGER
DO NOT ENTER THE ACOUSTIC ENCLOSURE FOLLOWING FIRE SHUTDOWN

UNTIL A MINIMUM OF 3 HOURS HAS ELAPSED. THIS WILL ALLOW MAXIMUM
CONCENTRATION LEVELS OF EXTINGUISHING TO BE MAINTAINED AND
SURFACE TO COOL. OXYGEN WILL BE PREVENTED FROM ENTERING THE
ACOUSTIC ENCLOSURE, REDUCING THE RISK OF RE-IGNITION AND POSSIBLE
INJURY.
! DANGER
IN CASE OF WATER-FOG FIRE FIGTHING SYSTEM, THE DISCHARGE INSIDE OF

THE PROTECTED AREA CAUSES SUBSTANTIAL DECREASE IN VISIBILITY AND
IS HAZARDOUS FOR RESPIRATION.
BEFORE ACCEDING TO THE AREA, BLOCK THE AUTOMATIC DISCHARGE
SYSTEM AND CLOSE WITH LOCKS THE VALVES ON ALL OF THE DISCHARGE
PIPINGS. AN APPROPRIATE PROCEDURE MUST BE PREPARED BY THE PLANT
MANAGER.
! DANGER
WHEN THE FIRE-FIGHTING SYSTEMS ENTERS OPERATION THE DISCHARGE IS

ANNOUNCED BY AN ACOUSTIC SIGNAL INSIDE OF AND IN THE VICINITY OF
THE PROTECTED AREA.
UPON HEARING THIS SIGNAL ANY PERSONS WHO MIGHT BE IN THE AREA
MUST LEAVE IT IMMEDIATELY, CLOSING THE DOOR.
BEFORE ENTERING THE AREA AFTER ALL OF THE DISCHARGES HAVE TAKEN
PLACE, ENSURE THAT THE FIRE HAS BEEN COMPLETELY EXTINGUISHED AND
CANNOT START AGAIN. THEN VENTILATE THE AREA ABUNDANTLY BEFORE
ENTERING IT.
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! DANGER
VENTS, DISCHARGES, DRAINS CAN INVOLVE RISK OF INTOXICATION, FIRE

AND EXPLOSION AND MUST BE ADEQUATELY CONVEYED. FOLLOW THE
INSTRUCTIONS GIVEN IN THE OPERATIONAL TECHNICAL DOCUMENTS (P&ID)
ANNEXED TO THE INSTRUCTION MANUAL.
! DANGER
COMBUSTED GASES PRESENT HIGH TEMPERATURE, LACK OF OXYGEN AND

SUBSTANCES WHICH ARE DANGEROUS IF INHALED. THE TURBINE EXHAUST
DUCTS MUST THUS BE INSPECTED FREQUENTLY AND KEPT IN PERFECT
EFFICIENCY TO AVOID LEAKAGE.
! DANGER
DO NOT USE INFLAMMABLE PRODUCTS FOR CLEANING ANY PART OF THE

MACHINE.
OBSERVE THE PRESCRIPTIONS FOR USE REPORTED IN THE SAFETY CHART
FOR THE PRODUCT.
! DANGER
VERIFY THE FUNCTIONING OF THE GAS AND FIRE DETECTORS ACCORDING

TO THE INSTRUCTIONS GIVEN IN THE RELEVANT SECTION OF THE
INSTRUCTION MANUAL.
! DANGER
IN EXPLOSIVE HAZARDOUS AREA IT IS PROHIBITED TO SMOKE, USE FREE

FLAME OR DEVICES THAT COULD BE A SOURCE OF IGNITION.
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1.10.8 Description of symbols used for signaling residual risk,

prohibition and obligation.
In the following are reported symbols that can be used for signaling
residual risk, prohibition and obligation with relative description.
"Limb crushing" residual risk (color yellow and black on machines,

black and white in instruction manuals)
"Entangling and dragging" residual risk (color yellow and black on

machines, black and white in instruction manuals)
"Falling" residual risk (color yellow an black on machines, black and

white in instruction manuals)
"Slipping and falling " residual risk (color yellow and black on
"High noise level” residual risk (color yellow and black on machines,
"Dangerous temperatures " residual risk (color yellow and black on

"Dangerous voltage" residual risk (color yellow and black on

"Toxic and poisonous substances" residual risk (color yellow and

black on machines, black and white in instruction manuals)
Generic risk signal, requires additional explanations in order to

identify the hazard associated with it (color yellow and black on
machines, black and white in instruction manuals).
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"Explosion area" residual risk (color yellow and black on machines,

"Suspended loads" residual risk (color yellow and black on machines,

PROHIBITION
“No access to unauthorised persons” signal (color red and black on

Signal for prohibition to carry out maintenance or servicing with parts

in motion (color red and black on machines, black and white in
instruction manuals)
Signal for prohibition to use scarves or ties (color red and black on
Signal for prohibition to remove safety devices and guards (color red
and black on machines, black and white in instruction manuals)
Signal for prohibition to use open flames and to smoke (color red and
black on machines, black and white in instruction manuals)
Generic prohibition signal, requires additional explanations to identify

the prohibition associated with it (color red and black on machines,
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Obligation
Signal for obligation to read and understand the instructions before

carrying out any operation on the plant (color white and blue on
machines, black and white in instruction manuals).
Signal for obligation to use protective gloves (color white and blue on
Signal for obligation to use a protective shield (color white and blue
on machines, black and white in instruction manuals)
Signal for obligation to use hearing protection (color white and blue
on machines, black and white in instruction manuals)
! DANGER
THE REMOVAL OF WARNING PLATES AND SAFETY DEVICES, WHICH PLAY A

SAFETY ROLE, IS FORBIDDEN. INOBSERVANCE OF THIS RULE CAUSES THE
LOSS OF THE GUARANTEE RIGHTS AND FULL LIABILITY BY THE PURCHASER.
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1.11 INFORMATION ON HAZARDS IN CASE OF FAILURE
The machine and its auxiliaries are designed according to the "Fail safe"
philosophy. In case of failure in the electric, hydraulic or pneumatic system
the group is stopped in safe conditions for both the machine and the
operators.
The control system is also designed according to the "Fail safe" philosophy.
Any faults in the control system will be identified by self-diagnostic programs,
which determine a positioning of the output signals to which safe conditions
correspond.
Failure due to breakage of the devices containing pressurized and/or

dangerous fluids, or to erroneous assembly/disassembly of the components
of systems containing pressurized fluids, may lead to conditions of danger for
the operator, such as the presence of dangerous gases, projection of fluids at
high pressure or temperature. For such hazards, refer to the paragraph on
residual risks relevant to mechanical hazards and those deriving from
materials and substances.
In case of failure due to breakage of parts of the machinery during operation,

the projection of parts is possible (although with minimum probability); for this
event refer to the paragraph on residual risks relevant to mechanical
hazards.
Startup of the machine requires confirmation of the command on the unit

control panel (or the DCS), so that the risk of accidental startup is highly
improbable. However, in the case of Station remote control, it will be
necessary to provide a procedure for notifying station personnel before
startup. This procedure will be prepared by the plant manager.
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1.12 GENERAL INFORMATION OF WARNING
The following precautions concern the Turbocompressor must be observed

during all service procedures.
Failure to observe one of these precautions can result in damage or
destruction to the machine.
The order in which these precautions appear does not imply any order of
importance.
! WARNING
TAKE MAXIMUM CARE TO AVOID IMPACT WHILE HANDLING THE MACHINE AND
ITS PARTS.
! WARNING
PRIOR TO PUTTING THE MACHINE IN SERVICE, ENSURE THAT THE SUCTION

SYSTEM IS CLEAN AND THAT NO OBJECTS HAVE BEEN FORGOTTEN INSIDE IT.
! WARNING
CAREFULLY OBSERVE ALL OF THE INDICATIONS ON THE MONITOR AND THE

INSTRUMENTATION PRIOR TO STARTUP AND DURING OPERATION. THE SPEED
OF THE MACHINE, THE “FIRING TEMPERATURE” AND THE MEASUREMENTS OF
EXHAUST TEMPERATURE AND POWER OUTPUT (WHEN AVAILABLE) ARE THE
BEST INDICATORS OF CORRECT OPERATION OF THE MACHINE.
! WARNING
IN CASE OF STOPPING FOR MALFUNCTION, DO NOT ATTEMPT ANOTHER

START BEFORE THE CAUSE HAS BEEN FOUND AND CORRECTED.
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! WARNING
CLOSE FOR PROTECTION ALL OF THE DUCTS OPENED DURING MAINTENANCE

TO PREVENT THE ENTRY OF EXTRANEOUS MATERIALS INTO THE SYSTEMS;
AVOID USING INSULATING TAPE.
! WARNING
AVOID BENDING CABLES; REPEATED BENDING OF CABLES COULD CAUSE

THEM TO BREAK.
! WARNING
KEEP FIRE-FIGHTING BOXES, COVERS, DOORS, AND PANELS CLOSED, WITH

ALL OF THE FASTENERS SCREWED TIGHT, WHEN ACCESS FOR INSPECTION IS
NOT REQUIRED.
! WARNING
WHEN DISCONNECTING ELECTRIC CABLES DO NOT USE TRACTION FORCE ON

THEM; DISCONNECT GRASPING ONLY THE CONNECTORS.
! WARNING
ENSURE THAT CHECK VALVES AND CONTROL VALVES ARE INSTALLED

ACCORDING TO THE CORRECT DIRECTION OF FLOW.
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! WARNING
ENSURE THAT ANY MALFUNCTIONING PARTS ARE CUT OUT AND THAT A «DO
NOT USE» SIGN IS PLACED ON THE SWITCHES. AVOID IN ANY CASE USING
THE TURBINE IF ALL OF ITS PARTS AND ACCESSORIES ARE NOT IN PERFECT
CONDITION.
! WARNING
IF THE TURBINE MUST REMAIN IDLE FOR LONG PERIODS OF TIME, IT MUST BE
PROTECTED ON THE INSIDE WITH SACKS OF VPI (VAPOUR PHASE INHIBITOR)
AND THE OPENINGS MUST BE SEALED.
SIGNS MUST BE POSTED TO NOTIFY THE PRESENCE OF THE SACKS.
THE SACKS OF VPI SHALL BE REMOVED PRIOR TO STARTING AGAIN.
THE SAFETY RECOMMENDATIONS RELEVANT TO THE VPI PRODUCT UTILIZED
MUST BE OBSERVED.
IF THE COMPRESSOR MUST REMAIN IDLE FOR LONG PERIODS OF TIME, IT
MUST BE PRESSURIZED ON THE INSIDE WITH INERT GAS (NITROGEN). ANY
DAMAGE CAUSED BY A PERIOD OF IDLENESS DURING WHICH THE PRODUCT
HAS NOT BEEN PUT IN MAINTENANCE CONDITIONS, SUCH AS TO ENSURE ITS
PERFECT PRESERVATION, WILL BE AT THE EXPENSE OF THE CUSTOMER.
BEFORE THE TURBUCOMPRESSOR IS STARTED AGAIN, IT MUST BE

INSPECTED BY GE OIL & GAS NUOVO PIGNONE PERSONNEL, WHO WILL
DECIDE, ON THE BASIS OF THE STATE OF PRESERVATION OBSERVED, WHAT
ACTION SHOULD BE TAKEN.
! WARNING
IF ANY PART OF THE TURBINE AND/OR COMPRESSOR AND/OR GENERATOR

ROTOR APPEARS DAMAGED DUE TO CRACKS, SLITS OR REMOVAL OF
MATERIAL, IT IS RECOMMENDED THAT THE GE OIL & GAS NUOVO PIGNONE
TECHNICAL SERVICE BE CONTACTED.
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! WARNING
FOR THE FIRST STARTUP OF THE MACHINE, PLACE A TEMPORARY FILTER ON

THE SUCTION PIPING, CLOSE TO THE COMPRESSOR; THIS FILTER CAN BE
REMOVED WHEN ALL OF THE PIPING ARE CLEAN.
PRIOR TO STARTING THE LUBE OIL SYSTEM IT WILL BE NECESSARY TO

PRESSURIZE WITH NITROGEN OR AIR THE THIRD SEAL (WITH CARBON RINGS
OR LABYRINTH TYPE) PLACED BETWEEN THE MECHANICAL GAS SEAL AND
THE BEARINGS (REFER TO PARAGRAPH RELEVANT TO STARTING OF THE
GAS SEAL SYSTEM).
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1.13 EUROPEAN ATEX DIRECTIVE INFORMATION
! DANGER
SUBSTITUTION WITH NON-ORIGINAL SPARE PARTS OR PARTS OTHER THAN

THOSE RECOMMENDED BY THE MANUFACTURER IS FULL RESPONSIBILITY OF
THE USER AND CAUSES IMMEDIATE DECAY OF THE GUARANTEE, OF THE
ATEX CERTIFICATE AND, IN GENERAL, OF CONFORMANCE WITH THE CE
MARKING AND THE RELATIVE DIRECTIVES.
THE MANUFACTURER DISCLAIMS ALL LIABILITY FOR DAMAGE TO PERSONS
AND/OR THINGS ARISING FROM THE USE OF NON-ORIGINAL SPARE PARTS.
IN ADDITION, NON-COMPLYING WITH THESE PRECAUTIONS OR SAFETY
REGULATIONS AND/OR REMOVING OR CHANGING ANY SAFETY GUARDS, AS
WELL AS THE EXPIRATION OF THE MANUFACTURER'S WARRANTY AND THE
ADOPTION OF FULL LIABILITY ON THE PART OF THE USER, CAN CAUSE
INCIDENTS, EVEN SERIOUS.
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ITEM Description
1 Macchine NP - (NP Machine)
‘Turbina’
(Turbine)
2 Tipo Macchine NP - (NP machine type)
Codice Turbina es. PGT25+DLE
(Turbina type ex. PGT25+DLE)
3 Matricole Macchine NP (NP SERIAL NUMBER)
Matricole es.’642-149/go6487/c12194’
(NP SERIAL NUMBER Ex.’642-149/go6487/c12194’)
4 Anno (Year)
Es.’2003’
(Ex. ‘2003’)
5 Dettagli delle Macchine NP - (Details of NP machine)
Per Turbine a Gas: Tipo di Alimentazione, Potenza ISO, Temperatura di
scarico al camino.; Per compressori: Pressione di mandata, Portata
nominale; Per Turbine a vapore: Pressione nominale ingresso/uscita,
Temperatura nominale ingresso/uscita, Portata nominale
(For Gas Turbines. Type of fuel gas supply, ISO power, stack exhaust
temperature; for compressors: delivery pressure, rated flow; for steam
turbines: nominal inlet/outlet pressure, nominal inlet/outlet temperature,
rated flow)
6 Tipo di Certificazione - (Type of Certification)
Es.’II 3G’
(EX. ‘II 3G’)
7 N°. Ente Notificato - (Notified Authority No.)
es.’0722’
(ex ‘0722’)
8 Numero di Certificato - (Certificate Number)
Es.’CESI 03ATEX 088X’
(Ex.’CESI 03ATEX 088X’)
9 Temperatura ambiente / Certif. (Certified ambient temperature)
Es.’-20¸+40°C’
(Ex.’-20¸+40°C’)
10 Note - (Notes)
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EXPLOSION PROTECTION LABELLING
ATEX label information
P R O T E C T IO N E X P L O S IV E A T M O S P H E R E
If d iffe re n t
c o n d itio n s a re
II 3 G E E x n L IIA T 2 re q u ire d u s e “X ”
T1 4 5 0 °C
T2 3 0 0 °C
I M in in g SURFACE T3 2 0 0 °C
GROUP TEM PERATURE T4 1 3 5 °C
II N o n -m in in g
T5 1 0 0 °C
T6 8 5 °C
1 H ig h le v e l o f p ro te c tio n
(E x p lo s iv e a tm o s p h e re s
IIC A c e ty le n e
p re s e n t c o n tin u o s ly )
HAZARD IIC H y d ro g e n
2 H ig h le v e l o f p ro te c tio n
CATEG O RY IIB E th y l
(E x p lo s iv e a tm o s p h e re s
CATEG O RY IIA P ro p a n e
p re s e n t fre q u e n tly )
3 N o rm a l le v e l o f
p ro te c tio n (E x p lo s iv e << o >>O il im m e rs io n
a tm o s p h e re s << p >>P re s s u riz a tio n
in fre q u e n tly ) << q >>P o w d e r F illin g
<< d >>F la m e p ro o f
e n c lo s u re
HAZARD D D u s t A tm o s p h e re
<< e > > In c re a s e d S a fe ty
TYPE G G a s A tm o s p h e re
<< ia > > o r < < ib > > In trin s ic
S a fe ty
P R O T E C T IO N << m > > E n c a p s u la tio n
C o m p lia n c e w ith o n e << n > > N o n -in c e n d iv e
C O M P L IA N C E
o r m o re s ta n d a rd s A - N o n -s p a rk in g
C - S p a rk in g
R - R e s tric te d -
N o te : W h e n s p e c ia l c o n d itio n s a re c o v e re d b y th e c o m p o n e n t a n “X ” b re a th in g
s h o u ld in d ic a te th is (i.e . D iffe re n t te m p e ra tu re ra n g e , a tm o s p h e ric L - E n e rg y -lim ite d
c o n d itio n s , s p e c ia l c o n s id e ra tio n s fo r o p e ra tio n ). A ll th is c o n d itio n s P - E n c lo s u re w /
w ill th e n b e in d ic a te d o n th e c o m p o n e n t’s d o c u m e n ta tio n .
P re s s u riz a tio n
Temperature class
Flammable gases and vapours are divided into temperature classes for their
inflammability on hot surfaces.
Temperature Maximum surface

class temperature [°C]
T1 450
T2 300
T3 200
T4 135
T5 100
T6 85
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Type of mechanical protection against ignition
The type of mechanical protection against ignition describes the type of measures
used to prevent ignition in a potentially explosive atmosphere.
European Standard Protection mode Protection symbol

13463-1 Basic method and N/A
requirements
13463-2 Protection by flow restricting fr

enclosure
13463-3 Protection by flameproof d

enclosure
13463-4 Protection by inherent safety g
13463-5 Protection by constructional c

safety
13463-6 Protection by control of ignition b

sources
13463-7 Protection by pressurisation p
13463-8 Protection by liquid immersion k
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Type of electrical protection against ignition
The type of electrical protection against ignition describes the type of measures
used to prevent ignition in a potentially explosive atmosphere.
European Practice Zone ATEX CENELC IEC

Cat. EN 60079
General 50014 -0
Requirements
Oil-immersion 1,2 2,3 50015 -6
Ex "o"
Pressurization 1,2 2,3 50016 -2
Ex "p"
Powder-filling 1,2 2,3 50017 -5
Ex "q"
Flameproof 1,2 2,3 50018 -1
Ex "d"
Icreased Safety 1,2 2,3 50019 -7
Ex "e"
Intrinsic Safety 0,1,2 1,2,3 50020 -11
Ex "ia"
Intrinsic Safety 1,2 2,3 50020 -11
Ex "ib"
Intrinsically Safe 50039 -25
Systems
Encapsulation 1,2 2,3 50028 -18
Ex "m"
Non-incendive 2 3 50021 -15
Ex "n"
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Ex atmosphere
The Ex atmosphere describes the type of potentially explosive atmosphere in a

zone.
Ex atmosphere Meaning
G Flammable gases and vapours
D Flammable dusts
Equipment group / Area of use / Zone / Category
The zone depends on the probability of occurrence of a potentially explosive

atmosphere and differentiates between gases and dusts.
The category describes the safe design of the product and depends on the zone.
Equipment Zone Category Frequency of occurrence Safe design

group /Area of dangerous, potentially
of use Explosive atmospheres
1 / underground comparable 0 M1 — very high
(G)
and 1 (G)
1 / underground comparable 2 M2 — high
(G)
II / other 0(G) 1 Constantly or over long very high
20 (D) periods or frequently
II / other 1(G) 2 occasional (any faults high

21 (D) occurring may not become
source of ignition)
II / other 2(G) 3 unlikely; if it does occur, normal

22 (D) then rarely and short-term (In
normal operation, surface
temperature may not become
source of ignition)
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APPENDIX
The information contained in this chapter is intended as an aid to the Plant Manager to create the
safety procedures, as he shall have to consider also the hazards and information contained in this
document.
A.1 PERSONAL PROTECTION EQUIPMENT (PPE)
Some indications on the use of personal protection equipment are given

below.
By Personal Protection Equipment (PPE) we mean any equipment destined

to be worn and kept by a worker in order to protect him against one or more
risk liable to jeopardize safety and health at work, as well as any accessory
intended for that purpose.
Any other work garment or equipment not expressly destined to worker
protection is not a PPE.
PPE shall be used when risks cannot be removed or reduced efficiently by
prevention, work organization and collective protection equipment. In
practice, PPE cannot represent an alternative to technically feasible
prevention systems, but can only be a supplement to residual or occasional
risks.
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PPE shall comply with provisions of law and meet following general
requirements:
News on protections provided

INFORMATION Limits of use
Pot-life before expiration
REQUIREMENTS Clear directions for use in a language
understandable by workers
Protection efficiency
Protection duration
Expiry date
SAFETY REQUIREMENTS Harmlessness
Absence or risks caused by the same PPE
Solidity
Reduced discomfort
PERFORMANCE Hindrance effects limitations
Practical functionality
REQUIREMENTS Compatibility with other PPE (simultaneous use
when a worker is subject to multiple risks)
Lightness
Ergonomic properties
Limited dimensions
COMFORT Transportability
Thermal comfort
Hygiene (PPE used by several workers)
It being understood that PPE offer protection against chemical-physical-

biological risks (hygienic risks) or against risks caused by injuries, they shall
anyway be suitable for existing risks, from the qualitative and quantitative
viewpoint.
The selection of the appropriate PPE shall not be accidental. The plant
manager shall identify the best equipment, resultig from the experience and
technique in order to safeguard worker physical integrity in relation with a
specified risk.
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The selection of a given PPE instead of another is determined by a

comparison between:
 Requirements resulting from risk assessment

 Substances characteristics
 Methods of use and workers exposition level
 Working environment conditions.
! DANGER
WORKERS WILL HAVE FOLLOWING OBLIGATIONS:

 THEY SHALL USE PPE PUT AT THEIR DISPOSAL AND FOLLOW
OPERATING INSTRUCTIONS RECEIVED WITH CARE.
 THEY SHALL TAKE CARE OF PPE, WITHOUT MODIFYING THEIR
CHARACTERISTICS ON THEIR OWN INITIATIVE
 THEY SHALL IMMEDIATELY NOTIFY ANY BREKAGE OR DEFECT OF PPE
PUT AT THEIR DISPOSAL TO THE PLANT MANAGING AUTHORITY,
MANAGER OR PERSON IN CHARGE;
 THEY SHALL COMPLY WITH PROCEDURES RELATING TO PPE RETURN
AT THE END OF WORKING TIME.
A not exhaustive list of operators’ main personal protection equipment is

shown below.
Body Protection
Head protection – Hair
Helmet
Quite frequently during work performance, head is subject to several
hazardous conditions such as shocks, fall of material from above etc. It is
therefore necessary to protect your head with a suitable helmet.
In general, safety helmets are made of strong plastic material (thermoplastic
polycarbonate) or strengthened material (fiberglass) or metal (aluminium or
light alloys).
Helmets shall have following characteristics:
 Be Suitable for and adjustable to user head size;
 Shock absorbing;
 Perforation-proof;
 Sunlight and rain proof;
 Not inflammable;
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Dielectric properties (perforation strain shall not exceed 10 Kv);

Be disinfectable and washable;
Its weight shall not exceed 425 g (helmets with visors), 475 g (helmets with
annular brim) and 550 g (special helmets), except possible accessories .
! DANGER
IN ORDER TO ENSURE MAXIMUM HELMET PROTECTION EFFICIENCY, IT WILL

BE NECESSARY TO COMPLY WITH FOLLOWING METHODS OF USE:
 KEEP YOUR HELMET FIRMLY TIGHTENED ON YOUR HEAD, BY
FASTENING THE SPECIAL BUCKLE UNDER YOUR THOAT
 CHECK INTEGRITY OF ALL HELMET COMPONENTS DAILY;
 CLEAN YOUR HELMET PERIODICALLY, IN COMPLIANCE WITH CLEANING
METHODS SPECIFIED BY THE MANUFACTURER; AVOID USING SOLVENTS
OR OTHER CHEMICALS WHICH MIGHT DETERIORATE ITS STRUCTURE.
 DO NOT MODIFY OR REMOVE ANY HELMENT ORIGINAL COMPONENT.
AS A GENERAL RULE, SINCE IT IS NOT ALWAYS POSSIBLE TO EXCLUDE “A
PRIORI” HEAD HAZARDS, IT IS RECOMMENDED TO USE CONSTANTLY A
SAFETY HELMET WHEN PERFORMING SPECIFIC TYPES OF WORK.
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Hand-arm protection
General considerations
When carrying out specific work entailing risks for hands and arms, it is
necessary to use suitable protection equipment such as gloves.
As a general rule, following behaviour should be adopted:
 Use specific gloves according to the type of work to be carried out;
 Use gloves with a constant thickness, withouh holes and easy to wear;
 In the event of toxic substances, use sufficiently long gloves, at least
up to your forearm;
 Do not use gloves which adhere to your skin too closely, in order to
limit sweating;
 Check for integrity of protection equipment, every day;
 Avoid using deteriorated a/or torn protections;
 Avoid using gloves for excessively long working cycles (their extended
use leads to formation of mold and bacteries capable to infect even
the smallest wound or excoriation because of dirt accumulation and
perspiration absorption);
Avoid using gloves worn by other operators.
Protection Gloves against physical agents (mechanical, thermal and

electrical).
Physical, mechanical and thermal agents
In the event of heavy and physically exhausting work, in thermal processes,
etc, it will be necessary to use extremely strong gloves made of different
material such as kevlar, leather, cotton etc. They can also be reinforced with
metal or other strong materials.
In the event of work exposing hands at high temperature, it is recommended
that aramidic fiber gloves be used; this material has a high shear resistance,
is hard wearing and heat resistant (it can resist for about 6 minutes at 220 °C
before glove inside temperature reaches a burn level of 78 °C).
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Electricity
As regards contact hazard with live equipment, it is essential to use insulating
gloves, made of rubber latex, on which the maximum bearable voltage, which
may go from 5.000 through 30.000 V shall be written.
! DANGER
IT WILL BE NECESSARY TO ADOPT FOLLOWING BEHAVIOUR :

 NEVER WORK ON EQUIPMENT WHOSE VOLTAGE EXCEEDS THAT
SHOWN ON YOUR GLOVES;
 CLEAN GLOVES REGULARLY ACCORDING TO METHODS SPECIFIED BY
THE PRODUCER;
 STORE GLOVES IN A SUITABLE PLACE;
 CHECK FOR GLOVE INTEGRITY BEFORE USE.
Safety glove against chemical agents

In the event of activities entailing contact with chemicals such as solvents,
corrosive material and chemicals in general, it will be necessary to use safety
gloves which shall be fit for the handled chemical product (non-corrodible,
waterproof, etc.), as shown below (not exhaustive list).
! DANGER
FOLLOWING BEHAVIOUR SHALL BE ADOPTED:

 CLEAN GLOVES REGULARLY ACCORDING TO METHODS SPECIFIED BY
THE PRODUCER;
 STORE GLOVES IN A SUITABLE PLACE;
 CHECK FOR GLOVE INTEGRITY BEFORE USE.
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Natural PVC 20 PVC 50

Chemical Nitrile Neoprene
rubber ºC ºC
Acetic acid (30%) S B B M M
Acetone B S S S M
Amile acetate S M S S S
Benzene S M S S S
Calcium hypochlorite M S B B B
Hydrochloric acid (30%) B B B B B
Chloroform S S S S S
Petrol S B M S M
Ethyl oxide S B S S S
Ethyl alcohol B B B M B
Ethyl glycol B B B B B
Hydrofluoric acid (60% at

B B M S B
26°C max)
Formaldehyde (40% at amb.

S B M / B
Temperature)
Freon (liquid) B M M M B
Grease S M M S M
Hydrogen peroxide S M M S M
Kerosene S B M S M
Lube oils S S M M M
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Natural PVC 20 PVC 50

Chemical Nitrile Neoprene
rubber ºC ºC
Methyl alcohol (water sol.

B B B B B
6%)
Nitric acid (20% at 50°C) S M B B M
Nitric acid 70% S M M S S
Paints S B B M B
Sodium hydroxide (35% at

M B B M M
32°C max)
Sodium hydroxide (10% at

B B M M B
66°C max)
Sulphuric acid (about 50%) B B B B B
Sulphuric acid (about 80%) S M M M M
Sulphuric acid (about 90%) S S M S S
Toluol S S S S S
Legend:
Resistance of the various materials with which safety gloves can be made and chemicals:
S = low resistance,
M = medium resistance,
B = good resistance.
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Symbols adopted for safety gloves
European standards provide for the use of pictograms allowing the selection
of the right type of gloves for the risk involved; each pictogram indicates
different performance level.
Pictogram Reference regulatory standard Performance levels i
a Abrasion resistance 0-4
b Blade cutting resistance 0-5

EN 388 Mechanical risks
c Tear resistance 0-4
d Perforation resistance 0-4
EN 388 Mechanical risks Impact risk
EN 388 Mecahnical risks Static electricity
Resistance to penetration of
EN 374 Chemical and
micro-organism through porous 1-3
micro-organism risks
materials, seams,etc.
EN 374 Chemical and Resistance to chemical

1-6
micro-organism risks damages (permeation time)
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Pictogram Reference regulatory standard Performance levels i
0-4
a Resistance to flame
0-4
b Resistance to contact heat
0-3
c Resistance to convective
heat
EN 407 Heat risks 0-4
d Resistance to radiating heat
e Resistance to cast material

0-4
spitting
f Resistance to large
0-4
quantities of cast material
a Resistance to convection 0-4

cold
EN 511 Protection against cold b Resistance to contact cold 0-4

temperatures
c Water proof 0-1
(0 permeable after
30 minutes)
EN 421 Protection against ionizing

radiations and radioactive
contamination
Feet-legs Protection
General Considerations
In the event of activities entailing feet and legs risks, it will be necessary to
wear safety shoes which may vary according to the type of hazard.
Feet and legs risks are numerous, some of them are listed below:
 Crushing;
 Sole perforation;
 Contact with white-hot material;
 Object fall;
 Collision against fixed obstacles;
 Electric discharges;
 Contact with chemicals;
 Slipping;
 etc.
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Safety shoes
Safety shoes may have different characteristics according to the type of
protection they have to provide:
 Toe-end shall be metal-reinforcd and all surfaces, edges and corners
shall be smooth and rounded;
 Shoes can be of the easy slip-off type;
 Shoe sole is provided with a perforation-proof sheet (should any risk of
sole perforation exist);
 In some conditions it may be necessary to install a metatarsal
protection;
In the event of activities entailing vibrations risks, it will be possibile to use
dampening type soles.
! DANGER
IN ORDER TO ENSURE A LONG DURATION AND MAINTENANCE OF

FUNCTIONAL CHARACTERISTICS, IT WILL BE NECESSARY TO KEEP SHOES
CLEAN AFTER USE. LET THEM DRY IN A WELL VENTILATED PLACE, AWAY
FROM ANY SOURCE OF HEAT AND REMOVE ANY SOIL OR OTHER SUBSTANCE
RESIDUE.
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Protection of organs and sensitive parts

Eyes-face protection
When performing activities entailing any risk of eyes/face damage, it will be
necessary to use special protections such as goggles and visors.
Risk elements which may cause damages to eyes and face, are listed below:
MECHANICAL AGENTS
Splinters, collision with solid material, compressed air, etc.
OPTICAL AGENTS
Infrared rays, laser rays, very strong light, ultraviolet rays.
THERMAL AGENTS
Liquid or solid substances, radiant heat.
CHEMICAL AGENTS
Fluids (gas or liquid) solid substances.
! DANGER
WHEN USING PROTECTION EQUIPMENT FOR EYES AND FACE IT WILL BE

NECESSARY TO ASOPT FOLLOWING BEHAVIOUR:
 CLEAN REGULARLY GLASSES AND VISORS ACCORDING TO METHODS
SPECIFIED BY THE PRODUCER;
 STORE GLASSES AND VISORS IN AN APPROPRIATE PLACE;
 CHECK FOR GLASSES AND VISORS INTEGRITY BEFORE USE;
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Glasses shall fit tightly to your face.
Goggles for protection against dust, sprays and liquids

When activities require the use of pressure fluids a/o chemicalx which may
spurt, such as during work on pipes or liquid transfer, it will be necessary to
use glasses to fully protect eyws, such as goggles.
Usually, this type of protection can also be used directly on reading glasses.
Safety glasses against splinters

In the event of activities entailing the production of splinters, it will be
necessary to wear special splinter-proof glasses for side protection or
goggles.
Safety glasses against dust, spurts and liquids

In the event of welding operations, it will be essential to wear glasses and
special shields, both against incandescent metal spurts and for the different
types of radiations emitted during welding.
Protection equipment vary as a function of welding type. It is essential to use
the most suitable protection for the type of welding performed.
Visor for face protection

Visors are used in the event of material projection and bursts of flame etc.
Visors cannot provide side protection, therefore, in the event of activities
which may produce sprinkling a/o substances dispersed in the air, it will be
necessary to use goggles.
Visors provide good eyes and face protection allowing also good ventilation.
As a general rule, visors can be fixed to safety helmets or directly on the
head through a special harness.
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Ear protection
General considerations
Many activities generate noise which may cause damages to ears auditory
power. The reduction of such capacity depends on sound wave intensity,
duration and frequency. Furthermore, auditory damages are not curable.
There are several ear protection types and it is necessary to identify the most
suitable equipment for the type of noise and the exposed operator
characteristics.
! DANGER
WHEN USING EAR PROTECTION EQUIPMENT, IT WILL BE NECESSARY TO

OBSERVE FOLLOWING RULES:
 CLEAN PROTECTION REGULARLY, ACCORDING TO METHODS
SPECIFIED BY THE PRODUCER;
 PROTECTION REPLACEMENT SHALL BE CARRIED OUT ACCORDING TO
METHODS SPECIFIED BY THE PRODUCER;
 STORE PROTECTIONS IN AN APPROPRIATE PLACE;
 CHECK FOR PROTECTION INTEGRITY BEFORE THEIR USE.
Plugs
Plugs protect ears against high level noise if correctly introduced in the
auditory channel.
There are three types of plug:
 Mouldable plugs for all types of ear

These are disposable plugs, comfortable, healthy and economical.
 Custom-made plugs
These plugs are custom-made on the basis of the exact ear shape.
They are reusable, healthy, durable but need regular care and
cleaning.
 Pre-moulded plugs
These plugs are made of soft silicone, rubber or plastic and practically
suit any types of ear.
They are reusable, healthy, durable but need regular care and
cleaning.
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Channel capsules
Channel capsules are used to close auditory channel opening.
They are made of rubber material with a stiff core in order to maintain its
shape.
As a general rule, channel capsules can be used by people who have to
enter and exit quite frequently from a very noisy room.
Earcaps
Earcaps are made up of :
 Plastic cups filled with foamy material
 Pads covered with plastic and foam filled.
 A connecting strip which, counterweighted, maintains cups closely-fit
to ears.
 There are several types of earcups (as a function of the noise and
work type for which they are used) and they represent the only ear
protection for workers which cannot use plugs.
 Earcaps, together with ear plugs provide the maximum auditory
protection possible.
 Earcaps on their own can ensure a noise reduction of 15 to 30 dB.
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Respiratory system protection

In the event of working environment where a risk of gas, dust or any other
pollutant dispersed in the air exists, it is absolutely essential to wear suitable
protection equipment for the respiratory system.
It is clear that it will be necessary to use a specific PPE as a function of the
type of hazard.
! DANGER
ALL RESPIRATORY SYSTEM PROTECTION MEANS SHALL BE CHECKED

BEFORE USE, AND WORN ONLY BY TRAINED PERSONNEL; THEIR USE IS
STRICTLY INDIVIDUAL.
As a general rule, gases injurious to respiratory system can be :
 TOXIC
They modify normal blood and nervous system operation.
 SUFFOCATING- IRRITATING
They damage lungs and respiratory system
 AXPHYXIATING
They make breathing impossible.
Main types of PPE for the respiratory system protection are as follows:
 DISPOSABLE DUST-PROOF FILTERING FACE PROTECTIONS

This type of protection is efficient against non toxic dusts and in a few
cases, also against, toxic and injurious dusts. Their proper use
requires a clean and shaved face.
 DUST-PROOF FILTER MASKS

This type of protection (which may be a half-mask or a complete face
mask, with or without blower) is used to remove the finest and most
dangerous particles from breathed-in air.
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 SINGLE/MULTI-PURPOSE GAS FILTER MASKS

This type of protection (which usually cover the entire face) is used to
remove gases and toxic or injurious vapors from breathed-in air.
Gas filters are rated according to the type of gas they can filter and are
distinguished by a specific color according to the type of gas against
which they protect, as shown on the summarizing table.
! DANGER
GAS MASKS MAIN LIMITATIONS OF USE ARE AS FOLLOWS:

 OXYGEN PERCENTAGE IN THE AIR SHALL BE AT LEAST EQUAL TO 17%;
 GAS, VAPOURS AND AIR PARTICLE PERCENTAGES SHALL NOT EXCEED
THOSE SPECIFIED ON THE FILTER;
 IN THE EVENT OF SIMULTANEOUS AND DOUBTFUL PRESENCE OF GAS
AND AEROSOL, IT WILL BE NECESSARY TO USE A COMBINED FILTER (IF
AIR GAS FILTER IS USED, AEROSOL SHALL NOT BE PRESENT, AND
VICEVERSA);
 IN ORDER TO ENSURE MAXIMUM TIGHT-FITTING OF GAS MASKS, THEY
SHALL BE USED ONLY ON CLEAN AND SHAVED FACES;
 AS A GENERAL RULE, GAS FILTER MASKS SHALL NOT BE USED IN
CONFINED ENVIRONMENTS (SEWAGE, TRENCH DUCTS, ETC).
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 BREATHING APPARATUSES
This protection equipment intakes air from absolutely not polluted
areas and send it to areas where the worker has to operate for an
extended lapse of time and where oxygen is lacking. These breathing
apparatuses consist of fans or compressed air systems.
 SELF-CONTAINED BREATHING APPARATUS

These instruments allow workers to operate in environments with
polluted and low oxygen content air, for not very long time (and
according to thoxygen reserve contained in a portable bottle or
cartridge attached to the self-contained breathing apparatus).
As a general rule, self-contained breathing apparatus are easier to
wear and effective in emergency conditions.
! DANGER
WHEN USING THIS TYPE OF EQUIPMENT, IT IS ALWAYS NECESSARY TO USE A

SAFETY HARNESS WITH LIFE ROPE. THE WORKER PERFORMING ANY
EMERGENCY OPERATION SHALL BE IN CONSTANT TOUCH WITH OTHER
OPERATORS IN CHARGE WITH SURVEILLANCE, OUTSIDE THE OPERATION
AREA.
Protections for specific work requirements
Fall protection (activities on scaffolding, ladders, etc.)
! DANGER
IN THE EVENT OF ACTIVITIES ENTAILING ANY RISK OF FALL (SCAFFOLDING,

LADDERS, ETC.) IT WILL BE NECESSARY TO USE SPECIAL PROTECTIONS,
SUCH AS SAFETY BELTS FOR OVERHEAD ACTIVITIES, SAFETY HARNESS FOR
LIFTING, FALL PREVENTION BELTS AND HARNESSES.
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 SAFETY BELT FOR OVERHEAD ACTIVITIES

This belt consists of a textile fiber and leather strap and is attached to
two large rings through a textile fiber rope or a chain.
This type of belt is used to secure the operator at work level, in the
event of activities at overhead positions.
 FALL PREVENTION SAFETY HARNESS

This harness consits of braces and tigh guards and is attached to a
safety rope which, in its turn, is attached to a fixed structure or through
a ring, to another tensioned rope, in order to limit any fall to not more
than 1,5 m.
It is used for stopping worker accidental fall from above or inside any
cavity.
 LIFTING SAFETY HARNESS

This harness consists of braces, tigh guards and a ring for rope
attachment, placed between worker shoulder blades.
This type of harness is used to lift workers who are taken ill or who
cannot be taken away from the working place in any other way.
Such harness shall be tight and not cause excessive strains on worker
and shall allow body lifting in a vertical position.
 HIGH VISIBILITY GARMENTS AND EQUIPMENT (NIGHT WORK)

In the event of night work, but also during some day working where a
high worker visibility is required, it will be necessary to wear special
garments and working devices:
 HIGH VISIBILITY GARMENTS

These garments are totally or partially made with fluorescent materials
where fixed refractive inserts have been applied.
 HIGH VISIBILITY AUTONOMOUS EQUIPMENT

These are devices such as braces, undervests, jackets or other, made
of fluorescent or refractive materials which must be worn directly on
clothes.
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Symbols
Obligation to use protection gloves

(blue and white color on machines, black and white on
instruction and maintenance handbooks)
Obligation to use protection shields

Obligation to use ear protections

Obligation to use insulating gloves

Obligation to use eyes protection

Obligation to use safety helmet

Obligation to use safety shoes

Obligation to use respiratory system protection equipment

Obligation to use safety belts

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B.1 CLASSIFICATION, SYMBOLOGY AND LABELING OF THE PRODUCTS

ACCORDING TO THEIR FEATURES
B.1.1 Classification and symbology
The chemical products which represent a health or environmental

hazard have to be classified by the producer and each risk class has
to be countersigned by a graphic symbol; ten risk classes are
provided for by law.
Risk classes
Precautions to be
Risk description Product examples
Meaning Symbol taken
- Toxic and - Methanol, - To avoid any

Toxic
harmful substances combustible contact with the
(T)
and preparations alcohol, dry skin make use of
which represent a cleaners, sprays, the safety
Very Toxic health hazard even waterproofings equipment: gloves,
(T+) in small quantities. - Disinfectant, screen, overalls,
- When even creolin etc.
small quantities - Dry - Work outside
cause severe cleaners, or in a well
health problems, Trichloroethylene. ventilated room
the product is - Solvents whenever possible.
Harmful
labeled as “toxic”. - Cleaning - To observe
(N)
- The products products hygienic rules:
above penetrate - Wood wash hands, do not
the organism by treatment product eat or smoke at
inhalation, work.
- F The easily - Petroleum, - Keep the
Easily
inflammable gasoline products in well
Inflammable
products get - Combustible, ventilated room
(F) primed in presence alcohol or - Never use in
of a flame, a methanol the vicinity of a
source of eat - Turpentine, source of heat, or a
(heated surface) or white spirit hot surface, in
sparks. - Acetone presence of sparks
Extremely - F+ Product - Detergent for or non protected
Inflammable capable of taking brushes, paint flame.
(F+) fire very easily by solvents - No smoking!
means of a source - Spray - Do not wear
of energy (flame, painting, metallic nylon garments
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- For
combustion it is
necessary the
presence of a
comburent
substance, of the
Comburent oxygen and flame,
(O) combustible is
accelerated in
presence of a
comburent product
(substance
containing a lot of
oxygen)
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Risk classes
Precautions to be
Risk description Product examples
Meaning Symbol taken
- The - Substances - Keep the

corrosive for unplugging products in the
substances drains and original package
seriously harm removing tartar (containers
tissues as well as deposits perfectly closed,
other substances. - Caustic soda safety plug)
The reaction may - Acid, - Keep out of
Corrosive
occur in presence Sulphuric acid the reach of
(C)
of water or (batteries) children
humidity - Detergents - Pay attention
for ovens and to the position.
toilets Never put them on
- Products for window-sills, etc.
washing machines (fall hazard)
(humid) - Protect eyes,
- Continuous - Bleach skin, etc. against
contact with irritant - Turpentine ejections.
products may - Ammonia - Pay attention
cause inflammation - Sealant whenever the
of the skin and product is
mucous membrane decanted or
spread. Make use
of gloves and
protective goggles
- Hygiene is of
Irritant the utmost
(Xi) importance: Wash
hands and face
after use.
- Abundant 10
minute rinsing may
be effective as
emergency
operation
- Corrosive
aerosol products
are dangerous
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- Explosion is - Any type of - Avoid

a very quick aerosols (even overheating and
combustion when empty) are shocks, shade from
depending on the potential bombs sunrays
product features, when exposed at - Never store
temperature temperatures near sources of
Explosive (source of heat), above 50°C. heat, lamps and
(E) contact with other - Air purifier radiators.
products (reaction), - Hair spray - Not smoking
shocks, frictions, - Dyes
etc. - Paints
- Antifreeze
for windshield
- Etc
- Substance: - Active - Eliminate the
- very toxic to aquatic products in product or its
organisms pesticides residuals as well as
Dangerous - toxic to fauna - CFC dangerous wastes
for - dangerous for the - Avoid
environment ozone layer environment
(N) contamination
thanks to a proper
storage
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B.1.2 Simbology, labeling and risk phrases
A label with the phrases “R” describing the main risks and the
precautions “S” to be taken (prudence advices) must be reported,
written in readable, ineffaceable characters, and in the
commercialization country mother tongue, on the original packaging.
LEGEND:
6. Name, address and telephone number of the manufacturer, distributor or

importer.
7. Identification of the product, in case of pure product or substance it is
the mere chemical denomination of the commercialized product. In case
of a preparation it is the denomination of the commercialized product.
Anyway, whenever toxic, very toxic, harmful or corrosive substance
exceed a certain maximum concentration, the relative chemical
denomination must bear the inscription:
“contains……………”
8. One or two black symbols on an orange background correspondent to

the most serious dangers caused by the substance or preparation. Each
symbol is accompanied by an explanation in full: F = easily flammable;
Xn = harmful, etc.
9. “R” phrases: most serious risks related to the product (substance or
preparation) reported as standard phrases defined by law:
10. "S" phrases: advices on the precautions to be taken while using the
product (substance or preparation)
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! WARNING
NOT ALWAYS THE LAW REQUIRES THE APPOSITION OF THE COMPLETE

LABEL: SOME PRODUCTS OR SOME KIND OF PACKAGES CAN HAVE LABELS
WHICH LACK “R” OR “S” PHRASES OR OTHER INDICATIONS WHICH HAVE
BEEN CONSIDERED NOT ESSENTIAL BY THE MANUFACTURER
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B.1.3 Risk phrases
Code Description
R1 Explosive when dry
R2 Risk of explosion by shock, friction, fire or other source of ignition
R3 Extreme risk of explosion by shock, friction, fire or other sources of
R4 Forms very sensitive explosive metallic compounds
R5 Heating may cause an explosion
R6 Explosive with or without contact with air
R7 May cause fire
R8 Contact with combustible material may cause fire
R9 Explosive when mixed with combustible material
R10 Flammable
R11 Highly flammable
R12 Extremely flammable
R13 Extremely flammable liquefied gas
R14 Reacts violently with water
R15 Contact with water liberates extremely flammable gases
R16 Explosive when mixed with oxidizing substances
R17 Spontaneously flammable in air
R18 In use, may form inflammable/explosive vapor-air mixture
R19 May form explosive peroxides
R20 Harmful by inhalation
R21 Harmful in contact with skin
R22 Harmful if swallowed
R23 Toxic by inhalation
R24 Toxic in contact with skin
R25 Toxic if swallowed
R26 Very toxic by inhalation
R27 Very toxic in contact with skin
R28 Very toxic if swallowed
R29 Contact with water liberates toxic gas
R30 Can become highly flammable in use
R31 Contact with acids liberates toxic
R32 Contact with acid liberates very toxic gas
R33 Danger of cumulative effects
R34 Causes burns
R35 Causes severe burns
R36 Irritating to eyes
R37 Irritating to respiratory system
R38 Irritating to skin
R39 Danger of very serious irreversible effects
R40 Possible risk of irreversible effects
R41 Risk of serious damage to the eyes
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Code Description
R42 May cause sensitization by inhalation
R43 May cause sensitization by skin contact
R44 Risk of explosion if heated under confinement
R45 May cause cancer
R46 May cause heritable genetic damage
R47 May cause birth defects
R48 Danger of serious damage to health by prolonged exposure
R49 May cause cancer by inhalation
R50 Very toxic to aquatic organisms
R51 Toxic to aquatic organisms
R52 Harmful to aquatic organisms
R53 May cause long-term adverse effects in the aquatic environment
R54 Toxic to flora
R55 Toxic to fauna
R56 Toxic to soil organisms
R57 Toxic to bees
R58 May cause long-term adverse effects in the environment
R59 Dangerous to the zone layer
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B.1.4 Safety phrases
Code Description
S1 Keep locked up
S2 Keep out of the reach of children
S3 Keep in a cool place
S4 Keep away from living quarters
S5 Keep contents under ... (there follows the name of a liquid)
S6 Keep under ... (there follows the name of an inert gas)
S7 Keep container tightly closed
S8 Keep container dry
S9 Keep container in a well-ventilated place
S12 Do not keep the container sealed
S13 Keep away from food, drink and animal foodstuffs
S14 Keep away from ... (a list of incompatible materials will follow).
S15 Keep away from heat
S16 Keep away from sources of ignition
S17 Keep away from combustible material
S18 Handle and open container with care
S20 When using, do note at or drink
S21 When using, do not smoke
S22 Do not breathe dust
S23 Do not breathe vapor (to be specified by manufacturer)
S24 Avoid contact with skin
S25 Avoid contact with eyes
In case of contact with eyes, rinse immediately with plenty of water
S26
and seek medical advice
S27 Take off immediately all contaminated clothing
After contact with skin, wash immediately with plenty of soap-suds (to
S28
be specified by manufacturer)
S29 Do not empty into drains
S30 Never add water to this product
S33 Take precautionary measures against static discharges
S34 Avoid shock and friction motions
S35 This material and its container must be disposed of in a safe way
S36 Wear suitable protective clothing
S37 Wear suitable gloves
S38 In case of insufficient ventilation, wear suitable respiratory equipment
S39 Wear eye/face protection
To clean the floor and all objects contaminated by this material,
S40
use…….(there follows suitable cleaning material)
S41 In case of fire and/or explosion do not breathe fumes
S42 During fumigation / spraying wear suitable respiratory equipment
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Code Description
(to be specified by manufacturer)
In case of fire use…(there follows the type of fire-fighting equipment
S43
to be used)
In case of you feel unwell seek medical advice (show the label
S44
whenever possible)
In case of accident or if you feel unwell, seek medical advice
S45
immediately (show the label whenever possible).
If swallowed, seek medical advice immediately and show this
S46
container or label
Keep at temperature not exceeding ……….. °C (to be specified by
S47
manufacturer)
S48 To be kept wet with (there follows a material name)
S49 Keep only in the original container
S50 Do not mix with ……………. (to be specified by manufacturer)
S51 Use only in well ventilated areas
S52 Not recommended for interior use on large surface areas
S53 Avoid exposure – obtain special instructions before use
Obtain pollution control authority consent before discharging into
S54
the plants for the treatment of waste-waters.
Make use of the best available treatment techniques before
S55
discharging into the sewerage or into the aquatic environment
Do not discharge into sewerage or in the environment; dispose of this
S56
material at special waste collection point.
S57 Use appropriate container to avoid environmental contamination
S58 Dispose of as dangerous waste
S59 Refer to manufacturer/supplier for information on recovery/recycling
This material and its container must be disposed of as hazardous
S60
waste
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B.1.5 Abbreviations used in Toxicity data
The table below gives the main abbreviations which will be found in
the toxicity data for chemicals.
Abbreviation Description
asn Aspergillus nidulans
ast Ascites tumor
bcs Bacillus subtilis
bfa body fluid assay
bmr bone marrow
brd bird (domestic or lab)
bwd wild bird species
chd child
ckn chicken
CL ceiling concentration
clr Chlamydomonas reinhardi
ctl cattle
cyt cytogenetic analysis
D day
dck duck
dlt cominant lethal test
dmg Drosophila melanogaster
dnd DNA damage
dni DNA inhibition
dnr nNA repair
dns unscheduled DNA synthesis
dom domestic animal (goat, sheep)
dpo Drcsophila pseudo-obscura
emb embryo
esc Escherichia cold
eug Euglena gracilis
eye administration into eye (irritant)
fb fiber
fbr fibroblast
frg frog
gm gram
gpg guinea pig
grb gerbil
grh grasshopper
H hour
ham hamster
hla HeIa cell
hma host-mediated assay
hmi Haemophilus influenzae
hmn human
hor horse, donkey
I intermittent
ial intraaural
IARC International Agency for Research on Cancer
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iat intraarterial
ice intracerebral
icv intracervical
idr intradermal
idu intraduodenal
ihl inhalation
imm immersion
imp implant
ims intramuscular
inf infant
ipc intraplacental
ipl intrapleural
ipr intraperitoneal
irn intrarenal
isp intraspinal
itr intratracheal
itt intratesticular
iu international unit
iut intrauterine
ivg intravaginal
ivn intravenous
kdy kidney
kg kilogram
klp Klebsiella pneumoniae
L liter
LC50 lethal concentration 50 percent kill
LCLo lowest published lethal concentration
LD50 lethal dose 50 percent kill
LDlo lowest published lethal dose
leu leukocyte
Liq liquid
lng lung
lvr liver
lym lymphocyte
M minute
m3 cubic meter
mam mammal (species unspecified)
man man
ug microgram
umol micromole
mg milligram
mky monkey
mL milliliter
MLD mild irritation effects
mma microsomal mutagenicity assay
mmo mutation in microorganisms
mmol millimole
mmr mammary gland
mnt micronucleus test
MOD moderate irritation effects
mol mole
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mppcf million particles per cubic foot
mrc gene conversion and mitotic recombination
msc mutation in mammalian somatic cells
mul multiple routes
mus mouse
n/a not available
ng nanogram
nml non-mammalian species
nmol nanomole
NOAEL No Observed Adverse Effect Level
nsc Neurospora crassa
ocu ocular
ofs other fish
omi other microorganisms
oms other mutation test systems
oin other insects
open open irritation test
orl oral
ORM Other Regulated Material (DoT)
oth other cell types
otr oncogenic transformation
ovr ovary
par parenteral
pg picogram
pgn pigeon
pic phage inhibition capacity
pig pig
Pk peak concentration
pmol picomole
post after birth
ppb parts per billion (v/v)
pph parts per hundred (v/v) (percent)
ppm parts per million (v/v)
ppt parts per trillion (v/v)
preg pregnant
qal quail
rat rat
rbt rabbit
rec rectal
rns rinsed with water
S second
sal salmon
sat Salmonella typhimurium
sce sister chromatic exchange
scu subcutaneous
SEV severe irritation effects
skn administration onto skin
sln sex chromosome loss and nondisjunction
slt specific locus test
slw silkworm
smc Saccharomyces cerevisiae
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spm sperm morphology
spr sperm
sql squirrel
srm Serratia marcescens
ssp Schizosaccharomyces pombe
STEL short term exposure limit
TC toxic concentration (other than lowest
concentration)
TCLo lowest published toxic concentration
TD toxic dose (other than lowest toxic dose)
TDLo lowest published toxic dose
tes testis
TLV Threshold Limit Value
tod toad
trk turkey
trn heritable translocation test
TWA time weighted average
unr unreported
W week
wmn woman
Y year
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C.1 INSTRUCTIONS ON PROCESS GAS CONTAINING H2S (PROCESS GAS

10PPM) (hydrogen sulfide or sulfureted hydrogen)
 NOTE
PRESENT INSTRUCTIONS AIM AT PROVIDING THE PERSONNEL WITH BASIC

SAFETY INFORMATION IN CASE OF PRESENCE OF H2S UPON USE AND
MAINTENANCE OF MACHINES SUPPLIED BY GE OIL&GAS –NUOVO PIGNONE
SPA.
IN CASE OF DOUBT OR NEED FOR FURTHER INFORMATION, PLEASE CONTACT
THE GE OIL & GAS -NUOVO PIGNONE SPA REGIONAL LEADER. IN ANY CASE,
FOR THE DETERMINATION OF OPERATING PROCEDURES, REFER TO THE
LOCAL REGULATION IN FORCE CONCERNING ALLOWED EXPOSURE LIMITS.
Health hazard information
The exposure to minimum concentrations of Hydrogen sulfide gas can cause

serious and even lethal injuries to any living being.
The effects of H2S exposure on human beings vary depending on its
concentration and are listed herein after:
Concentration EFFECTS
in air (ppm)
<1ppm Strong smell of rotten eggs
10 ppm Max. limit allowed by ACGIH for 8 hour exposure.
Probable eye irritation
15 ppm Max. limit allowed by ACGIH for exposure  15 minutes.
50 ppm The sense of smell can be paralysed after 15 minutes of
exposure.
In case of longer exposure: migraine, pulmonary edema, and eye
injuries.
100 ppm The sense of smell can be paralysed after 3 minutes of exposure.
Coughing, difficulty in breathing, eye pain, drowsiness.
200 ppm The sense of smell is immediately paralysed. Eye and upper
respiratory tract irritation. Any exposure exceeding 20 minutes
can cause irreversible pulmonary edemas.
300 ppm High concentration, which can cause immediate poisoning and
death.
Conjunctivitis and respiratory tract irritation.
500 ppm Unconsciousness after short exposure.
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Concentration EFFECTS
in air (ppm)
500 ppm Unconsciousness after short exposure.
Respiratory paralysis, fainting and unconsciousness.
The victim requires immediate resuscitation an artificial
respiration
>1000 ppm Immediate unconsciousness.
Permanent brain injuries or death.
The presence of hydrogen sulfide gas cannot be detected by the sense of

smell, since it is immediately paralysed in case of high concentrations.
! DANGER
RELEVANT PERSONNEL MUST BE PERFECTLY AWARE OF H2S SPECIFIC

RISKS, AND PROPERLY TRAINED ON PERSONAL PROTECTION DEVICES, H2S
DETECTING DEVICES AND OPERATING PROCEDURES (WHICH MUST BE
DEFINED BY PLANT MANAGER).
! DANGER
REMEMBER: 50% OF THE LETHAL INJURIES DUE TO H2S CONCERN

RESCUERS.
THE PLANT MANAGER IS RESPONSIBLE FOR DEFINING SUITABLE
EMERGENCY PROCEDURES.
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H2S effects on safety appliances
If water is not present, hydrogen sulfide gas is not corrosive for metals.
Vice versa, if water is present, H2S can rapidly corrode metals, thus causing
immediate breaking of metal components (containers, piping, moving
components).
Hydrogen sulfide gas can alter the solidity of metals, thus making them
extremely fragile and easily breakable.
Another dangerous effect is the self-ignition of pyrophoric iron sulphide

(FeS). In case of contact with oxygen, self-combustion might occur.
Hydrogen sulfide is a flammable gas (LEL=4.0% , UEL=44.0%).
H2S effects on the environment
Any H2S concentration exceeding 1ppm in the environment might cause the
risks listed on previous paragraph.
Any H2S concentration in the air, even below 1ppm, can cause olfactory
pollution.
Air quality is damaged by concentrations above 0.02 ppm.
Wide areas around the polluting source might thus be contaminated.
Do not allow any minimum dispersion of H2S in the atmosphere (vents must
generally be directed to the torch).
Determination of potential h2s sources
Potential H2S sources are:

 Leakage from machine components coupling seals (ex: centrelines,
machine components connections, connections between machine and
piping/instruments)
 Leakage or breaking of process lines and relevant instruments.
 Leakage or breaking of fuel gas lines and relevant instruments.
 Leakage or breaking of sealing system lines and relevant instruments.
 Leakage from safety valves on process, fuel gas and sealing system
lines (to manifold in torch).
 Leakage from vents of process, fuel gas, or sealing system lines (to
manifold in torch).
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Upon maintenance of the above-mentioned systems, or of any other plant

component where hydrogen sulfide might accumulate, the line must be
preventively decontaminated through fluxing.
Plant manager is responsible for determining maintenance operations to

perform and ensuring their application.
Determination of dangerous areas
Plant engineering company shall develop the area classification drawing.

Such classification considers H2S presence probability and its maximum
concentration in each area.
The classification also considers dispersion and wind effects.
Such information is fundamental for drawing up safety procedures (by plant

manager); dangerous areas are generally classified as follows:
 areas with possible concentration below 10 ppm

 areas with possible concentration between 10 ppm and 200 ppm
 areas with possible concentration above 200 ppm
Design rules (outline)
The design of machines and auxiliaries to be installed in plants processing

gas with hydrogen sulfide requires special safety precautionary measures,
which vary depending on H2S concentration.
As far as corrosion prevention is concerned, special materials are employed,

in conformity with NACE regulations (for those intervals where NACE
regulations can be applied).
The drawings describing supply limits connections contain specific

instructions for the Customer, for a correct management of vents (in general
max. allowed presence of H2S, temperature, delivery, pressure and back
pressure).
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As far as plant is concerned, the circuits that might contain H2S (even
accidentally) are fitted with the following safety devices:
 vent manifolds to torch

 double block and bleed of each circuit section subject to ordinary
maintenance. Such device is installed in case of H2S concentrations
50ppm.
 Valves fitted with special sealing and leakage collection devices.
Depending on H2S concentration in the gas, the technical measures to take

vary from a notice indicating the presence of H2S (to be put by plant
manager), to the compulsory use of personal portable detectors, of self
contained breathing apparatuses, or the installation of fix detectors.
Safety regulations on the workplace (operation)
The personnel working in potentially contaminated areas (included

authorized visitors) must be perfectly trained on the activities to perform.
Plant manager is responsible for elaborating the training program.
The instructions contained in present sections must be included in the
program.
Plant manager shall prepare the Permits to work and apply them to the
activities to carry out in the dangerous areas.
According to such system, accesses must be preventively authorized by
written authorisation, generally issued by the safety manager, who will
specify the operations to perform, and relevant safety procedures and
devices on the permit to work.
Plant manager will be responsible for drawing up the procedures including
the information contained in present document.
Special precautionary measures must be also taken during normal
operational activities, depending on area classification and the circumstances
influencing control level.
Such precautions include monitoring with personal portable appliances,
ready-to-use respirator (see paragraph on safety devices) and the respirator
worn.
Plant manager shall prepare an emergency and first aid plan based upon all
potential occurrences and he shall also supervise the constant training of
ordinary personnel and of emergency and first aid squads.
Plant manager shall furthermore define – in agreement with local Authorities -
emergency plans for further risks outside the Plant.
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Safety regulations on the workplace (maintenance)
Besides the safety regulations set forth in the above paragraph, special
safety measures must also be taken before performing any maintenance
procedure on the plant (machines included).
The precautions concerning maintenance operations might also include the
use of respirators.
Considering the dangerousness of H2S, in addition to the prescriptions
contained in chapter “Safety Instructions” concerning lock-out tag-out, further
measures must be taken:
 double block and bleed of H2S source circuit.
 Depressurisation of the circuit. If not possible, eliminate all ignition
sources. Special attention must be paid to wind direction: wind sleeves
must be provided. Certain operations must be forbidden in case of
windless conditions.
 Flux circuits with suitable gas (generally nitrogen), until a sufficient
quantity of gas containing H2S has been removed. Upon measuring the
residual concentration of H2S in ppm, consider that a few catalytic
detectors might not operate properly in nitrogen atmosphere.
 Ensure the activity does not imply access to confined spaces; if it does,
specific working procedures must be adopted.
Special attention must be paid to the treatment of non-metallic components

(elastomers and plastics) which were in contact with H2S. Hydrogen sulfide
is absorbed by such materials and their removal (for checks or replacement)
causes a gradual release of the H2S contained.
 A few of such components are listed below:

 Gaskets on process circuits, fuel gas and/or seal gaskets.
 Machine inner components having sealing functions (o-rings, PTFE
rings, gaskets, etc.)
 Sealing components (ring and o-ring) of dry gas seals.
Such components, once removed, must be properly treated (ex. Stored in

airy and controlled access places, until destruction), in compliance with local
prescriptions for the treatment of dangerous waste.
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Safety and warning measures
Safety and warning measures include: notices, fix and portable detectors,
breathing masks and self-contained breathing apparatuses.
Those areas where H2S might be present, even accidentally, must be
properly indicated with notices and relevant instructions in all working
languages.
Notices must comply with local regulations if any, or with ISO international
standards.
Fix H2S detectors are generally employed when H2S concentration is above
1% of gas volume (10.000 ppm).
Fix detectors must be placed in the points of H2S highest concentration or
possible accumulation, determined by a specific study which considers
possible sources, wind directions and speeds, and plant structure.
Fix detectors require regular testing, calibration and maintenance.
Fix detectors not only indicate H2S concentration, but they also produce an
acoustic and visual signal when a prearranged threshold is exceeded; the
user must be properly trained on the correct use and limits of such
instruments.
Breathing devices based on adsorbent filters must be employed in case of

possible concentrations below 200 ppm and they must be accurately
selected according to their function; in general, they are only employed for
allowing the worker to reach a safe area in emergency conditions.
Self contained breathing apparatuses generally consist of a mask and a
connection to a compressed air bottle. The pressure in the mask must be
higher than atmospheric pressure, in order to prevent any gas infiltration
inside the mask. Self contained breathing apparatuses with a small reserve
of compressed air can be employed for reaching a safe area, in emergency
conditions.
The users of breathing apparatuses must be properly trained on the correct

use and maintenance of such devices. Before using such apparatuses, the
workers must undergo all relevant physical tests.
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H2S material safety data sheet
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INSTALLATION AND OPERATING INSTRUCTIONS FOR

PRESSURE EQUIPMENTS
1 PROTECTION FOR TRANSPORT, STORAGE, HANDLING.................................... 93
2 MOUNTING, INCLUDING ASSEMBLING ................................................................. 93
3 PUTTING INTO SERVICE ......................................................................................... 95
4 USE............................................................................................................................ 95
5 MAINTENANCE, INCLUDING CHECKS BY THE USER .......................................... 96
6 INSPECTION ............................................................................................................. 96
8 PROTECTIVE DEVICES AND OTHER FITTINGS .................................................... 99
9 IDENTIFICATION..................................................................................................... 101
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1 PROTECTION FOR TRANSPORT, STORAGE, HANDLING

‘1.1 Transport and storage
The equipment has been protected for the transport and storage prior to erection as necessary against physical
damage and / or corrosion which may occur due to the method and conditions of transport and the time which may
elapse before erection, up to maximum of 3 months. For longer periods, protection shall be restored by user at
storage site, with particular attention to the protection of machined surfaces, and the compatibility therewith, as
regards corrosion, of any material used for physical protection.
‘1.2 Handling
Only for equipments provided with brackets / lugs: during loading and unloading operations brackets / lugs shall be
used with purpose to avoid the possibility of distortion of the equipment and any of its parts.
It is strictly forbidden to lift or to move the equipment by fastening others braces like nozzles or supports without
written permission of the manufacturer. Any damage must be notify immediately to the manufacturer.
2 MOUNTING, INCLUDING ASSEMBLING

‘2.1 Installation of the equipment
The equipment shall be installed in accordance with applicable requirements of State or Local Authorities, and with
applicable regulations.
Before installing the equipment, personnel must check the integrity of the nameplate and all the information are well
readable.
Personnel must control than the equipment is in good conditions and no damage has been occurred during transport
and handling.
The position of the equipment is indicated on the drawing(s). If provided with supports, the equipments must be
installed by the supports forecast on the equipment.
It is not allowed to support equipment by means of adjacent piping, unless so specifically stated by the designer (see
drawing(s)).
‘2.2 Levels
The equipment shall be installed to the correct levels and vertical lines within the limits agreed with the owner/user
(see drawing(s)).
To facilitate drainage of static horizontal equipment, the longitudinal fall should be at least 1 in 200 (see drawings). .
‘2.3 Foundations
Foundations shall be adequate to support the equipment and its maximum content, including hydraulic test
condition.
Only for equipments provided with supports (brackets, lugs, legs, etc.): the type of equipment support (brackets,
lugs, legs, etc.) shown in the assembly drawing(s) may be used to transmit loads to foundations. Each hole in the
base plates must have its own foundation bolt. If not indicated on the drawing(s), the material for anchorage bolts
shall be at least Class 8.8 of EN 20898-1 or equivalent, and bolt diameter shall be not smaller than the hole diameter
minus 3 mm.
‘2.4 Equipment placement and access

The equipment shall be installed with sufficient clearance from associated structures and equipment to provide safe,
efficient working by operators and to provide ready access for cleaning, inspections, and maintenance.
Equipments having manholes, hand holes, or cover plates to permit inspection of the interior shall be so installed
that these openings are accessible.
Only for equipments provided with supports: supports shall be so arranged as to provide adequate facility for the
inspection of every part of the equipment, with sufficient access to all parts of the exterior to permit proper
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inspection, unless the equipment is of such size and is so connected that it may readily be removed from its
permanent location for inspection.
Improper placement next to other equipment, chemicals, flammable materials, etc. may lead to a premature failure.
Fire can weaken the equipment materials; chemicals may cause severe corrosion and failure before the next
scheduled inspection; inadequate structural supports can lead to failure of nozzles or adjacent piping; vibration or
failure of adjacent equipment may damage the equipment. These are just a few of the possibilities.
Where necessary, ladders and platforms shall be installed to give access to valves and other control device (if any)
placed on equipment connections.
Safety and control devices (if any), shall be located and installed so that they are readily accessible fore operation,
inspection, maintenance and removal.
‘2.5 Assembly
The equipment has to be assembled complete with all its parts included blind flanges and internals (if any) fully
assembled to the equipment.
The assembly of equipment to its adjacent connections (inlet, outlet, etc.) must be done by well trained personnel.
The type of connections may be (see drawing(s)):
- Flanged connection
- Threaded connections
- Quick opening connections
- Butt weld end nozzles
The flanged connections must be ensured with gaskets and bolt indicated on the drawings if not already forecast on
the supply.
For the threaded connections must be used special sealing to be chosen according to the operating temperature. In
case of no indications before assembly the threaded connections, assembler must inform the manufacturer in order
to supply specific information.
The assembly of quick special opening must be made with the bolts and accessories supplied with the equipment.
It is strictly forbidden to change or modify the bolts or the gaskets or any other accessories supply with the
equipment to join the connection.
Butt welds end nozzles shall be welded according to welding procedure, and then cleaned and inspected, as
indicated in equipment drawing, by qualified personnel.
‘2.6 Filling and discharge

Where a discharge connection is provided to discharge the fluid content, the discharge piping shall be attached to a
valve and shall lead to a safe valve location.
The filling and discharge system shall be designed provided and installed by User / Manufacturer of the assembly
under their responsibility. Filling and discharge shall be made in a manner to prevent danger to person or damage to
the operation of equipment or environment and preferably to a place where the discharge is visible.
Only heat exchangers: filling and discharge of heat exchanger shall be executed gradually with simultaneous
circulation of fluids through both sides.
‘2.7 Substitution of removable parts

In general, removable parts as bolts, nuts, blind flanges, plugs, etc. may be replaced, if necessary ( e. g. lost ) with
parts of same material standard specification, grade, size and (if applicable) pressure rating class indicated on the
bill of material shown on the drawing(s) and other design documents.
Substitutions of removable parts may fall in the scope of in-service laws and regulations valid at place of
installation, to be followed by the user.
In case of same type of material should be not available, the responsible of repair or substitution should notify the
lack of fastening and he can not install others materials without previous authorization of the PED manufacturer.
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‘2.8 Repairing
User is obliged to inform the manufacturer for any maintenance on the equipment that can seriously modify the safe
operating condition of the equipment. Any repairing on the equipment must be carried out by qualified personnel.
Substitution of parts, or repair, by welding fall in the scope of in-service laws and regulations valid at place of
installation, to be followed by the user.
The responsible of substitution of parts or repair by welding can not operate without previous authorization of the
PED manufacturer. In lacking of this authorization, responsibility and warranty will be considered expired for the
whole equipment in which such operation should have been made.
If not in conflict with local in-service laws and regulations, following should be used as code of practice:
‘- National Board Code ANSI/NB-23 latest edition.
‘- Only for vessel in petroleum refinery service, in addition, API RP 510 latest edition.
3 PUTTING INTO SERVICE

Only for equipments provided with supports (brackets, lugs, legs, etc.): the equipments must be fixed to its supports
before operating.
Qualified personnel should check at least:

 Correct position of the equipment;
 No material has been left during assembling in the internal of the equipment;
 Cleanness of the internal according to the drawing(s);
 All the connections are fully and correct assembled;
 All the joint are correct fitted;
 All the bolts are correct closed;
 The foundation bolts (if any) are all in place and correct closed;
 All the safety instrument (if any) are in place and correct assembled;
 No evidence of damage to any parts of the equipment;
 Safety devices and alarms (if any) are connected on the whole of the equipment.
Starting the operating of the equipment (or of the assembly of which the equipment is part) must be done according
the PED operating instructions and plant engineering procedure of the owner/user.
If the equipment is supplied with stickers, in order to inform about the risk of pressurization prior of installation of
safety devices, they shall be considered and strictly followed.
All the information regarding the operating conditions (pressure and temperature) are indicated on the nameplate
installed on the equipment, and/or on technical documentation furnished with the equipment.
Only for vessels: the position of the nameplate is indicated on the drawing(s).
Operating the equipment to proper design data indicated on the nameplate must always be done by a qualified
personnel.
At least at half of the operating pressure a step must be done in order to check the following point by a qualified
personnel:
 Lacks;
 Correct fastening;
 Distortion or damage;
 Safety accessories are well visible and readable.
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4 USE
The use of the equipment should be carried out only by specialized personnel.
The use of the equipment is strictly obliged to the data indicated on the nameplate and on the drawing(s), the
operating instructions and/or other technical documentation furnished with the equipment.
It is forbidden to use the equipment for other scope and other pressure and temperature different from the ones
indicated on the nameplate and drawing.
It is strictly forbidden to open any closure, joints or other parts during operating.
It is strictly forbidden to tight bolts or thread during operating.
During operation only authorized personnel can stand near the equipment and only after having followed all the
safety instructions issued by the plant safety responsible of the owner/user..
Only for heat exchangers: the safe operation of the vessel is assured only if both sides are feeded with fluids of type,
composition, service pressure and temperature indicated on the drawing. The risk of lack of feeding of the colder
fluid, drop of its pressure, and of failure of feeding pumps shall have been analyzed with one of methods addressed
on Par. 8 of these instructions, and the risk reduced with use of adequate protection system, able to stop the warmer
flow, activate the alarms, etc. designed by User / Manufacturer of assembly; in any case, the Manufacturer of the
vessel does not assume responsibility of the correct operation of the protection system.
5 MAINTENANCE, INCLUDING CHECKS BY THE USER

Maintenance must always be done at room temperature and atmospheric pressure. It is strictly forbidden any
maintenance to either the equipment, parts, components or instruments during the operating of the equipment.
The return to operating must be done after verifying that all the procedure indicated by the plant engineering are
satisfy.
The equipments can reach its operating pressure and temperature indicated on the nameplate and drawing(s) and/or
other technical documentation furnished with the equipment only after a positive check.
6 INSPECTION
Inspections should be made according to the Engineering/user plant procedure or, in lacking of any procedure, the
National Board Code ANSI/NB-23 latest edition should be followed (if not in conflict with local laws and
regulations for in-service).
Only for vessels in petroleum refinery service: in addition to above, API RP 510 latest edition shall be followed if
not in conflict with local laws and regulations for in-service).
For equipment (and assembly of which the equipment is part) assembled or installed in Italy by the user, D.M. 329
of Dec. 1st 2004 has to be followed (if not specifically exempted).
The type of inspection given to equipment shall take into consideration the condition of the equipment and the
environment in which it operates. This inspection may be external or internal, and use a variety of nondestructive
examination methods. The inspection method may be performed when the equipment is operating on-stream or
depressurized, but shall provide the necessary information that the essential sections of the equipment are of a
condition to continue to operate for the expected time interval. On-stream inspection, included while under pressure,
may be used to satisfy inspection requirements provided the accuracy of the method can be demonstrated.
Inspection of environment in which the equipment operates includes:

 External painting or coating in order to established if there is any possibility further ambient corrosion;
 Good conditions of instruments and safety apparatuses (if any);
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 Tight of foundation bolts (if any).
‘6.1 EXTERNAL INSPECTION
The purpose of an external inspection is to provide information regarding the overall condition of the equipment. In
particular:
Insulation or other covering (if any). If it is found that external coverings such as insulation and corrosion
resistant linings are in good condition and there is no reason to suspect any unsafe condition behind them, it is not
necessary to remove them for inspection of the equipment. However, it may be advisable to remove small portions
of the coverings in order to investigate their condition and the condition of the metal.
Evidence of leakage. Any leakage of gas, vapor or liquid shall be investigated. Leakage coming from behind
insulation coverings, supports or settings, or evidence of past leakage shall be thoroughly investigated by removing
any covering necessary until the source is established.
Structural attachments. The equipments mountings (if any) shall be checked for adequate allowance for expansion
and contraction, such as provided by slotted bolt holes or unobstructed saddle mountings. Attachments of legs,
saddles, skirts or other supports (if any) shall be examined for distortion or cracks at welds.
Equipment connections. Manholes, reinforcing plates, nozzles or other connections should be examined for cracks,
deformation or other defects. Bolts and nuts should be checked for corrosion or defects. Weep holes in reinforcing
plates shall remain open to provide visual evidence of leakage as well as to prevent pressure build up between the
equipment and the reinforcing plate. Accessible flange faces shall be examined for distortion and to determine the
condition of gasket-seating surfaces.
Abrasives. The surface of the equipment shall be checked for erosion.
Dents. Dents in an equipment are deformations caused by their coming in contact with a blunt object in such a way
that the thickness of metal is not materially impaired. In some cases, a dent can be repaired by mechanically pushing
out the deformation, followed by an adequate check for material integrity.
Distortion. If any distortion is suspected or observed, the overall dimensions of the equipment shall be checked to
determine the extent and seriousness of the distortion.
Cuts or gouges. Cuts or gouges can cause high stress concentrations and decrease the wall thickness. Depending
upon the extent of the defect, it may be necessary to repair the area by welding or patching. Blend grinding may be a
useful method of eliminating some minor types of cuts or gouges.
Surface inspection. The surfaces of shell and heads shall be examined for possible cracks, blisters, bulges, and
other evidence of deterioration, giving particular attention to the skirt and to support attachment and knuckle regions
of the heads.
Weld joints. Welded joints and the adjacent heat affected zones shall be examined for cracks or other defects.
Superficial NDE is recommended.
‘6.2 INTERNAL INSPECTION (FOR EQUIPMENTS WHERE APPLICABLE)
The following activities shall be performed to support the inspection:

Inspection plugs and covers shall be removed;
Equipment shall be sufficiently cleaned to allow for visual inspection of internal and external surfaces.
If the geometry of the equipment does not permit physical access, appropriate instruments (e.g. mirror, masgnifier,
borescope, fiberscope) shall be used.
A general visual inspection is the first step in making an internal inspection. All parts of the equipment shall be
inspected for erosion, blistering, deformation, cracking and laminations. In particular:
Equipment connections. Threaded connections shall be inspected to ensure that an adequate number of threads are
engaged. All openings leading to any external fittings or controls shall be examined as thoroughly as possible to
ensure they are free from obstructions.
Equipment closures (if any). Any closures, which are used frequently in the operation of an equipment,
shall be checked by the Inspector for adequacy and wear. A check shall also be made for cracks at areas
of high stress concentration.
Equipment internals (if any). Where equipment is equipped with removable internals, these internals
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need not be completely removed, provided assurance exists that deterioration in regions rendered
inaccessible by the internals is not occurring to an extent that might constitute an hazard or to an extent
beyond that found in more readily accessible parts of the equipment. If a preliminary inspection reveals
unsafe conditions, steps shall be taken to remove or repair such parts so that a detailed inspection may
be made. .
The above indicated inspections are not limiting to any eventual further control that the qualified personnel could by
themselves carried out in order to establish the remaining life of the equipment.
‘6.3 INSPECTION INTERVALS

New equipment is placed in service to operate under their conditions for a period of time determined by the service
conditions. If the equipment is to remain in operation, the allowable conditions of service and length of time before
the next inspection shall be based on the condition of the equipment as determined by the inspection.
The maximum period before the first internal inspection or a complete on-stream evaluation of equipment shall not
exceed one-half of the estimated life or four years, whichever is less.
Each next period between internal inspections or a complete on-stream evaluation of equipment shall not exceed
one-half of the estimated remaining life of the equipment or two years, whichever is less. Where the remaining
operating life is less then two years, the inspection interval may be the full remaining safe operating life.
Lifetime of new equipment

The estimated lifetime of new equipment is 10 years. The user, under his exclusive responsibility, may decide to
extend the life on the basis of the records of the results of periodic inspections.
‘6.4 EQUIPMENTS SUBJECTED TO FATIGUE
Equipments with pressure variation less than 5% of the design pressure

They are not considered to be subject to fatigue.
Equipments with pressure variation larger than 5% of the design pressure
Except otherwise specified in the design technical documentation, equipment not specifically calculated to resist
fatigue are intended for maximum fatigue lifetime as follows:
for equipments wall thicknesses calculated by formulas according to ASME code(s):
‘- 1000 cycles, in which the pressure variation exceeds 20% of the design pressure, for equipments not containing
pad type nozzles and no integral attachments; but 400 cycles, in which the pressure variation exceeds 15% of the
design pressure, for equipments containing pad type nozzles and no integral attachments; or,
For equipments calculated by formulas according to European codes:
‘- 500 cycles.
If a condition of fatigue is applicable, following provisions apply.
Periodic inspections
‘a) Each equipment for which the number of allowable load cycles N has been fixed shall undergo an internal
inspection at the latest when half of the load cycles fixed has been reached.
As a result of the type of operation, the intervals between internal tests may be shorter in accordance with laws and
regulations of the country of installation.
The user is obliged to record the number of load cycles arising by suitable means and, if necessary, to arrange for
internal inspection.
‘b) If the operating conditions assumed in the calculation deviate in terms of a grater cyclic loading or if damage to
the pressure-bearing wall is to be expected before the end of the inspection intervals owing to other operational
influences, they shall be reduced in accordance with national regulations.
‘c) In-service inspections are of particular importance; they permit early detection of incipient damage. For this
purpose, the internal inspections shall be supplemented by non-destructive tests on highly loaded locations. Surface
cracks tests and ultrasonic tests are the methods to be considered here. For the examinations of readily accessible
areas, the outside surface of the equipment can also be subjected to ultrasonic testing.
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‘d) If no cracks are detected during an internal inspection, the next internal inspection shall be performed following
a special agreement within the shortest interval resulting from the national regulations however at the latest. When
half of the fixed number of load cycles has been reached. This also applies if the allowable number of load cycles is
exceeded.
‘e) The inspection described in a) to d) for cyclic loading during operation may be waived if the component is
designed to withstand an operational load cycle number of 2000000.
Consideration of special operating conditions

If corrosion-induced crack formation (fatigue crack corrosion, strain-induced crack corrosion) hydrogen-induced
crack formation in compressed hydrogen is to be expected, it shall be taken into account that the fatigue strength
value will not only fall considerably below the value without these influences, but that it may also cause fatigue
cracks even after a very high number of load cycles (>10000000).
Measures to be taken when the design lifetime has been reached

‘a) If the allowable number of load cycles for a component or the allowable value for cumulative damage according
to calculation has been reached, non-destructive tests according to above shall be performed as completely as
possible at a certain number of highly loaded locations to be laid down with the relevant third party.
‘b) If no cracks are found in the tests conducted as described in a), continuous operation is permitted. The
prerequisite for this is that no fatigue damage is found in the non-destructive tests conducted in the inspection
intervals which correspond to 50% of the operating time specified in a). After this operating time has been reached,
further measures shall be agreed for each individual case in accordance with national regulations.
‘c) Should cracks or crack-like defects or other more extensive damage established in the tests carried out as
described in a) or b), the component or the structural element concerned shall be replaced, unless continued
operation is deemed to be permitted by virtue of appropriate measures to be agreed in accordance with national
regulations.
‘d) The following design, manufacturing or process-related measures can be considered appropriate to allow
continued operation:
‘d1) Removal of cracks by grinding. If as a result of grinding too thin a wall thickness is obtained, repair welding
shall only be carried out in cooperation with the manufacturer within the context of national regulations;
‘d2) Grinding the welds to remove all notches;
‘d3) Removal of restraints to expansion: e.g.: replacement of cracked rigid stiffeners by joints not restraining
expansion;
‘d4) Change in mode of operation.
8 PROTECTIVE DEVICES AND OTHER FITTINGS

The equipment may be supplied with stickers in order to inform about the risk of pressurization prior of installation
of safety devices.
Safety devices and alarms are not part of supply. In any case each equipment shall be provided with protective
devices in accordance with the requirements of PED and Construction Code indicated on the drawing(s).
Protective devices shall be conform to the law requirements of the country where the equipment shall be installed
and, where required, acceptable to the Inspecting Authority competent for the survey of the plant in-service.
When any such device is not provided by the equipment, the User / Manufacturer of the assembly shall be
responsible for ensuring that it is supplied and fitted prior to placing the equipment into service. Design of protective
devices, which are not provided by the manufacturer of the equipment, is full responsibility of the User /
Manufacturer of the assembly.
Protective devices and fittings shall be:

 located and installed so that they are readily accessible for operation, inspection, maintenance and removal;
 arranged to afford maximum protection against accidental damage.
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The equipment, marked CE having been subjected to a conformity assessment procedure, at site of installation will
operate as an item of an assembly. The Manufacturer of the equipment does not control if the assembly, of which the
equipment is part:
‘- is assembled and installed by a manufacturer or by an user;
‘- is , or not, marked CE as a whole, by a manufacturer;
‘- is, or not, subjected to local laws and regulations for putting them into service.
Compliance with in-service local laws and regulations and, in case of plants with hazard due to particular dangerous
products, compliance with Directive 96/82/EC (in Italy implemented with D.L. 334 of 1//08/99) are exclusive
responsibility of the user.
‘8.1 PRESSURE RELIEVING DEVICES
Each equipment (or each chamber of a multi-chamber equipment) shall be protected by one or more pressure-
relieving devices that shall prevent the pressure from rising to more then 110 percent of the design pressure of the
equipment.
Types of pressure relief devices to be designed, installed, used

Device designed to recluse and prevent the further flow of fluid after normal conditions have been restored. The
valve automatically discharges compressible fluid, or liquid to atmosphere or to a reduced pressure system, so as to
prevent a predetermined pressure being exceeded. It is activated by the static pressure upstream of the valve.
Pressurization of the equipment is forbidden in lacking of one of following types of pressure relief devices:
Safety valve: the (compressible) is discharged to atmosphere;
Relief valve: the (non-compressible) fluid, (i.e. liquid) is discharged to atmosphere or to a reduced pressure system.
Non-reclosing pressure relief devices

As alternative of pressure relief devices, non-reclosing pressure relief devices, designed to remain open after
operation, or rupture disk devices may be used under full responsibility of the Customer / user.
‘8.2 INSTALLATION
Interconnected equipments
Equipments (or chambers of equipments) which are connected together in a system by piping of adequate capacity,
may be considered as one unit in determining the number and capacity of pressure-relief devices provided that no
valve is fitted that could isolate any equipment from the relief devices unless the equipment is simultaneously
opened to atmosphere.
Inlet connection
The connection between the relief devices and the equipment shall be as short as practicable, shall have bore area
equal at least to the area of the relief devices inlet, and shall not reduce the discharge capacity of the relief devices
below the capacity required for the equipment. .
‘8.3 DISCHARGE FROM PRESSURE RELIEF DEVICES
Safe discharge to atmosphere

(Except lethal fluids and other special fluids considered in the relevant application code) fluid may be discharged
from a static equipment to atmosphere provided that the discharge is outside of and away from buildings, preferably
though a vertical pipe to a height of at least 2 m above the equipment or the building there the equipment is
installed. All relief devices shall be arranged so that the discharge does not impinge on the equipment, and will not
prevent effective operation of the device.
Safe discharge to lower pressure systems
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Discharge to lower pressure systems is permissible provided that the receiving system can accept the additional load
without causing an unacceptable back pressure.
Discharge pipes
Discharge pipes from pressure-relief valve shall be sized so that, under maximum discharge conditions, the built-up
of back pressure at the outlet of the valve as the result of the valve discharging does not reduce the relieving
capacity of the valve below that required to protect the equipment.
The bore of the discharge pipe shall be not less than the bore of the outlet of the pressure-relief device.
Discharge piping shall run as directly as practicable to the point of final release.
Discharge piping shall be adequately and independently supported to prevent transmittal of forces due to the mass of
the tube, discharge reaction and the thermal expansion strain
Forces acting on safety or relief valve should be kept to a minimum under all conditions of operation.
Discharge pipes shall be designed to facilitate drainage or shall be fitted with an open drain to prevent liquid from
lodging on the discharge side of the device.
Common discharge pipes

Where it is not feasible to provide each pressure-relief device with a separate discharge pipe, a discharge pipe
common to a number of devices on one or more equipment may be used. The size of common discharge pipe
serving two or more pressure-relief devices that may reasonably be expected to discharge simultaneously, shall
ensure that the required total discharge capacity can be achieved. The total pipe area should be at least equal the sum
of their outlet areas, with due allowance for pressure drop in the downstream sections.
9 IDENTIFICATION
Identification of the equipment is made by its serial no. The serial no is stamped on the nameplate and on the
equipment nearby the nameplate support in order to avoid change of the nameplate.
Information shown on the nameplate are considered part of these instructions.
Drawing(s) and other technical documentation supplied with the equipment are considered part of these operating
instructions for all information not specifically covered by these instructions.
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Safety2 Safety Instruction STD

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Nuovo Pignone

SAFETY INSTRUCTION STD

Electronically approved draw. GE NuovoPignone Internal DT-'N'

1. Gas Turbine (TU/GA) Safety Instructions……..pag.3

2. Turbocompressor (TU/GA + CO/CE) Safety Instructions…….pag.102

3. Turbogenerator (TU/GA + EL. Generator) Safety Instructions…….pag.210

4. Centrifugal Compressor (CO/CE) Safety Instructions…….pag.309

5. Motocompressor (Electric Motor + CO/CE) Safety Instructions……pag.415

6. Steam Turbine (TU/VA) Safety Instructions……..pag.520

7. Turbocompressor (TU/VA + CO/CE) Safety Instructions…….pag.618

8. Turbogenerator (TU/VA + EL. Generator) Safety Instructions…….pag.726

9. Turbogenerator (TU/VA + EL.Generator) Safety Instructions…….pag.824

REV DESCRIZIONE - DESCRIPTION A 2/3

1. SAFETY INSTRUCTIONS .................................................................................. 103

REV DESCRIZIONE - DESCRIPTION A 102 / 103

For the purpose of favoring immediate consultation of this document, it is

In compliance with the provisions of the directives applicable to the supplied

Personnel operating on the plant must have sufficient knowledge of the

REV DESCRIZIONE - DESCRIPTION A 103 / 104

FAILURE TO OBSERVE SAFETY REGULATIONS AND/OR THE REMOVAL OR

REV DESCRIZIONE - DESCRIPTION A 104 / 105

1.2 SYMBOLS USED IN THE MANUAL

These warnings have been subdivided into three categories depending on

THIS SYMBOL EVIDENCES A PROCEDURE, A PRECAUTION OR A CONDITION

THIS SYMBOL EVIDENCES A PROCEDURE, PRECAUTION OR CONDITION

THIS SYMBOL EVIDENCES ONE OR MORE DATA NECESSARY TO PERSONNEL

REV DESCRIZIONE - DESCRIPTION A 105 / 106

The information outlined below provides indications necessary to identify the

REV DESCRIZIONE - DESCRIPTION A 106 / 107

THE HAZARD WHICH CAUSES THE RISK CONSIDERED IN THIS DEFINITION:

REV DESCRIZIONE - DESCRIPTION A 107 / 108

Safety measures consisting of utilizing the specific technical means known as

Element of a machine used in a specific manner to provide protection

A GUARD CAN BE FIXED OR INTERLOCKED.

REV DESCRIZIONE - DESCRIPTION A 108 / 109

1.4 INTENDED USE OF A MACHINE

Use to which the machine is destined in accordance with the indications

AS CONCERNS INCORRECT USE, THE FOLLOWING BEHAVIOR IN PARTICULAR

REV DESCRIZIONE - DESCRIPTION A 109 / 110

ALWAYS VERIFY BOTH THE OPERATING CHARACTERISTICS AND THE SAFETY

IT IS PROHIBITED TO USE THE COMPRESSOR FOR COMPRESSING DIFFERENT

REV DESCRIZIONE - DESCRIPTION A 110 / 111

NUOVO PIGNONE RECOMMEND AT THE CUSTOMER TO BE EXTREMELY

DUE OF THE HIGH SAFETY IMPACT, ONLY NUOVO PIGNONE OR NUOVO

THE UNAUTHORIZED MODIFICATION OF SUCH PARAMETERS/LOGICS

REV DESCRIZIONE - DESCRIPTION A 111 / 112

1.5 IDENTIFICATION OF HAZARDOUS ZONES

During the stages of installation and maintenance on the Turbocompressor

 presence of inflammable gas at high pressure in the turbine feed systems;

REV DESCRIZIONE - DESCRIPTION A 112 / 113

Acoustic Enclosure over the turbine and its auxiliaries

When an acoustic enclosure is provided, within it are present both the

REV DESCRIZIONE - DESCRIPTION A 113 / 114

1.6 ACOUSTIC ENCLOSURE ACCESS PRACTICE INFORMATION

DURING MACHINE OPERATING NOBODY MUST BE PRESENT INSIDE OR

The restricted access also applies to a stopped machine until cool-down is

Based on Manufacturer experience the enclosure access is necessary for

At first start up or after an overhaul for:

Access for any other reason is forbidden.

REV DESCRIZIONE - DESCRIPTION A 114 / 115

It is anyhow strictly forbidden to enter the acoustic enclosure in the

 During an expected and remarkable load variation